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Hitachi EX 3600-6, Operator'S Manual

The Hitachi EX 3600-6 Operator's Manual is a comprehensive guide for users seeking seamless operation of this powerful excavator. Available for download absolutely free, this manual provides detailed instructions and invaluable insights for optimal performance. Enhance your productivity and master the EX 3600-6 by accessing the manual on manualshive.com.

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MAINTENANCE 

7-102 

 

Check Tightening Torque 
--- every 250 hours 

Check the tightness of mounting bolts, hose connections 
and fittings every 250 hours. Tighten to torque specifica-
tions if any are loose.   
 
Torque Specifications for Hose Connections: 

Fastening Torque 

Wrench 

Size 

(mm) 

N

⋅

m (kgf

⋅

m) (lbf

⋅

ft) 

19 

11.5 to 14.5 

(1.2 to 1.5) 

(8.7 to 10.5)

24 

19.5 to 24.5 

(2 to 2.5) 

(14.5 to 18) 

27 

29.5 to 34 

(3 to 3.5) 

(21.5 to 25.5)

 

Torque Specifications for Compressor Mounting Bolts: 

Fastening Torque 

Wrench 

Size 

(mm) 

N

⋅

m (kgf

⋅

m) (lbf

⋅

ft) 

10 

19.5 to 29.5 

(2 to 3) 

(14.5 to 21.5)

 

Torque Specifications for Liquid Tank: 

Fastening Torque 

Wrench 

Size 

(mm) 

N

⋅

m (kgf

⋅

m) (lbf

⋅

ft) 

10 

7.8 to 11.5 

(0.8 to 1.2) 

(5.8 to 8.7) 

 

 

 

M146-07-001 

Summary of Contents for EX 3600-6

Page 1: ... JAPAN E 2006 08 This book is printed on recycled paper Serial No 001001 and up Hydraulic Excavator PART NO EM18M 1 1T 3600 6 URL http www hitachi c m com EX3600 6 HYDRAULIC EXCAVATOR OPERATOR S MANUAL EM18M 1 1T ...

Page 2: ...ifications the warranty will become void and field improvements may be denied Setting fuel delivery above specifications or otherwise overpower ing machines will result in such action Moreover when replacement parts are required be sure to use genuine Hitachi parts Failure to do so may result in voiding the warranty and or denial of field im provements Only qualified experienced operators official...

Page 3: ...IDENTIFICATION NUMBER NOTE HCM18M00P00001001 PRODUCT IDENTIFICATION NUMBER PIN ENGINE TYPE AND SERIAL NUMBER TYPE MFG NO TRAVEL MOTOR TYPE AND SERIAL NUMBER TYPE MFG NO LEFT FRONT MFG NO LEFT REAR MFG NO RIGHT FRONT MFG NO RIGHT REAR M18M 00 001 M146 07 018 M18M 00 002 M145 07 079 Marks to indicate the start and end of the PIN ...

Page 4: ...RIGHT MFG NO REAR LEFT MFG NO REAR RIGHT HYDRAULIC PUMP TYPE AND SERIAL NUMBER TYPE MFG NO 1 2 MFG NO 3 4 MFG NO 5 6 MFG NO 7 8 FRONT TYPE AND SERIAL NUMBER LOADING SHOVEL TYPE MFG NO BUCKET TYPE AND SERIAL NUMBER LOADING SHOVEL TYPE MFG NO M146 07 028 M146 07 059 M146 07 060 M117 12 003 ...

Page 5: ...L NUMBER BACKHOE ARM TYPE MFG NO BUCKET TYPE AND SERIAL NUMBER BACKHOE TYPE MFG NO CONTROL VALVE TYPE AND SERIAL NUMBER TYPE MFG NO UPPER LEFT MFG NO UPPER RIGHT MFG NO LOWER LEFT MFG NO LOWER RIGHT M146 07 060 M146 07 061 M146 01 020 M18M 00 003 Upper Right Upper Left Lower Right Lower Left ...

Page 6: ... 24 Beware of Exhaust Fumes S 24 Precautions for Welding and Grinding S 25 Avoid Heating Near Pressurized Fluid Lines S 25 Avoid Applying Heat to Lines Containing Flammable Fluids S 25 Remove Paint Before Welding or Heating S 26 Beware of Asbestos Dust S 26 Prevent Battery Explosions S 27 Service Air Conditioning System Safely S 27 Handle Chemical Products Safely S 28 Dispose of Waste Properly S 2...

Page 7: ... The Cab 3 14 Stopping the Engine in Emergency Except In The Cab 3 15 DRIVING THE MACHINE Drive the Machine Carefully 4 1 Steering the Machine Using Pedals 4 2 Steering the Machine Using Levers 4 3 Travel Mode Switch 4 4 Travel Alarm 4 5 Traveling 4 6 Operating on Soft Ground 4 7 Raise One Track Using Boom and Arm 4 7 Towing Machine a Short Distance 4 8 Operating Ground Condition 4 9 Precautions f...

Page 8: ...r 7 81 Clean Air Cleaner Outer Element 7 81 Replace Air Cleaner Outer and Inner Elements 7 81 G Cooling System 7 83 Check Coolant Level 7 84 Check DCA4 Concentration in Coolant 7 85 Replace Coolant Filter 7 93 Change Coolant 7 94 Clean Radiator Interior 7 94 Clean Radiator Core 7 96 H Air Conditioner 7 97 Recirculation Air Filter 7 97 Ventilation Air Filter 7 98 Check Refrigerant Quantity 7 99 Che...

Page 9: ...CONTENTS SPECIFICATIONS Specifications 12 1 Working Range Loading Shovel 12 2 Working Range Backhoe 12 3 INDEX 14 1 ...

Page 10: ...azardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs Some safety signs don t use any of the designated signal words above after the safety al...

Page 11: ...r are in tended to illustrate basic safety procedures of machines However it is impossible for these safety messages to cover every hazardous situation you may encounter If you have any questions you should first consult your supervisor and or your authorized dealer before operat ing or performing maintenance work on the machine 003 E01B 0003 SA 003 PREPARE FOR EMERGENCIES Be prepared if a fire st...

Page 12: ...rating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating the machine 005 E01A 0438 SA 438 PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises 006 E01A 0434 SA ...

Page 13: ...Store them in their specified locations 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 objects and or explosives away from the machine A...

Page 14: ...ippery conditions on platforms steps and handrails when leaving the machine 008 E01A 0439 SA 439 ADJUST THE OPERATOR S SEAT A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations The seat should be adjusted whenever changing the operator for the machine The operator should be able to fully depress the ped als and to correctl...

Page 15: ... SAFELY Bystanders can be run over Take extra care not to run over bystanders Confirm the location of bystanders before moving swinging or operating the machine Always keep the travel alarm and horn in working con dition if equipped It warns people when the machine starts to move Use a signal person when moving swinging or oper ating the machine in congested areas Coordinate hand signals before st...

Page 16: ... be jump started be sure to follow the instructions shown in the OPERATING THE EN GINE chapter The operator must be in the operator s seat so that the machine will be under control when the engine starts Jump starting is a two person operation Never use a frozen battery Failure to follow correct jump starting procedures could result in a battery explosion or a runaway ma chine S013 E01A 0032 SA 03...

Page 17: ...vations and road shoulders When working on an incline or on a road shoulder employ a signal person as required Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist When the footing is weak reinforce the ground before starting work When working on frozen ground be extremely alert As ambient temperatures rise footing becomes...

Page 18: ...ll personnel obey the signal person s directions 018 E01A 0481 SA 481 CONFIRM DIRECTION OF MACHINE TO BE DRIVEN Incorrect travel pedal lever operation may result in seri ous injury death Before driving the machine confirm the position of the undercarriage in relation to the operator s position If the travel motors are located in front of the cab the machine will move in reverse when travel ped als...

Page 19: ...g on a slope may cause the machine to slip or overturn possibly resulting in serious injury or death When driving up or down a slope keep the bucket facing the direction of travel approximately 0 5 to 1 0 m 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 ...

Page 20: ...ound Turn the auto idle switch and the H P mode switch off Run the engine at slow idle speed without load for 5 minutes to cool down the engine Stop the engine and remove the key from the key switch Pull the pilot control shut off lever to LOCK position Block both tracks and lower the bucket to the ground Thrust the bucket teeth into the ground if you must park on a grade Position the machine to p...

Page 21: ...NDERS BEFORE MOVING MACHINE USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED ALWAYS KEEP THE SIGNAL PERSON IN VIEW Use hand signals which conform to your local regula tions when work conditions require a signal person No machine motions shall be made unless signals are clearly understood by both signalman and operator Learn the meanings of all flags signs and markings used on the job...

Page 22: ... E01A 0386 SA 386 NEVER POSITION BUCKET OVER ANYONE Never lift move or swing bucket above anyone or a truck cab Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket 023 E01A 0487 SA 487 AVOID UNDERCUTTING In order to retreat from the edge of an excavation if the footing should collapse always position the undercar riage perpendicular to the edge ...

Page 23: ...Keep the bucket low to the ground and close to the machine Reduce operating speeds to avoid tipping or slipping Avoid changing direction when traveling on grades NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable Reduce swing speed as necessary when swinging loads Be careful when working on frozen ground Temperature increases will cause the ground t...

Page 24: ...WITH CAUTION If the front attachment or any other part of the machine hits against an overhead obstacle such as a bridge both the machine and the overhead obstacle will be damaged and personal injury may result as well Take care to avoid hitting overhead obstacles with the boom or arm 028 E01A 0389 SA 389 AVOID POWER LINES Serious injury or death can result if the machine or front attachments are ...

Page 25: ...arefully Never move it suddenly Keep all persons will away from the load Never move a load over a person s head Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground Never attach a sling or chain to the bucket teeth They may come off causing the load to fall 030 E01A 0014 SA 014 PROTECT AGAINST FLYING DEBRIS If flying debris hit eye...

Page 26: ...SA 390 HANDLE FLUIDS SAFELY AVOID FIRES Handle fuel with care it is highly flammable If fuel ig nites an explosion and or a fire may occur possibly re sulting in serious injury or death Do not refuel the machine while smoking or when near open flame or sparks Always stop the engine before refueling the machine Fill the fuel tank outdoors All fuels most lubricants and some coolants are flam mable S...

Page 27: ...he LOCK posi tion 10 Allow the engine to cool If a maintenance procedure must be performed with the engine running do not leave machine unattended If the machine must be raised maintain a 90 to 110 angle between the boom and arm Securely support any machine elements that must be raised for service work Never work under a machine raised by the boom Inspect certain parts periodically and repair or r...

Page 28: ...7 SA 287 SUPPORT MACHINE PROPERLY Never attempt to work on the machine without securing the machine first Always lower the attachment to the ground before you work on the machine If you must work on a lifted machine or attachment securely support the machine or attachment Do not support the machine on cinder blocks hollow tires or props that may crumble under continuous load Do not work under a ma...

Page 29: ...uction gears are under pressure As pieces may fly off be sure to keep body and face away from AIR RELEASE PLUG to avoid injury GEAR OIL is hot Wait for GEAR OIL to cool then gradually loosen AIR RELEASE PLUG to release pressure 503 E01B 0344 SA 344 STORE ATTACHMENTS SAFELY Stored attachments such as buckets hydraulic hammers and blades can fall and cause serious injury or death Securely store atta...

Page 30: ...o become hot during operation The engine hoses lines and other parts become hot as well Wait for the oil and components to cool before starting any maintenance or inspection work 505 E01B 0498 SA 039 SA 225 REPLACE RUBBER HOSES PERIODICALLY Rubber hoses that contain flammable fluids under pres sure may break due to aging fatigue and abrasion It is very difficult to gauge the extent of deterioratio...

Page 31: ...ulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard take care to protect hands and body from high pressure fluids Wear a face shield or goggles for eye protection If an accident occurs see a doctor familiar with this type of injury immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may r...

Page 32: ...lectrical cables and wires Check before each shift or after eight 8 to ten 10 hours operation for missing or damaged terminal caps DO NOT OPERATE MACHINE if cable or wires are loose kinked etc Clean up Flammables Spilled fuel oil antifreeze fluid and window washer fluid and trash grease debris accumulated coal dust and other flammables may cause fires Prevent fires by inspecting and cleaning the m...

Page 33: ...be repaired or replaced before operating the machine 508 E02A 0393 EVACUATING IN CASE OF FIRE If a fire breaks out evacuate the machine in the follow ing way Stop the engine by turning the key switch to the OFF position if there is time Use a fire extinguisher if there is time Exit the machine In an emergency if the cab door or front window can not be opened break the front or rear window panes wi...

Page 34: ...ea still smoldering 523 E01A 0818 SA 818 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to your self and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable mate rials Pressurized lines can be accidentally cut when heat goes beyond the immediate fl...

Page 35: ...ainers and other flammable ma terial from area Allow fumes to disperse at least 15 minutes before welding or heating 511 E01A 0029 SA 029 BEWARE OF ASBESTOS DUST Take care not to inhale dust produced in the work site Inhalation of asbestos fibers may be the cause of lung cancer Depending on the wok site conditions the risk of in haling asbestos fiber may exist Spray water to pre vent asbestos from...

Page 36: ...se terminals may produce sparks Securely tighten all terminals Battery electrolyte is poisonous If the battery should ex plode battery electrolyte may be splashed into eyes pos sibly resulting in blindness Be sure to wear eye protection when checking elec trolyte specific gravity 512 E01B 0032 SA 032 SERVICE AIR CONDITIONING SYSTEM SAFELY If spilled onto skin refrigerant may cause a cold contact b...

Page 37: ...oducts used with your ma chine 515 E01A 0309 SA 309 DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the envi ronment and ecology Potentially harmful waste used with HITACHI equipment includes such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinkin...

Page 38: ...SAFETY SIGNS S 29 SS3091469 M146 07 080 ...

Page 39: ...SAFETY SIGNS S 30 SS 442 M146 01 022 SS 445 SS 688 1 SS 446 SS 2835 2 SS 742 Loading Shovel 1 2 ...

Page 40: ...SAFETY SIGNS S 31 SS 410 SS 2835 SS3108517 M18G 01 011 ...

Page 41: ...SAFETY SIGNS S 32 SS 413 M146 01 024 M146 01 025 SS4193223 M146 01 025 ...

Page 42: ...SAFETY SIGNS S 33 SS 449 M146 01 027 SS 710 SS 2836 SS 3091472 SS 2837 ...

Page 43: ...SAFETY SIGNS S 34 MEMO ...

Page 44: ...ylinder 5 Arm Cylinder 6 Boom Cylinder 7 Boom 8 Cab 9 Emergency Rope Hook 10 Emergency Rope Case 11 Fuel Tank 12 Radiator 13 Counterweight 14 Stairway 15 Travel Device 16 Track Shoe Loading Shovel M18M 01 001 Backhoe M18M 01 002 3 13 6 12 11 9 7 6 5 4 15 5 10 8 3 2 1 7 2 1 14 16 ...

Page 45: ...f the machine Never mount or dismount a moving machine Thoroughly remove and clean slippery materi als such as mud and or grease from the steps and or hand rails OPERATING STAIRWAY WARNING Check that no personnel are present around the machine before beginning operation Never operate the machine when any person nel are present near machine Lower the stairway only after checking that no obstruction...

Page 46: ...lock 3 is disengaged The alarm continues to sound until stairway is fully extended Retracting 1 Press and hold the RETRACT button 4 until the stairway is fully retracted When the button is re leased the stairway stops retracting 2 Be sure to pull the lever 2 down to engage the lock 3 after fully retracting NOTE The alarm stops to sound when the stairway start to retract The alarm stops to sound wh...

Page 47: ...art the engine Run the engine at a slow speed 5 Close the valve 4 fully The stairway starts to retract 6 Open the valve 4 gradually to slow down the re tracting speed before the stairway is fully retracted 7 After fully retracted open the valve 4 fully and close the valve 3 fully 8 Pull the lever down to engage the lock 9 Stop the engine 10 Install the cover 2 and the step 1 11 Contact your author...

Page 48: ...elt 6 around your chest 5 While holding two ropes move to the outside fence and face toward the cab as long as the two ropes are held emergency escape device will not operate 6 As soon as the ropes are released your body is slowly lowered Descend while softly pushing the machine surface by hand to prevent the body from turning 7 After landing immediately take life belt 6 off and evacuate to a safe...

Page 49: ...result in serious personal injury or death Avoid the risk of injury or death while evacuating from the machine during a fire by checking the following regularly Always check if left window 1 can be opened and closed smoothly before starting the engine If it fails to open or close smoothly repair the window Left win dow 1 can be used as an emergency exit Malfunction of emergency escape device 5 wor...

Page 50: ...h cab door 12 step 9 sidewalk 7 and lower stairway 8 If the engine compartment sidewalk 7 is on fire first evacuate from cab 11 through cab door 12 to cab side platform 10 Then get off the machine using emergency device 5 Emergency device 5 is provided in the case located on the left outside wall of the cab See the EMER GENCY ESCAPE section If the fire is around cab door 12 evacuate the cab by ope...

Page 51: ...ravel Lever 6 Right Travel Pedal 7 Right Control Lever Horn Switch 8 Right Console 9 Operator s Seat 10 Bucket Close Pedal For Loading Shovel 11 Bucket Open Pedal For Loading Shovel 12 Pilot Control Shut Off Lever 13 Rear Console 14 Trainer s Seat 15 Hot Cool Box M18M 01 006 M18M 01 007 M18G 01 016 2 3 4 5 6 8 9 7 1 13 12 11 10 14 15 ...

Page 52: ...REEN When key switch is turned to the ON position starting check screen will be displayed at first 1 Coolant Level Check Indicator 2 Engine Oil Level Oil Pan Check Indicator 3 Engine Oil Level Reserve Tank Check Indicator 4 Hydraulic Oil Level Check Indicator Level check indicators will become green when fluid levels are appropriate M18G 01 018 M18M 01 008 1 2 3 4 ...

Page 53: ...emperature Indicator 19 Engine Warning Indicator 20 Prelub Indicator 21 Hydraulic Oil Level Indicator 22 Auto Lubrication Indicator 23 Hydraulic Oil Overheat Indicator 24 Stairway Position Indicator 25 Fast Filling Indicator 26 Tension Indicator 27 Auto Idle Indicator 28 Travel Mode Indicator 29 Electric Lever Indicator 30 Emergency Engine Stop Indicator 31 Electlical Equipment Box Indicator 32 Pu...

Page 54: ...Instead reduce load and run the engine at high idle or auto idle HYDRAULIC OIL TEMPERATURE GAUGE White zone A Low temperature Warming up op eration is required Blue zone B Normal operating temperature Red zone C High temperature Hydraulic oil is overheating If needle enters the red zone C reduce load immediately and run the engine at high idle or auto idle to cool down until needle returns to the ...

Page 55: ...re HOUR METER The right hand number indicates tenth six minutes of an hour WARNING INDICATORS Warning indicators described below ALTERNATOR INDICATOR When alternator output is low alternator indicator will come ON Check the electrical system NOTE When key switch is turned to the ON position this indicator normally stays ON until the engine starts M18M 01 039 M18M 01 040 M18M 01 015 M144 01 023 ...

Page 56: ...ormally stays ON until the engine starts ENGINE OIL PRESSURE INDICATOR When engine oil pressure is low engine oil pressure indicator in yellow or red will come on Engine power will be reduced automatically Stop the engine immediately Check the fault code on the monitor and contact your authorized dealer NOTE Cold oil low oil level or operating on a steep slope may cause indicator to come ON COOLAN...

Page 57: ...t Stop the engine and check on operating condition FUEL TEMPERATURE INDICATOR When fuel temperature is high fuel temperature indicator in yellow or red will come ON and engine power will be re duced automatically Stop the engine and check fuel cooler for restriction and clean fins HYDRAULIC OIL LEVEL INDICATOR When hydraulic oil level in the hydraulic oil tank is lower than the warning level hydra...

Page 58: ...RICATION INDICATOR When auto lubrication toggle switch on panel near grease can is in the AUTO GREASING position auto lubrication indicator A in green will come ON If the grease can is empty or auto lubrication system is malfunctioning auto lubrication warning indicator B in red will come ON When the switch is in the MANUAL GREASING or OFF position manual greasing indicator C or greasing OFF indic...

Page 59: ...INDICATOR When the cushion cylinder is retracted to the stroke end due to material packing around the front idler tension in dicator will come ON and travel will stop automatically Drive the machine to remove the packed material in the opposite direction against the direction the machine was being driven Check the track sag and the adjuster cylinder accumulator for any abnormality ELECTRIC LEVER I...

Page 60: ... Stop the engine immediately and contact your authorized dealer NOTE When key switch is turned to the ON position this indicator normally stays ON for approxi mately 2 seconds HYDRAULIC OIL OVERHEAT INDICATOR When hydraulic oil overheats hydraulic oil overheat indicator will come ON Reduce load immediately and run the engine at high idle or auto idle to cool down until needle of hydraulic oil temp...

Page 61: ...cleaner elements are clogged air cleaner restriction indicator will come ON Clean or replace the elements ELECTRICAL EQUIPMENT BOX INDICATOR When electric equipment box is opened electrical equipment box indicator will come on When electric equipment box is closed electrical equipment box indi cator will go off STATUS INDICATORS Status indicators described below will become green AUTO IDLE INDICAT...

Page 62: ...cator A will come ON And when the travel speed mode is shifted to fast with travel mode switch fast travel mode indicator B will come ON PRELUB INDICATOR When the engine start switch is pressed the prelub motor drives until the engine starts This indicator stays on during the prelub motor operation M117 01 043 M585 01 010 M117 01 047 A B ...

Page 63: ...n lamp will come ON in yellow And when electrical signals from controllers or sensors are judged abnormal faults code will be displayed on the monitor and caution lamp will also come ON in yellow KEY PAD The monitor display can be operated with key pad MONITOR CONTRAST SWITCH The monitor contrast can be adjusted with monitor contrast switch Clockwise Turn Brighter Illumination Counterclockwise Tur...

Page 64: ...d with washer switch 1 Washer fluid will squirt and the wiper will operate as long as washer switch 1 is pressed The wiper will operate four seconds more after washer switch 1 is released WIPER DELAY SELECTOR SWITCH When the wiper switch is turned to the intermittent position the interval between wiper operation can be adjusted in four stages with wiper delay selector switch 1 as follows SHORT pos...

Page 65: ...trol panels are provided in the cab each designated for one of the three air conditioners Component Designation 1 Front Air Flow Vents 2 Side Air Flow Vents 3 Rear Air Flow Vents NOTE Direction of air flowing out of each vent can be changed by adjusting the louver 4 Air Conditioner Front Panel 5 Air Conditioner Side Panel 6 Air Conditioner Rear Panel M18G 01 036 M18M 01 018 M18M 01 003 M18G 01 017...

Page 66: ...r indicator 12 will light when the air conditioner is turned ON Ventilation Shift Switch 9 Press ventilation shift switch 9 to shift ventilation to circulation mode Press it again to shift it to fresh air mode Ventilation indicator 13 Circulation Fresh Air NOTE When the fresh air mode is selected the cab is slightly pressurized preventing dust from en tering into the cab Temperature Control Switch...

Page 67: ...e blower fan speed is increased from OFF to low to medium and to high Each time blower control switch 11 is pressed the blower fan speed is decreased from high to me dium to low then it will be turned OFF Blower Speed Indicator 15 Each part of the indicator indicates blower fan speed as follows High Speed Medium Speed II Medium Speed I Lo M18G 01 039 11 15 ...

Page 68: ...to turn on the blower fan Warm air will flow from the vents Use temperature control switch 10 and blower control switch 11 to adjust the temperature inside the cab DEHUMIDIFYING AND HEATING To prevent the windshield from clouding Set the temperature to the highest setting using tempera ture control switch 10 Repeatedly press tempera ture control switch 10 until all temperature indicators 14 turn o...

Page 69: ...he temperature to the lowest setting using temperature control switch 10 Repeatedly press temperature control switch 10 until only the leftmost indicator 14 is on Press blower control switch 11 to turn on the blower fan Air will flow from the vents VENTILATION THE CAB Turn on the fresh air indicator 13 using ventilation switch 9 Set the temperature to the lowest setting using temperature control s...

Page 70: ...e frequency Automatic Search Function Press and hold one tuning switch 5 for more than half a second then release The frequency display will move up to the next higher frequency station To go up to the next higher frequency station press and hold the tuning switch UP To go down to the next lower frequency station press and hold the tuning switch DOWN In order to deactivate the automatic search fun...

Page 71: ...e set mode will be selected 3 Press time set button H or M 8 to set the clock Each time set button H or M 8 is pressed the time display will increase by one If time set button H or M 8 is pressed and held the time display will change continuously When setting the hour press time set button H 8 When setting the minute press time set button M 8 The time is displayed in 12 hour standard If either of ...

Page 72: ...Light Switch 5 Entrance Light Switch 6 Auto Idle Switch 7 Fast Filling Switch 8 Key Switch 9 Buzzer Stop Switch 10 Travel Mode Switch 11 Maintenance Light Switch 12 Work Light Switch 13 Engine Stop Switch KEY SWITCH 1 OFF Power OFF 2 ACC Horn Radio etc 3 ON Power ON M18M 01 041 M18G 01 034 1 2 3 8 1 2 3 4 5 6 7 8 13 12 11 10 9 ...

Page 73: ...ch to the NORMAL position before attempting to restart the engine NOTE Do not use this switch when performing any in spection service work ENGINE START SWITCH When engine start switch is kept pressed the engine will continue to crank until the engine starts ENGINE STOP SWITCH When engine stop switch is kept pressed until the engine stops rotating completely the engine will stop M18M 01 004 M18M 01...

Page 74: ...ATION 1 31 ENGINE SPEED CONTROL DIAL Engine speed can be controlled with engine speed control dial The fully clockwise position 1 Fast Idle The fully counterclockwise position 2 Slow Idle M18M 01 004 M18G 01 040 1 2 ...

Page 75: ...urned ON On the cab roof toward front 2 pieces On the room under the cab toward front 2 pieces On the step in front of the right unit toward front 2 pieces On the back of the engine unit toward left back 1 piece On the back of the engine unit toward right back 1 piece On the side of the engine unit toward left side 1 piece M18M 01 005 M18M 01 019 M18G 01 017 M18M 01 038 1 3 4 2 1 1 1 1 1 ...

Page 76: ...RATOR S STATION 1 33 DOME LIGHT SWITCH All 2 dome lights 1 located on the front and rear part of the cab ceiling will be turned ON with dome light switch M18M 01 019 M18G 01 043 M18G 01 044 1 1 Front Rear ...

Page 77: ...ece In pump room 1 piece In engine room 2 pieces In radiator room 1 piece In oil cooler room 1 piece On engine unit for the control valve 1 piece M18M 01 005 M18M 01 025 M18M 01 026 M18G 01 033 M18M 01 022 M18M 01 023 M18M 01 024 1 In Oil Cooler Room 1 In Engine Room 1 In Room Under the Cab On Engine Unit For the Control Valve 1 1 1 In Pump Room 1 1 ...

Page 78: ...trance lights 1 will be turned ON with entrance light switch NOTE Entrance lights 1 will stay ON depending on the delayed power OFF time after the key switch is turned OFF with entrance light switch ON M18G 01 033 M18M 01 027 M18M 01 028 M18M 01 005 1 1 1 ...

Page 79: ...e Slow travel mode indicator is displayed in the part 1 of monitor Fast mode Fast travel mode indicator is displayed in the part 1 of monitor AUTO IDLE SWITCH Auto idle mode will be turned ON with auto idle switch Auto idle Indicator 2 will come ON when auto idle mode is turned on M18M 01 019 M18M 01 010 M18M 01 019 M18M 01 010 1 2 ...

Page 80: ...nded 6 Electric lever system is abnormal Electric lever indicator 29 comes ON also When buzzer stop switch is pressed the buzzer will stop sounding However indicators will stay ON The buzzer is kept deactivated even after the switch is released until the key switch is turned OFF and is turned ON again or after all abnormalities are eliminated During deactivation if a new abnormal condition occurs ...

Page 81: ...e engine while adding oil NOTE While fast filling panel is lowered the machine will not be able to swing 7 Add fuel hydraulic oil gear oil engine oil coolant and grease via the fast filling panel 8 Start the engine and run it at slow idle 9 Press fast filling system switch again 10 Fast filling panel 1 will start to go up 11 When fast filling panel 1 is completely raised it will stop going up auto...

Page 82: ...OPERATOR S STATION 1 39 REAR CONSOLE 1 Cigar Lighter 2 Fuse Box 3 DLU Download Connector 4 ECM Data Link Connector M18M 01 007 T18G 01 02 026 2 1 4 3 ...

Page 83: ...o sound while horn switch is kept pressed WARNING If horn 1 does not sound when pressed immediately stop the engine and contact your authorized dealer Operating the machine with a malfunctioning horn may result in personal injury or death M18M 01 006 M18M 01 038 1 ...

Page 84: ...e of the cushion seat while pulling lever 1 up Seat Fore Aft Adjustment Pull lever 2 up to adjust the seat fore aft position The adjusting positions are provided in 4 places in 15 mm increments Armrest Height Adjustment WARNING When armrest lock lever 7 is raised the armrest will suddenly be moved up to the maximum height by spring force If armrest lock lever 7 is raised with the arm placed on the...

Page 85: ...pply air from the compressor Pull lever 3 once and release it The seat height should automatically adjust corresponding to your weight When further adjustment is required pull lever 3 continuously to raise the seat height further When lever 3 is pushed downward the seat height is lowered Seat Armrest Backrest Fore Aft Adjustment Pull lever 4 to adjust the fore aft position of the seat armrest and ...

Page 86: ...ile keeping your back in contact with the backrest If the backrest is tilted forward without your back contacting the backrest the backrest may be suddenly tilted possibly resulting in injury to your back Lumbar Support Adjustment Turn dial 8 to adjust the lumber support position Headrest Adjustment Headrest 9 position can be adjusted in 7 positions in 100 mm increments in the up down direction an...

Page 87: ...arance Seat Belt 1 Securely insert the end of seat belt 1 into buckle 2 Confirm that seat belt 1 is not twisted 2 Pull out the end of belt 1 and securely insert it into buckle 2 Confirm that belt 1 is not twisted NOTE If belt 1 is locked before the end is securely inserted into buckle 2 release the end of belt 1 to completely return it to the original position Then retry 3 Push button 3 on buckle ...

Page 88: ... window can be opened Pull out lock pin 2 to unlock and open the cab left window Rotate the knob to open the cab left window WARNING Do not keep the cab left window open when the machine is parked on a slope or while the wind is blowing hard The cab left window may close accidentally possibly resulting in personal in jury When opening or closing the cab left window take extra care not to catch fin...

Page 89: ...OPERATOR S STATION 1 46 MEMO ...

Page 90: ... completion of local re assembly be sure to operate the machine with the travel speed switch set to the slow speed mode Check lower rollers and front idlers every 10 minutes for excessively high temperature Perform correct break in procedures for the front attachment pins 1 Operate the engine horsepower up to about 80 of full load 2 Avoid excessive engine idling 3 Check indicator lights and gauges...

Page 91: ...ng points at the regular intervals Grease the front attachment pins every day 3 Retighten bolts at the regular intervals 4 Re drive in the tooth point holding wedges 5 Check the monitor for any abnormality while operat ing the machine 6 Operate the machine after thoroughly warming up the engine and hydraulic oil 7 Check the machine for any abnormal operations while operating the machine ...

Page 92: ...cation points PROTECTIVE DEVICES Check guards shields and covers FIRE PREVENTION Clean machine of debris SAFETY Walk around machine to clear all persons from machine area Backhoe Front Attachment Bucket Cylinder Boom Link A Link B Arm Arm Cylinder T146 01 03 002 Loading Shovel Front Attachment Engine Counterweight Oil Cooler Radiator Lower Roller Pump Air Cleaner Battery Muffler Front Idler Washer...

Page 93: ...pilot control shut off lever 1 is in the LOCK position 2 Confirm that all control levers are placed in neutral 3 Adjust the seat to allow full pedal and control levers stroke with operator s back against the backrest Fasten the seat belt M18M 01 018 LOCK Position 1 ...

Page 94: ...ch fluid level visually at the regular intervals 4 Make sure that all checking items indicate NORMAL If one of the level checks indicates ABNORMAL check the fluid level concerned and add as needed In case other items indicate ABNORMAL contact your authorized dealer 5 The monitor will automatically shift from starting check screen 2 to meter check screen 8 NOTE When key switch 1 is turned to the ON...

Page 95: ...l check screen 11 shows up only when the engine is not running 3 Meter check screen 8 will be displayed again with button 10 on key pad 6 Warning indicators of alternator 12 pump transmis sion oil level 13 will stay ON M18G 01 018 M18G 03 005 M18M 03 001 M18M 01 009 10 8 11 Key Pad 12 13 Monitor Display Key Pad ...

Page 96: ...appear Press button 16 on key pad and current fault list 17 will be displayed Meter check screen 8 will be displayed again with button 18 on key pad After confirming the faults messages on display report the error codes Cummins or HCM or both to your authorized dealer M18G 03 005 M18M 03 002 M18M 03 003 16 18 14 17 15 Key Pad 8 ...

Page 97: ...l appear Press button 21 on key pad current alarm list 22 will be displayed Meter check screen 8 will be displayed again with button 18 on key pad After confirming the alarm messages on display report the error codes Cummins or HCM or both to your authorized dealer M18G 03 005 M18M 03 004 M18M 03 005 21 19 22 20 18 Key Pad 8 ...

Page 98: ... MONITOR SCREEN FLOW 1 M18M 01 008 M18M 03 001 M18M 01 009 M18M 03 005 M18M 03 003 Meter Check Screen Power ON Starting Check Screen Level Check Screen Automatic If Engine is not running Current Alarms List Current Faults List ...

Page 99: ...i cator remains lit while this function is operat ing Hold the engine start switch 4 until the en gine starts after Prelub indicator 5 goes OFF IMPORTANT Prevent damage to the starter Never run the starter continuously for more than 15 seconds If the engine fails to start wait for 2 to 3 minutes and try again 5 After the engine has started immediately release the engine start switch 4 IMPORTANT Af...

Page 100: ... Turn the engine speed control dial 2 to the slow idle position 3 Press and hold engine start switch 3 until the engine starts Prelub indicator 4 will light 4 The starter will rotate to start the engine after Prelub indicator 4 goes OFF 5 A shot of ether will be injected 6 After the engine has started release the engine start switch 3 7 Be sure to remove the ether container once the en gine is sta...

Page 101: ...w idle 5 Coolant temperature gauge 4 indicates the blue or white zone 6 Hydraulic oil temperature gauge 5 indicates the blue or white zone 7 Engine noise and exhaust gas are normal NOTE Handy engine troubleshooting can be done by checking the exhaust gas color Check with the engine running with no load after sufficient warm up operation Colorless or faint blue normal proper combustion Black abnorm...

Page 102: ...se only 24 volt booster batteries When the machine batteries are exhausted start the engine using booster batteries as shown below Connecting the booster batteries 1 Stop the engine of the machine on which booster batteries are mounted 2 Connect one end of red cable to the positive terminal of machine batteries 1 and the other end to the positive terminal of booster batteries 2 3 Connect one end o...

Page 103: ...sconnect the other end of black negative cable from booster batteries 3 3 Disconnect red positive cable from booster batteries 2 4 Disconnect red positive cable from machine batteries 1 M117 03 002 Machine Batteries Booster Batteries To Upperstructure of the Machine Red Upper Lower Black Connecting the Booster Batteries 4 3 2 1 ...

Page 104: ...n 4 Run the engine at slow idle without load for 5 minutes 5 Press and hold engine stop switch 4 until the engine completely stops rotating IMPORTANT Turbocharger may be damaged if the engine is not properly shut down 6 Turn key switch 5 to the OFF position Remove the key from the key switch 5 7 Pull pilot control shut off lever 1 to the LOCK position M18M 01 018 M18M 01 019 M18G 01 034 4 2 5 ON A...

Page 105: ...position when emergency engine stop is required in the cab 2 Engine will stop simultaneously and emergency stop indicator 3 will come ON In addition the air pressure is bled from the hydraulic oil tank 3 Turn emergency engine stop switch 2 to the NORMAL position and return the conditions to the normal engine stop before attempting to restart the engines NOTE Do not use emergency engine stop switch...

Page 106: ...stop is required except in the cab 2 In the engine room 1 In the pump room 1 In the oil cooler room 1 In the radiator room 2 Engine will stop and emergency stop indicator 3 will come ON NOTE The air pressure will not be bled from the hydraulic oil tank 3 Turn emergency engine stop switch 2 to the NORMAL position and return the conditions to the normal engine stop before attempting to restart the e...

Page 107: ...OPERATING THE ENGINE 3 16 MEMO ...

Page 108: ...e tracks using boom move machine carefully to prevent damage to drive train and tracks If engine stops under load remove the load Start engine immediately Run the engine 30 seconds in slow idle speed before you add load Select a route that is as flat as possible Steer machine as straight as possible making small gradual changes in di rection When driving over rough terrain reduce engine speed to l...

Page 109: ...aveling FORWARD TRAVEL Push down on front A of both pedals REVERSE TRAVEL Push down on rear B of both pedals NEUTRAL POSITION C When the travel pedals are placed in neutral travel brakes automatically will be applied to hold the ma chine RIGHT TURN Push down on front of left pedal LEFT TURN Push down on front of right pedal SHORT TURN Spin turn Push down the front of one pedal and the rear of the ...

Page 110: ...ravel motors before traveling FORWARD TRAVEL Push both levers forward A REVERSE TRAVEL Pull both levers rearward B NEUTRAL POSITION C When the travel levers are placed in neutral travel brakes automatically will be applied to hold the ma chine RIGHT TURN Push left lever forward LEFT TURN Push right lever forward SHORT TURN Spin turn Push one lever forward and pull the other rearward M104 04 001 M1...

Page 111: ...rm the travel mode using the indicators after chang ing modes When descending steep slopes avoid quick ac celeration and deceleration in the fast travel mode Damage to the travel motors may result Fast speed rabbit or slow speed turtle can be se lected by pushing travel mode switch 1 at any engine speed Indicator lights 2 show mode selection To decrease travel speed for traveling on a slope or in ...

Page 112: ... machine is traveling WARNING If the travel alarm does not sound when the travel levers or pedals are operated immediately stop the engine and contact your authorized dealer for repair Operating with the travel alarm malfunctioning may result in a seri ous accident 1 Travel Alarm M18M 04 004 1 ...

Page 113: ...wer rollers Before traveling on them check the strengths of bridges and road shoulders and reinforce if neces sary Use wood plates in order not to damage the road sur face Be careful of steering when operating on asphalt roads in summer When crossing train tracks use wood plates in order not to damage them Do not make contact with electric wires or bridges When crossing a river measure the depth o...

Page 114: ... ground Tow the machine if it becomes stuck but can still operate its engine Be sure to attach a towing wire correctly Refer to the TOWING MACHINE A SHORT DISTANCE section on the next page RAISE ONE TRACK USING BOOM AND ARM WARNING Keep the angle between boom and arm 90 to 110 and position the bucket s round side on the ground Swing the upperstructure 90 and lower the bucket to raise track off gro...

Page 115: ...h wire rope tow lines as illustrated at right and slowly tow your machine to firm ground using another machine Be sure to attach the wire ropes around the track frames of both machines as illustrated To prevent the wire ropes from being damaged place some protective material between the track frame and the wire ropes IMPORTANT Slowly tow keeping the tow line hori zontal and in a straight line with...

Page 116: ... move the machine into an area that has a water depth that is greater than 1 100 mm 3 ft 7 in from the ground If the footing is weak and water flow is fast take special care not submerge the swing bearing swing pinion gears due to the machine sinking and the force of strong water current If submerge the swing bearing swing pinion gears and center joint by mistake do not operate the machine with su...

Page 117: ... change the direction to ensure safe operation Avoid swinging the upperstructure on slopes Never attempt to swing the upperstructure downhill The machine may tip over If swinging uphill is unavoidable carefully operate the upperstructure and boom at slow speed If the engine stalls on a slope immediately lower the bucket to the ground Return the control levers to neutral Then restart the engine Be ...

Page 118: ...RTANT Turbocharger may be damaged if the engine is not properly shut down 4 Move engine speed control Dial 1 to the slow idle position Run the engine approximately 5 minutes to cool the engine 5 Press and hold engine stop switch 2 until the engine completely stops rotating 6 Turn key switch 3 to OFF Remove the key from the key switch 7 Pull pilot control shut off lever 4 to the LOCK posi tion IMPO...

Page 119: ...DRIVING THE MACHINE 4 12 MEMO ...

Page 120: ...e operating The machine is equipped with a label showing the control patterns of the levers and pedals IMPORTANT When digging avoid hitting tracks with boom cylinders When digging over the end of the tracks travel motors should be at the rear to maximize machine stability and lift ca pacity When a lever is released it will automatically return to neutral and that machine function will stop 1 Arm R...

Page 121: ...ore operating The machine is equipped with a label showing the control patterns of the levers and pedals IMPORTANT When digging avoid hitting tracks with boom cylinders When digging over the end of the tracks travel motors should be at the rear to maximize machine stability and lift ca pacity When a lever is released it will automatically return to neutral and that machine function will stop 1 Swi...

Page 122: ...efore operating The machine is equipped with a label showing the control patterns of the levers and pedals IMPORTANT When digging avoid hitting tracks with boom cylinders When digging over the end of the tracks travel motors should be at the rear to maximize machine stability and lift ca pacity When a lever is released it will automatically return to neutral and that machine function will stop 1 A...

Page 123: ... before operating The machine is equipped with a label showing the control patterns of the levers and pedals IMPORTANT When digging avoid hitting tracks with boom cylinders When digging over the end of the tracks travel motors should be at the rear to maximize machine stability and lift ca pacity When a lever is released it will automatically return to neutral and that machine function will stop 1...

Page 124: ...OPERATING THE MACHINE 5 5 BUCKET OPEN CLOSE PEDALS LOADING SHOVEL 9 Bucket Closing 10 Bucket Opening M18M 01 006 M18G 05 004 10 9 10 9 ...

Page 125: ...eaving the Machine 1 Park the machine on a firm level surface Lower the bucket to the ground Return all control levers to neu tral Properly shut down the engine 2 Pull pilot control shut off lever 1 up into the full LOCK position Before Starting Operation 1 Confirm that pilot control shut off lever 1 is pulled up to the LOCK position After starting the engine 1 Confirm that all control levers and ...

Page 126: ...th engine speed control dial The fully clockwise position 1 Fast Idle The fully counterclockwise position 2 Slow idle Before stopping the engine always turn engine speed control dial to the slow idle position and run the engine five minutes at slow idle M18M 01 004 M18G 01 040 1 2 ...

Page 127: ...that the engine speed will unex pectedly increase when any control lever is operated causing unexpected machine movement thus possibly resulting in serious personal injury Prevent the machine from unexpected move ment Be sure to turn auto idle switch 1 off when unexpected machine movement is unde sirable Note that auto idle function can be turned on or off only when the key switch is in ON positio...

Page 128: ...iddle of the white zone B in the following procedures before starting to work 1 Run the engine at slow idle for 5 minutes 2 Increase the engine speed to middle speed by oper ating the engine speed control dial 3 Run the en gine for 5 minutes with the bucket held in the rolled out tilted out position Do not operate other functions than the bucket at this time 3 Increase the engine speed to the maxi...

Page 129: ... the engine for at least 5 minutes on slow idle 2 Run the engine for at least 5 minutes at medium speed 3 Extend the bucket cylinder to the far stroke end Do not operate bucket control lever 1 for over 30 seconds at this time 4 Retract the bucket cylinder to the near stroke end Do not operate bucket control lever 1 for over 30 seconds at this time 5 Repeat procedures 3 and 4 until the bucket worki...

Page 130: ...equipment appropriate for the job such as a hard hat etc when operating the machine Clear all persons and obstacles from area of operation and machine movement Always beware of the surroundings while operating When working in a small area surrounded by obsta cles take care not to hit the upperstructure against obstacles When loading onto trucks bring the bucket over the truck beds from the rear si...

Page 131: ...re to investigate the area first and confirm that no danger of the cliff or bank collapsing exists If any possibility of cliff or bank collapsing exists do not work on the area Soft ground may collapse when operating the machine on it possibly causing the machine to tip over When working on a soft ground is re quired be sure to reinforce the ground first using large pieces of steel plates strong a...

Page 132: ... tracks parallel to the trench After digging to the desired depth move the machine as required to continue the trench NOTE When crowding the arm it is normal for the arm to pause briefly at the lowest point of its curve as shown This is due to the fact that the force of gravity pulls the arm down quickly and it takes a moment for the hydraulic force in the cylinder to catch up This does not indica...

Page 133: ...ION WARNING Do not use travel as an additional digging force Severe machine damage may re sult Do not raise rear of machine to use the machine s weight as additional digging force Severe ma chine damage may result M145 05 011 M145 05 012 WRONG WRONG ...

Page 134: ...oads on every pass are more productive than a faster cycle with a partially filled bucket Full load should be the first objective followed by speed to increase productivity WARNING Do not attempt to break ledge rock by extending the arm to maximum reach and drop ping the front of the bucket on the bucket teeth for penetration Serious damage to the machine can result Once the trench is open ledge r...

Page 135: ...ging is unavoidable keep a distance of at least 3 m between the rear end of the bucket and the front end of the undercarriage 2 Never dig with the bucket fully retracted and the bucket teeth stuck in the ground as the front attach ment will be subjected to excessive force 3 Do not use the rear of the bucket for grading opera tion as this will damage it 4 Do not push rocks or other heavy materials ...

Page 136: ...the bucket forward 5 Do not use the weight of the base machine to pry earth as illustrated Doing so will damage the base machine and may cause personal injury 6 Machine stability is greater when the load is posi tioned parallel with the tracks Machine stability is reduced when the load is swung to the side and when operating the front attachment perpendicular to the tracks Sudden stop of boom lowe...

Page 137: ... Do not attach sling chain to the bucket teeth Secure sling chain tightly to the load to be lifted Wear gloves when securing sling chain Fasten sling chain to bucket loop with the bucket curled and arm retracted Coordinate hand signals with your signal man before starting Be aware of the location of all persons in the working area Attach a hand line to load and make sure person holding it is well ...

Page 138: ...e or floods Park the machine referring to the PARKING THE MACHINE in the DRIVING THE MACHINE section 2 Fill the fuel tank with fuel 3 Clean the machine 4 If anti freeze or long life coolant is not used in cold weather be sure to drain coolant from the radiator and the engine jacket Also be sure to put a No Water in Radiator tag in a visible place if the coolant has been drained M117 05 023 ...

Page 139: ...OPERATING THE MACHINE 5 20 MEMO ...

Page 140: ...eneral appearance noise heat etc Check for loose or missing parts If there is any problem with your machine repair it before operating or contact your authorized dealer IMPORTANT y Use only recommended fuel and lu bricants y Use only genuine HITACHI parts y Failure to use recommended fuel lu bricants and genuine Hitachi parts will result in loss of Hitachi product warranty y Never adjust engine go...

Page 141: ...our machine in more adverse conditions you should ser vice it at SHORTER INTERVALS Lubricate make service checks and adjustments at intervals shown on periodic maintenance chart 2 lo cated on the inside of the cab rear right USE CORRECT FUELS AND LUBRICANTS IMPORTANT Always use recommended fuels and lu bricants Failure to do so will result in machine damage and loss of Hitachi product war ranty M1...

Page 142: ... 7 Before performing any work on the machine attach a Do Not Operate tag on the right control lever 8 Ground Disconnector This machine is equipped with a battery ground dis connector located outside of engine unit compart ment on the right side The battery ground circuit can be disconnected by pulling disconnector lever 2 down before replacing the battery checking the elec trical system or perform...

Page 143: ...E 7 4 10 Before starting to check and or service the inside of the engine compartment turn engine stop switch 4 located at the engine compartment entrance to the EMERG STOP position to assure safety M18M 07 002 4 ...

Page 144: ...The access doors 1 may close accidentally possibly resulting in personal injury When opening or closing the access doors 1 take extra care not to catch fingers between the base machine and the access doors 1 To keep the access door open lower rod 2 into a gap on the platform or into locking hole 3 as illus trated M146 07 015 M18M 07 003 M18M 01 005 2 2 3 1 1 1 1 ...

Page 145: ...INSPECTION MAINTENANCE LIGHTS All 7 maintenance lights 1 will be turned ON with mainte nance light switch Use switch 5 located on the switch panel in the cab to turn on off these lights M18M 01 019 M18M 01 005 5 1 1 1 ...

Page 146: ...he chain has no damage If any damage such as wear or breaks are found replace with new one 1 Remove chain 1 from hook 3 located on the left upper front cab and from handrail 5 2 Install the free end of chain 1 to right hook 7 to at tach the chain 3 Check that chain 1 is securely installed to both hooks 6 and 7 4 Before re starting machine operation remove chain 1 from right hook 7 After hanging th...

Page 147: ... cap 1 slowly and remove the cap only after releasing the internal pressure completely 1 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 2 Turn cap 1 counter clockwise about 30 at which point stop cap 1 to release the air 3 Turn cap 1 further and remove cap 1 4 Align the projected part of cap 1 with the projected part of the case and install cap 1 3 Connect suction hos...

Page 148: ...op of oil cooler 7 Close 2 stop valves 8 on the suction pipes under the hydraulic oil tank 8 Turn electric pump 2 switch ON The pump starts to draw oil 9 After drawing oil turn electric pump 2 switch OFF 10 Install plugs 6 and 7 Close stop valve 5 Disconnect suction hose 3 of electric pump 2 M18M 07 010 M18M 07 008 M18M 07 009 M18M 07 063 M18M 07 064 Main Pump Plugs Return Line B 5 6 4 Section B 8...

Page 149: ... Radiator Lower Roller Pump Air Cleaner Battery Muffler Front Idler Washer Tank Fuel Tank Track Adjuster Accumulator Upper Roller Boom Cylinder Level Cylinder Bucket Cylinder Dump Cylinder Hydraulic Oil Tank Control Valve Side Frame Travel Device Swing Device Lubricator Emergency Evacuation Equipment Arm Bucket Boom Cab Air Fan Bucket Engine Oil Re serve Tank Stairway Arm Cylinder Water Tank ...

Page 150: ...d valves actuated by the electric control levers pedals send pilot oil from the pilot pumps to the control valves moving their spools This spool movement routes the pump delivery oil to the cylin ders and motors 3 Relief valves of sufficient capacity are provided in the control valves full flow filters and the pilot and oil cooler circuits in order to protect each circuit from abnormally high pres...

Page 151: ...VALVE Arm 25 HYDRAULIC OIL TANK 26 FULL FLOW FILTER 27 LOW PRESSURE RELIEF VALVE 28 BYPASS FILTER 29 DRAIN FILTER 30 SUCTION FILTER 31 SUCTION MANIHOLD 32 ENGINE 33 PUMP TRANSMISSION 34 MAIN PUMP No 1 35 MAIN PUMP No 2 36 MAIN PUMP No 3 37 MAIN PUMP No 4 38 MAIN PUMP No 5 39 MAIN PUMP No 6 40 MAIN PUMP No 7 41 MAIN PUMP No 8 42 RADIATOR FAN DRIVE PUMP 43 OIL COOLER FAN DRIVE PUMP 44 PILOT PUMP 45 ...

Page 152: ...FLOW FILTER 27 LOW PRESSURE RELIEF VALVE 28 BYPASS FILTER 29 DRAIN FILTER 30 SUCTION FILTER 31 SUCTION MANIHOLD 32 ENGINE 33 PUMP TRANSMISSION 34 MAIN PUMP No 1 35 MAIN PUMP No 2 36 MAIN PUMP No 3 37 MAIN PUMP No 4 38 MAIN PUMP No 5 39 MAIN PUMP No 6 40 MAIN PUMP No 7 41 MAIN PUMP No 8 42 RADIATOR FAN DRIVE PUMP 43 OIL COOLER FAN DRIVE PUMP 44 PILOT PUMP 45 AIR CON COMP DRIVE PUMP 46 PUMP TRANSMIS...

Page 153: ...f all hoses as shown below and replace or retighten any defective parts found as necessary Consult your authorized dealer for correct replacement No Periodic Replacement Parts Q ty in Use Replacement Intervals Pump Delivery Hoses 1 Main Pumps to High Pressure Filters 8 2 High Pressure Filters to Blocks 4 3 Blocks to High Pressure Pipes 4 4 High Pressure Pipes to Control Valves 4 5 Fan Pumps to Oil...

Page 154: ...jury may result due to falls of the front penetration of high pressure oil into the skin or fire Regardless of regular replacement intervals if hoses are found to be defective by periodic inspection refer to pages 7 70 and 7 80 be sure to repair or replace them before operating the machine Be sure to replace seals such as O rings and hose clamps along with replacing hoses Consult your authorized d...

Page 155: ...ers 1 8 High pressure filters to Blocks 2 4 Blocks to High pressure pipes 3 4 High pressure pipes to Control valves 4 4 Fan pumps to oil cooler fan motor and radiator fan motor 5 4 Pump Delivery Hoses Tail hoses 6 6 Front Hoses Control Valves to Front 7 2 M146 07 096 7 3 3 4 4 ...

Page 156: ...MAINTENANCE 7 17 Hoses Q ty in Use Loading Shovel Front Hoses Main Frame to Boom 8 16 Hoses Q ty in Use Backhoe Front Hoses Main Frame to Boom 9 16 M146 07 097 M146 07 017 8 9 ...

Page 157: ...7 18 Hoses Q ty Travel Hoses Control Valves to Center Joint 10 4 Swing Hoses Control Valves to Swing Motors 11 8 M18M 07 018 M18M 07 016 M18M 07 017 M18M 07 025 10 11 11 11 11 Swing Motors Swing Motors Center Joint ...

Page 158: ...ses Hoses Q ty in Use Fuel Tank to Engine 12 3 Engine to Fuel Cooler 13 5 Fuel Cooler to Fuel Tank 14 5 M18M 07 023 M18M 07 024 M18M 07 019 M18M 07 020 M18M 07 021 M18M 07 022 14 12 14 13 13 12 13 14 14 13 13 14 Fuel Cooler 12 ...

Page 159: ...ngine Oil Change Reserve TankÏ Standard 258L Ú 68 2 US gal Ä Ì Ì 4 Replace Engine Oil Filter 4 Ä NOTE Ä First time only Ì When change engine oil change the oil in engine oil pan and reserve tank at the same time Ú Total quantity of oil Engine Oil Pan and Reserve Tank achieves 500 hours replacement interval It differs according to the kind of engine oil used The capacity of reserve tank is 280L 74 ...

Page 160: ...raulic oil used See recommended oil chart First time only E FUEL SYSTEM See Page 7 74 Tank capacity 7450 liter 1970 US gal Interval hours Parts Quantity 10 50 250 500 1000 1500 2000 1 Drain Fuel Tank Sump 1 2 Drain Fuel Filter Sediment Stage 1 filter 3 Weekly or as required 3 Replace Fuel Element Stage 1 filter 3 4 Replace Fuel Filter Stage 2 filter 3 Check Fuel Hoses for leak loose 5 Check Fuel H...

Page 161: ...ter and Genuine Hitachi Long Life Coolant As long as Genuine Hitachi Long Life Coolant is used the service intervals between changing the coolant is once every two years or every 4000 hours whichever comes first H AIR CONDITIONER See Page 7 97 Interval hours Parts Quantity 10 50 250 500 1000 1500 2000 Cleaning 3 As required 1 Recirculation Air Filter Replacement 3 Replace per 4 cleaning Cleaning 3...

Page 162: ... Rope and Rope Mounting Hardware 1 3 Check Auto Lubrication System 1 Check 2 4 Seat Belt Replacement 2 At least once every 3 years 5 Check Washer Tank 2 As required 6 Air Horn Compressor Filter Cleaning 1 As required 7 Check and Adjust Track Sag 2 8 Check Accumulator and Track Adjuster Cylinder Circuit 2 Every year 9 Clean Side Frame Area 2 10 Check Tightening Torque of Bolts and Nuts NOTE First t...

Page 163: ...lable M18M 03 007 Brand Names of Recommended Grease Swing Internal Gear Front Joint Pins Swing Bearing Where to be applied Manufacturer 20 to 50 C 4 to 122 F British Petroleum BP Energrease LS EP2 BP Energrease LS EP1 Caltex Oil Multifax EP2 Multifax EP1 Esso Beacon EP2 Beacon EP1 Idemitsu Kosan Daphne Coronex Grease EP2 Daphne Coronex Grease EP1 Mobil Oil Mobilux EP2 Mobilux EP1 Nippon Oil Epinoc...

Page 164: ... for the fittings on the loading shovel front 1 Park the machine on a level surface 2 Lower the bucket to the ground 3 Pull the pilot control shut off lever to the LOCK position 4 Apply grease to fittings until grease can be seen escaping from greasing places 5 Take care not to supply excessive grease Manually greasing places are as illustrated below 1 Grouped Grease Fittings 1 Bucket Ñ Lubricatio...

Page 165: ...MAINTENANCE 7 26 2 Grouped Grease Fittings 2 Boom Ñ Lubrication Points 3 Grouped Grease Fittings 3 Boom Foot M146 07 084 M18M 07 029 2 3 3 ...

Page 166: ...MAINTENANCE 7 27 4 Grouped Grease Fittings 4 Arm Ñ Lubrication Points M146 07 085 4 ...

Page 167: ...on the backhoe front except for the bucket and link 1 Park the machine on a level surface 2 Lower the bucket to the ground 3 Pull the pilot control shut off lever to the LOCK position 4 Apply grease to fittings until grease can be seen escaping from greasing places 5 Take care not to supply excessive grease Manually greasing places are as illustrated below 1 Grouped Grease Fittings 1 Bucket Ñ Lubr...

Page 168: ...MAINTENANCE 7 29 2 Grouped Grease Fittings 2 Boom Ñ Lubrication points M18M 07 034 M18M 07 035 3 Grouped Grease Fittings 3 Boom Foot Ñ Lubrication points M18M 07 033 M18M 07 029 2 3 3 ...

Page 169: ...MAINTENANCE 7 30 4 Grouped Grease Fittings 4 Arm Ñ Lubrication points M18M 07 036 4 ...

Page 170: ... handrails 1 Park the machine on a level surface 2 Lower the bucket to the ground 3 Pull the pilot control shut off lever to the LOCK position 4 With the upperstructure stationary apply grease to the twenty four grease fittings 5 Raise the bucket several inches off the ground and rotate the upperstructure 45 1 8 turn 6 Lower the bucket to the ground 7 Repeat the procedure three times beginning wit...

Page 171: ...hut down 4 Run the engine at slow idle speed without load for five minutes 5 Press and hold the engine stop switch until stopping the engine completely Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK position 7 Open cover 1 on the right side of the upper structure 8 Remove cover 1 on the underside of the swing gear housing and thoroughly remove old grease fro...

Page 172: ...ket to the ground Pull the pilot control shut off lever to the LOCK position Use handrails 1 Park the machine on a level surface 2 Lower the bucket to the ground 3 Pull the pilot control shut off lever to the LOCK position 4 With the upperstructure stationary apply grease to the one grease fitting 5 Total amount of grease to be applied is approximately 5 to 6 strokes by grease lubricator M18M 07 0...

Page 173: ... automatically locks the hose IMPORTANT Run the engine at slow speed whenever the lubricator is used 5 Insert the end of the grease gun in the desired fitting and pull gun lever automatically adds grease to the fitting Storing Grease Hose After Finishing Greasing 1 Slightly pull out the hose reel 5 unlocks automatically winds and stores the hose 2 Move auto lubrication toggle switch 3 located in o...

Page 174: ...one 3 Install follower plate 8 into the grease can 4 Install cover assembly 6 on the lubricator housing while aligning grease tube with the hole on the follower plate in order not to push down the plate into grease when installing the cover Tighten wing nuts 7 NOTE Greasing can be made from the ground through the fast filling panel installed at the rear section of the machine Refer to page 1 38 fo...

Page 175: ...circulated between engine oil pan and reserve tank by the pump on reserve tank Engine Oil Viscosity Requirements Classification of Oil API Service Class Type Viscosity Grade SAE Temperature Ranges CF 4 All Season Multigrade 15W 40 18 to 50 C 0 to 122 F Standard CG 4 All Season Multigrade 15W 40 18 to 50 C 0 to 122 F CH 4 All Season Multigrade 15W 40 18 to 50 C 0 to 122 F Premium CI 4 All Season Mu...

Page 176: ...f the marks static H and L Be sure to use only the oil to meet requirement and check the oil level in the reserve tank Engine Oil Level in Reserve Tank check daily IMPORTANT For most accurate readings check the oil level every day before starting the machine Be sure the machine is on a level surface 1 Stop the engine 2 Remove dipstick 3 Wipe oil off with a clean cloth Reinsert dipstick 3 3 Remove ...

Page 177: ...red oil from the engine oil pan to the reserve tank b Flashing This signal indicates that the Pump 1 and 2 are running and oil is being transferred from the reserve tank to the engine oil pan IMPORTANT The signal should alternate between periods of Steady and Flashing so that required engine oil level is being maintained on during operation NOTE If the LED monitor does not work contact your author...

Page 178: ... you are not burned from hot oil 8 Prepare a container of 260 liter 68 7 US gal or more capacity for the drain oil 9 Remove drain plug 1 near the engine oil pan 10 Open drain cock 2 to drain the engine oil 11 Check if foreign material like metal particles are included in the drain oil by filtering it with a clean cloth 12 Tighten drain plug 1 and close drain cock 2 securely 13 Unscrew main filter ...

Page 179: ... for at least 10 minutes before checking NOTE Oil can be refilled from the ground using the Fast Filling panel located in the rear of the base machine Refer to page 1 38 for the Fast Filling panel operation Change Engine Oil in Reserve Tank every 500 hours first time after 50 hours 1 Run the engine to warm oil DO NOT run the engine until oil is hot 2 Park the machine on a level surface 3 Lower the...

Page 180: ...ve the line of premium or standard in accordance with the oil you use on dipstick 9 NOTE Checking the oil level immediately after shut down will result in inaccurate readings Be sure to allow the oil to settle for at least 10 minutes before checking NOTE Oil can be refilled from the ground using the Fast Filling panel located in the rear of the base machine Refer to page 1 38 for Fast Filling pane...

Page 181: ...ve on the reserve tank opens The shut off valve open indicator 6 lights up 4 Oil can begin filling the reserve tank through the shut off valve 5 When the oil in the reserve tank reaches the proper full level the shut off valve closes and full indicator 7 lights up 6 Turn power switch 4 to the OFF position to turn the power off M18M 01 020 7 6 4 5 ...

Page 182: ...polloil Gear HE90 Mobil Oil Mobilube GX90 Nippon Oil Gear Lube SP90 Shell Oil Shell Spirax EP90 Remarks API GL 4 Class NOTE The machine is filled with oil marked by when shipped from the factory Recommended brands of Class CD oils API Service Classi fication are shown in the chart below If any oil other than these recommended oils is used the oil must be Class CD or CF API Service Classification a...

Page 183: ...device Pump Transmission Oil Level Check every 50 hours first time after 10 hours IMPORTANT For most accurate readings be sure the machine is on a level surface 1 Stop the engines NOTE Refer to page 3 13 for stopping the engines properly 2 Remove dipstick 1 Wipe oil off with a clean cloth Reinsert dipstick 1 3 Remove dipstick 1 again Read level Oil level must be between the circle marks on dipstic...

Page 184: ...ration Be sure to wait for oil to cool before starting work 8 Prepare a container of 55 liter 14 5 US gal or more capacity for the drain oil 9 Remove drain plug 3 on the pump transmission housing and loosen cock 4 to drain the oil 10 Check if foreign material like metal particles are included in the drain oil by filtering it with a clean cloth 11 Tighten drain plug 3 and cock 4 securely Fill the p...

Page 185: ...coat of lubri cating oil to the gasket sealing surface prior to in stalling the cartridge filter 3 Position cartridge filter 5 to the filter head Tighten by hand until the seal touches the filter head tighten an additional three fourths turn Be careful not to over tighten Clean Breather every 500 hours Remove breather cap 6 and clean the element M146 07 068 M18M 07 042 6 5 ...

Page 186: ... 8 Remove dipstick 1 Wipe oil off with a clean cloth Reinsert dipstick 1 9 Remove dipstick 1 again Read level Oil level must be between the top and notch on dipstick 1 10 If necessary remove oil supply plugs and add oil Be sure to use only reccomended oil See reccomended Gear Oil Chart Refer to next page to know how to add oil 11 Recheck oil level 12 Install dipsticks 1 13 Close cocks 5 after chec...

Page 187: ...oil 9 Remove drain plug 3 and loosen drain cock 2 to drain oil 10 Check if foreign material like metal particles are in cluded in the drain oil by filtering it with a clean cloth 11 Tighten drain cock 2 and drain plug 3 12 Remove oil supply plug 4 and fill with 75 L 20 US gal oil Be sure to use only recommended oil see Recommended Gear Oil Chart 13 Confirm that the oil level is between the top and...

Page 188: ...gradually loosen oil level check plug air release plug 1 to release pressure 7 After gear oil has cooled slowly loosen oil level check plug air release plug 1 to release pressure 8 Remove oil level check plug 1 Oil must be up to the bottom of hole 9 If necessary after oil supply plugs 3 have been removed add oil until oil flows out of the oil level check plug hole Be sure to use only reccomeded oi...

Page 189: ... drain oil 10 Remove drain plugs 2 to drain oil 11 Check if foreign materials like metal particles are in cluded in the drain oil by filtering it with a clean cloth 12 Wrap the threads of drain plug 2 with sealing type tape Install drain plug 2 Tighten the plug to 69 Nxm 7 kgfxm 51 lbfxft 13 Remove oil level check plug 1 14 After oil supply plug 3 has removed add oil until oil flows out of the oil...

Page 190: ...ind of hydraulic oil used See recommended oil chart Ä First time only M18M 03 007 Brand Names of Recommended Hydraulic Oil Kind of Lubricant Hydraulic Oil Where to be applied Hydraulic System Change Interval 4000 hours 2500 hours 2000 hours Environmental Temp Manufacturer 20 to 50 C 4 to 122 F 10 to 50 C 14 to 122 F 20 to 50 C 4 to 122 F 10 to 50 C 14 to 122 F 20 to 50 C 4 to 122 F 10 to 50 C 14 t...

Page 191: ...s hydraulic oil and lubricants are com pletely cooled and after releasing residual pressure 3 1 Bleed air from the hydraulic oil tank to release in ternal pressure 3 2 Allow the machine to cool down Note that servicing heated and pressurized hydrau lic components may cause hot parts and or oil to fly off or escape suddenly possibly resulting in per sonal injury 3 3 Keep body parts and face away fr...

Page 192: ...ue specifications on the right side Do not over tighten 5 When adding hydraulic oil always use the same brand of oil do not mix brands of oil As the machine is filled with Super EX 46HN when it is shipped from the factory use it as a general rule When selecting to use another brand of oil listed in the table Brand names of recommended hydraulic oil be sure to completely replace the oil in the syst...

Page 193: ...ry add oil WARNING Keep body and face away from cap 3 Turn cap 3 slowly and remove the cap only after releasing the internal pressure completely To add oil 9 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 10 Turn cap 2 counterclockwise about 30 at which point stop cap 2 to release the air 11 Turn cap 2 further and remove cap 2 12 Align the projected part of cap 2 with...

Page 194: ... slowly and remove the cap only after releasing the internal pressure completely 7 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 8 Turn cap 1 counterclockwise about 30 at which point stop cap 1 to release the air 9 Turn cap 1 further and remove cap 1 10 Align the projected part of cap 1 with the projected part of the case and install cap 1 WARNING Do not loosen the d...

Page 195: ...t load for five minutes 6 Stop the engine Remove the key from the key switch 7 Pull the pilot control shut off lever to the LOCK posi tion 8 Clean the top of the hydraulic oil tank to keep dirt out of the hydraulic system WARNING Keep body and face away from cap 1 Turn cap 1 slowly and remove the cap only after releasing the internal pressure completely 9 Insert the wrench as shown and turn the wr...

Page 196: ...h new one and check that it is correctly installed 22 Bleed any air remaining in the hydraulic system NOTE Refer to page 7 58 for bleeding air properly 23 Confirm that the oil level is at the mark on gauge 5 Start the engine and operate all cylinders and motors at slow speed for about 15 minutes Stop the engine after bleeding air from the hydraulic circuit sufficiently Ten to twenty minutes later ...

Page 197: ...nnectors 2 when air stops and oil flows from pipe connectors 2 3 Start the engine and run at slow idle 4 Purge air from the hydraulic system by running the engine at slow idle and operating the control levers slowly and smoothly for 15 minutes 5 Position the machine as illustrated in the oil level checking procedure 6 Stop the engine Remove the key from the key switch 7 Pull the pilot control shut...

Page 198: ...raulic oil and components may be hot just after operation Be sure to allow oil and components to cool before starting work WARNING Keep body and face away from cap 1 Turn cap 1 slowly and remove the cap only after releasing the internal pressure completely 7 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 8 Turn cap 1 counterclockwise about 30 at which point stop cap 1...

Page 199: ... metal par ticles and debris in the bottom of the filter case Excessive amounts of brass and steel particles can indicate a failed hydraulic pump motor valve or an impending failure A rubber type of material can indicate cylinder packing failure 13 Discard element 7 and O ring 4 14 Install a new element 7 valve 6 and spring 5 15 Install filter cover 2 with a new O ring 4 16 Install and tighten bol...

Page 200: ... Hydraulic oil and components may be hot just after operation Be sure to allow oil and components to cool before starting work WARNING Keep body and face away from cap 1 Turn cap 1 slowly and remove the cap only after releasing the internal pressure completely 7 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 8 Turn cap 1 counterclockwise about 30 at which point stop c...

Page 201: ...s and steel particles can indicate a failed hydraulic pump motor valve or an impending failure A rubber type of material can indicate cylinder packing failure 13 Inspect filter element 5 and the filter housing for metal particles and debris 14 Discard O ring 4 and element 5 15 Install new element 5 into the filter housing 16 Install filter cover 3 with new O ring 4 17 Install and tighten bolts 2 t...

Page 202: ...rol shut off lever to the LOCK posi tion WARNING Hydraulic oil and components may be hot just after operation Be sure to allow oil and components to cool before starting work WARNING Keep body and face away from cap 1 Turn cap 1 slowly and remove the cap only after releasing the internal pressure completely 9 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 10 Turn cap ...

Page 203: ...ter housing 9 NOTE Remove element and inspect for materials on element and in bottom of filter housing Exces sive amounts of foreign materials can indicate abnormalities in the system 15 Inspect filter element 8 and filter housing 9 for for eign materials 16 Install new filter element 8 valve 6 and spring 5 into filter housing 9 17 Install washer 3 cover 4 and new O ring 7 18 Tighten bolts 2 to 88...

Page 204: ...emove rod assembly 2 2 Clean the inside of the hydraulic oil tank and the suc tion filters 3 Before installing check dimensions of rod assembly 2 by referring the figure below Securely re install the rod assembly into pipe 3 4 Replace the O ring with new one and check that it is correctly installed before re installing cover 1 Se cure cover 1 with bolts 5 Bleed any air remaining in the hydraulic s...

Page 205: ...rod assembly 2 2 Clean the inside of the hydraulic oil tank 3 Replace the element of rod assembly 2 4 Before installing check dimensions of rod assembly 2 by referring the figure below Securely re install the rod assembly into pipe 3 5 Replace the O ring with new one and check that it is correctly installed before re installing cover 1 Se cure cover 1 with bolts 6 Bleed any air remaining in the hy...

Page 206: ...om pletely 7 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 8 Turn cap 1 counter clockwise about 30 at which point stop cap to release the air 9 Turn cap 1 further and remove cap 1 10 Align the projected part of cap with the projected part of the case and install cap 1 11 Remove bolts 2 cover 3 and strainer assembly 6 from housing 7 12 Discard O rings 4 and 5 and stra...

Page 207: ... surface Clean the oil cooler core using compressed air 0 2 MPa 2 kgf cm 2 or less or tap water Upper and lower covers 2 and 3 can be removed from oil cooler frame 1 Remove the covers to clean the cooler core thoroughly Four oil coolers 4 units are arranged in both series and parallel Clean all the cooler units IMPORTANT If upper cover 2 and lower cover 3 are incorrectly installed the cooler per f...

Page 208: ...d Park the machine on a firm level surface Lower the bucket to the ground Stop the engine Remove key from the key switch Pull the pilot control shut off lever to the LOCK position Check for missing or loose clamps kinked hoses lines or hoses that rub against each other damaged oil cooler and loose oil cooler flange bolts for leaks Check hoses lines and oil cooler at the check points indicated belo...

Page 209: ...s Hose Hose Hose ends and fittings Crack 4 Crack 5 Exposed reinforcement 6 Blister 7 Bend 8 Collapse 9 Deformation or Corrosion 10 Replace Replace Replace Replace Replace Replace Use proper bend radius Replace NOTE Refer to the illustrations in Fig 1 for each check point location or for a descrip tion of the abnormality Use genuine Hitachi parts M115 07 145 M115 07 146 M115 07 147 M115 07 148 M115...

Page 210: ...sing Deformation Replace Replace Replace NOTE Refer to the illustrations in Fig 2 for each check point location or for a descrip tion of the abnormality Use genuine Hitachi parts Table 3 Oil cooler Interval hours Check Points Abnormalities Remedies Every 250 hours Contact surfaces of flange joints Oil cooler Leak 14 Leak 15 Replace O ring and or retighten bolts Replace NOTE Refer to the illustrati...

Page 211: ...petroleum jelly to hold it in place 4 Tighten 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 re place O ring 1 and check for cor...

Page 212: ...or obvious defects IMPORTANT Defects in the tube flare cannot be re paired Overtightening a defective flare fitting will not stop a leak 2 Tighten fitting 7 by hand 3 Tighten fitting 7 or nut 8 to the torque values shown Do not allow hose 5 to twist when tightening fittings Width across flats mm 19 22 27 Nxm 29 5 39 93 kgfxm 3 4 9 5 Fastening torque lbfxft 21 5 29 69 M202 07 051 7 9 8 10 5 ...

Page 213: ...soline is used accidentally fire will break out resulting in serious personal injury or death Recommended Fuel Use only high quality DIESEL FUEL OIL in accordance with JIS K 2204 ASTM2 D or equivalent For further details refer to the manual for Commins Engine Refueling 1 Park the machine on a firm level surface 2 Lower the bucket to the ground 3 Turn the auto idle switch off 4 Check fuel gauge 1 o...

Page 214: ... sure to select a charging pump of appropriate capacity when fueling to avoid overflowing 9 A filter is provided in the filler port Clean the filter in light oil at the regular interval 10 Reinstall filler cap 2 NOTE Fuel can be supplied from the ground using the fast filling panel located in the rear of the base machine Refer to page 1 38 for the fast filling panel operation NOTE Full of the tank...

Page 215: ...off lever to the LOCK posi tion 7 Open drain cock 1 for several seconds to drain wa ter and sediment Close drain cock 1 Drain Fuel Filter Sediment Weekly or as required Water visible in clear bowl 1 Stop the engine WARNING Fuel may be hot just after operation Be sure to wait for fuel to cool before starting work 2 Loosen fuel vent cap 2 to open 3 Loosen drain valve 3 to drain water 4 Collect water...

Page 216: ...r cover 6 A new o ring is supplied with the new filter 6 Remove filter element 7 Be sure the sealing grommet is removed from the center stud 7 Install new filter element 7 supplied with a sealing grommet inserted into the element on the center stud by pushing down 8 After checking the new o ring supplied with the new filter at clear cover 6 is in place install clear cover 6 and collar 4 Hand tight...

Page 217: ...n on filters 2 from the filter head dis card filters 4 Fill the filter with clean fuel Apply a light even coat of lubricating oil to the gasket sealing surface prior to installing the filter 5 Position filter 2 to the filter head Tighten by hand until the seal touches the filter head tighten an addi tional one half to three fourths turn 6 Open cock 1 on the inlet line NOTE Be sure to tighten the f...

Page 218: ...e Remove key from the key switch Pull the pilot control shut off lever to the LOCK position 2 Check for kinked hoses and hoses that rub against each other parts for leaks Check hoses at the check points indicated below for leaks and other damage that may result in future leaks If any abnormalities are found replace or re tighten them as shown in Table 4 3 Repair or replace any loose or damaged hos...

Page 219: ...s Hose Hose Hose ends and fit tings Crack 4 Crack 5 Exposed rein forcement 6 Blister 7 Bend 8 Collapse 9 Deformation or corrosion 10 Replace Replace Replace Replace Replace Replace Use proper bend radius Replace NOTE Refer to the illustrations in Fig 4 for each check point location or for a description of the abnormality Use genuine Hitachi parts M115 07 145 M115 07 146 M115 07 147 M115 07 148 M11...

Page 220: ... engine Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK posi tion 7 Remove wing nut 1 Remove outer element 2 WARNING Use reduced compressed air pres sure Less than 0 2 MPa 2 kgf cm 2 28 psi Clear area of bystanders guard against flying chips and wear personal protection equipment includ ing goggles or safety glasses 8 Clean outer element 2 using compressed ai...

Page 221: ...d inner 4 elements together 2 Remove wing nut 1 and outer element 2 3 Clean the filter housing 3 interior before removing inner element 4 4 Remove nut 5 and inner element 4 5 First install inner element 4 and nut 5 and then in stall outer element 2 and wing nut 1 M117 07 015 M117 07 016 2 4 3 5 1 ...

Page 222: ...er coolant mix of water antifreeze and anti corrosive agent DCA4 NOTE DCA4 is a brand name of Dry Chemical Addi tive manufactured by the America Fleetguard Co 1 Water Use soft water with fewer impurities or tap water as a coolant If hard water with many impurities is used the anti corrosive agent DCA4 will be neutralized and loose its effect as an anticorrosive agent 2 Long Life Coolant Long Life ...

Page 223: ...entially causing scalding Slowly loosen cap 1 to re lease pressure after the system has cooled and then remove Check that the coolant level is between the HIGH and LOW marks on water tank level gauge 2 If the coolant level is below the LOW mark remove cap 1 on the water tank and add coolant via the opening M18M 07 046 M18M 07 047 2 2 Low Level 1 High Level ...

Page 224: ...e concentration range of 1 2 to 3 units per 3 78 L 1 US gal of coolant DCA4 concentration is adjusted by replacing the DCA4 containing filter and or adding DCA4 liquid Coolant Filter The following solid DCA4 containing coolant filter is available Application Fleetguard Part No Cummins Part No Hitachi Part No Number of DCA Units Check and Maintenance WF 2076 3100309 4460208 23 DCA4 Liquid The follo...

Page 225: ...Cause Symptoms Emergency Measure Inhaling The nose smarts Breathe fresh air Long or repeated exposure The skin smarts Wash with fresh water Take off clothes contaminated with DCA4 and clean them thor oughly Splashing in eyes The eyes smart Wash immediately with fresh wa ter for 15 minutes and see a phy sician Swallowing Drink a lot of carbonated bever ages and see a physician 2 Disposal Be careful...

Page 226: ...ing Coolant Filter every 500 hours DCA4 deteriorates its function after being used for a long time Normally replace it every 500 hours However when the DCA4 concentration is measured When the antifreeze or LLC concentration is 50 If over 3 units concentration is measured no replace ment is required allowing the replacement hour to extend up to max 1000 hours Checking Coolant Concentration 1 If a l...

Page 227: ...n through color change The antifreeze concentration checked by this method should be just a guide line When the exact antifreeze concentration is required measure it using a specified equipment 3 Do not use diluted coolant for measurement Collect coolant into the attachment beaker Directly dip the test paper into the collected coolant Compare the reagent color change on the test paper with the col...

Page 228: ...32 C or lower The effective life time of the reagent is printed on the upper section of the CC2602 container Do not use any reagents after the effective life time expires If the reagent color has changed to light brown or pink avoid using such reagent If the color specimen was spoiled wipe stain with a cloth Do not use any soap or solvent The reagent color continues to change from soon after being...

Page 229: ...o light brown use another test paper 3 Dip the test paper into the collected coolant for one second After taking up the test paper desiccate the extra coolant 4 Wait 45 seconds Then compare the changed re agent color on the test paper with the color specimen and determine the coolant concentration by following procedures 1 Take a record of the anti freeze concentration by comparing the color on re...

Page 230: ...ox represents the values to be applied when the LLC concentration is 50 When the LLC concentration is 40 or less do not determine by color Determine by figure val ues 9 Record the measured coolant additive agent concen tration value on the maintenance record sheet as ref erence data when performing next maintenance ser vices Concentration Check Table GLYCOL FREEZEPOINT F SODIUM MOLYBDATE LEVEL SOD...

Page 231: ...ance service Replace the coolant filter every 500 hours 3 0 or more Keep using the coolant until concentration is reduced to 3 units without replacing the filter Use the filter up to the next 500 hour replacement time maximum useable time limit 1000 hours In case concentra tion is over 4 0 units replace the total coolant and conduct the initial charge in accordance with Item in this manual 50 Nece...

Page 232: ...ct coolant when re placing water filter to avoid ground contamination and for safety Be sure to tighten the filter by hand If any tools are used for tightening breakage or deformation of the filter head may arise For details other than filter replacement intervals re fer to the manual for Cummins En gine 1 Move shut off valves knob 2 to the OFF position 2 Remove filters 1 and discard it 3 Apply a ...

Page 233: ...y Re move impurity such as water scale at the same time 3 Close drain cocks 4 and 5 and reinstall the hoses 2 and 3 Fill the radiator with soft water containing less impurity or tap water and a radiator cleaner agent via the water tank cap 1 And fill the water tank in same way between the HIGH and LOW marks on water tank level gauge 6 Reinstall water tank cap 1 4 Start the engine and run it at a s...

Page 234: ...lant 8 Confirm that the coolant level is between the marks H and L on gauge 6 Start the engine and run at slow idle speed for about 5 minutes Stop the engine after bleeding air from the cooling system sufficiently Check coolant level again and add coolant if neces sary NOTE Coolant can be refilled from the ground using the Fast Filling panel located in the rear of the base machine Refer to page 1 ...

Page 235: ...zzle 200 mm 8 in or more away from the core face in order not to cause any damage 1 Remove cover in front of the radiator Clean radiator core with compressed air Less than 0 2 MPa 2 kgf cm 2 28 psi or water 2 Remove the covers 1 beside radiators and remove the covers 2 between radiator core 3 and after cooler core 4 3 Clean radiator core 3 and aftercooler core 4 from space between cores in same wa...

Page 236: ...using compressed air Less than 0 2 MPa 2 kgf cm 2 to clean filters IMPORTANT Plugged inner or outer air filter will re duce cooling capacity of the air condi tioner Be sure to clean them periodi cally Cleaning As required 1 Recirculation air filters 2 three pieces are located in room 1 under the cab Open cover 3 Remove recirculation air filters 2 2 Clean recirculation air filters with compressed a...

Page 237: ...ted in room 1 under the cab Remove ventilation air filters 2 2 Clean ventilation air filters 2 with compressed air Less than 0 2 MPa 2 kgf cm 2 or a soft brush Replace Air Filter Replace per 4 cleaning Changing interval of ventilation air filters 2 differs de pending on environmental conditions If the cooling capacity decreases after cleaning ventila tion air filters 2 caused by filter plugging re...

Page 238: ...t quantity lowers cooling effect of the air conditioner Check the re frigerant quantity through sight glass on liquid tanks 2 three pieces 1 Start the engine and run at fast idle speed 2 Turn the air conditioner and blower fan speed to the high speed 3 Press temperature control switch repeatedly until the air temperature is maximum cool 4 Check the refrigerant quantity through sight glass M18M 03 ...

Page 239: ...ssary Start the engine and run for 10 minutes Check belt tension by depressing the midpoint between the hydraulic motor and compressor pulleys with the thumb Deflection must be 13 to 14 mm 0 5 to 0 6 in at a depressing force of approximately 98 N 10 kgf 22 lbf If tension is not within specifications loosen the com pressor mounting bolts to adjust belt tension M18M 07 053 M146 07 071 M146 07 001 2 ...

Page 240: ...or gog gles when using compressed air Less than 0 2 MPa 2 kgf cm 2 28 psi to clean condenser core Remove condenser cover 2 three pieces located in room 1 under the cab Use compressed air Less than 0 2 MPa 2 kgf cm 2 28 psi to clean the condenser core three pieces M18M 07 053 M18G 07 086 1 2 ...

Page 241: ...ns Fastening Torque Wrench Size mm N m kgf m lbf ft 19 11 5 to 14 5 1 2 to 1 5 8 7 to 10 5 24 19 5 to 24 5 2 to 2 5 14 5 to 18 27 29 5 to 34 3 to 3 5 21 5 to 25 5 Torque Specifications for Compressor Mounting Bolts Fastening Torque Wrench Size mm N m kgf m lbf ft 10 19 5 to 29 5 2 to 3 14 5 to 21 5 Torque Specifications for Liquid Tank Fastening Torque Wrench Size mm N m kgf m lbf ft 10 7 8 to 11 ...

Page 242: ...cludes replenishment of refrig erant inspection and replacing if necessary of inner and outer air filters line connections pressure switches and inspection and cleaning of evaporator 2 Off season maintenance 1 Operate the compressor once a week at low speed for several minutes in order to maintain its parts in well lubricated condition Be sure to run the engine at slow idle and air temperature to ...

Page 243: ...horized dealer WARNING Never allow to wash the electric parts in the machine by water Example harness con trol box and relay box etc Batteries WARNING Battery gas can explode Keep sparks and flames away from batteries Use a flashlight to check the battery electrolyte level Do not continue to use or charge the battery when electrolyte level is lower than specified Explosion of the battery may resul...

Page 244: ... If the battery is used with the electrolyte level lower than the specified lower level the battery may deteriorate quickly IMPORTANT Don t refill electrolyte more than the specified upper level Electrolyte may spill damaging the painted surfaces and or corroding other machine parts NOTE In case electrolyte is refilled more than the specified upper level line or beyond the bottom end of the sleeve...

Page 245: ...he accurate 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 il lustrations check the level When the electrolyte level is lower than the bottom end of the sleeve re fill with distilled water or commercial battery fluid up to the bottom end of the sleeve Be sure to refill with distilled water befor...

Page 246: ...he specific gravity for the electrolyte varies depending on electrolyte temperature The spe cific gravity should be kept within the range shown below Charge the battery if the specific gravity is below the limit Recommended range of specific gravity by electrolyte temperature Working range Fluid temp 68 F 104 F 40 F 40 C 20 C 40 C 4 F 32 F 0 C 20 C 1 21 1 22 1 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30...

Page 247: ... of charge This difference could overload one of the batteries and cause it to fail IMPORTANT Do not pull the disconnector lever 1 down during operation NOTE Ground Disconnector This machine is equipped with a battery ground disconnector located outside of engine unit compartment on the right side The battery ground circuit can be disconnected by pulling disconnector lever 1 down before replacing ...

Page 248: ...POWER 10A 12 OPT C U MAIN POWER 10A 13 OPT C U KEY ON SIG 5A 14 OPT C U KEY ON SIG 5A 15 MC KEY ON SIG 5A 16 ELU PWM POWER RELAY 5A 17 DLU OPT KEY SW ON SIG 5A 18 19 ECM LAMP POWER 5A 20 HMU KEY ON SIG 5A 21 WASHER MOTOR RELAY 5A 22 TRAVEL SPEED SELECT RELAY 5A 23 A C MAIN RELAY FRONT 5A 24 A C MAIN RELAY SIDE 5A 25 A C MAIN RELAY REAR 5A 26 BATTERY RELAY 5A 27 A C CONTROL AMP FRONT 5A 28 A C CONT...

Page 249: ... 56 57 58 59 ENG OIL RESERVE TANK PUMPING UNIT 15A 60 OIL PUMP 20A 61 WORK LIGHT 1 10A 62 WORK LIGHT 2 10A 63 WORK LIGHT 3 10A 64 WORK LIGHT 4 10A 65 WORK LIGHT 5 10A 66 WORK LIGHT 6 10A 67 MAINTENANCE LIGHT 1 10A 68 MAINTENANCE LIGHT 2 10A 69 MAINTENANCE LIGHT 3 10A 70 MAINTENANCE LIGHT 4 10A 71 72 73 ENTRANCE LIGHT 1 10A 74 75 WIPER MOTOR LOW 30A 76 WIPER MOTOR HIGH 30A 77 WASHER MOTOR 10A 78 FA...

Page 250: ...R 5A 6 RADIO BACKUP 5A 7 ELU KEY ON SIG 5A 8 IDU KEY ON SIG 5A 9 DLU KEY ON SIG 5A 10 BUZZER 5A 11 KEY ON SIG CONTROL BOX 5A 12 ECM KEY ON SIG 5A 13 RADIO ACC 5A 14 AIR HORN COMP ACC SIG 5A 15 LIGHTER 10A 16 TERMINAL ACC 10A 17 TERMINAL 12V 15A 18 19 MONITOR CONTROL UNIT 5A 20 PILOT CONTROL SHUT OFF LEVER SW 5A M18M 01 007 T18G 01 02 030 A 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ...

Page 251: ...r console in the cab 12 volts and 24 volts terminal are located in the rear con sole Use this terminal to power electrical devices of 12 volts and 24 volts rating Fuses for this terminal are pro vided with 5 ampere and 10 ampere fuses M18M 01 007 T18G 01 02 026 M18M 07 062 1 24V 5A 24V 10A 12V 10A ...

Page 252: ... No 1 2 3 4 5 6 7 8 9 10 75A 75A 75A 75A 75A 75A 45A 75A 45A 75A FUSE BOX FUSE No 1 2 4 to 12 55 FUSE BOX FUSE No 31 to 33 69 70 FUSE BOX FUSE No 30 34 to 36 48 to 50 73 FUSE BOX FUSE No 37 to 39 44 to 47 53 59 60 67 68 77 to 79 FUSE BOX FUSE No 61to 66 FUSE BOX FUSE No 41 51 52 75 76 OPTION TERMINAL ENGINE STARTER RELAY ECM POWER FOLDING STAIRWAY RELAY Fuse No 11 12 13 10A 5A 30A ENG OIL FILL SYS...

Page 253: ...MAINTENANCE 7 114 High Current Fuse Connection Table 2 No Amp 1 2 3 400A 250A 250A PRELUB RELAY FOLDING STAIRWAY MOTOR 1 FOLDING STAIRWAY MOTOR 2 M18M 07 056 1 2 3 ...

Page 254: ...ions 3 Check before each shift or after ten 10 hours of op eration for loose kinked hardened or frayed electri cal cables and wires Check before each shift or after ten 10 hours of missing or damaged terminal caps DO NOT OPERATE MACHINE if cable or wire are loose kinked etc Check cables and harnesses at the check points in dicated below for damage that may result in future short circuits If any ab...

Page 255: ...art edge Replace Replace Replace Replace Connector 3 Degree of Hardening Loose locking Contact with part edge Damaged and crushed parts Loose or worn part Replace Lock Replace Replace Replace Terminal and termi nal cover 4 Degree of hardening of cover Cracks Worn cover Missing cover Loose locking Replace Replace Replace Replace Reconnect Daily Clamps of the har nesses or connec tors 5 Missing Clam...

Page 256: ... function every 250 hours following the procedures below 1 Start the engine and run at slow idle 2 Turn emergency engine stop switch 1 to the EMERG STOP position 3 Confirm that the engine stops If any abnormalities are found be sure to repair them before operating the machine M18M 01 004 1 NORMAL EMERG STOP ...

Page 257: ...ation System 1 Check 2 4 Seat Belt Replacement 2 At least once every 3 years 5 Check Washer Tank 2 As required 6 Air Horn Compressor Filter Cleaning 1 As required 7 Check and Adjust Track Sag 2 8 Check Accumulator and Track Adjuster Cylinder Circuit 2 Every year 9 Clean Side Frame Area 2 10 Check Tightening Torque of Bolts and Nuts NOTE First time only M146 07 051 M18M 03 007 T146 01 03 002 2 1 3 ...

Page 258: ...ts may use different tooth as semblies 2 Replacing procedure WARNING Guard against injury from flying pieces of metal Wear goggles or safety glasses 1 Install point 1 and locking pin 3 The side of the locking pin marked up must be installed upward as shown in the figure 2 Use a 7 to 10 kg 15 to 22 lb hammer and drive out wedge 4 3 Drive the wedge so that the difference between the top of wedge and...

Page 259: ...part using gas when the lower end of wedge 4 projects from the bottom sur face of point 1 5 Replace the wedge 4 with oversize wedge 110W2 4202527 when its top is flush with the upper surface of point 1 6 When wedge 4 tends to come out of point 1 apply spot welding to wedge 4 and spool 3 af ter driving the wedge in point 1 NOTE When installing new point and shroud 5 re move the hooks attached to th...

Page 260: ...y Evacuation Equipment and Hanger daily Inspect emergency evacuation equipment 1 and hanger 2 before operating the machine If any item is worn and or damaged replace the equipment and or hanger with genuine Hitachi parts M146 07 002 2 1 ...

Page 261: ...so check grease piping for leakage 1 Move auto lubrication toggle switch 1 located in front of oil cooler to the MANUAL position Check that the grease pump begins operating and indicator pins 2 retract 2 Move auto lubrication toggle switch 1 to the AUTO LUB position Indicator pin positions are as follows Indicator pins 2 are retracted while the grease pump is operating Indicator pins 2 are extende...

Page 262: ... the AUTO LUB position Disconnect hose 6 at coupler 7 The grease pump intermittently delivers grease for approximately one minute with an interval of 10 minutes according to the greasing schedule preset at the factory The greas ing schedule interval and volume can be adjusted as shown next page IMPORTANT Do not adjust greasing interval to be too long or the greasing volume to be too small M146 07 ...

Page 263: ...um de livery position of 0 168 cm 3 0 010 in 3 Turn adjusting nut 10 counterclockwise approximately 10 turns This is the maximum delivery position of 1 165 cm 3 0 071 in 3 Select appropriate greasing volume be tween the maximum and minimum volumes Tighten locknut 11 NOTE Injectors 2 have been adjusted as shown be low at the time of shipment Front attachment joint pins Maximum Swing bearing Minimum...

Page 264: ...a grease gun Refer to pages 7 24 to 7 35 of this manual After finishing greasing disconnect hose 7 from cou pler 6 release grease pressure in hose reel 12 via the grease gun NOTE When manual greasing is selected the auto lubrication indicator on the monitor display will come on This is not abnormal M18M 07 037 M18M 07 038 M146 07 105 12 6 7 1 ...

Page 265: ...replace the seat belt or component before operating the machine We recommend that the seat belt be replaced every three years regardless of its apparent condition Check Windshield Washer Fluid Lever as required Windshield washer tank 2 is located in room 1 under the cab Check fluid in windshield washer tank 2 If the fluid level is low remove cap of windshield washer tank 2 and add fluid via the op...

Page 266: ...MAINTENANCE 7 127 Clean Air Horn Compressor Filter as required Air horn compressor 2 is located in room 1 under the cab Remove the cap 3 and clean the filter M18M 07 053 M18M 07 066 M18M 07 067 1 2 3 ...

Page 267: ...to 620 mm 22 8 in to 24 4 in NOTE When operating the machine on sand gravel snow or mud providing longer track sag is rec ommended in the above mentioned value range Precautions for Adjusting Track Sag 1 When measuring track sag after adjusting be sure to rotate the raised track one full rotation 2 When adjusting track sag lower the bucket to the ground to raise one track off the ground Repeat thi...

Page 268: ... loosen the track 3 If grease does not drain smoothly slowly rotate the raised track 4 When proper track sag is obtained turn valve 1 clockwise and tighten to 147 Nxm 15 kgfxm 108 lbfxft Tighten the Track WARNING It is abnormal if the track remains tight after turning valve 1 counterclockwise or if the track is still loose after charging grease to fit ting 2 In such cases NEVER ATTEMPT TO DIS ASSE...

Page 269: ...escapes gradually IMPORTANT Low pressure in the track adjuster cyl inder circuit will cause damage to the track adjuster and travel device Be sure to check the accumulator and adjuster cylinder circuit regularly to maintain correct circuit pressure Consult your authorized dealer when checking accu mulator Check Side Frame Area daily Soil or rocks stuck in the side frame area will disturb smooth ro...

Page 270: ...r mounting bolt 20 16 30 390 40 290 12 Battery mounting bolt 6 16 10 20 2 15 13 Cab mounting bolt 18 10 27 300 31 220 14 Cab bed mounting bolt 12 49 19 110 11 81 15 Cab cushion rubber mounting bolt 12 40 19 110 11 81 Swing bearing mounting bolt Upperstructure 56 60 85 9810 1000 7230 16 Swing bearing mounting bolt Track 56 60 85 9810 1000 7230 17 Counterweight mounting bolt 56 11 85 6860 700 5060 1...

Page 271: ...6 19 950 97 0 700 700 71 5 520 280 28 5 205 M27 41 19 1400 143 1030 1050 107 770 400 41 0 295 M30 46 22 1950 200 1440 1450 148 1070 550 56 0 410 M33 50 24 2600 265 1920 1950 200 1440 750 76 5 550 M36 55 27 3200 325 2360 2450 250 1810 950 97 0 700 IMPORTANT Make sure bolt and nut threads are clean before installing Apply lubricant e g white zinc B solved into spindle oil to bolts and nuts to sta bi...

Page 272: ...xm 320 kgfxm 2310 lbfxft 2 Engine bracket mounting bolts Engine flywheel side a Tool 50 mm Torque 1950 Nxm 200 kgfxm 1440 lbfxft b Tool 30 mm Torque 540 Nxm 55 kgfxm 400 lbfxft Engine fan side c Tool 32 mm Torque 740 Nxm 75 kgfxm 540 lbfxft M18M 07 058 M18M 07 059 M18M 07 060 a b c ...

Page 273: ...ool 50 mm Torque 1910 Nxm 195 kgfxm 1410 lbfxft 5 Pump transmission mounting bolt Tool 19 mm Torque 110 Nxm 11 kgfxm 81 lbfxft 6 Pump mounting bolts Main pump Tool Hex Wrench 36 mm Torque 950 Nxm 97 kgfxm 700 lbfxft Fan pump Tool Hex Wrench 30 mm Torque 550 Nxm 56 kgfxm 410 lbfxft M146 07 052 M146 07 053 M18M 07 059 M146 07 054 ...

Page 274: ...e pump mounting bolt Tool 22 mm Torque 140 Nxm 14 kgfxm 103 lbfxft 9 Control valve mounting bolts Tool 30 mm Torque 390 Nxm 40 kgfxm 290 lbfxft 10 Swing device mounting bolts Tool 55 mm Torque 2550 Nxm 260 kgfxm 1880 lbfxft Tool 36 mm Torque 950 Nxm 97 kgfxm 700 lbfxft 146 07 076 M146 07 076 M146 07 055 M146 07 028 ...

Page 275: ... 40 kgfxm 290 lbfxft 12 Battery mounting bolts Tool 10 mm Torque 20 Nxm 2 kgfxm 15 lbfxft 13 Cab mounting bolt Tool 27 mm Torque 300 Nxm 31 kgfxm 220 lbfxft 14 Cab bed mounting bolt Tool 19 mm Torque 110 Nxm 11 kgfxm 81 lbfxft M146 07 028 M146 07 080 M18M 07 061 M146 07 057 ...

Page 276: ...MAINTENANCE 7 137 15 Cab cushion rubber mounting bolts Tool 19 mm Torque 110 Nxm 11 kgfxm 81 lbfxft M146 07 063 M146 07 064 Front Side Rear Side ...

Page 277: ...mm Torque 9810 Nxm 1000 kgfxm 7230 lbfxft Track Remove cover A and check the tightening torque Tool 85 mm Torque 9810 Nxm 1000 kgfxm 7230 lbfxft 17 Counterweight mounting bolt Tool 85 mm Torque 6860 Nxm 700 kgfxm 5060 lbfxft M144 07 100 M146 07 023 M146 01 022 M18M 07 069 A ...

Page 278: ...g bolt Tool 30 mm Torque 390 Nxm 40 kgfxm 290 lbfxft 19 Upper roller mounting bolt Tool 32 mm Torque 740 Nxm 75 kgfxm 540 lbfxft 20 Lower roller mounting bolt Tool 70 mm Torque 4710 Nxm 480 kgfxm 3470 lbfxft M145 07 079 M146 07 077 M117 07 089 ...

Page 279: ...rque 1370 Nxm 140 kgfxm 1010 lbfxft 22 Travel device mounting bolts A Tool 46 mm Torque 1910 N m 195 kgf m 1410 lbf ft B Tool 60 mm Torque 4410 N m 450 kgf m 3250 lbf ft C Tool 30 mm Torque 390 N m 40 kgf m 290 lbf ft M146 07 058 M145 07 048 M145 07 079 C B A ...

Page 280: ...MAINTENANCE 7 141 23 Side frame mounting bolt Tool 85 mm Torque 9810 N m 1000 kgf m 7230 lbf ft 24 Track pin retaining bolt Tool 46 mm Torque 1910 N m 195 kgf m 1410 lbf ft M145 07 095 M117 07 089 ...

Page 281: ...Front pin retaining bolts Loader Tool Torque mm N m kgf m lbf ft A 19 88 9 65 B 24 205 21 152 C 36 932 95 690 D 30 540 55 400 E 19 Hex Wrench 1029 105 760 M146 07 018 M118 07 053 M118 07 114 M118 07 115 C D B B A E A B D C ...

Page 282: ...pin retaining bolt Backhoe A Tool 30 mm Torque 390 N m 40 kgf m 290 lbf ft B Tool 24 mm Torque 205 N m 21 kgf m 152 lbf ft C Tool 36 mm Torque 932 N m 95 kgf m 687 lbf ft M146 07 018 T146 01 03 002 M146 07 078 A A A B C A C A C C ...

Page 283: ...MAINTENANCE 7 144 MEMO ...

Page 284: ...r service intervals Electrical Equipment Clean them regularly in particular the terminals of the alternator and starter Rocky Ground Tracks Carefully operate while checking for cracks damage and loose bolts and nuts Loosen the tracks a little more than usual Front Attachment Standard attachment may be damaged when digging rocky ground Reinforce the bucket before using it or use a heavy duty bucket...

Page 285: ...MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 9 2 MEMO ...

Page 286: ...rust agent to the coolant In cold weather add an antifreeze or drain the coolant completely Be sure to attach a No Water in Ra diator tag on a clearly visible location if the sys tem is drained 9 Loosen the alternator belt 10 Paint necessary areas to prevent rust 11 Store the machine in a dry protected place If stored outside cover with a waterproof cover 12 If the machine is stored for a long tim...

Page 287: ...ps as well a Check condition of all hoses and con nections b Warm up the engine c Stop the engine d Install new fuel filters Replace the en gine oil filter and fill the engine with oil IMPORTANT If the machine has not been used for a long time oil films on sliding sur faces may have broken down Cy cling hydraulic functions for travel swing and digging two to three times is necessary to lubricate t...

Page 288: ... a short one second pause when the warning lamp 4 and the stop lamp 5 is off The numbers of the recorded Cummins fault code will then flash on stop lamp 5 There will be a one second pause between each number When the number is done flashing warning lamp 4 will flash again The number will repeat in the same sequence In case more than one Cummins fault codes are recorded the first Cummins fault code...

Page 289: ...starter Wrong engine oil Drain oil Use correct oil Air filter plugged Replace elements Fuel filter plugged Remove air from fuel system Clean fuel tank strainer Engine compression low See your authorized dealer Leaks in fuel system Check fuel system connections Air in fuel system Bleed air Engine oil level low Add oil Engine Knocks Runs Ir regularly or Stops Plugged air intake system Clean filter a...

Page 290: ...ffler and run engine Engine is too hot or cold See below Engine failure See your authorized dealer Valve clearance Check and adjust valves Intake or exhaust system leakage See your authorized dealer Engine Overheats Low coolant level Add coolant Thermostat See your authorized dealer Engine overloaded Check hydraulic relief valves Radiator cap faulty Install new cap Radiator core or or fuel cooler ...

Page 291: ...d dealer Engine temperature too high Check cooling system Wrong oil Drain oil Use correct oil Engine Uses Too Much Oil Wrong oil Drain oil Use correct oil Oil leaks Check engine oil drain plug Engine temperature too high Check cooling system Plugged air cleaner Clean element or install new element Internal engine component wear See your authorized dealer Engine Uses Too Much Fuel Plugged or dirty ...

Page 292: ...ove exhaust elbow and air inlet hose and inspect Oil Dripping from Turbocharger Adapter Damaged or worn bearings and or worn seals See your authorized dealer Inspect and clean air cleaner Check for proper engine service intervals or dirt enter into engine Excessive crankcase pressure Check vent tube to ensure tube is not plugged Clean Turbocharger oil return line carbon build up where line passes ...

Page 293: ...arter solenoid See your authorized dealer Starter Repair or replace start motor Starter pinion jammed in flywheel gear Repair or replace starter Major engine failure See your authorized dealer Starter Solenoid Chatters Poor connections at batteries or starter Clean connections Low battery charge Recharge or replace batteries Starter solenoid hold in windings open See your authorized dealer Starter...

Page 294: ...on Excessive electrical load from added accessories Remove accessories or install higher output alternator Loose or corroded electrical connections on battery ground strap starter or alternator Inspect clean or tighten electrical connections Battery voltage low Change or replace battery Alternator or regulator See your authorized dealer Indicator circuit See your authorized dealer Noisy Alternator...

Page 295: ...ight in Gauge Panel is Inoperative Fuse Replace fuse Sender Do sender check Wiring harness failure See your authorized dealer Fuse Replace fuse Coolant Temperature Gauge Does Not Work Gauge See your authorized dealer Gauge sender Do coolant temperature gauge sender check Wiring harness See your authorized dealer Fuel Gauge Does Not Work Fuse Replace fuse Gauge See your authorized dealer Wiring har...

Page 296: ...er See your authorized dealer HYDRAULIC SYSTEM Problem Cause Solution Hydraulic Functions are Slow Low oil level Fill reservoir to full mark Cold oil Warm up hydraulic oil to normal cycle times Wrong oil Drain tank Use correct oil Engine speed too low Increase speed or see your authorized dealer Pilot circuit See your authorized dealer Worn pump See your authorized dealer Restricted pump suction l...

Page 297: ... Improperly adjusted hydraulic components See your authorized dealer No oil in system Fill with correct oil Worn cylinder packings See your authorized dealer Relief valve See your authorized dealer Hydraulic pump See your authorized dealer No Hydraulic Functions Noise from pumps Lack of hydraulic oil Add oil Damaged suction line or hose See your authorized dealer Clogged suction filter Clean Hydra...

Page 298: ...pair or replace Piston seals leaking See your authorized dealer One Cylinder Does Not Work or Has Little Power Cylinder rod damaged See your authorized dealer Pilot lines Repair or replace Electric lever See your authorized dealer Both Side Travel Motors Do Not Work Center joint failure Electric lever Pilot lines See your authorized dealer See your authorized dealer See your authorized dealer Trav...

Page 299: ...oblem Cause Solution Auto Idle Does Not Work Fuse Replace Auto Idle switch Replace Pilot pressure switch Replace Failure of connector contact Repair or replace Wiring harness Repair or replace Engine speed control lever sensor Replace Controller See your authorized dealer Controller on the engine See your authorized dealer Failure of connector contact Repair or replace Wiring harness Repair or rep...

Page 300: ...dius 6780 mm 22 ft 3 in D Minimum Ground Clearance 905 mm 2 ft 12 in E Counterweight Clearance 2440 mm 8 ft 0 in F Overall Width of Upperstructure 8360 mm 27 ft 5 in G Undercarriage Length 8700 mm 28 ft 7 in H Undercarriage Width 6770 mm 22 ft 3 in I Sprocket Center to Idler Center 6660 mm 21 ft 10 in J Track Shoe Width 1270 mm 4 ft 2 in Grouser shoe Ground Pressure 189 kPa 1 93 kgf cm 2 27 4 psi ...

Page 301: ...um Level Crowding Distance 8870 mm 29 ft 1 in C Level Crowding Distance 5050 mm 16 ft 7 in D Maximum Digging Reach 15220 mm 49 ft 11 in E Maximum Cutting Height 16300 mm 53 ft 6 in F Maximum Dumping Height 10990 mm 36 ft 1 in G Maximum Digging Depth 3910 mm 12 ft 10 in NOTE The dimensions do not include the height of the shoe lug E F D B C A G ...

Page 302: ...gging Reach 18190 mm 59 ft 8 in B Maximum Digging Reach on grond 17610 mm 57 ft 9 in C Maximum Digging Depth 8580 mm 28 ft 2 in D Maximum Cutting Height 17690 mm 58 ft 1 in E Maximum Dumping Height 11590 mm 38 ft 0 in NOTE The dimensions do not include the height of the shoe lug E A B C D ...

Page 303: ...SPECIFICATIONS 12 4 MEMO ...

Page 304: ...attern Backhoe 5 1 Control Lever ISO Pattern Loading Shovel 5 3 Coolant Level Indicator 1 14 Coolant Overheat Indicator 1 13 Coolant Temperature Gauge 1 11 Cooling 1 25 Cooling System 7 83 Correct Maintenance and Inspection Procedures 7 1 Cummins Fault Code Lamps and Diagnostic Switches 11 1 D DRIVING THE MACHINE 4 1 Defrosting 1 26 Dehumidifying And Heating 1 25 Designations And Functions Of Cont...

Page 305: ... 2 1 Open Access Doors for Service 7 5 Opening Cab Left Window 1 45 Operate Only from Operator s Seat S 7 Operate the Machine Safely 5 12 Operate with Caution S 15 Operating Backhoe 5 13 Operating Ground Condition 4 9 Operating Stairway 1 2 Operating Tips 5 15 Operating on Soft Ground 4 7 Overnight Storage Instructions 5 19 P Park Machine Safely S 17 Parking the Machine 4 11 Parking the Machine on...

Page 306: ...G 11 1 Tachometer 1 11 Tension Indicator 1 16 Towing Machine a Short Distance 4 8 Transmission 7 43 Transporting the Machine 10 2 Travel Alarm 4 5 Travel Mode Indicator 1 19 Travel Mode Switch 1 36 4 4 Traveling 4 6 Turning Power ON 3 3 U Understand Signal Words S 1 Use Correct Fuels and Lubricants 7 2 Use Handholds and Steps S 5 Use a Chain to Prevent Falling Accidents 7 7 Using Booster Batteries...

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