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Hitachi ZW 120-6, Operator'S Manual

The Operator's Manual for the Hitachi ZW 120-6 is available for free download on our website. This comprehensive manual provides detailed instructions and guidelines for optimal usage, maintenance, and troubleshooting of this powerful machinery. Enhance your equipment knowledge by downloading the manual from 88.208.23.73:8080 today.

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CONTENTS

Steps..................................................................................................1-94
Rear Grille ........................................................................................1-94

Opening the rear grille ..........................................................1-94
Closing the rear grille ............................................................1-94

Grease Gun Box .............................................................................1-94
Vandal-Proof Devices ..................................................................1-95
Seat Belt ...........................................................................................1-96

BREAK-IN

 ...........................................................................................2-1

Break-in Operation for New Machine .......................................2-1

OPERATING ENGINE

 .....................................................................3-1

Inspect Machine Daily Before Starting ....................................3-1
Check Before Starting ....................................................................3-3
Starting Engine ................................................................................3-5
Starting in Cold Weather...............................................................3-7
Check After Starting .......................................................................3-8
Using Booster Batteries .................................................................3-9
Warming Up Operation ..............................................................3-11
Warming Up Operation in Cold Weather .............................3-12
Stopping Engine ...........................................................................3-14

DRIVING MACHINE

 .......................................................................4-1

Driving the Machine .......................................................................4-1
Starting to Move ..............................................................................4-2
Parking Brake Switch ......................................................................4-4
Drive Speed Change.......................................................................4-5
Changing Forward/Reverse Drive Direction ..........................4-5
Steering Wheel .................................................................................4-6
Stop and Restart of Driving .........................................................4-7
Precautions for Driving on Slopes ..........................................4-10
Precautions for Driving Speeds ...............................................4-11
Precautions to be Taken if Machine Failure Occurs ..........4-12
Stop the Machine .........................................................................4-13
Parking .............................................................................................4-15
Emergency Evacuation ...............................................................4-16

OPERATING MACHINE

 .................................................................5-1

Control Lever .....................................................................................5-1
Control Lever Lock Switch ............................................................5-2
Ride Control Switch (Optional) ...................................................5-3
Lift Arm Kick Out ..............................................................................5-5
Bucket Auto Leveler........................................................................5-6
Before Operation .............................................................................5-8
Precautions for Operation ............................................................5-8
Ensure Safety When Operating on Road Shoulders ...........5-8
Avoid Overloading ..........................................................................5-9
Avoid Rapid Steering Changes and/or Sudden Braking ...5-9
Avoid Operation with Biased Loads .........................................5-9
Excavation .......................................................................................5-10
Grading ............................................................................................5-12
Loading ............................................................................................5-13
Dozing ..............................................................................................5-16
Scooping .........................................................................................5-16
Removing Snow ............................................................................5-17
Lifting Wheel Loader ...................................................................5-17
Precautions for After Operations ............................................5-18

TRANSPORTING

 .............................................................................6-1

Transporting by Road ....................................................................6-1
Transporting by Trailer ..................................................................6-1
Loading / Unloading on Trailer ...................................................6-2
Fastening Machine for Transporting ........................................6-4
Transporting Wheel Loader (Urgent Situation) ....................6-5
Towing Method ................................................................................6-9
Lifting Machine .............................................................................6-10

MAINTENANCE

 ...............................................................................7-1

Correct Maintenance and Inspection Procedures ...............7-1
Check the Hour Meter Regularly ................................................7-3
Layout ..................................................................................................7-4
Preparations for Inspection and Maintenance .....................7-7
Lock Frames .......................................................................................7-9
Inspection/Maintenance Access Side Cover .......................7-10
Rear Grille ........................................................................................7-11
Inspection and Maintenance Table ........................................7-12
Kind of Oils ......................................................................................7-16
List of Consumable Parts ...........................................................7-19
A. Greasing ......................................................................................7-21
B. Engine ..........................................................................................7-27

Check Engine Oil Level ..........................................................7-27
Change Engine Oil ..................................................................7-28
Replace Engine Oil Filter .......................................................7-30

C. Power Train ................................................................................7-31

Check Transmission Oil Level ..............................................7-31
Change Transmission Oil ......................................................7-32
Clean Transmission Strainer ................................................7-32
Replace Transmission Oil Filter ...........................................7-34
Change Axle Oil .......................................................................7-36
Check Surroundings Around Axle and Covers for Oil 

Leaks ......................................................................................7-38

Clean Transmission Air Breather ........................................7-38

D. Hydraulic System .....................................................................7-39
Inspection and Maintenance of Hydraulic Equipment ...7-39

Check Hydraulic Oil Level ....................................................7-41
Change Hydraulic Oil/Clean Hydraulic Oil Tank ...........7-42
Clean Suction Filter ................................................................7-42
Replace Hydraulic Tank Oil Filter .......................................7-44
Replace HST Charge Filter ....................................................7-46
Replace Air Breather Element .............................................7-48
Check Pilot Circuit Accumulator Function, Gas  

Leakage, Looseness, and Damage ..............................7-49

Replace Pilot Circuit Accumulator ....................................7-50
Check Ride Control Accumulator Function, Gas  

Leakage, Looseness, and Damage ..............................7-50

Check Gas Pressure in Ride Control Accumulator 

(Optional) .............................................................................7-50

Check Hoses and Lines .........................................................7-51

E. Fuel System ................................................................................7-56

Check Fuel Level ......................................................................7-56
Drain Water and Sediment from Fuel Tank ....................7-58
Drain Fuel Pre-Filter ................................................................7-59
Replace Fuel Main Filter Element ......................................7-61
Replace Fuel Pre-Filter Element .........................................7-62
Check Fuel Hoses ....................................................................7-63

F. Air Cleaner ...................................................................................7-64

Summary of Contents for ZW 120-6

Page 1: ...NA1 2 ZW120 6 WHEEL LOADER OPERATOR S MANUAL PRINTED IN JAPAN E 2018 07 URL http www hitachi c m com ENMNSC NA1 2 PART NO Wheel Loader Operator s Manual Serial No 005201 and up This book is printed on recycled paper ...

Page 2: ...dealer Warranty is provided as a part of Hitachi s support program for customers who operate and maintain their equipment as described in this manual The warranty is explained on the warranty certificate which you should have received from your dealer This warranty provides you with the assurance that Hitachi will back its products where defects appear within the warranty period In some circumstan...

Page 3: ...ACHINE OPERATOR S STATION BREAK IN OPERATING ENGINE DRIVING MACHINE OPERATINGMACHINE TRANSPORTING MAINTENANCE MAINTENANCEUNDERSPECIALENVIRONMENTALCONDITIONS STORAGE TROUBLESHOOTING OPTIONAL ATTACHMENTS SPECIFICATIONS INDEX INDEX ENMNSC NA1 2 MACHINE NUMBERS ...

Page 4: ......

Page 5: ...ce Rubber Hoses Periodically S 28 Avoid High Pressure Fluids S 28 Prevent Fires S 29 Evacuating in Case of Fire S 31 Beware of Exhaust Fumes S 31 Precautions for Welding and Grinding S 31 Precautions for DEF AdBlue S 32 Avoid Heating Near Pressurized Fluid Lines S 33 Avoid Applying Heat to Lines Containing Flammable Fluids S 33 Precautions for Handling Accumulator and Gas Damper S 33 Remove Paint ...

Page 6: ...erator Pedal 1 52 Brake Inching Pedal 1 52 Tilt Telescopic Lever Steering Column Tilt Pedal 1 53 Slow Speed L Select Switch 1 54 Right Console 1 55 Multi Function Joystick Type 1 55 Control Lever 1 56 Control Lever Lock Switch 1 57 Armrest Adjust Handle 1 58 Traction Control Switch 1 59 Power Mode Switch 1 60 Aftertreatment Device Regeneration Switch 1 61 Manual Regeneration Procedure 1 62 Ride Co...

Page 7: ...6 1 Loading Unloading on Trailer 6 2 Fastening Machine for Transporting 6 4 Transporting Wheel Loader Urgent Situation 6 5 Towing Method 6 9 Lifting Machine 6 10 MAINTENANCE 7 1 Correct Maintenance and Inspection Procedures 7 1 Check the Hour Meter Regularly 7 3 Layout 7 4 Preparations for Inspection and Maintenance 7 7 Lock Frames 7 9 Inspection Maintenance Access Side Cover 7 10 Rear Grille 7 11...

Page 8: ...ace Seat and Seat Belt 7 96 Check ROPS cab Mounting Bolts 7 96 Check Windshield Washer Fluid Level 7 96 Check Play Amount in Steering Wheel Stroke 7 97 Check Accelerator Pedal Operation and Exhaust Gas Color and Noise 7 98 Check Rearview Mirror and Inside Rearview Mirror 7 99 Check Steps and Handrails for Damage and Looseness 7 99 Clean Engine Compartment and Hood 7 100 Check Sound Absorbing Mat A...

Page 9: ... when inquiring any information on the machine and or components Fill these serial Nos in the blank spaces in this group to immediately make them available upon request Machine TYPE PRODUCT IDENTIFICATION NUMBER Engine TYPE MFG NO SCR Selective Catalytic Reduction Catalyst TYPE MFG NO DOC Diesel Oxidation Catalyst TYPE MFG NO MNSC 00 001 MNSC 00 002 MNSC 00 003 MNSC 00 004 ...

Page 10: ...MACHINE NUMBERS 2 MEMO ...

Page 11: ...tes a potentially hazardous 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 signs are located near specific hazards General precautions are listed on CAUTION safety signs Some safety signs do not use any of the designated signal words...

Page 12: ...material caused by unauthorized modifications will void Hitachi Warranty Policy Never attempt to modify or disassemble the inlet exhaust parts and the muffler filter Avoid giving shocks on the muffler filter by striking elements with other objects or dropping the elements Failure to do so may affect the exhaust gas purifying device possibly damaging it or lowering its performance Do not use attach...

Page 13: ...bers for doctors ambulance service hospital and fire department posted near your telephone Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job You may need A hard hat Safety shoes Safety glasses goggles or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and ...

Page 14: ... or earplugs to protect against objectionable or uncomfortably loud noises Inspect Machine Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury In the walk around inspection be sure to cover all points described in the Inspect Machine Daily Before Starting section in the operator s manual SA 435 SA 434 ...

Page 15: ...s control lever lock switch or control levers which may result in serious injury or death Avoid storing transparent bottles in the cab Do not attach 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 operating the machine Keep all flammable...

Page 16: ...se bolts Never get on and off the machine with tools in your hands Never Ride Attachment Never allow anyone to ride attachment or the load This is an extremely dangerous practice Adjust Operator s Seat A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperations The seat should be adjusted whenever changing the operator for the machin...

Page 17: ...h to the lock position Turn the key switch OFF to stop the engine Before leaving the machine close all windows doors and access covers and lock them Fasten Your Seat Belt If the machine should overturn the operator may become injured and or thrown from the cab Additionally the operator may be crushed by the overturning machine resulting in serious injury or death Prior to operating the machine tho...

Page 18: ...ly repair it Ensure the cab door windows doors and covers are securely locked Check the mirrors and the monitor in the CAB for problems If there is any problem replace the problem part s or clean the mirror camera and the monitor Refer to Rear View Monitor section on the cleaning of the camera and the monitor Handle Starting Aids Safely Starting fluid Starting fluid is highly flammable Keep all sp...

Page 19: ... neutral Before starting the engine confirm the safety around the machine and sound the horn to alert bystanders Jump Starting Battery gas can explode resulting in serious injury If the engine must be jump started be sure to follow the instructions shown in the OPERATING ENGINE chapter in the operator s manual The operator must be in the operator s seat so that the machine will be under control wh...

Page 20: ...force ground edges and road shoulders as necessary Keep the machine well back from the edges of excavations 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 with 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 st...

Page 21: ...OPS and FOPS Any modification of the ROPS structure will modify its performances and its certification will be lost ROPS Roll Over Protective Structure FOPS Falling Object Protective Structure Provide Signals for Jobs Involving Multiple Machines For jobs involving multiple machines provide signals commonly known by all personnel involved Also appoint a signal person to coordinate the job site Make...

Page 22: ... of the possibility of slipping and or turning over the machine when driving on a slope When driving on level ground hold the bucket at mark A 300 mm 12 in above the ground as illustrated Avoid traveling over any obstacles Drive the machine slowly when driving on rough terrain Avoid quick direction changes Failure to do so may cause the machine to turn over If the engine stops while driving the st...

Page 23: ...in serious injury or death When driving up or down a slope keep the bucket facing the direction of travel approximately 200 to 300 mm approximately 8 to 12 in A above the ground If the machine starts to skid or becomes unstable immediately lower the bucket to the ground and stop Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn If the direction mus...

Page 24: ...may result in personal injury and or death Avoid rapid drive direction changes which could possibly cause personal injury and or death Drive on Snow Safely Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces The machine may slip more easily than expected on frozen snow surfaces even if the inclination is small Reduce speed when driving Avoid fast ...

Page 25: ...el ground when possible to park machine Do not park the machine on a grade Lower the bucket to the ground Put the forward reverse lever switch in neutral and pull up the parking brake switch lever in the ON parking brake position Run the engine at low idle speed without load for 5 minutes to cool down the engine Stop the engine and remove the key from the key switch Turn the control lever lock swi...

Page 26: ... entangled in the machine Keep all personnel away from the machine by sounding the horn and or using hand signals Use extra care to be sure no one is in from the articulation area before turning the machine Keep windows mirrors and lights in good condition Reduce travel speed when dust heavy rain fog etc reduce the visibility In case good visibility is not obtained use a signal person to guide you...

Page 27: ...EERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when operating on a grade possibly resulting in serious injury or death To avoid tipping Be extra careful before operating on a grade Prepare machine operating area flat Keep the bucket low to the ground and close t...

Page 28: ...lines If a fiber optic cable should be accidentally severed do not look into the end Doing so may result in serious eye injury Contact your local diggers hot line if available in your area and or the utility companies directly Have them mark all underground utilities Perform Truck Loading Safely Do not operate the machine involuntarily Unexpected machine movement may cause personal injury and or d...

Page 29: ... Lightning Lightning may strike the machine If lightning comes close immediately stop the operation and take the following action When you are around the machine or operating cab less machine evacuate to a safe place far away from the machine When you are in the cab stay in the cab until lightning has passed and safety is secured Close the cab doors and windows Lower the bucket to the ground and s...

Page 30: ...h Never attach a sling or chain to the bucket teeth or to the attachment fork or grapple for example They may come off causing the load to fall Protect Against Flying Debris If flying debris hit eyes or any other part of the body serious injury may result Guard against injury from flying pieces of metal or debris wear goggles or safety glasses Keep bystanders away from the working area before stri...

Page 31: ... for 5 minutes Turn key switch to OFF to stop engine Remove the key from the key switch Turn the control lever lock switch to the lock position Close windows roof vent and cab door Lock all access doors and compartments Store Attachments Safely Stored attachments such as buckets hydraulic hammers and blades can fall and cause serious injury or death Securely store attachments and implements to pre...

Page 32: ...el ground 2 Always use a ramp or deck strong enough to support the machine weight 3 Use the low speed gear 4 Never steer the machine while being on the ramp If the traveling direction must be changed while being on the ramp unload the machine from the ramp reposition the machine on the ground then try loading again 5 After loading install the lock bar to securely hold the articulation mechanism 6 ...

Page 33: ...ne 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 flammable Store flammable fluids well away from fire hazards Do not incinerate or puncture pressurized containers Do not store oily rags they can ignite and burn spontaneously Securely tighten the fuel and oil filler caps...

Page 34: ...8 Turn the control lever lock switch to the lock position 9 Lock bar connects the front and rear frames 10 Allow the engine to cool If a maintenance procedure must be performed with the engine running do not leave machine unattended Never work under a machine raised by the lift arm Inspect certain parts periodically and repair or replace as necessary Refer to the section discussing that part in th...

Page 35: ...work on the machine attach a Do Not Operate tag on the control lever This tag is available from your authorized dealer 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 th...

Page 36: ...to perform the job Have it done by your authorized dealer or a qualified repair service Always maintain the correct tire pressure DO NOT inflate tire above the recommended pressure When inflating tires use a chip on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly Use a safety cage if available Inspect tires and wheels daily Do no...

Page 37: ... Skin contact with escaping hot water or steam can cause severe burns Avoid possible injury from hot spraying water DO NOT remove the radiator cap until the engine is cool When opening turn the cap slowly to the stop Allow all pressure to be released before removing the cap The hydraulic oil tank is pressurized Again be sure to release all pressure before removing the cap Hot fluids and surfaces E...

Page 38: ...may result in severe burns gangrene or otherwise serious injury or death Avoid High Pressure Fluids Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury blindness or death Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of ...

Page 39: ...ssure lines Never install bent or damaged lines pipes or hoses Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance Check for Shorts Short circuits can cause fires Clean and tighten all electrical connections Check before each shift or after eight 8 to ten 10 hours operation for loose kinked hardened or frayed electrical cables and wires ...

Page 40: ...erials such as dead leaves from entering However flammable materials which have passed through the wire screen may cause fires Check and clean the machine every day and immediately remove accumulated flammable materials Check Key Switch If a fire breaks out failure to stop the engine will escalate the fire hampering fire fighting Always check key switch function before operating the machine every ...

Page 41: ...to remove the exhaust fumes or open doors and windows to bring enough outside air into the area White smoke may be generated during the aftertreatment device regeneration Do not attempt to do aftertreatment device manual regeneration in a badly ventilated indoors Precautions for Welding and Grinding Welding may generate gas and or small fires Be sure to perform welding in a well ventilated and pre...

Page 42: ...urther inhaling ammonia gas at a high concentration may cause breathing to stop due to shock from the irritation Protective equipment safety glasses impermeable rubber or plastic gloves etc must be worn when handling it and the washing of hands with tap water when done must be strictly enforced If DEF AdBlue should get on hands feet etc wash it off with a large amount of water If it gets in the ey...

Page 43: ...eat to Lines Containing Flammable Fluids Do not weld or flame cut pipes or tubes that contain flammable fluids Clean them thoroughly with nonflammable solvent before welding or flame cutting them Precautions for Handling Accumulator and Gas Damper High pressure nitrogen gas is sealed in the accumulator and the gas damper Inappropriate handling may cause explosion possibly resulting in serious inju...

Page 44: ... Asbestos and Silicon Dust and Other Contamination Take care not to inhale dust produced in the work site Inhalation of asbestos fibers may be the cause of lung cancer Inhalation of silicon dust and other contamination may cause sickness Depending on the work site conditions the risk of inhaling asbestos fiber silicon dust or other contamination may exist Spray water to prevent asbestos fibers sil...

Page 45: ...ly tighten all terminals Connect terminals to the correct electrical poles Failure to do so may cause damage to the electrical parts or fire Battery electrolyte is poisonous If the battery should explode battery electrolyte may be splashed into eyes possibly resulting in blindness Be sure to wear eye protection when checking electrolyte specific gravity Service Air Conditioning System Safely If sp...

Page 46: ...mical products used with your machine Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with HITACHI equipment includes such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do ...

Page 47: ... to avoid skin contact with exhaust gas It may cause severe burns White smoke may be generated during aftertreatment device regeneration Do not attempt to perform aftertreatment device manual regeneration in a badly ventilated area Do not touch water coming directly out of the aftertreatment device The water is mildly acidic by oxidation catalyst mounted in the aftertreatment device If filter wate...

Page 48: ...d dealer for the type of communication terminal Specific Absorption Rate SAR measured by 10 g per unit of communication terminal equipments Type A Type B E GSM900 0 573 W kg 914 8 MHz 0 12 W kg 897 6 MHz DCS 1800 0 130 W kg 1710 2 MHz 0 06 W kg 1748 0 MHz WCDMA Band I 0 271 W kg 1950 0 MHz 0 05 W kg 1950 0 MHz WCDMA Band VIII 0 10 W kg 892 6 MHz This data was measured by having each type of commun...

Page 49: ... do so may cause damage or fire on the machine and the communication terminal Before removing or installing the communication terminal consult your authorized dealer Do not pinch or forcibly pull cables cords and connectors Failure to do so may cause damage or fire on the machine and the communication terminal due to short broken circuit ...

Page 50: ...re safe machine operation Always keep the safety signs clean In case a safety sign is broken or lost immediately obtain a new replacement and affix it again in position on the machine Use the part No indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer SAFETY SIGNS SS 4042 3 4 5 6 9 15 10 23 25 24 23 13 26 19 18 16 17 28 2 1 21 22 12 1...

Page 51: ...machine during operation 3 Cab Inside Right Front Column First safety sign from the top dWARNING Prior to operation maintenance disassembling and transportation of the machine be sure to read and understand the Operator s Manual 4 Cab Inside Right Front Column 2nd safety sign from the top dDANGER Electrocution Hazard Sign indicates an electrocution hazard if machine is brought too near electric po...

Page 52: ...ment to the ground lock the control levers and remove the key from the key switch 6 Cab Inside Right Front Column 4th safety sign from the top dWARNING Rollover Hazard To minimize the injury due to an overturning accident be sure to fasten the seat belt prior to operating the machine 7 Cab Inside Right Rear Column dCAUTION Steering Hazard 8 Cab Inside Left Rear Column dWARNING Runover Hazard Be su...

Page 53: ... an incorrect method the machine suddenly may start to move Start the engine from the operator s seat only 11 Engine Housing dWARNING Explosion Hazard Do not use ether This engine is equipped with electric heater starting aid Use of ether could cause explosion and could result in death or serious injury 12 Both Sides Bottom of Rear Frame Side Cover dWARNING Entanglement Hazard Sign indicates a haz...

Page 54: ... result Do not touch until cool 14 Both Sides of Rear Frame Side Cover dWARNING Entanglement Hazard Sign indicates a hazard of rotating parts such as fan Turn off before inspection and maintenance 15 Inside Engine Housing 16 Inside Battery Box dCAUTION Shock Hazard Sign indicates an electrical hazard from handling the cable Read the manual for safe and proper handling SS56400 52841 4478724350 4478...

Page 55: ...s Take care not to touch electrolyte 19 Inside Battery Box dDANGER Explosion Hazard Do not cause electrical arcing from jumper cables or accidental placement of metal objects on the battery terminals Read and understand the operator s manual 22 Engine Housing dWARNING Burn Hazard Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot Allow r...

Page 56: ...e machine 25 Left Side of Front Frame dWARNING Crush Hazard The articulation area becomes a pinch point when steering the machine Keep all personnel away from the articulation area during operation of the machine 26 Both Sides Bottom of Rear Frame Side Cover dWARNING Runover Hazard Unless the machine is correctly parked the machine may run away possibly creating a dangerous situation such as a per...

Page 57: ...ch as a cardiac pacemaker Please read the instruction manual carefully and follow the instructions before using this machine 28 Top of Battery Recycle Batteries Batteries contain lead and acid Obey all local and federal laws and regulation on disposal of batteries and electrolyte solution label 44774 23030 label 44787 25020 ...

Page 58: ...SAFETY SIGNS S 48 MEMO ...

Page 59: ...Rear Fender 12 Articulation Lock Bar 13 Front Fender 14 Lift Arm Cylinder 15 Lift Arm 16 Exhaust Pipe 17 Hydraulic Oil Tank 18 Rear Combination Light Turn Signal Hazard Light Tail Light Brake Light Backup Light 19 Counterweight 20 Towing Pin 21 Radiator Various Coolers 22 Rear Work Light 23 DEF AdBlue Tank 24 Aftertreatment Device 25 Grease Gun Box 26 Rear Under Mirror 13 14 15 22 21 20 19 18 10 1...

Page 60: ...s very dangerous dWARNING Never attach a wire on the foot holds 1 or handrails 2 to lift the cab or main body or while transporting the machine on a truck or trailer as it is dangerous The door handle 3 is not a handrail Do not hold the door handle 3 as a handrail when getting on and off the machine Do not hold the steering wheel forward reverse lever or control levers when getting on and off the ...

Page 61: ... Be sure to use fuel that complies with JIS K 2204 EN 590 or ASTM D 975 that contains 15 ppm or lower sulfur If the fuel described above is not used exhaust gas that exceeds regulation values may be discharged and serious engine problems may occur Refill DEF AdBlue which meets Japanese Industrial Standards JIS or International Organization for Standardization ISO If improper liquid diesel oil kero...

Page 62: ...not attempt to perform a manual regeneration in a poorly ventilated area Consult your authorized dealer for checking or repairing the aftertreatment device fNOTE White deposits may accumulate inside the aftertreatment device The aftertreatment device is automatically regenerated to remove accumulated white deposits at regular intervals It is called auto regeneration The auto regeneration may start...

Page 63: ... the aftertreatment device may be damaged Immediately move the machine to a safe area and perform manual regeneration If approximately 48 hours have passed without regeneration being carried out the engine trouble alarm will be displayed on the monitor Refer to the page 1 62 Consult your nearest authorized dealer Both auto and manual regenerations restore aftertreatment device function It is not a...

Page 64: ...N 1 6 Cab Features 1 Front Defroster 2 Front Console 3 Operator s Seat 4 Right Console 5 Document Holder 6 Hot Cool Box 7 Rear Defroster 8 Glove Compartment 9 Cup Holder 10 Floor Mat MNEC 01 035 1 1 1 2 3 4 6 5 7 8 9 10 ...

Page 65: ...ake Inching Pedal Both right and left sides are interlocked 11 Front Rear Wiper Switch 12 Forward Reverse Lever Shift Switch 13 Steering Column Tilt Pedal 14 Tilt Telescopic Lever 15 Turn Signal Lever Light Switch High Low Beam Switch 16 Key Switch 17 Slow Speed L Select Switch 18 Auxiliary 19 Auxiliary 20 Auxiliary 21 Ash Tray 22 Cigar Lighter 1 2 3 4 5 6 7 8 1 9 10 12 11 14 13 15 16 21 22 MNDB 0...

Page 66: ...7 Auxiliary 8 Traction Control Switch 9 Power Mode Switch 10 Forward Reverse Selector Switch 11 Emergency Steering Operation Check Switch Optional 12 Auxiliary 13 Auxiliary 14 Auxiliary 15 Aftertreatment Device Regeneration Switch 16 Auxiliary 17 Auxiliary 18 Ride Control Switch 19 Armrest Adjust Handle 20 Armrest 21 Auxiliary 22 Horn Button MNDB 01 005 1 2 3 4 5 6 8 7 9 10 11 12 13 14 15 16 17 19...

Page 67: ...arning Indicator 19 Fuel Gauge 20 Power Mode Indicator 21 Monitor Display Mode Selector 22 Not Used 23 Monitor Display Selector Up 24 Preheat Indicator 25 Monitor Display Selector Down 26 Forward Reverse Selector Switch Indicator 27 Monitor Display 28 Not Used 29 Engine Trouble Indicator 30 Overheat Indicator 31 Coolant Temperature Gauge 32 Engine Oil Low Pressure Indicator 33 Not Used 34 Not Used...

Page 68: ...vel decreases The service indicator comes ON if one of the following cases as described below occurs Immediately stop the engine Check the cause of the trouble If the alternator voltage decreases or becomes excessively high If any abnormality is found in engine operation If any abnormality is found in HST operation If the HST oil temperature is kept higher than the specification for a short period...

Page 69: ...se the parking brake Brake Oil Level Indicator Red dWARNING Stop machine operation if the brake oil level decreases Failure to do so may result in personal injury or death If the indicator comes ON immediately stop machine operation If the brake oil level becomes low the brake oil level indicator and the service indicator will light and the alarm buzzer will sound Immediately move the machine to a...

Page 70: ...rnator and the battery system Engine Trouble Indicator Red Lighting If any serious abnormality occurs in the engine and or engine related parts the red indicator will light If the engine trouble indicator and the service indicator light immediately move the machine to a safe area set the machine in the park position and stop the engine Consult your nearest authorized dealer for machine inspection ...

Page 71: ...s If the engine oil pressure becomes low the low engine oil pressure indicator will light the service indicator will flash and the alarm buzzer will sound Immediately move the machine to a safe area set the machine in the park position and stop the engine Inspect the engine oil pressure system and the oil level for any abnormality fNOTE Cold oil temperature or operating on a steep slope may also c...

Page 72: ...sion oil temperature is continued for a long period of time the service indicator comes ON and the warning buzzer sounds Immediately stop operation of the machine and run the engine at low idle speed to reduce the HST oil temperature Seat Belt Indicator Red The seat belt indicator lights for 5 seconds after the engine is started to warn operator to fasten the seat belt Water Separator Indicator Re...

Page 73: ...he remaining fuel amount is indicated by the needle Refuel before the needle reaches in the red range E When the needle reaches in the red range E the fuel level indicator lights fNOTE The fuel level indicator may light even if the indicator needle does not reach the red range E depending on the tilt angle of machine HST Oil Temperature Gauge The HST oil temperature is indicated with a needle When...

Page 74: ... the turn signal and the turn signal indicator start flashing High Beam Indicator Blue When the head lights are used at the high beam position the indicator will light Work Light Indicator Yellow When the work lights are turned ON this indicator will light M4GB 01 032 M4GB 01 033 M4GB 01 034 ...

Page 75: ...t Maintenance Indicator Yellow Indicates that the maintenance times for the following items are approaching Each time the ignition key is turned ON the indicator comes ON for 30 seconds The indicator lights 20 hours before the specified maintenance time arrives Items to be indicated Hydraulic oil change Hydraulic oil filter replacement 1 3 Transmission oil change Transmission oil filter replacemen...

Page 76: ... 3 Monitor Display Selector Up 4 Monitor Display Selector Down 5 Speedometer 6 Information Display 7 Traction Control Indicator 8 Forward Reverse and Shift Position Indicator 9 Ride Control Indicator 10 ECO Indicator 11 DEF AdBlue Level Gauge MPTC 01 019 1 4 3 2 8 9 10 5 11 6 7 MPTC 01 020 ...

Page 77: ...dicator 1 displays the machine driving status selected FNR lever and shift positions FNR Forward Reverse Position Indicator FNR position indicator 2 displays the selected position of forward F neutral N reverse R lever 3 Letters F N R are constantly displayed F R N 3 MNDB 01 002 2 1 MPTC 01 020 MNSC 01 001 ...

Page 78: ...tion shift position indicator 3 displays the actually selected shift stage Forward 2 stages Reverse 2 stages Traction Control Indicator When traction control switch 2 is ON traction control indicator 1 lights F Low Speed L High Speed H R N 4 MNDB 01 002 MNSC 01 001 MNSC 01 001 1 2 3 MNDB 01 005 ...

Page 79: ...r 1 indicates the present machine driving speed While information display 2 is indicating the drive distance each time monitor display mode selector 3 is pressed the indicated speed unit alternates between km h and MPH MPTC 01 020 1 MPTC 01 019 2 3 ...

Page 80: ... is turned ON ECO Indicator ECO indicator 3 lights when the engine runs in energy efficient condition It becomes OFF when the driving speed is 2 km h 1 24 mph or lower or under heavy driving load DEF AdBlue Level Gauge DEF AdBlue level gauge 4 displays the remaining DEF AdBlue amount MPTC 01 020 3 4 1 MNDB 01 005 2 ...

Page 81: ...ne speed and output level control is as follows Level Gauge Alarm Indicator Buzzer Status Inducement Red light Buzzer sounds once 0 3 seconds DEF AdBlue level is low Refill DEF AdBlue Red slow blink Buzzer sounds once 1 2 seconds DEF AdBlue is insufficient Refill DEF AdBlue Red slow blink Red light Buzzer sounds once 1 2 seconds DEF AdBlue tank is empty Refill DEF AdBlue Engine output and speed ar...

Page 82: ...er sounds once 0 3 seconds Urea SCR system is broken Red slow blink Buzzer sounds every 1 2 seconds Urea SCR system is broken Engine output and speed are restricted Consult your nearest authorized dealer for service Red fast blink Red blink Buzzer sounds every 1 2 seconds Red fast blink Buzzer sounds every 0 3 seconds ...

Page 83: ...o return to engine start ready screen 5 While displaying INFO screen when monitor display selector 3 is pressed each INFO screen is displayed Display order of Items in the normal display mode Clock 24H Hour Meter Odometer INFO Press switch 3 Hour Meter of Hydraulic Oil Hour Meter 1 of Hydraulic Oil Filter Hour Meter 3 of Hydraulic Oil Filter Hour Meter of Transmission Oil Hour Meter of Transmissio...

Page 84: ...ed press monitor display selector 2 once at a time to display the INFO Fuel Consumption Indicates the present fuel consumption When this display is indicated press monitor display selector 2 once at a time to return to the clock display When monitor display selector 3 is pressed this screen is shifted to the Average Fuel Consumption Rate Average Fuel Consumption Rate Indicates the average fuel con...

Page 85: ...omes 0 hour maintenance indicator 4 will light While displaying screen F when monitor display selector 2 is pressed the screen is returned to fuel consumption screen B When monitor display selector 3 is pressed screen G of Hydraulic oil filter 3 hour meter is displayed Refer to page 1 32 for the resetting of oil change and filter replacement intervals Hydraulic Oil Filter 3 Hour Meter Screen G and...

Page 86: ...ur meter is displayed Refer to page 1 35 for the resetting of oil change and filter replacement intervals Engine Oil Hour Meter Screen M and time screen N indicating the remaining hours up to engine oil change are alternately displayed When the remaining hour reading becomes 0 hour maintenance indicator 4 will light While displaying screen N when monitor display selector 2 is pressed the screen is...

Page 87: ...to page 1 38 for the resetting of oil change and filter replacement intervals DEF AdBlue Supply Module Main Filter Hour Meter Screen W and time screen X indicating the remaining hours up to DEF AdBlue supply module main filter replace are alternately displayed When the remaining hour reading becomes 0 hour maintenance indicator 4 will light While displaying screen X when monitor display selector 2...

Page 88: ...aying screen Z when monitor display selector 2 is pressed the screen is returned to fuel consumption display B When monitor display selector 3 is pressed screen A of INFO is displayed Refer to page 1 31 for the resetting of oil change and filter replacement intervals 3 2 1 4 MPTC 01 019 Remaining hours before replacement is displayed Axle Oil Hour Meter Press button 3 Alternate display V W B A Pre...

Page 89: ...ompleted Keep pressing switch 1 until the desired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time switch 3 is pressed the displayed hours will change in the order of 2000 0 1500 0 1000 0 When the desired time is displayed release switch 1 to complete resetting operation Keep pressing switch 1 Remaining...

Page 90: ...t when the machine was shipped from the factory is 1000 0 While displaying the change interval hours keep pressing switch 1 fNOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time switch 3 is pressed the displa...

Page 91: ...sired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time switch 3 is pressed the displayed hours will change in the order of 500 0 250 0 100 0 When the desired time is displayed release switch 1 to complete resetting operation Keep pressing switch 1 Remaining hours before replacement is displayed Press bu...

Page 92: ...e machine was shipped from the factory is 1000 0 While displaying the change interval hours keep pressing switch 1 fNOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time switch 3 is pressed the displayed hours...

Page 93: ...rval set when the machine was shipped from the factory is 500 0 While displaying the replacement interval hours keep pressing switch 1 fNOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time switch 3 is pressed...

Page 94: ...achine was shipped from the factory is 500 0 While displaying the change interval hours keep pressing switch 1 fNOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time switch 3 is pressed the displayed hours wil...

Page 95: ...en the machine was shipped from the factory is 500 0 While displaying the replacement interval hours keep pressing switch 1 fNOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time switch 3 is pressed the displa...

Page 96: ...ine was shipped from the factory is 1000 0 While displaying the replacement interval hours keep pressing switch 1 fNOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time switch 3 is pressed the displayed hours ...

Page 97: ...chine was shipped from the factory is 2000 0 While displaying the change interval hours keep pressing switch 1 fNOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time switch 3 is pressed the displayed hours wil...

Page 98: ...2 or 3 to increase or decrease the figure displayed on the screen respectively After displaying the desired month determine the displayed month by pressing monitor display mode selector 1 Then move to the next setting screen 3 Day Setting Press monitor display selector 2 or 3 to increase or decrease the figure displayed on the screen respectively After displaying the desired day determine the disp...

Page 99: ...Pedal 10 Brake Inching Pedal Both right and left sides are interlocked 11 Front Rear Wiper Switch 12 Forward Reverse Lever Shift Switch 13 Steering Column Tilt Pedal 14 Tilt Telescopic Lever 15 Turn Signal Lever Light Switch High Low Beam Switch 16 Key Switch 17 Slow Speed L Select Switch 18 Auxiliary 19 Auxiliary 20 Auxiliary 21 Ash Tray 22 Cigar Lighter 1 2 3 4 5 6 7 8 1 9 10 12 11 14 13 15 16 2...

Page 100: ...turn forward reverse selector switch 4 in the OFF position Refer to 1 65 for forward reverse selector switch 4 Shift Switch Quick Shift Switch QSS Shift Switch Rotate shift switch 2 to shift the gear Forward L H Reverse L H Select a proper shift for the work IMPORTANT When shift switch 2 is shifted while traveling at high speed H occasionally the HST warning indicator may flash and the buzzer may ...

Page 101: ... with forward reverse lever 4 by mistake Before starting the engine set neutral lever lock 1 in the LOCK position Pull UNLOCK Push LOCK Steering IMPORTANT When steering wheel 2 is fully turned the front and the rear frames come in contact with the stoppers so that the steering wheel does not rotate further If the steering wheel is forcibly turned further the engine may stall or malfunction of the ...

Page 102: ...N 1 44 Turn Signal Lever Indicates the drive change direction to persons and or other vehicles by operating turn signal lever 7 Return turn signal lever 7 to neutral manually L Left Turn R Right Turn 7 L R N MNDB 01 003 ...

Page 103: ...ght switch position keeps lit even if the key switch is turned OFF It is used as a parking light when parking the machine on a public road If light switches are in any position other than OFF when the key switch is turned OFF a buzzer will sound continuously for a maximum of 100 seconds to prevent forgetting to turn off the vehicle s clearance light Stop the buzzer by either turning the light swit...

Page 104: ...e headlight beam turns downward and high beam indicator 8 goes OFF Key Switch dWARNING Before starting the engine return the forward reverse lever to neutral N apply the parking brake lock the neutral lever lock and lock the control lever Refer to the descriptions in the OPERATING ENGINE section for the detail information Never turn key switch 9 OFF while traveling the machine Failure to do so wil...

Page 105: ...rozen windshield Use anti freeze type washer fluid Squirt windshield washer fluid on the dry windshield before operating the wiper Besides continuous operation of the wiper with windshield at semiarid condition sprinkling of snow or rain may cause failure of the wiper Use wiper intermittently to protect it from damage In case of machine equipped with hot wire heater for windshield continuous opera...

Page 106: ...he front windshield wiper operates at slow speed INT The front windshield wiper intermittently operates OFF The front windshield wiper stops moving and the wiper blade is returned to the pre start position Washer fluid squirts from the front nozzle and the front windshield wiper operates Washer fluid squirts from the rear nozzle and the rear windshield wiper operates Rear windshield wiper operates...

Page 107: ... failure occurs use this switch to inform other vehicles that the machine is in an emergency situation When the position marked with on hazard switch 1 is pressed front and rear turn signals hazard light 2 on both right and left sides start flashing Press the opposite side of hazard switch 1 to turn the hazard signals 2 OFF M4GB 01 065 1 1 MNDB 01 002 2 2 2 2 MNSC 01 010 MNSC 01 032 ...

Page 108: ...sition to turn front work lights 2 ON Rear work lights 3 stay OFF When the side with mark on switch 1 is pressed both front work lights 2 and rear work lights 3 are turned ON dCAUTION Do not turn the work lights ON while driving on a public road 1 MNDB 01 002 3 3 1 2 2 MNSC 01 032 MNFA 01 011 MNSC 01 010 ...

Page 109: ...brake indicator 2 will be lit Press the OFF side of parking brake switch 1 to release the parking brake Check that parking brake indicator 2 goes OFF by pressing the switch twice with clicks fNOTE The parking brake is released by hydraulic pressure only when the engine is running To ensure safe operation when the parking brake is applied even though the forward reverse lever is moved to forward F ...

Page 110: ...als clean to prevent dust and or grit from accumulating The brake may become inoperable dWARNING Do not allow your foot to ride on the brake pedal unless necessary The machine brake is applied by stepping on the brake pedal 1 or 2 When the brake pedal is stepped on the HST pump becomes neutral causing the travel speed to reduce When the brake pedal is stepped on further the service brake is activa...

Page 111: ...ation to the desired position Push lever 1 until it contacts the stopper ensuring the steering column is locked By depressing steering column tilt pedal 2 the steering column moves forward and the distance between the operator s seat and the steering wheel increases allowing operator to get on and off the machine easily After moving the steering column forward pull the steering wheel to the operat...

Page 112: ...54 Slow Speed L Select Switch Maximum speed can be selected from 7 km h to 11 5 km h range by operating slow speed L select switch 2 while shift switch 1 is in the low speed L position MNDB 01 001 1 2 MNDF 01 019 2 LO SPEED ...

Page 113: ... 7 Auxiliary 8 Traction Control Switch 9 Power Mode Switch 10 Forward Reverse Selector Switch 11 Emergency Steering Operation Check Switch Optional 12 Auxiliary 13 Auxiliary 14 Auxiliary 15 Aftertreatment Device Regeneration Switch 16 Auxiliary 17 Auxiliary 18 Ride Control Switch 19 Armrest Adjust Handle 20 Armrest 21 Auxiliary 22 Horn Button MNDB 01 005 1 2 3 4 5 6 8 7 9 10 11 12 13 14 15 16 17 1...

Page 114: ...e F Detent The lift arm is held in the raise position G Detent When the multi function joystick lever is moved from the bucket dump position to the bucket tilt position the multi function joystick lever is maintained in this position D Bucket Tilt The bucket is tilted back taking the transportation position N Hold The bucket is stopped and held in that position E Bucket Dump The bucket is tilted f...

Page 115: ...hine or leaving the machine at the end of the shift Refer to section 5 2 for details Control lever lock switch 1 is provided to prevent the machine unexpectedly operated even if the operator mistakenly comes in contact with the bucket and or lift arm control lever when getting on or off the machine When control lever lock switch 1 is placed to UNLOCK position control lever lock indicator 2 goes OF...

Page 116: ...vided so that the operator can operate the lever with an arm on the armrest for comfort and ease Loosen handle 1 and position the armrest height to fit the operator s preference tighten handle 1 to fix the armrest L Loosen R Tighten MNDB 01 005 M4GB 01 077 L L R R 1 ...

Page 117: ...events tire slip on the slippery road and improves working efficiency by controlling the maximum tractive force when digging load is high ON Use for work on slippery road surfaces such as removing snow This reduces the maximum tractive force OFF This mode is suited for normal operation 1 MNDF 01 022 1 MNDB 01 005 MPTC 01 020 2 ...

Page 118: ...ctiveness Crushed Rocks in Larger Diameter Crushed Concrete Stone in higher specific gravity Cohesive soil Each time the upper side of the switch mark is pressed the power mode changes ON OFF alternately When the power mode is activated power mode indicator 2 will light on the monitor panel fNOTE When turning the key switch ON the power mode always starts from OFF state Before operating the machin...

Page 119: ... Switch This switch is for performing manual regeneration of the aftertreatment device When the need for aftertreatment device regeneration is indicated press aftertreatment device regeneration switch 1 to start manual regeneration 1 1 MNDB 01 005 MNSC 01 011 ...

Page 120: ...l regeneration is needed aftertreatment device warning indicator 5 and service indicator 6 will light The manual regeneration is needed Before starting manual regeneration be sure to check the following No person is present around the machine Keep flammable objects away from the muffler Fuel level indicator is not lit 1 Park the machine in a safe place Lower the front attachment onto the ground 2 ...

Page 121: ... and the front attachment lock switch the regeneration process is aborted When the process is aborted start over again 4 When the regeneration is finished aftertreatment device warning indicator 5 and service indicator 6 will be turned OFF If indicators 5 and 6 do not turn OFF start over the regeneration process again Failure of regeneration process may happen in the conditions other than above su...

Page 122: ... on the working equipment causing gas leakage The ride control switch damps the vertical vibration of the front attachment during drive operation so that comfortable machine ride quality is obtained As stable drive operation is achieved bucket load spill can be prevented AUTO When ride control switch 1 is turned to AUTO the drive speed sensor and the controller are activated Then when the drive sp...

Page 123: ... to depress the brake pedal to ensure safety 2 When forward reverse selector switch 1 is turned ON while both forward reverse lever 3 and forward reverse switch 2 are in the neutral N position forward reverse indicator 4 is lit 3 Set forward reverse switch 2 to F or R fNOTE When forward reverse lever 3 is set to other than the neutral N position while forward reverse switch 2 is operating forward ...

Page 124: ... seated in the original position Using Cigar Lighter Port as External Power Source Use the cigar lighter port to supply power to lighting equipment for servicing the machine IMPORTANT 24 V DC electric power is available from the cigar lighter port on this machine The maximum current is 5A 120W Never connect accessories that use power other than 24 V Damage to the batteries and accessories may resu...

Page 125: ...OPERATOR S STATION 1 67 MNDB 01 003 Ash Tray dWARNING Take precautions against fires Use ash tray 1 when smoking in the cab 1 ...

Page 126: ...d Heating Maximum cooling or heating can be obtained by pressing the top side mark on temperature control switch 32 C 90 F or the bottom side mark 18 C 64 F respectively Preheating During preheating the cab in winter with the foot vent selected the air volume is reduced to Low until the coolant temperature rises to prevent cool air from entering the cab Cool head warm feet operation fans cool air ...

Page 127: ... 10 Mode Switch 11 AUTO Switch 12 Air Conditioner Switch 13 Circulation Fresh Air Switch 14 Defroster Switch fNOTE Except for the foot vent 4 and defroster vent 5 all vents are provided with louvers to adjust the air flow direction In addition the louvers on the front vent and rear vent can be completely opened and closed by hand MNDB 01 011 1 6 13 12 11 9 8 7 10 14 3 5 5 5 4 2 MNEC 01 035 MNDB 01...

Page 128: ...wer switch 7 is pressed the blower speed is decreased by one increment fNOTE In the AUTO mode operation the fan speed will be automatically controlled with the fan speed indicator flashing LCD 8 Displays the set status of the air conditioner operating temperature fan speed and vent mode Temperature Display Indicates the set temperature 18 to 32 0 C 65 to 90 F by 0 5 C 0 9 F increments at the panel...

Page 129: ... the set temperature is increased by 0 5 C 0 9 F increments Decreasing Temperature Each time the bottom side mark on temperature control switch 9 is pressed the set temperature is decreased by 0 5 C 0 9 F increments Temperature Mode Change Centigrade Fahrenheit Press both and marks on the temperature control switch for longer than 5 seconds at the same time to change the temperature mode Centigrad...

Page 130: ...tch 10 is pressed the vent location can be changed in 6 stages as illustrated below AUTO Press defroster switch 14 to change defroster vent mode AUTO mode The air vent location is automatically selected Temperature Control Switch 9 Sets temperature in the cab Temperature in the cab can be set from 18 0 to 32 0 C 65 to 90 F by pressing temperature control switch 9 Temperature can be set by 0 5 C 0 ...

Page 131: ...12 The air conditioner will turn on and the air conditioner indicator will be lit when air conditioner switch 12 is pressed Circulation Fresh Air Switch 13 It switches over the air intake port to circulation mode and fresh air mode Icon of the selected mode will light Circulation mode 15 Fresh air mode 16 IMPORTANT When running the air conditioner for a long time turn the lever to Fresh position o...

Page 132: ...to adjust flow 4 Operate mode switch 10 to change foot defroster mode Cool Head Warm Feet Operation Cool and warm air is simultaneously supplied to the head vents and feet vents respectively 1 Press blower switch 7 to adjust the blower speed 2 Press MODE switch 10 to display the front and rear vent mark on LCD 8 Turn A C ON by using air conditioner switch 12 Control air temperature inside the cab ...

Page 133: ...nsides of the windows become clouded during rainy weather or on humid days operate the air conditioner to aid in keeping the windows clear When the atmosphere is very damp and if the air conditioner has run excessively the outside of the windows may become clouded If this happens turn off the air conditioner to adjust the temperature in the cab Off Season Air Conditioner Maintenance To protect eac...

Page 134: ... with backrest when not in use 2 Turn adjustment knob 2 for desired lumbar support 3 Lift handle 3 and allow the back cushion to angle forward or lean backward into the cushion Release the handle at desired position 4 With the key turned ON push the knob 4 to increase the air pressure This will raise the seat and make a firmer ride Pull the knob 4 to reduce the air pressure air will be vented This...

Page 135: ...e IMPORTANT Never connect accessories that use power other than 12 V Damage to the batteries and accessories may result Do not supply power to accessories for a long time without running the engine The batteries may be discharged 1 Remove the cover 2 Insert the socket of the accessory to be used into the electric power output port 3 Turn the key switch 7 ON Power is supplied to the connected acces...

Page 136: ...a safety valve to prevent excess current from flowing in the electrical system The fuse capacity varies depending on its corresponding circuit Be sure to replace the blown fuses only with the specified ones When checking fuses check the fuse box A B and slow blow fuses 1 2 and 3 in this order Capacity of slow blow fuses 1 100A 2 2 65A 2 3 45A 1 MNEC 01 047 Fuse Box A Machine Front Fuse Box B 1 3 2...

Page 137: ...14 ROTARY BEACON 10 A 3 WIPER FRONT 15 A 13 SEAT HEATER 20 A 2 LIGHTER 10 A 12 OPTION 2 20 A 1 DC DC UNIT 10 A 11 Fuse Box B 10 HST 1 15 A 20 9 MC 10 A 19 HI BEAM 10 A 8 ECM 30 A 18 WIPER REAR 10 A 7 CONTROLLER 10 A 17 WORKING LAMP REAR 20 A 6 FLASHER 10 A 16 LOADER CONTROL 10 A 5 HORN 10 A 15 FUEL PUMP 10 A 4 OPTION 1 20 A 14 POWER ON 2 10 A 3 ROOM LAMP 5 A 13 POWER ON 1 10 A 2 LIGHTNG 5 A 12 AC3...

Page 138: ...ol box 1 so that food or a drink can be temporarily stored Use a container with a tight cap in the hot cool box Tray and Drink Holder IMPORTANT Tray 2 is not a waterproof type Be careful not to spill liquid on the tray Place a bottle with a plug or cap on drink holder 3 MNEC 01 048 1 MNEC 01 046 2 3 ...

Page 139: ...OPERATOR S STATION 1 81 ROPS Cab ROPS cab 1 is standard equipment 1 ROPS Cab 2 Speakers 3 Front Room Light 4 Sun Visor MNEC 01 052 4 M4GB 01 114 M4GB 01 113 2 3 1 MNSC 01 010 ...

Page 140: ...OPERATOR S STATION 1 82 5 Radio 6 Cab Switch Panel Optional 7 Room Rear View Mirror 8 Rear Room Light 9 Emergency Evacuation Hammer 10 Coat Hook 5 7 6 MNEC 01 534 MNEC 01 536 M4GB 01 117 8 9 10 ...

Page 141: ...e operation positions ON Light 2 comes and stays ON Neutral When the cab door is opened light 2 comes ON When closed light 2 goes OFF OFF Light 2 goes OFF Rear Room Light Switch 3 ON Rear room light 4 comes and stays ON Switch 3 OFF Rear room light goes OFF OFF ON M4GB 01 114 M4GB 01 117 M4GB 01 119 M4GB 01 120 2 2 3 3 1 1 ...

Page 142: ...p down to a desired hook preset Emergency Evacuation Hammer In case the cab door becomes difficult or impossible to open if an emergency situation occurs evacuate from the machine by breaking the windowpane using the provided hammer Coat Hook Use to hang your coat hat etc M4GB 01 117 4 MNEC 01 052 MNEC 01 536 ...

Page 143: ...MPORTANT Do not use for a long time with the engine stopped Doing so will drain the battery Once the mirror is defogged turn OFF the switch Press the upper part of the switch to turn ON the rear view mirror heater While operating the heater indicator 6 lights Press the lower part of the switch to turn OFF the heater and indicator 2 4 2 1 5 3 MNEC 01 534 ON OFF 6 MNEC 01 539 ...

Page 144: ...bility can be obtained Adjust the mirrors so that persons standing on left and right back end of the machine or object with height of 1 m and 30 cm in diameter can be recognized from the operator s seat Always keep the mirrors clean Room Rear View Mirror Always keep room rear view mirrors 2 clean Cab Door dCAUTION When closing the door securely close the door Before leaving the operator s seat sec...

Page 145: ...knob 5 pull lever 6 to disengage the door lock Window Open Close Levers When window open close levers 7 on both sides are simultaneously pressed from left and right sides toward center the window is unlocked allowing the windowpanes to move When window open close levers 7 are released stoppers are engaged in the nearest steps so that the window is locked in that position M4GB 01 128 M4GB 01 129 M4...

Page 146: ... may come off possibly causing falling accident Push the door toward the outside of the cab to fully open the door 180 Cab Door Release Lever dCAUTION When keeping the door open open the door until latch 10 on the cab securely locks the door When disengaging the door lock push door lock disengage levers 8 and 9 downward MNEC 01 055 10 M4GB 01 117 M4GB 01 132 M4GB 01 133 Left door lock disengage le...

Page 147: ... turning the battery disconnect switch OFF be sure to turn key switch OFF and wait 1 minute or more after the engine stops If the battery disconnect switch is turned OFF within 1 minute after the engine stops it may result in malfunction of the electrical system When turning the battery disconnect switch from OFF to ON preset radio station and the clock may be reset Set them again Use the battery ...

Page 148: ... operating the machine with battery disconnect switch 2 ON close the cover 2 When turning lever 1 90 counterclockwise the lever is lateral to the ground battery disconnect switch 2 turns OFF Lever 1 can be removed from battery disconnect switch 2 when it is in OFF position Take care for not missing lever 1 3 Store lever 1 removed from switch 2 on holder 3 2 1 3 1 1 ON ON OFF OFF MNSC 01 014 MNSC 0...

Page 149: ...ng the machine be sure to disengage the lock bar 1 from the front frame and fasten the lock bar to the rear frame with pin and β form lock pin 2 Articulation lock bar 1 locks the front and rear frames to prevent articulation between front frame 3 and rear frame 4 when servicing or transporting the machine 1 3 3 4 4 2 MNSC 01 017 MNSC 01 018 ...

Page 150: ...nt excessive wear of tires avoid towing operation requiring more than the available towing force Available towing force 71 kN 7200 kgf 15961 lbf Towing pin 4 is located on the rear end of the base machine It is used for towing other machine or fastening the machine on a trailer deck for transportation Tie or loop the towing rope and let it pass through the hole Secure it with the β shaped lock pin...

Page 151: ...unexpectedly close Take care not to pinch your fingers when opening closing side covers 1 As the side cover flips up by itself care should be taken not to contact with the cover when opening it Before checking around the engine be sure to lock the cover in position with locking rod 3 provided inside the side cover Never attempt to stand on fenders 2 if side covers 1 are provided with fenders 2 fNO...

Page 152: ... driving the machine always check that rear grille 2 is not open Rear grille 2 may spring open Take care not to come in contact with the rear grille Opening the rear grille Push open close Button 1 laterally to open rear grille 2 sideward allowing the fuel tank to be refilled and or the radiator and othe cooling system to be cleaned Closing the rear grille While holding the rear grille slowly clos...

Page 153: ...o battery cover 1 DEF AdBlue tank 2 and grease gun box 3 Fuel tank cap 4 side covers 5 rear grille 6 air conditioner fresh air filter 7 and expansion tank cap 8 can be locked with the keys 5 8 1 7 3 4 6 MNSC 01 026 MNSC 01 029 MNSC 01 027 MNEC 01 055 2 MNSC 01 028 MNSC 01 033 ...

Page 154: ...t belt every three years regardless of its appearance Seat Belt 1 Seat belt 1 on this machine is a recoiling type 2 Confirm that seat belt 1 is not twisted Securely insert the end of seat belt 1 into buckle 2 fNOTE When trying to insert seat belt 1 into buckle 2 in case the belt is suspended to extend and does not come out further fully retract the belt to the original position and try to extend a...

Page 155: ...iently perform break in operation Machine life and performance will be greatly affected by the extent of operation and maintenance of the machine during the initial operation Perform break in operation for the first 100 hours Check the machine before starting the engine After starting the engine sufficiently perform warm up operation Avoid sudden starting sudden acceleration and sudden braking whi...

Page 156: ...BREAK IN 2 2 MEMO ...

Page 157: ...o cracks and damage observed 3 No excessive wear observed 4 No metal pieces stones or other foreign material found 3 Wheel Disk Mounting condition of the wheel disk is correct 4 Lights and Turn Signals They light up or flash normally without contamination and damage 5 Outside Rear View Mirror and Inside Rear View Mirror Appropriate visibility obtained 6 The portions where abnormality was found at ...

Page 158: ...Washer fluid 9 Level leaks and contamination of the DEF AdBlue tank 10 DEF AdBlue leaks of pipe lines and hoses 11 Clean around the aftertreatment device 9 Loader 1 Oil leaks and damage to cylinders pipe lines and hoses 2 Looseness wear and missing of the cutting edge 3 Wear and damage of the bucket 4 Lubrication state of the loader front 5 Damage to the pin lock bolts stoppers and links 6 Loosene...

Page 159: ...tral N position and neutral lever lock 3 is in the LOCK position fNOTE Unless forward reverse lever 2 and forward reverse switch 6 are in neutral N the engine will not start 3 Push parking brake switch 1 and check that parking brake switch 1 is in the ON position After the engine starts and checking indicator bulbs refer to page 3 5 check that the parking brake indicator is ON 4 Check that control...

Page 160: ...ar view mirror 8 and room rear view mirror 9 so that the best rear visibility can be obtained 7 While seated on the operator s seat with your back in contact with the backrest adjust each function of the seat so that the brake pedal can be fully stepped on 8 Fasten seat belt 10 8 9 10 MNEC 01 045 M4GB 01 126 7 MNDB 01 005 ...

Page 161: ...ey go OFF afterward Any indicator and or warning light that fails to light at this time is a burned bulb However discharge warning indicator 5 will continue to stay ON and it will go OFF only after the engine is started Preheating will automatically start with the key switch ON Preheat indicator 6 will automatically come ON 5 Check that parking brake indicator 7 is ON When preheat indicator 6 goes...

Page 162: ...n as the engine starts release the key switch The key switch will automatically return to the ON position After the engine starts perform idling operation without depressing accelerator pedal 3 to warm up the machine dWARNING After starting the engine start the machine operation only after confirming that the engine speed changes by operating accelerator pedal 3 Otherwise the machine or the front ...

Page 163: ...ically return to the ON position Do not depress accelerator pedal 3 when starting the engine After the engine starts perform idling operation without depressing accelerator pedal 3 to warm up the machine After starting the engine perform warm up operation as described on page 3 11 dWARNING After starting the engine start the machine operation only after confirming that the engine speed changes by ...

Page 164: ...tem and the oil level 3 Check that engine coolant temperature gauge 3 is within the range 4 fNOTE When the key switch is turned ON the indicators and warning lights light up and the buzzer sounds for about 2 seconds as a check for whether any lamp s or buzzer are burnt out Check engine noise and exhaust gas color Check that the engine noise and exhaust gas color is normal fNOTE Check the exhaust g...

Page 165: ...r than specified Explosion of the battery may result Park the machine and a machine with the booster batteries on a dry or concrete surface not on steel plates If the machine is parked on steel plates the machine is equivalent to a continuously grounded machine so that dangerous unexpected current flow may result Never connect a positive terminal to a negative terminal as a dangerous short circuit...

Page 166: ... batteries as far away as possible from the bracket 1 4 After securely connecting the booster cables start the engine on the booster battery mounted machine 1 5 Start the engine on the machine 1 6 After the engine starts disconnect booster cables 1 and 2 in the following steps 2 Disconnecting the booster cables 2 1 Disconnect black negative cable 2 from grounding bolt 3 first 2 2 Disconnect the ot...

Page 167: ...rform warm up operation not only to protect the hydraulic components from being damaged but also to ensure safe operation If the machine is operated excessively with the hydraulic oil temperature below 20 C 68 F damage to the hydraulic components may result After starting the engine sufficiently perform warm up operation as described below before operating the machine until the hydraulic temperatu...

Page 168: ...sure to perform warm up not only to protect the hydraulic components from being damaged but also to ensure safe operation fNOTE Illumination such as headlight work light or room light may become dim during the engine preheat operation at cold temperature 1 Run the engine at slow idle speed for more than 5 minutes The engine speed automatically increases from slow idle to 1000 min 1 rpm and enters ...

Page 169: ... fNOTE Do not continuously operate the control lever for more than 10 seconds at this time 5 Slowly retract the bucket cylinder to stroke end fNOTE Do not continuously operate the control lever for more than 10 seconds at this time 6 Repeat steps 4 to 5 above until the loader front operating speed becomes normal When the atmospheric temperature is lower than 0 C 32 F extend the warming up operatio...

Page 170: ...harger possibly causing damage to the turbocharger 2 Run the engine at slow idle speed for 5 minutes to cool the engine 3 Press LOCK side of control lever lock switch 2 4 Turn the key switch 1 to OFF position to stop the engine fNOTE The machine employs an automatic tensioner which adjusts the fan belt tension automatically When the engine is stopped the automatic tensioner may make a belt slip so...

Page 171: ...fter raising the lift arm set the machine to the driving position fully tilt the bucket backward 3 Before driving on public roads set the machine to the driving position as illustrated to the right Be sure to press LOCK side of control lever lock switch 1 so that the linkage will not move even if the control levers are accidentally moved 4 After starting the engine be sure to run the engine at slo...

Page 172: ...nfirm the safety around the bucket Avoid turning ride control switch 3 optional to ON position while traveling the machine Failure to do so may automatically move the lift arm up or down Refer to page 1 64 for detailed information of ride control switch 3 1 Check that none of the warning indicators except parking brake indicator 1 on the monitor panel is ON 2 Set the front attachment in the drivin...

Page 173: ...reverse lever 10 to either forward F or reverse R position move the shift switch 11 to the desired position The transmission gear position can be shifted in 2 ranges in the forward and 2 ranges in the reverse mode Select the most appropriate transmission gear position according to the type of the work engaged in or the driving road conditions 6 Release brake pedals 6 and step on accelerator pedal ...

Page 174: ...the parking brake after parking the machine on level ground fNOTE While running the engine when the parking brake is applied with forward reverse lever 3 in neutral parking brake indicator 2 comes ON 2 While running the engine when the parking brake is applied with forward reverse lever 3 in either the forward F or reverse R position parking brake indicator 2 comes ON and the alarm buzzer sounds F...

Page 175: ... or less Changing Forward Reverse Drive Direction dWARNING Before changing the drive direction confirm that the drive direction is clear To ensure operator s safety and ensure the longevity of the power train system change the machine drive direction only after sufficiently reducing the drive speed Be sure to change the machine drive direction only when the machine travel speed is 13 km h or slowe...

Page 176: ...as it is extremely dangerous and may cause the machine to turnover IMPORTANT When steering wheel 1 is fully turned the front and the rear frames come in contact with the stoppers so that steering wheel 1 does not rotate further If steering wheel 1 is forcibly turned further the engine may stall or malfunction of the steering system may result Turn steering wheel 1 toward the direction you intend t...

Page 177: ...e to return the forward reverse lever to neutral N turn the parking brake switch ON and apply the parking brake to ensure safety operation 4 During drive operation the machine drive position may be changed due to inner hydraulic oil leaks When required to rectify the drive position stop driving return the forward reverse lever to neutral apply the parking brake by turning the parking brake switch ...

Page 178: ...s complete avoid running the engine at fast speed under no load If any abnormal condition such as an abnormal noise or smell is notified while driving immediately stop the engine and inspect the machine for any trouble Avoid using sudden steering or braking as much as possible because not only own machine but also other machines may become involved in a hazardous condition Driving speeds of this m...

Page 179: ...er shafts in water or mud Avoid driving in water as much as possible If driving in water or mud is unavoidable do not allow the machine to be submerged deeper than allowable depth A up to the bottom of the axle housing Reduce the allowable depth in case the river bed is feared to be rugged or water is flowing fast When driving operating on muddy ground mud can easily accumulate on the frame even i...

Page 180: ...er on a steep slope Failure to do so may possibly cause the machine to turn over When descending a slope travel the machine in the slow drive gear range using sufficient engine braking Do not drive the machine at a speed faster than the maximum travel speed In case the engine stalls on a slope immediately step on the brake pedal as strongly as possible lower the loader front to the ground and stop...

Page 181: ...machine travels faster than the speed set at each speed gear range service indicator 1 and the HST warning indicator 2 flash the buzzer sounds When the indicator flashes and the buzzer sounds release the accelerator pedal in order to reduce the speed Speed Control Function This controls the speed in order to prevent from overrunning faster than the warning setting speed Travel Speed Warning Settin...

Page 182: ...rgency signal light Use a red flag or light Tie a piece of cloth like a handkerchief to an easy to see place such as the door or the rear end of the machine Check the failed part If possible repair the machine by yourself while ensuring safety and paying attention to the traffic conditions of other vehicles dWARNING Do not spill oil on the road surface Failure to do so may cause the following vehi...

Page 183: ...ket with the surface of the ground and lower the bucket to the ground by operating control lever 6 5 Press LOCK side of control lever lock switch 8 IMPORTANT This machine is equipped with a turbocharged engine Therefore if the engine is stopped without performing cooling down operation the lubricant on the turbocharger bearing surfaces may desiccate due to the intense heat present possibly causing...

Page 184: ...the batteries Be sure to turn key switch to OFF position before leaving the machine 7 Turn key switch 9 to OFF position to stop the engine Remove the key from the switch Place neutral lever lock 4 to the LOCK position 8 Before leaving the machine close and lock all the windows cab doors and covers 9 4 9 MNDB 01 001 MNDB 01 053 ...

Page 185: ...h 1 ON IMPORTANT This machine is equipped with a turbocharged engine Therefore if the engine is stopped without performing cooling down operation the lubricant on the turbocharger bearing surfaces may desiccate due to the intense heat present possibly causing damage to the turbocharger 4 Run the engine at low idle speed to cool the engine for 5 minutes 5 Press LOCK side of control lever lock switc...

Page 186: ...ake pedal The brake oil pressure is quickly reduced so that the brake becomes inoperable If the machine does not stop even if the brake pedal is stepped on press the parking brake switch ON side to stop the machine The steering wheel will become hard to rotate as the hydraulic system becomes inoperable In the event any symptom mentioned above occurs immediately trace the cause of the problem In ca...

Page 187: ...Raise F Detent The lift arm is held in the raise position G Detent When the multi function joystick lever is moved from the bucket dump position to the bucket tilt position the multi function joystick lever is maintained in this position D Bucket Tilt The bucket is tilted back taking the transportation position N Hold The bucket is stopped and held in that position E Bucket Dump The bucket is tilt...

Page 188: ...before transporting the machine or leaving the machine at the end of the shift Control lever lock switch 1 is provided to prevent the machine unexpectedly operated even if the operator mistakenly comes in contact with the bucket and or lift arm control lever when getting on or off the machine When control lever lock switch 1 is placed in UNLOCK position the control lever becomes operable Control L...

Page 189: ...o do so may allow the front attachment to unexpectedly move up or down when the ride control system is activated When operating the machine with the ride control ON reduce the machine speed Ride control accumulator will carry high pressure if sudden impact load is applied on the working equipment causing gas leakage The ride control damps the vertical vibration of the front attachment during drive...

Page 190: ...perable When ride control switch 1 is turned to AUTO mode ride control indicator 2 on the monitor display comes ON OFF When ride control switch 1 is turned OFF ride control indicator 2 on the monitor display goes OFF and the ride control system becomes inoperable When the key switch is in the OFF position the ride control system does not operate even if ride control switch 1 is in AUTO position Wh...

Page 191: ... away from the vicinity of the machine The lift arm kick out system automatically stops the lift arm at the preset height when raising the lift arm When shipping the machine from the factory the kick out system is adjusted so that the lift arm is stopped at a slightly lower position than the maximum height Adjust the lift arm stop position by moving the position of proximity switch 1 When adjustme...

Page 192: ...sitioner is preset so that the bucket is stopped with the bucket bottom parallel with the road surface For example after discharging material into a truck or a hopper when control lever 4 is placed to detent position G the lever is held in that position Then when the bucket is returned to the preset angle position the bucket is automatically stopped and the lever is returned to hold N The bucket a...

Page 193: ...utting edge 1 After moving the bucket to the desired digging angle stop the engine 2 Loosen bolts 1 of the proximity switch mounting bracket Slide the end edge of leveler bar 2 up to the center of the sensitive area orange color Then tighten bolts 1 3 After adjustment start the engine Check that the bucket can be stopped at the preset angle position M4FC 05 001 1 2 ...

Page 194: ...ng any operations Use the machine equipped with FOPS and ROPS if the machine is to be operated in the areas where the possibility of falling stones exists If operation on soft ground is required operate the machine only after reinforcing the ground Be sure to wear close fitting clothing and safety equipment appropriate for the job such as a hard hat etc when operating the machine Clear all persons...

Page 195: ...ne side Damage to the machine may result Avoid Rapid Steering Changes and or Sudden Braking dWARNING Always maintain a flat work site surface Avoid rapid steering changes and sudden braking while raising the lift arm with the bucket loaded to prevent the machine from turning over Avoid Operation with Biased Loads dWARNING Avoid abusive machine operation by allowing the bucket to receive biased loa...

Page 196: ...of the ground Penetrate the bucket into the accumulated soil while driving the machine forward 2 After the bucket has sufficiently penetrated the soil raise the lift arm while driving the machine forward further and occasionally tilt the bucket back to fill the bucket Sometimes set the bucket in the tilt position to fill up material in the bucket 3 If it is difficult to penetrate the soil with the...

Page 197: ...downward 0 to 10 degrees and dig the ground while driving the machine forward as described below Always take care not to apply loads to only to one side of the bucket 1 Position the bucket teeth slightly downward 2 While driving the machine forward tilt the bucket so that the ground surface is gradually separated 3 Adjust the digging depth by operating the lift arm 4 Drive the machine with the buc...

Page 198: ...driving the machine forward severe loads are applied to the front attachment possibly causing cracks or damage to the front attachment 1 After filling soil into the bucket dump the bucket gradually to disperse soil while driving the machine in reverse 2 Lower the bucket teeth tips onto the ground Grade and level the ground surface while driving the machine in reverse with the bucket teeth tips dra...

Page 199: ...bucket at the lowest possible height Refrain from allowing the bucket to come in contact with the bucket stopper as much as possible when removing adhered material like clay from the bucket Failure to do so may result in damage to the front attachment Remove material stuck to the bucket by washing with water Loading is dumping the handling material onto a truck or into a hopper Loading work is per...

Page 200: ...t arm raised to a high enough position never operate steering wheel Slowly drive the machine Never rapidly operate the machine to prevent turning over accident A wheel loader performs work process of loading carrying and dumping in sequence Generally when the carrying distance is 30 to 100 m this method is employed Make an upgrade slope of approx 3 around a hopper when dumping into the hopper Be s...

Page 201: ...und the center of the dump body In case the dump body is longer than twice the bucket width load from the front to rear position of the dump body in order 3 When dumping sticky material such as clay move the bucket lever back and forth to lightly hit the bucket to the stoppers Take a steering angle as small as possible to operate the machine efficiently 4 Before raising the lift arm to the maximum...

Page 202: ...tachment Dozing stands for a working method performed by a wheel loader using the wheel loader bucket in place of a bulldozer blade This operation method is employed when reclaiming land or dumping material into a hopper Set the bucket bottom parallel with the ground surface and drive the wheel loader forward Scooping dWARNING Do not allow the machine to engage in piling up material on a soft grou...

Page 203: ...hine Use tire chains on all four wheels Pay attention to the presence of the utility facilities such as fire hydrants manholes curbs roadside drains etc The facilities or the machine may be damaged Lifting Wheel Loader dWARNING Be sure to use lifting tools and set the articulation lock bar in the LOCK position Never allow any person to ride on the machine to be lifted Never allow any person to ent...

Page 204: ...er operation and then coat rust preventive oil to protect the machine from rusting If the machine continues to be used with rust developing oil leaks may occur IMPORTANT If hard rain is expected or the machine is to be stored wrap the muffler with a tarpaulin to prevent water from entering the muffler 3 Clean the machine 4 If anti freeze or long life coolant is not used in cold weather be sure to ...

Page 205: ...ork lights and turn signal lights are waterproof 5 1 Clean and dry the machine thoroughly Clean each cylinder rod plated areas and the radiator with extra care 5 2 After positioning the machine for storage carefully coat each cylinder rod plated areas and the control valve spools with rust preventive oil 5 3 Lubricate all pins while referring to A Greasing Section in the Maintenance Guide List dCA...

Page 206: ...OPERATING MACHINE 5 20 MEMO ...

Page 207: ... as dimensional limits weight limits and traffic regulations In some cases getting approval from the authority concerned disassembling the machine to bring it within dimensional limits or weight limits of local regulations may become necessary Transporting by Trailer Provide an appropriate trailer while referring to the weight and dimensions shown in the specifications When transporting the machin...

Page 208: ...d flatbed Dirty ramps loading docks and flatbeds with oil mud or ice on them are slippery and dangerous 2 Place blocks 1 against the truck and trailer wheels while using a ramp or loading dock 3 Ramps must be sufficient in width length and strength Be sure that the incline of the ramp is less than 15 4 Loading docks must be sufficient in width and strength to support the machine and have an inclin...

Page 209: ... Loading 1 Load the machine so that the centerline of the machine aligns with the centerline of the trailer flatbed 2 Slowly drive the machine on the ramp 3 Lower the bucket onto the trailer deck 4 Stop the engine 5 Operate the control lever several strokes to relieve pressure in the cylinders 6 Press LOCK side of the control lever lock switch 7 Remove the key from the key switch 8 Securely close ...

Page 210: ... the parking brake Slowly rest the bucket on the trailer deck or load carrying platform 2 Wedge wooden blocks 1 front and rear each tire to fasten the machine in position 3 Securely fasten the base machine and the front attachment to the load carrying platform with sufficient wire ropes The machines for export are provided with lifting holes Optional Use these holes for securing the machine 1 MNEC...

Page 211: ...the wheel loader by self traveling Observe the rules and regulations associated to this wheel loader and travel carefully Recommended tire pressures and traveling speeds may vary depending on the type of tires used and the road conditions Consult your nearest authorized dealer Check the tire pressure before self traveling when the tires are cool After driving the wheel loader for one hour allow th...

Page 212: ...o that the steering and brake system are operable Release the parking brake If the engine is inoperable Removing the propeller shaft When the parking brake cannot be released manually release the parking brake Refer to the Releasing Parking Brake on page 6 7 Then disconnect the front and rear propeller shafts At this time wedge wheel stoppers to all tires to prevent the machine from moving The ste...

Page 213: ...rake system be sure to lock tires with wheel stoppers dCAUTION As soon as towing operation is complete connect the parking brake Use towing only when moving the machine to a place where the machine is inspected and or serviced Avoid towing to move the machine over a long distance Releasing the parking brake is made manually only when the parking brake switch becomes inoperable due to any abnormali...

Page 214: ... before starting operation IMPORTANT Before starting the operation clean plugs and bolts 1 Remove two easily accessible diagonally located two bolts out of four bolts 2 from parking brake cover 1 2 Remove release bolts 3 2 places upper and lower 3 Insert release bolts 3 without washer to the plug holes of bolts 2 removed at procedure 1 Insert them deep into the inner screw holes and tighten bolts ...

Page 215: ... the front axle and wire ropes to prevent damage to wire ropes Towing from the rear side of the machine When using wire ropes be sure to attach wire ropes to the drawbar pin Always use the lock pin after completely inserting the drawbar pin to prevent the wire rope from coming off Attach wire ropes to the machine as illustrated when the machine must be unavoidably towed such cases when the machine...

Page 216: ...the control lever lock switch to the LOCK position to prevent the machine from moving unexpectedly Rigidly secure the front and rear frames using the articulation lock bar so that the machine front and rear frames are not articulated Incorrect lifting procedure and or incorrect wire ropes attachment will cause the machine to move shift while being lifted resulting in machine damage and or personal...

Page 217: ... doors and covers and lock them 6 Please use wire rope and a support bar that is long enough so they do not come in contact with the machine body when the machine is lifted Refer to the section Length and Load of Wire Rope Support bar for more detailed information Wrap a protective cover around the wire ropes as required to prevent the machine from being damaged Be sure to use the specified liftin...

Page 218: ...TRANSPORTING 6 12 MEMO ...

Page 219: ...y result in serious injury or death and or machine breakdown Failure to use recommended fuel lubricants and genuine Hitachi parts will result in loss of Hitachi product warranty Never adjust engine governor or hydraulic system relief valve Protect electrical parts from water and steam Never spray high pressure water or steam to the transmission oil filler port and vicinity of the axle air breather...

Page 220: ...vice Communication Terminal Operation It is not necessary to check or operate the communication terminal however if any abnormality is found consult your nearest authorized dealer Before installing any covering attachment such as a head guard consult your nearest authorized dealer Never spray water on the communication terminal and the wirings Inquire on the proper way to recycle or dispose of oil...

Page 221: ...5 This manual recommends grouping the intervals into three categories as follows Daily Check To be conducted daily before operation Monthly Check To be regularly conducted once per month Annual Check To be regularly conducted once per year Check and maintenance intervals shown in this manual are those for the machines to be operated under normal conditions In case the machine is operated under mor...

Page 222: ... 16 Radiator Oil Cooler and Other Cooling System 17 Batteries 18 Fuel Tank 19 Rear Combination Lamp 20 Engine 21 DEF AdBlue Tank 22 Rear Axle 23 Rear Propeller Shaft 24 Brake Oil Tank 25 Transmission 26 HST Motor 27 Center Propeller Shaft 28 Steering Cylinder 29 Front Propeller Shaft 30 Front Axle 31 Front Combination Lamp 32 Lift Arm Cylinder 33 Bucket Pin 34 Bucket Link Pin 35 Bolt on Cutting Ed...

Page 223: ...he following marks are used in the maintenance guide table Grease Front Joint Pin Cylinder Pin Propeller Shaft Hydraulic Oil Engine Oil Hydraulic Oil Filters Pilot Filter HST Charge Filter Hydraulic Oil Tank Filter Suction Filter Air Breather Element Engine Oil Filter Axle Gear Oil Final Drive Differential Gear Coolant Fuel Transmission Oil Transmission Fuel Filter Fuel Main Filter Pre Filter Tran...

Page 224: ...er Pin 7 22 5 Hydraulic Oil Filter Hydraulic Tank 7 44 16 Grease Propeller Shaft Center Support 7 24 6 Hydraulic Oil 7 42 17 Grease Propeller Shaft Universal 7 25 7 Coolant 7 69 18 Grease Brake Pedal 7 26 8 Fuel Main Filter Fuel Pre Filter 7 61 19 HST Charge Filter 7 46 9 Fuel Oil Diesel Fuel 7 56 20 DEF AdBlue 7 120 10 Engine Oil 7 28 21 DEF AdBlue Supply Module Main Filter 7 122 11 Grease Axle S...

Page 225: ...nd or maintenance work 1 Park the machine on a solid level surface 2 Lower the working tools such as the bucket to the ground 3 Turn ride control switch 3 OFF 4 Place forward reverse lever 4 to neutral and place neutral lever lock 6 to lock position 5 Apply the parking brake Turn parking brake 5 ON 6 Wedge the tires 7 Run the engine at low idle speed for 5 minutes to cool the engine Turn key switc...

Page 226: ...operator s seat to be ready to stop the engine any time while communicating with other workers When working around moving parts is unavoidable pay special attention to ensure that hands feet and clothing do not become entangled If parts or tools are dropped or inserted into the fan or the belt they may fly off or be cut off Do not drop or insert parts and tools into the moving parts Move control l...

Page 227: ...it movement between the front 4 and rear frames 3 Avoid accidents due to unexpected movement of the machine 1 Align the front 4 and rear frame 3 centers with each other 2 Remove β form pin 2 Rotate articulation lock bar 1 and install it to front frame 4 3 Install β form pin 2 to lock the articulation lock bar 1 in position 3 2 1 2 1 4 MNSC 01 017 MNSC 01 018 ...

Page 228: ...d the cover may move suddenly Be careful not to come in contact with the cover Before inspecting around the engine be sure to secure side cover 1 with holding rod 4 In case the machine is equipped with the fenders 2 on side covers 1 never ride on the fenders 2 When opening side cover 1 pull latch 3 fNOTE When required to inspect the machine for a long time with side cover 1 kept open lock side cov...

Page 229: ... that rear grille 2 will not open Push rear grille 2 open close button 1 to open rear grille 2 to side so that refilling the fuel tank or cleaning of the cooling fan can be conducted When closing rear grille 2 while supporting the rear grille slowly turn and push in the rear grille until a click sound is heard 1 2 2 MNSC 01 023 MNSC 01 024 ...

Page 230: ...k DEF AdBlue Level 7 117 Check Fuel Hoses 7 63 Change Engine Oil 7 28 Replace Engine Oil Filter 7 30 Clean Radiator Oil Cooler and Other Cooling System 3 7 70 Drain Water and Sediment from Fuel Tank 7 58 Replace Fuel Main Filter Element 7 61 Check Engine Cylinder Head Bolts 5 7 101 Check Engine Compression Pressure 5 7 101 Check and Clean Starter and Alternator 7 101 Replace DEF AdBlue Supply Modu...

Page 231: ... Greasing Center Propeller Shaft Spline 3 7 25 Change Axle Oil 7 36 Retighten Front Axle and Rear Axle Support Mounting Bolts 7 101 Greasing Front Propeller Shaft 3 7 24 Greasing Center Propeller Shaft 3 7 25 Greasing Rear Propeller Shaft 3 7 25 Steering system Check Play Amount in Steering Wheel Stroke 7 97 Greasing Steering Cylinder 1 2 7 22 7 23 fNOTE 1 Add grease daily during first 50 hours of...

Page 232: ...Tank Oil Filter 7 44 Replace Air Breather Element 7 48 Check Pilot Circuit Accumulator Function Gas Leakage Looseness and Damage 7 49 Check Gas pressure in Ride Control Accumulator Optional 7 50 Change Hydraulic Oil and Clean Suction Filter 4 7 42 Replace Pilot Circuit Accumulator Every 4000 hours or once every two years whichever comes first 7 50 fNOTE 1 Add grease daily during first 50 hours of ...

Page 233: ...nesses and Fuses 7 77 Check Battery Electrolyte Level 7 73 Check Electrolyte Specific Gravity 7 74 Air Conditioner Clean Replace Air Conditioner Circulation Fresh Air Filters and Double Filters if equipped 3 7 88 7 90 Check Air Conditioner Fan Belt Every 250 hours or three months 7 93 Check Refrigerant Every 250 hours or three months 7 94 Check Air Conditioner Condenser Every 250 hours or three mo...

Page 234: ...LGI EP 2 Alternative Products Specification NLGI 2 EP IMPORTANT Hitachi Genuine Greases are specially designed and tested to provide optimum performance for Hitachi construction machinery hence we recommend to use Hitachi Genuine Greases Do not use greases which do not meet the above specification or requirements Use of unsuitable grease may lead to damage which is excluded from Hitachi Warranty P...

Page 235: ...achinery hence we recommend to use Hitachi Genuine Engine Oils Do not use oils which do not meet the above specification or requirements Use of unsuitable oil may lead to engine damage which is excluded from Hitachi Warranty Policy Brand Names of Recommended Transmission Oil Kind of Oil Transmission Oil Application Manufacturer INPO Transmission 25 to 45 C 4 to 113 F Hitachi Transmission Oil 10W I...

Page 236: ...ng to JCMAS HK VG46W Change Interval 2000 hours 1500 hours fNOTE A different interval of oil change may be required for Alternative Products For details contact your authorized dealer IMPORTANT Hitachi Genuine Hydraulic Oils are specially designed and tested to provide optimum performance for the machine hence we recommend to use Hitachi Genuine Hydraulic Oils Do not use oils which do not meet the...

Page 237: ...er 4305118 Hydraulic Tank Oil Filter 4129280 Transmission Oil Filter 4630525 Hydraulic Tank Air Breather Element 4437838 HST Charge Filter 4630525 DEF AdBlue Supply Module Main Filter YA00051592 2 Drive Belts Part No Air Conditioner Drive Belt YA00025584 3 Bucket Parts Part No Quantity Cutting Edge Center 2641882061 1 Right and Left side 2641882071 2 Bolt 5643051061 7 Nut 5660054751 7 O Ring Bucke...

Page 238: ...d Light YA00020460 24V 75 70W Clearance Light 263G247101 24V 75 70W Turn Signal Light 263G247091 24V 75 70W Rear Combination Light Rear Combination Light Assembly Right LED YA00044902 Rear Combination Light Assembly Left LED YA00044902 Bulb Turn Signal Light 4661236 24V 21W Work Light Work Light Assembly 4326800 5 Slow Blow Fuses Part No 45A 4315323 65A 263G244421 263F242231 100A 2681242871 ...

Page 239: ...contamination around the grease fitting add grease After greasing thoroughly remove the old grease that was pushed out from the seals 1 One point each to right and left bucket pins 1 every 500 hours 250 hours at first time only 2 One point each to bucket link pins 2 and 3 every 500 hours 250 hours at first time only 3 One point to bucket cylinder rod pin 4 every 500 hours 250 hours at first time o...

Page 240: ... cylinder pins 8 every 500 hours 250 hours at first time only 6 One point each to right and left lift arm pivot pins 9 every 500 hours 250 hours at first time only 7 One point each to front right and left steering cylinder pins 10 and 11 every 500 hours 250 hours at first time only 10 Cylinder right front 11 Cylinder left front 9 8 7 10 11 MNSC 07 001 MNSC 07 002 ...

Page 241: ...and left steering cylinder rod pins 12 and 13 every 500 hours 250 hours at first time only Left rear 12 Right rear 13 9 One point each to upper and lower frame center hinge pins 14 and 15 every 100 hours Upper 14 Lower 15 14 15 12 13 MNSC 07 003 ...

Page 242: ...t 16 Rear 17 11 One point to front propeller shaft universal 18 every 2000 hours fNOTE When the machine is continuously operated under severe conditions for a long time shorten the greasing intervals 12 One point to propeller shaft center support 19 every 1000 hours 18 19 M4FJ 07 026 16 17 MNSC 07 004 ...

Page 243: ...20 every 2000 hours One point to center propeller shaft universal rear 22 every 2000 hours 14 One point to center propeller shaft splines 21 every 2000 hours 15 Two points to rear propeller shaft universal 23 every 2000 hours 20 21 22 23 M4FJ 07 028 M4FJ 07 003 M4FJ 07 004 ...

Page 244: ...MAINTENANCE 7 26 24 16 Two points to brake pedal 24 every 1000 hours 17 One point to brake pedal linkage 25 every 1000 hours 25 M4FC 07 014 M4FC 07 015 ...

Page 245: ...ge 1 If the oil level is below the lower limit mark add the recommended engine oil via oil filler 2 If the oil level exceeds the upper limit mark remove drain plug 3 and then drain oil Recheck the oil level Specified Range fNOTE Level the engine when adding oil or inspecting oil level When required to check the oil level after operating the machine first stop the engine Wait for more than 15 minut...

Page 246: ...at the same time 1 Park the machine following the same procedures as described on page 7 7 for preparation of inspection maintenance work 2 Clean the areas around the drain plug and the oil filter 3 Arrange a 20 liter 5 3 US gal capacity container to receive the drain oil 4 Remove drain plug 2 provided on the fuel tank side to allow oil to drain 5 Drain oil from oil filter cartridge 1 6 Allow oil ...

Page 247: ...er oil filler cap 4 12 Check that the oil level is between the maximum and minimum level scales on oil level gauge 5 Then start the engine 13 After starting the engine check the sealing surfaces for any oil leakage 14 Keep the engine running at low idle speed for 5 minutes and stop the engine About 15 minutes later recheck the oil level If necessary add oil 3 4 MNSC 07 008 5 MNSC 07 009 ...

Page 248: ...low foreign matter such as dirt to enter the oil filter Be careful not to damage the filter body when removing or installing the filter Never reuse a cartridge type element 1 4 Remove cartridge type element 1 by turning it counterclockwise with a filter wrench 5 After coating a new cartridge gasket with engine oil turn the cartridge clockwise until the gasket comes in contact with the sealing surf...

Page 249: ...s of Recommended Transmission Oil Check the oil level before starting the engine Pull out oil level gauge 1 Check for mixing of foreign matter or contamination in the oil Wipe oil level gauge 1 with cloth re insert it into the pipe to the end and then pull it out again The oil level should be between the upper and lower marks on oil level gauge 1 If the oil level is below the lower limit mark add ...

Page 250: ... those listed in the Brand Names of Recommended Transmission Oil 1 Operate the machine until the transmission oil is heated to the appropriate temperature 2 Park the machine following the same procedures as described on page 7 7 for preparation of inspection maintenance work 3 Install articulation lock bar 4 to the front and rear of the frame by following the procedures described on page 7 9 IMPOR...

Page 251: ... 6 4 used from suction tube 8 9 Remove strainer 7 and clean it If straner 7 is damaged replace with a new one Replace the gasket and the O ring with new ones 10 Install strainer 7 O ring and gasket Tighten bolts 6 4 used 11 Refill the specified amount of oil through transmission oil filler port 10 Transmission oil 8 L 2 1 US gal 12 Start the engine and keep it running for two minutes 13 Check that...

Page 252: ...on of inspection maintenance work 2 Install articulation lock bar 4 to the front and rear of the frame by following the procedures described on page 7 9 3 Remove the inspection cover for left side step IMPORTANT Do not allow foreign matter such as dirt to enter cartridge type element 5 When installing or removing cartridge type element 5 be careful not to damage cartridge type element 5 Do not reu...

Page 253: ...n contact with the seal surface on filter head 6 further tighten the element by 3 4 turns Take care not to damage cartridge type element 5 as it may become deformed if overly tightened fNOTE When installing the element take care not to allow O ring 7 to break due to twisting Check for oil leaks around the mounting surface of cartridge type element 5 Replace the element at the regular intervals The...

Page 254: ...lock bar to the front and rear of the frame by following the procedures described on page 7 9 3 Clean the areas around drain plug 1 and oil level plug 2 4 Arrange a container of 30 liters 7 9 US gal capacity to receive the drain oil 5 Remove oil level plug 2 6 Remove drain plug 1 to drain the oil 7 Securely tighten drain plug 1 8 Refill the specified amount of oil through oil level plug 2 hole unt...

Page 255: ...ont and rear of the frame by following the procedures described on page 7 9 3 Clean the vicinity of oil level plug 2 4 Remove oil level plug 2 Clean the tip of dipstick 3 connected to oil level plug 2 with a clean cloth 5 Make the plug lower surface contact to the axle seat face Oil level must be between marks H and L 4 on the dipstick 3 Refill as necessary 2 3 4 Proper M4GB 07 039 M4FJ 07 032 ...

Page 256: ... dCAUTION Be sure to wear safety glasses when cleaning air breather 1 with compressed air 1 Clean the vicinity around air breather 1 before removing air breather 1 2 Put a cover on the air breather port to prevent foreign matter from entering 3 Clean air breather 1 using compressed air If completely contaminated wash air breather 1 with a cleaning solvent and reinstall it 4 Take care not to allow ...

Page 257: ...ts only after components hydraulic oil and lubricants are completely cooled and after releasing residual pressure 2 1 Release internal pressure 2 2 Be sure to relieve the air pressure from the hydraulic oil tank by pressing air bleed valve 1 2 3 Allow the machine to cool down Note that servicing heated and pressurized hydraulic components may cause hot parts and or oil to fly off or escape suddenl...

Page 258: ...nnecting them The life of twisted hoses will be shortened considerably Carefully tighten low pressure hose clamps Do not overtighten them 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 name...

Page 259: ... drain oil down to the appropriate level using a pump 1 Park the machine following the same procedures as described on page 7 7 for preparation of inspection maintenance work 2 Check oil level with level gauge 1 on hydraulic oil tank The oil must be between the marks on the gauge If necessary add oil fNOTE During the cold weather season check the oil level after warming up the hydraulic oil by ref...

Page 260: ...ntenance work 2 Install articulation lock bar 1 to the front and rear of the frame by following the procedures described on page 7 9 3 Before changing the hydraulic oil be sure to relieve the air pressure from the hydraulic oil tank by pressing air bleed valve 3 IMPORTANT When changing hydraulic oil take care not to permit foreign matter such as dirt water and or sand to enter into the hydraulic o...

Page 261: ...or lower the lift arm and tilt the bucket forward and backward Stop the engine Check for any oil leakage Check the oil level using level gauge 8 Bleed Air from the Hydraulic System After changing hydraulic oil or replacing the return filter pilot filter and or suction filter bleed air from the hydraulic system following the procedures below Bleed Air from the Hydraulic Circuit 1 After supplying oi...

Page 262: ...to the front and rear of the frame by following the procedures described on page 7 9 3 Press air bleed valve 1 and relieve the air pressure from the hydraulic oil tank 4 Clean the vicinity around cover 2 5 Arrange a container and workshop towels to receive the spilled oil and the element 5 6 Loosen bolts 3 5 used to remove cover 2 and O ring When removing cover 2 slowly remove the cover while pres...

Page 263: ...efer to the descriptions for Bleed air from the hydraulic system in item If the machine is operated without bleeding the air mixed in the hydraulic circuit damage to the hydraulic pump may result fNOTE Replace the element at the regular intervals to maintain clean hydraulic oil and extend the service life of the hydraulic components ...

Page 264: ... to the front and rear of the frame by following the procedures described on page 7 9 3 Before replacing the filter element be sure to relieve the air pressure from the hydraulic oil tank by pressing air bleed valve 1 4 Remove the cover of left side step IMPORTANT Do not allow foreign matter such as dirt to enter cartridge type element 4 When installing or removing cartridge type element 4 be care...

Page 265: ...rmed if overly tightened fNOTE When installing the element take care not to allow O ring 6 to break due to twisting Check for oil leaks around the mounting surface of cartridge type element 4 8 After replacing the filter element bleed air from the hydraulic system and check the oil level in the hydraulic oil tank Refer to the descriptions for Bleed Air from the Hydraulic System in item If the mach...

Page 266: ...ve 1 3 Rotate cover 3 clockwise approx 1 4 turns Remove cap 2 by rotating it counterclockwise 4 Rotate cover 3 counterclockwise and remove it Remove element 4 5 Install new element 4 Tighten cover 3 clockwise After cover 3 come in contact with the inside element tighten the cover by 1 4 turn further 6 Manually tighten cap 2 clockwise to the end Hold cap 2 in position by hand to prevent the cap fro...

Page 267: ...ibed on page 7 7 for preparation of inspection maintenance work 2 Raise the lift arm at the maximum height and then set the lift arm control lever in the Neutral N position 3 Turn the key switch OFF to stop the engine 4 Turn the key switch ON but do NOT start the engine 5 Confirm the safety around the machine 6 Place the control lever to FLOAT position C and lower the bucket 1 m off the ground wit...

Page 268: ...tly heat the accumulator Do not weld the accumulator housing Be sure to release pressure before starting to work on the pipe lines Let the machine travel with the ride control switch turned AUTO and OFF to compare the machine s vertical vibration during travel Travel the machine at the speed faster than 5 km h 3 1 mph If the machine s vertical vibration is not dampened when letting the machine tra...

Page 269: ...us injury To avoid this hazard Park the machine on a firm level surface Lower the bucket to the ground Stop the engine Remove key from the key switch Push the control lever lock switch to the lock position 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 c...

Page 270: ...r replace hose or O ring Every 250 hours Hose covers Leak 4 Replace Hose ends Leak 5 Replace Hose covers Exposed reinforcement 6 Replace Hose covers Blister 7 Replace Hose Bend 8 Collapse 9 Replace Hose ends and Fittings Deformation or Corrosion 10 Replace M137 07 008 M115 07 145 M115 07 146 M115 07 147 M115 07 148 M115 07 149 9 10 8 6 7 4 5 3 2 1 2 3 3 2 1 2 3 Fig 1 ...

Page 271: ... 11 Replace Bolts Loose or leak 11 Retighten or replace O ring Welded surfaces on flange joints Leak 12 Replace Every 250 hours Flange joint neck Crack 13 Replace Welded surfaces on flange joints Crack 12 Replace Clamps Missing or deformation Loose bolts Replace or retighten M4GB 07 059 M4GB 07 060 12 13 12 Fig 2 13 11 ...

Page 272: ... fitting 2 by hand pressing the fitting joint together 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 correct O ring position before tightening the con...

Page 273: ...itting 7 or nut 8 to the torque values shown Do not allow hose 5 to twist when tightening fittings Tightening torque Tighten fittings to the torque values shown below Width across flats 17 mm 0 7 in 19 mm 0 7 in 22 mm 0 9 in 27 mm 1 1 in 36 mm 1 4 in Tightening torque N m 24 5 29 5 39 93 175 kgf m 2 5 3 0 3 9 9 3 17 5 lbf ft 18 0 22 0 29 0 69 129 7 9 8 10 5 M202 07 051 ...

Page 274: ...gine to start Recommended Fuel Use only super high quality or high quality DIESEL FUEL JIS K 2204 ASTM D 975 Besides using bad quality fuel drainage agent fuel additives gasoline kerosene or alcohol refueled or mixed with specified fuel may deteriorate performance of fuel filters and cause sliding problem at lubricated contacts in the injector Using fuel other than ultra low sulfur or low sulfur d...

Page 275: ...before fueling Do not smoke while you fill the fuel tank or work on fuel system 2 Check fuel gauge 1 of the monitor panel Add fuel if necessary IMPORTANT Keep all dirt dust water and other foreign materials out of the fuel system 3 To avoid condensation fill the tank at the end of each day s operation Take care not to spill fuel on the machine or ground Fuel tank capacity 140 liters 37 0 US gal 4 ...

Page 276: ...000 hours Before starting to operate the machine remove plug 2 from the tip of drain valve 1 on the fuel tank bottom and open drain valve 1 to drain water and or sediment from the fuel tank Plug 2 is installed to protect drain valve 1 from vandalism 1 2 MNSC 07 017 ...

Page 277: ...dicator blinks drain the water accumulated in the filter Draining Procedures 1 Rotate drain plug 2 on the bottom of fuel pre filter 1 case 4 Drain the water accumulated in the filter Place 0 5 liters 0 5 US qt or larger capacity container under drain plug 2 to collect the drained water 2 After draining water securely tighten drain plug 2 IMPORTANT After draining water from the fuel filter bleed ai...

Page 278: ...l pre filter or running the fuel tank dry be sure to bleed the air from the fuel system Bleed Air 1 Loosen air bleed plug 3 on the fuel main filter and turn the key switch ON 2 After stopping the electric fuel pump turn the key switch OFF After waiting for more than 30 seconds turn the key switch ON again 3 After the air is bleed tighten air bleed plug 3 4 Start the engine Check the fuel supply sy...

Page 279: ... for preparation of inspection maintenance work 2 Remove cartridge filter element 2 from fuel filter 1 with a filter wrench Be sure to retain fuel with a container to ensure safety and to protect the ground against contamination 3 Coat fuel to the gasket surface on new cartridge filter element 2 4 Install cartridge filter element 2 to fuel filter 1 by lightly turning the element by hand until the ...

Page 280: ...ion maintenance work 2 Remove cartridge filter 1 with a filter wrench Be sure to retain fuel with a container to ensure safety and to protect the ground against contamination 3 Coat fuel to the gasket surface on new cartridge filter element 2 4 Install cartridge filter element 2 to fuel filter 1 by lightly turning the element by hand until the seal surface makes contact with the gasket 5 Tighten t...

Page 281: ...oses According to the check points shown below check hoses for oil leaks and damage If any abnormality is found replace or retighten as instructed in the table Hose Interval hours Check Points Abnormalities Remedies Every 10 hours Hose ends Leak 1 Retighten or replace Hose covers Wear crack 2 Every 250 hours Hose covers Crack 3 Replace Hose ends Crack 4 Replace Hose Bend 5 Collapse 6 Replace Hose ...

Page 282: ...k at visual dust indicator 2 of air cleaner 1 to check whether the element is clogged If the centre of dust indicator 2 clear part appears red clean or replace the element After cleaning press reset button 3 on the end of visual dust indicator 2 and check to make sure the centre clear part is no longer red MNSC 07 051 2 1 3 ...

Page 283: ...TANT To clean elements 5 6 avoid giving shocks or striking element with other objects 3 Clean outer element 6 by blowing compressed air less than 0 69 MPa 7 kgf cm2 97 2 psi outward from the inside of the filter element Keep the air nozzle at least 50 mm away from the element when blowing on it with compressed air After cleaning be sure to check element 6 for any damage If any damage is found repl...

Page 284: ...sonous Antifreeze is poisonous if ingested it can cause serious injury or death Induce vomiting and get emergency medical attention immediately If antifreeze is accidentally splashed into eyes flush with water for 10 to 15 minutes and get emergency medical attention When storing antifreeze be sure to keep it in a clearly marked container with a tight lid Always keep ANTIFREEZE out of the reach of ...

Page 285: ...p and bottom of sight glass 3 or the coolant level is invisible which is below the bottom of sight glass 3 fill coolant until the coolant level exceeds the top of sight glass 3 When coolant in expansion tank 1 is below the appropriate level remove cap 2 on the expansion tank 1 and fill it to the base of the filler port The base of the filler port is the appropriate level When refilling a long life...

Page 286: ...t for any abnormality If any cracks are found replace the belt with a new one Replace Drive Belt every 3000 hours Consult your nearest authorized dealer for repair Replace Automatic Tensioner every 3000 hours Consult your nearest authorized dealer for repair MNSC 07 022 ...

Page 287: ...the frame by following the procedures described on page 7 9 3 Remove radiator cap 1 Open radiator drain cock 2 to completely drain the coolant Remove impurities such as scale at the same time 4 Close radiator drain cock 2 Supply low impurity soft water or tap water together with the specified LLC up to the radiator filler port When adding coolant do so slowly to avoid mixing air bubbles in the sys...

Page 288: ...p water with high delivery pressure is used for cleaning damage to the radiator oil cooler fins may result Keep the nozzle away from the core surface more than 500 mm If dirt or dust is accumulated on radiator 1 oil cooler 2 and intercooler 3 them cooling system performance decreases Clean the radiator 1 oil cooler 2 and intercooler 3 cores with compressed air pressure lower than 0 2 MPa 2 kgf cm2...

Page 289: ...on of such components is required consult your nearest authorized dealer Batteries dWARNING Battery gas can explode Keep sparks and flames away from batteries Do not keep tools metals or flammable materials around the battery or inside the battery room If a metal tool is placed across the battery terminal and a vehicle component such as the engine block sparks may be created possibly resulting in ...

Page 290: ...mmediately IMPORTANT Add water to batteries in freezing weather before you begin operating your machine for the day or else charge the batteries If the battery is used with the electrolyte level lower than the specified lower level the battery may deteriorate quickly Do not refill electrolyte more than the specified upper level Electrolyte may spill damaging the painted surfaces and or corroding o...

Page 291: ...curate electrolyte level in this case Therefore when the electrolyte 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 After refilling securely tighten the filler caps Be...

Page 292: ...aking soda or lime to help neutralize the acid 3 If splashed in eyes flush with water for 15 to 30 minutes Get medical attention immediately If acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or milk 3 Get medical attention immediately IMPORTANT Check the electrolyte specific gravity in each battery cell The lowest limit of the specific gravity for the electrolyte varies ...

Page 293: ...rent types of batteries may have different rates of charge This difference could overload one of the batteries and cause it to fail Check Monitor Functions and All Other Instrument Operation every 10 hours Run the engine at low idle speed when checking the instruments The monitor indicates alarm caution and confirmation status in red orange and normal operative condition in blue or green respectiv...

Page 294: ...y the parking brake and clear the machine s vicinity of other personnel The horn switch button is located at the steering wheel center and on the right console In case the machine is equipped with a multi function joystick lever the horn switch is located on the multi function joystick lever Horn 1 is located on the front frame Reverse buzzer 2 is located at the inside of the rear grille Check tha...

Page 295: ...ny burned mark or an abnormal smell is noticed on a harness consult your nearest authorized dealer Replace Fuse 1 If any electrical equipment becomes inoperable first check the fuses in the fuse boxes A B located in the right console behind the front control lever in the operator s station 2 One each spare fuse for respective fuse capacities is provided in the fuse boxes A B 3 Finally check slow b...

Page 296: ...0 A 4 WORKING LAMP FRONT 20 A 14 ROTARY BEACON 10 A 3 WIPER FRONT 15 A 13 SEAT HEATER 20 A 2 LIGHTER 10 A 12 OPTION 2 20 A 1 DC DC UNIT 10 A 11 Fuse Box B 10 HST 1 15 A 20 9 MC 10 A 19 HI BEAM 10 A 8 ECM 30 A 18 WIPER REAR 10 A 7 CONTROLLER 10 A 17 WORKING LAMP REAR 20 A 6 FLASHER 10 A 16 LOADER CONTROL 10 A 5 HORN 10 A 15 FUEL PUMP 10 A 4 OPTION 1 20 A 14 POWER ON 2 10 A 3 ROOM LAMP 5 A 13 POWER ...

Page 297: ...o the appropriate level Refill with the same brand of oil as described in the kind of oils Use of other oil vegetable oil may cause the failure and or malfunction of the brake 1 Park the machine following the same procedures as described on page 7 7 for preparation of inspection maintenance work 2 Brake oil tank 2 is located at the left front of the engine room The brake oil level should be betwee...

Page 298: ... vicinity 3 of the brake pedal remove the accumulated dust and or soil Check Brake Performance The machine must be stopped within 5 m 5 5 yd range after the brake is applied while driving at the speed of 20 km h 12 4 mph on a flat dry paved surface road Check Play in Brake Pedal Stroke Measure the pedal stroke at pedal tip 2 by pressing the pedal with your hand until you feel an intermittent feed ...

Page 299: ...e traveling direction Keep bystanders away from the machine Park the machine with no load applied on a 20 11 3 inclining dry surface slope The machine must not move with the parking brake switch 4 ON Should the machine move during inspection consult your nearest authorized dealer Get the brake system checked and repaired 4 MNDB 01 001 ...

Page 300: ...ed wet type brake Parking brake 2 is a wet type disk brake Parking brake 2 is mounted on the transmission side Consult your nearest authorized dealer for checking Change Brake Oil every 1000 hours or 1 year Consult your nearest authorized dealer for changing brake fluid M4FC 07 023 1 2 M4FJ 06 001 ...

Page 301: ...sure Even if only one tread pattern has worn out replace the tire with a new one Before operating the machine check the tires for any breaks damage or foreign matter When replacing one tire use a new tire having the same tread pattern and specification as the other tires Check Air Pressure 1 Measure air pressure when the tires are cool before operating the machine Standard Tire Standard Air Pressu...

Page 302: ... according to the types of tires to be installed Do not change the specifications of the registered machine by using unauthorized tire sizes 1 Park the machine following the same procedures as described on page 7 7 for preparation of inspection maintenance work 2 Install articulation lock bar to the front and rear of the frame by following the procedures described on page 7 9 3 Loosen all wheel bo...

Page 303: ...al Bias Bias Bias Radial 17 5 R25 L2 fNOTE Adjust air pressure according to the size and type of tires provided in the table above regardless of the tread pattern Adjust tire pressure in conformity with the work mode the machine is engaged in Consult your nearest authorized dealer for more detailed information Driving on Public Roads Standard pressure Loading excavation on normal ground surface St...

Page 304: ...tread design pattern optional will affect not only economy of tire but also safety of operation How to Check Wear Amount Tread Design Groove Depth Measure the groove depth at 1 4 tread width position shown with mark 1 in the figure Use limit of the groove depth shall be approx 85 of the new tire groove depth In case extreme uneven wear or exposed rubbing strips are found replace the tire even befo...

Page 305: ...ls Do not raise the machine off the ground higher than necessary When the front rear wheels are raised off the ground wedge wheel stoppers under the rear front wheels After the machine is raised off ground be sure to block the machine using rigid supports Never leave the machine to be supported only by jacks The rear wheels oscillate Insert wooden blocks between the axle and the frame to stop osci...

Page 306: ...the starter key Loosen wing nuts 3 and remove plate 2 Remove fresh air filter 4 dCAUTION When using compressed air pressure wear safety glasses or goggles IMPORTANT If compressed air delivery pressure is high damage to the filter fins may result Always use compressed air at the lower pressure than 0 2 MPa 2kgf cm2 29 psi Keep the nozzle more than 500 mm 19 7 in away from the core surface 2 Clean f...

Page 307: ...er causing malfunction or breakdown of the air conditioner Before installing the filter element clean off dust around the mounting area install the filter element with extra care 3 Install the cleaned fresh air filter or a new filter by following the filter removal procedure described in step 1 in the reverse order ...

Page 308: ... high damage to the filter fins may result Always use compressed air at the lower pressure than 0 2 MPa 2kgf cm2 29 psi Keep the nozzle more than 500 mm 19 7 in away from the core surface 2 Clean double filter 7 Clean double filter 7 using compressed air or by washing with water Washing procedure with water is as follows 2 1 Use tap water 2 2 Submerge the filter in water containing a neutral deter...

Page 309: ...ult 2 Clean circulation air filter 8 using a vacuum cleaner IMPORTANT Inappropriate installation of the filter may cause dust to enter into the air conditioner causing malfunction or breakdown of the air conditioner Before installing the filter element clean off dust around the mounting area install the filter element with extra care 3 Install the cleaned circulation air filter or a new filter by ...

Page 310: ...e the air conditioner in the cooling mode once a week to prevent lack of lubrication dWARNING Do not clean the compressor and receiver tank with steam The refrigerant gas pressure will increase possibly causing the hoses to break Check Air Conditioner Piping every 250 hours or 3 months dCAUTION If any leakage is found repair or replace the corresponding pipes Tighten the joint bolts to specificati...

Page 311: ... fins Check Air Conditioner Fan Belt every 250 hours or 3 months Check the belt for abnormal deflection and damage Check fan belt tension by depressing the midpoint shown with mark in the illustration with the thumb Deflection must be as follows with a depression force of approximately 64 N 6 5 kgf 14 4 lbf Deflection approx 7 mm 0 3 in Belt Tension Adjustment Procedure 1 Loosen lock nut 2 of tens...

Page 312: ...your nearest authorized dealer Type Refrigerant No Quantity kg lb HFC R134a 0 85 0 05 1 87 0 11 dCAUTION Do not dispose FREON into the atmosphere to prevent depletion of ozone layer and global warming Check Compressor and Pulley every 250 hours or 3 months Check the compressor and its vicinity for abnormality in operation oil stain or refrigerant leakage Check the pulley for abnormal noise Check t...

Page 313: ... the bucket bottom parallel to the ground Insert blocks under the bucket to support it Stop the engine 2 Loosen bolts 1 and nuts 2 Remove cutting edge 3 3 Install new cutting edge 3 If the reverse side of a cutting edge is not worn much use it again with the face reversed If both sides are worn out replace it with a new one 4 Tighten nuts 2 Tightening torque 1068 N m 107 kgf m 790 lbf ft 5 Retight...

Page 314: ...ace seat belt every 3 years regardless of appearance Inspect the seat for large play or damage Replace it if necessary Check ROPS cab Mounting Bolts every 10 hours Check the appearance of ROPS cab 3 for any abnormal damage or deformation Check Windshield Washer Fluid Level every 10 hours IMPORTANT Keep all dirt dust and other foreign materials out of the tank Use anti freeze type washer fluid in c...

Page 315: ...the steering wheel is fully turned and that the steering cylinder operates normally 1 Start the engine Turn the parking brake switch ON 2 Slightly lift the bucket above the ground Place the control lever lock in the lock position 3 While running the engine at slow speed slightly rotate the steering wheel knob in both clockwise and counterclockwise direction Measure the moving distance along the st...

Page 316: ...em Exhaust Gas Color and Noise dDANGER Ventilate the shop with fresh air when carrying out warm up operation indoors Failure to do so may cause intoxication by exhaust gas possibly resulting in personal death accident IMPORTANT Never attempt to modify the inlet and exhaust system Exhaust gas color is normally transparent or light blue Although exhaust gas color slightly becomes white immediately a...

Page 317: ...teps and Handrails for Damage and Looseness every 10 hours Check steps 3 and handrails 4 for any damage looseness and contamination If any slippery matter such as machine lubricants or mud becomes adhered to steps 3 and or handrails 4 remove such contaminant If steps 3 and or handrails 4 become damaged or loosened so that getting on and off the machine is difficult immediately repair or replace 1 ...

Page 318: ...nd or chips are accumulated in the engine compartment and or the areas above the engine Remove the accumulated chips and or dust if any Check Sound Absorbing Mat Around Engine every 10 hours dCAUTION If the sound absorbing mat in the engine compartment becomes unglued the mat may come in contact with high temperature sections of the engine possibly resulting in fires Check if the sound absorbing m...

Page 319: ...heck and repair Check and Clean Starter and Alternator every 1000 hours Consult your nearest authorized dealer for check and repair Retighten Front Axle and Rear Axle Support Mounting Bolts every 2000 hours 50 hours at first time only Check front and rear axle support mounting bolts for looseness Tightening torques of the front axle and rear axle support mounting bolts Front Axle Mounting Bolt Rea...

Page 320: ...ck and repair Clean EGR Cooler every 4500 hours Consult your nearest authorized dealer for check and repair Check Turbocharger every 4500 hours Consult your nearest authorized dealer for check and repair Check and Clean Injector Nozzle every 4500 hours Consult your nearest authorized dealer for check and repair ...

Page 321: ...ransmission mounting bolt Transmission side 16 8 24 176 to 225 17 5 to 22 5 130 to 166 8 HST motor mounting bolt 16 4 14 230 23 0 170 9 HST pump mounting bolt 16 12 2 4 24 17 210 90 21 0 9 0 155 66 10 Engine mounting bolt Bracket Front 12 8 19 90 9 0 66 Rear 12 16 8 4 19 24 90 210 21 0 155 11 Engine mounting bolt Cushion rubber 16 4 24 210 21 0 155 12 Aftertreatment device mounting bolt Bracket 8 ...

Page 322: ...9 27 300 30 220 14 20 550 55 410 400 40 300 170 17 125 30 400 40 300 17 22 750 75 550 550 55 410 220 22 162 32 24 950 95 700 700 70 520 280 28 205 36 27 1400 140 1030 1050 105 770 400 40 300 41 30 1950 195 1440 1450 145 1070 550 55 410 46 33 2600 260 1920 1950 195 1440 750 75 550 50 36 3200 320 2360 2450 245 1810 950 95 700 55 dCAUTION If counterweight mounting bolts are loosened consult your near...

Page 323: ...ting bolt Bolt dia mm in 20 0 8 Quantity 8 2 Rear axle support mounting bolt Front Rear Bolt dia mm in 20 0 8 20 0 8 Quantity 4 4 3 Wheel rim mounting bolt Bolt dia mm in 24 0 9 Quantity 48 M4GB 07 127 Front Rear M4FJ 07 017 M4FC 07 065 ...

Page 324: ...mounting bolt Bolt dia mm in 10 0 4 Quantity 20 5 Propeller shaft support bearing mounting bolt Bolt dia mm in 16 0 6 Quantity 2 6 Transmission mounting bolt Frame side Bolt dia mm in 16 0 6 Quantity 4 M4FC 07 066 M4FJ 07 026 M4FJ 07 018 ...

Page 325: ...ion mounting bolt Transmission side Bolt dia mm in 16 0 6 Quantity 8 8 HST motor mounting bolt Bolt dia mm in 16 0 6 Quantity 4 9 HST pump mounting bolt Bolt dia mm in 16 0 6 12 0 5 Quantity 2 4 M4FJ 07 018 M4FJ 07 019 M4FJ 07 050 ...

Page 326: ...ar Bolt dia mm in 12 0 5 12 0 5 16 0 6 Quantity 8 8 4 11 Engine mounting bolt Cushion rubber Bolt dia mm in 16 0 6 Quantity 4 12 Aftertreatment device mounting bolt Bracket Bolt dia mm in 8 0 3 10 0 4 12 0 5 Quantity 8 18 1 MNSC 07 035 MNSC 07 033 MNSC 07 033 ...

Page 327: ...Counterweight mounting bolt Bolt dia mm in 24 0 9 Quantity 4 14 Top center pin lock Bolt dia mm in 12 0 5 Quantity 1 15 Bottom center pin flange lock bolt Bolt dia mm in 24 0 9 Quantity 1 MNSC 01 032 MNSC 07 036 MNSC 07 037 ...

Page 328: ...front pin lock Bolt dia mm in 12 0 5 16 0 6 Quantity 10 3 17 Steering cylinder pin lock Bolt dia mm in 12 0 5 Quantity 4 18 Radiator frame mounting bolt Bolt dia mm in 12 0 5 16 0 6 Quantity 4 4 MNSC 07 001 MNSC 07 038 MNSC 07 039 ...

Page 329: ...1 19 Radiator mounting bolt Bolt dia mm in 8 0 3 Quantity 4 20 Intercooler mounting bolt Bolt dia mm in 8 0 3 Quantity 2 21 Oil cooler mounting bolt Bolt dia mm in 10 0 4 Quantity 4 MNSC 07 040 MNSC 07 040 MNSC 07 040 ...

Page 330: ... condenser mounting bolt Bolt dia mm in 10 0 4 Quantity 4 23 Air conditioner compressor mounting bolt Bolt dia mm in 8 0 3 Quantity 4 24 Cab cushion rubber mounting bolt Bolt dia mm in 16 0 6 Quantity 4 MNSC 07 041 MNSC 07 042 MNSC 07 052 ...

Page 331: ...MAINTENANCE 7 113 25 Cutting edge mounting bolt Bolt dia in 1 Quantity 7 M4GB 07 116 ...

Page 332: ...s and sensors When the machine is operated in dusty areas refer to the page 9 1 Maintenance Under Special Environmental Conditions 1 Open the right and left side cover 2 Check exhaust pipe 1 for cracks Check the aftertreatment device units for loose or disconnection 3 Check the connectors and harnesses of NOx sensors 2 temperature sensors 3 and dosing module 4 for abnormality 4 Close the side cove...

Page 333: ... AdBlue in 10 to 40 C 14 to 104 F environment In some cases specified urea solution is referred to by one or more of these names Aqueous Urea Solution 32 AUS 32 NOx Reduction Agent Catalyst Solution fNOTE AdBlue is produced from suppliers which are licensed by the VDA Verband der Automobilindustrie e V Diesel Exhaust Fluid DEF is certified by the API American Petroleum Institute Diesel Exhaust Flu...

Page 334: ...n fire occurs Wash out spilled DEF AdBlue with clean water Seal the container and store it in a well ventilated place If DEF AdBlue freezes the quality does not change just after freezing As long as sealed by an airtight stopper unless water evaporates DEF AdBlue will not deteriorate within the guarantee period Do not pour waste DEF AdBlue and its containers onto the ground and do not allow waste ...

Page 335: ...e job Wash DEF AdBlue with clean water when it contacts on the skin If DEF AdBlue is accidentally splashed into eyes flush with water for 15 minutes or longer and get emergency medical attention 1 Park the machine according to the instruction on Preparations for Inspection and Maintenance 7 7 2 DEF AdBlue tank 2 is located in the cover at left rear of the machine Open the DEF AdBlue tank cover 3 C...

Page 336: ...essure washer fNOTE Wipe spilled DEF AdBlue and wash spilled area with plenty of water The sound of flowing water may be heard from the tank after the engine stops It is the sound of returning DEF AdBlue from piping to the tank not a malfunction DEF AdBlue will freeze at low temperature and deteriorate ammonification at high temperature Store DEF AdBlue at temperature between 10 and 40 C 14 and 10...

Page 337: ...n it contacts with the skin If DEF AdBlue is accidentally splashed into eyes flush with water for 15 minutes or longer and get emergency medical attention IMPORTANT Take care not to allow dust to contaminate the area when carrying out the work 1 Remove strainer 1 from the filler port of the DEF AdBlue tank 2 Clean strainer 1 with compressed air pressure lower than 0 2 MPa 2 kgf cm2 30 psi or tap w...

Page 338: ... emergency medical attention IMPORTANT When contaminated or deteriorated DEF AdBlue is used malfunction may result Change DEF AdBlue periodically to keep cleanliness in the tank 1 Remove bolts 1 and cover 2 2 Place a 26 liter 6 9 US gal or larger capacity container under drain plug 3 3 Slowly loosen drain plug 3 to drain DEF AdBlue 4 Tighten drain plug 3 after draining DEF AdBlue Wrench size 13 mm...

Page 339: ...lls while filling IMPORTANT Replace the filter do not clean it Trying to clean and reuse it may cause a malfunction The inlet of the DEF AdBlue tank water supply is equipped with a filter 2 which must be replaced periodically When it is time to replace it consult the nearest Hitachi dealer 95Z7B 7 126 2 1 ...

Page 340: ...e mounting position after replacement White deposition may be observed when DEF AdBlue is dried naturally it is normal Wash out DEF AdBlue deposition with clean water Never use a high pressure washer 1 Park the machine according to the instruction on Preparations for Inspection and Maintenance 7 7 2 Open the side cover 3 Remove cap 1 from the DEF AdBlue supply module by using a 27 mm 1 1 in bihexa...

Page 341: ...nsult your authorized dealer Freezing Weather Fuel Use high quality fuel suitable for low temperature Check the fuel tank breather pipe freezing Lubricant Use high quality low viscosity hydraulic oil and engine oil Engine Coolant Be sure to use antifreeze Battery Fully charge the batteries regularly at shorter service intervals If not charged fully electrolyte may freeze Tires and Frames Keep tire...

Page 342: ...ine oil in the engine crankcase to cold weather type oil 4 Use fuel diesel fuel of an antifreeze type To prevent condensation of air into dew on the wall in the fuel tank fully refill the fuel tank with an antifreeze type diesel fuel 5 If the electrolyte in the battery case freezes damage to the battery case may result Maintain the batteries at fully charged condition After completing work turn al...

Page 343: ...ke several times 9 Road surfaces covered with snow especially when snow has been compacted will become frozen Use tire chains on four wheels 10 Take anti freeze measures after completing operation Cover the keyhole by sticking a tape on Rubber parts such as wiper may freeze Keep other parts away from the rubber parts Remove packed snow from around the undercarriage and inside the machine with a ba...

Page 344: ...MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 9 4 MEMO ...

Page 345: ...ved when opening the tank cap Do not inhale fumes directly from the water supply outlet or breather Prevention of Dust and Moisture Store the machine in a relatively dry garage and cover it Tools Inspect and repair then store Lubrication Operation No load Operation at a Slow Speed for Several Minutes If the oil films of the parts are broken and parts are rusted they will be worn abnormally when op...

Page 346: ...n before resuming operation of the machine Avoid quick operation Failure to do so may cause damage to the engine hydraulic equipment transmission axle etc due to insufficient lubrication If lubrication running is not performed for more than three months start the engine by following the procedure below 1 Crank the engine without injection input operate by starter motor for three seconds and stop 1...

Page 347: ...ion 7 Start the engine Run the engine at half speed for several minutes before full load operation 8 Repeat the process several times 9 Stop the engine Check each device for oil leaks 10 Replace the fuel filter and engine oil filter with a new one as needed Change engine oil 11 Check clamps of the suction hoses air cleaner hoses and radiator hoses Retighten them as needed Before operating the mach...

Page 348: ...STORAGE 10 4 MEMO ...

Page 349: ...or the engine troubleshooting Engine Auxiliaries Symptom Cause Solution Batteries will not charge Broken battery separator Replace Faulty regulator Adjust Replace Faulty ground line Repair Faulty alternator Repair Replace Batteries discharge quickly after being charged Shorted cable Repair Replace Shorted battery separator Repair Replace Increased sediment in battery Replace Coolant temperature is...

Page 350: ...jection pump or nozzle Repair Replace Reduced compression pressure Adjust Engine speed does not increase The accelerator pedal function is abnormal Replace the accelerator pedal or parts DEF AdBlue tank is empty Supply DEF AdBlue Although the engine cranks running speed is low and easy to stall Deteriorated engine oil Change engine oil Contaminated injection nozzle Replace Clogged fuel filter Repl...

Page 351: ...of main relief valve in control valve Adjust Lack of hydraulic oil Refill Trapped foreign matter in hydraulic oil tank suction filter Clean Aeration in suction side Retighten Only one actuator is inoperable Broken control valve spool Replace Trapped foreign matter in valve spool Repair Replace Broken pipe and or hose Repair Replace Loose pipe line joint Retighten Broken O ring at pipe line joint R...

Page 352: ...use Solution Heavy to operate Rusted joint Lubricate Repair Accelerator pedal play is excessive Worn joint Repair replace Consult your nearest authorized dealer Parking Brake Symptom Cause Solution Parking brake is dragging Oil leak due to worn parking brake piston D ring Repair Replace Faulty disk brake Repair Replace Faulty parking brake solenoide valve Repair Replace Parking brake does not work...

Page 353: ...ation Repair Adjust Consult your nearest authorized dealer Propeller Shaft Symptom Cause Solution Propeller shaft vibrates Bent propeller shaft Repair Replace Loosened parts Loss of balance Retighten Adjust Propeller shaft is noisy Excessively worn spline Replace Worn or seized spider bearing Replace Loosened parts Retighten Insufficient greasing Grease Consult your nearest authorized dealer Front...

Page 354: ...TROUBLESHOOTING 11 6 MEMO ...

Page 355: ...0 mm 6 ft F Ground Clearance 370 mm 1 ft 3 in G Bucket Hinge Height 3560 mm 11 ft 8 in H Dumping Clearance 45 2705 mm 8 ft 11 in I Dumping Reach 45 1010 mm 3 ft 4 in R1 Minimum Rotation Radius 4690 mm 15 ft 5 in R2 Minimum Rotation Radius 5430 mm 17 ft 10 in Travel Speed Forward Reverse 34 5 34 5 km h Transmission Speeds F R 2 2 Articulation Angle Left Right deg 40 Tire Size 17 5 25 12PR fNOTE BOC...

Page 356: ...SPECIFICATIONS 12 2 MEMO ...

Page 357: ...Refer to page 13 3 for information on hydraulic hose connection and disconnection Put the bucket attachment to be removed on a support such as a pallet if available 1 Horizontally lift the bucket by approx 20 cm above the pallet dWARNING Before leaving the machine apply the parking brake 2 Operate the quick coupler cylinder with hydraulic coupler switch 1 to remove pin 4 3 While pulling to slide l...

Page 358: ...ly bring the machine close to bucket attachment hook 3 and install the quick coupler to the hook 2 Slightly raise lift arm 4 Slowly tilt the bucket attachment backward by operating the bucket cylinder until stopper 5 comes in contact with the coupler 3 While pulling to slide lock switch continue to press switch installation position to install coupler cylinder pin 1 fNOTE In case the newly install...

Page 359: ...tachment hydraulic hoses to the machine hydraulic pipe lines After connecting the hydraulic hoses start the engine While operating the attachment control lever slowly move the attachment Check that no oil leaks from the hydraulic hose connectors When the attachment is removed joint the attachment hose female end to the male end Put dust caps to the machine hydraulic pipe line female and male ends ...

Page 360: ...13 4 OPTIONAL ATTACHMENTS HYDRAULIC TYPE QUICK COUPLER OPERATION MEMO ...

Page 361: ...al Operation and Exhaust Gas Color and Noise 7 98 Check After Starting 3 8 Check Air Conditioner 7 92 Check Air Conditioner Condenser 7 93 Check Air Conditioner Fan Belt 7 93 Check Air Conditioner Piping 7 92 Check and Clean Aftertreatment Device 7 114 Check and Clean Injector Nozzle 7 102 Check and Clean Starter and Alternator 7 101 Check and Replace EGR Device 7 102 Check and Replace Seat and Se...

Page 362: ...ystem 7 71 Emergency Evacuation 4 16 Emergency Evacuation Hammer 1 84 Engine 7 27 Engine Oil Change Interval Hour Meter 1 36 Engine Oil Filter Replacement Interval Hour Meter 1 37 Engine Oil Low Pressure Indicator Red 1 13 Engine Trouble Indicator Red 1 12 Ensure Safety Before Rising from or Leaving Operator s Seat S 7 Ensure Safety When Operating on Road Shoulders 5 8 Equipment of Head Guard ROPS...

Page 363: ... 1 65 Outside Rear View Mirror 1 86 Overheat Indicator Red 1 13 P Park Machine Safely S 21 Parking 4 15 Parking Brake Indicator Red 1 11 Parking Brake Switch 1 51 4 4 Perform Truck Loading Safely S 18 Power Mode Indicator Green 1 17 Power Mode Switch 1 60 Power Train 7 31 Practice Safe Maintenance S 24 Precautions for After Operations 5 18 Precautions for Communication Terminal S 37 Precautions fo...

Page 364: ...ort Maintenance Properly S 26 Switch Operation 1 90 Switches Steering Wheel and Pedals 1 41 T TRANSPORTING 6 1 TROUBLESHOOTING 11 1 Tightening and Retightening Torque of Nuts and Bolts 7 103 Tilt Telescopic Lever Steering Column Tilt Pedal 1 53 Tips for Optimal Air Conditioner Usage 1 75 Tire 7 83 Towing Method 6 9 Towing Pin 1 92 Traction Control Switch 1 59 Transmission Oil Change Interval Hour ...

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