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BREAK-IN

2-1

BREAKING IN NEW MACHINE

IMPORTANT: Operating a new machine at full load

without first breaking in can cause
scratches and/or seizures, consequently
affecting the service life of the machine.
Thoroughly perform break-in operation.

The service life and performance of the machine can be
greatly affected by operation and maintenance of the ma-
chine during the initial stage of operation. Perform break-in
operation with the engine output less than 80% of the
maximum output for the first 50 hours.

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Summary of Contents for ZAXIS 17U-2

Page 1: ......

Page 2: ...d maintain their equipment as described in this manual The warranty is explained on the warranty certificate which you should have received from your dealer This warranty provides you the assurance that Hitachi will back its products where defects appear within the warranty period In some circumstances Hitachi also provides field improvements often without charge to the customer even if the produc...

Page 3: ...OMPONENTS NAME OPERATOR S STATION BREAK IN OPERATING ENGINE DRIVING THE MACHINE TRANSPORTING MAINTENANCE CONSUMABLE PARTS LIST MAINTENENCEUNDERSPECIALENVIRONMENTALCONDITIONS OPERATION STORAGE TROUBLESHOOTING SPECIFICATIONS REFERENCE INDEX ...

Page 4: ...ly S 23 Avoid High Pressure Fluids S 23 Prevent Fires S 24 Evacuating in Case of Fire S 26 Beware of Exhaust Fumes S 26 Precautions for Welding and Grinding S 27 Avoid Heating Near Pressurized Fluid Lines S 27 Avoid Applying Heat to Lines Containing Flammable Fluids S 27 Remove Paint Before Welding or Heating S 28 Prevent Battery Explosions S 28 Handle Chemical Products Safely S 29 Dispose of Wast...

Page 5: ...ded Oils and Lubricants 7 10 A Greasing 7 11 Front Joint pins 7 11 Bucket and Link Pins 7 14 Swing Bearing 7 15 Swing Internal Gear 7 16 Control Lever Universal Joint 7 16 B Engine 7 17 Engine Oil 7 17 Change Engine Oil 7 17 Replace Engine Oil Filter 7 17 C Transmission 7 19 Travel Reduction Gear 7 19 D Hydraulic System 7 21 Inspection and Maintenance of Hydraulic Equipment 7 21 Check Hydraulic Oi...

Page 6: ...from Storage 10 2 TROUBLESHOOTING Engine 11 1 Electrical System 11 1 Hydraulic System 11 2 SPECIFICATIONS Specifications 12 1 Working Ranges 12 2 Shoe Types and Applications 12 3 Bucket Types and Applications 12 4 REFERENCE Additional Counterweight 13 1 INDEX 14 1 ...

Page 7: ...CONTENTS MEMO ...

Page 8: ...umbers are requested when inquiring any information on the machine and or components Fill these serial Nos in the blank spaces in this group to immediately make them available upon request MACHINE MODEL TYPE PRODUCT IDENTIFICATION NUMBER NOTE HCM1MS00X00010001 PRODUCT IDENTIFICATION NUMBER PIN M1MS 00 001 Marks to indicate the start and end of the PIN ...

Page 9: ...MACHINE NUMBERS MEMO ...

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

Page 11: ...messages in this SAFETY chapter are in tended to illustrate basic safety procedures of machines However it is impossible for these safety messages to cover every possible hazardous situation you may en counter If you have any questions concerning safety you should first consult your supervisor and or your nearest Hitachi dealer before operating or performing maintenance work on the machine SA 003 ...

Page 12: ...evers or other parts of the machine Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while oper ating the machine 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 lou...

Page 13: ...ens possibly causing a fire Do not wear radio or music headphones and do not use a cell phone while traveling or operating the machine Never allow hazardous materials such as combustible and or explosive material in the operator s space Do not leave a lighter in the cab If the temperature in the cab increases the lighter may explode USE HANDHOLDS AND STEPS Falling is one of the major causes of per...

Page 14: ...eat forward or backward and check again SA 378 FASTEN YOUR SEAT BELT If the machine should overturn the operator may be come injured and or thrown from the cab Additionally the operator may be crushed by the overturning machine resulting in serious injury or death Be sure to remain seated with the seat belt securely fastened whenever operating the machine Prior to operating the machine thoroughly ...

Page 15: ...ore starting to move or operate the machine sound the travel alarm and horn to alert bystanders Use a signal person when moving swinging or oper ating the machine in congested areas Locate the signal person so that the operator can always witness the signal person Coordinate the meanings of all safety signs hand signals and marks before starting the machine Ap point a person who is responsible to ...

Page 16: ...could result in a battery explosion or a runaway machine If the engine must be jump started be sure to follow the instructions shown in the OPERATING THE EN GINE chapter The operator must be seated 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 procedu...

Page 17: ... and job site Reinforce ground edges and road shoulders as necessary Keep the machine well back from the edges of excavations and road shoulders When working on an incline or on a road shoulder employ a signal person as required Never allow bystanders to enter the working area such as swing radius or traveling range When the footing is weak reinforce the ground before starting work When working on...

Page 18: ...ved Also appoint a signal person to coordinate the job site Make sure that all personnel obey the signal person s direc tions 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 towards t...

Page 19: ... a grade may cause the machine to slip or to overturn possibly resulting in serious injury or death When traveling up or down a grade keep the bucket in the direction of travel approximately 200 to 300 mm 8 to 12 in A above the ground so that lowering the bucket onto the ground can quickly stop the machine If machine starts to skid or becomes unstable lower the bucket immediately Traveling across ...

Page 20: ... stop a moving machine Park the machine in compliance with the safe parking procedures described on page S 17 to prevent the machine from running away Block both tracks and lower the bucket to the ground thrust the bucket teeth into the ground if you must park on a grade Park a reasonable distance from other machines SA 1297 ...

Page 21: ...DERS 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 regulations 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 a...

Page 22: ...a before operating the machine SA 667 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 Never allow the bucket to pass over anyone to avoid personal injury or death SA 668 AVOID UNDERCUTTING In order to retreat from the edge of an excavation if the fo...

Page 23: ...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 to become soft and make ground travel unstable 025 E01A 0540 4 SA 1301 NEVER ...

Page 24: ...TE 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 SA 673 AVOID POWER LINES Serious injury or death can result if the machine or front attachments are not kept a ...

Page 25: ...ipped with any of the necessary safety devices that could allow the machine to be used for craning operation SA 014 PROTECT AGAINST FLYING DEBRIS If flying debris such as soil rock fragments or metal pieces hit eyes or any other part of the body serious injury may result Guard against such injuries when working in a job site where possibility of flying pieces of metal or debris exist or when remov...

Page 26: ... to OFF to stop engine Remove the key from the key switch Before leaving the machine close all windows roof vent and cab door Lock all access doors and compartments SA 1306 HANDLE FLUIDS SAFELY AVOID FIRES Handle fuel with care it is highly flammable If fuel ignites an explosion and or a fire may occur possibly resulting in serious injury or death Do not refuel the machine while smoking or when ne...

Page 27: ... in width and strength to support the machine and have a gradient of less than 15 degrees 5 Slowly drive the machine 6 Avoid steering while driving up or down the ramp as it is extremely dangerous If steering is unavoidable first move back to the ground or flatbed modify traveling direction and begin to drive again 7 The top end of the ramp where it meets the flatbed is a sudden bump Take care whe...

Page 28: ...temperatures have cooled down to the safety range In case inspection maintenance must be performed with the engine runnning be sure to appoint an overseer Never lubricate or service the machine while moving it Repair the cracked windowpane before servicing the machine Failure to do so may cause personal injury Whe raising the machine above the ground using the front attachment function maintain th...

Page 29: ...efore performing any work on the machine attach a Do Not Operate tag in an easy to see place such as on the cab door or control lever Never attempt to operate the machine with a Do Not Operate tag attached Make it a rule for the inspection service person to hold the engine start key during inspection service work SA 287 SUPPORT MACHINE PROPERLY Never attempt to work on the machine without securing...

Page 30: ... the track adjuster is under high pressure Failure to follow the precautions below may result in serious injury blindness or death Do not attempt to remove GREASE FITTINGS or VALVE ASSEMBLIES As pieces of parts may fly off be sure to keep body and face away from the valve Travel reduction gears are under pressure As pieces of parts may fly off be sure to keep body and face away from AIR RELEASE PL...

Page 31: ...eam can cause severe burns To prevent possible injury from hot spraying water stop the engine Begine to work after the engine and radiator are sufficiently cooled DO NOT remove the radiator cap until the engine is cool When opening turn the cap slowly to the stop Allow all pressure to be release before removing the cap The hydraulic oil tank is pressurized Again be sure to release all pressure by ...

Page 32: ...ult in severe burns gangrene or otherwise serious injury or death SA 019 AVOID HIGH PRESSURE FLUIDS Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury blindness or death Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines Make sure that all connectors are completely connected before applying pressure Se...

Page 33: ...or damaged clamps lines hoses oil cooler and oil cooler flange bolts Do not bend or strike high pressure lines Never install bent or damaged lines pipes or hoses Check for Shorts Short circuits can cause fires Clean and tighten all electrical connections Check before each shift or after eight 8 to ten 10 hours operation for loose kinked hardened or frayed electrical cables and wires Check before e...

Page 34: ...mperature parts such as a muffler or exhaust pipe Check Heat Shield Covers around Engine Compartment If the engine compartment heat shield cover becomes broken or lost fire may break out If the engine compartment heat shield cover becomes broken or lost repair or replace it before operating the machine Check Key Switch If fire breaks out failure to stop the engine will escalate the fire hampering ...

Page 35: ...extinguisher if there is time Exit the machine using handrails and or steps SA 393 BEWARE OF EXHAUST FUMES Prevent asphyxiation Engine exhaust fumes can cause sickness or death If you must operate the machine in a building be sure there is adequate ventilation Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area SA 016...

Page 36: ...ldering SA 818 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area Install temporary f...

Page 37: ...rs and other flammable material from area SA 029 PREVENT BATTERY EXPLOSIONS Battery gas can explode Keep sparks lighted matches and flame away from the top of battery Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer Do not charge a frozen battery it may explode Warm the battery to 16 C 60 F first Do not continue to use or charge the battery when t...

Page 38: ...the correct procedures and use recommended equipment See your nearest Hitachi dealer for MSDS SA 309 DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with HITACHI equipment includes such items as oil fuel coolant brake fluid filters and batteries When draining fluid use a leakproof container with a capacity larger than ...

Page 39: ...SAFETY S 30 MEMO ...

Page 40: ...affixed on the machine to ensure safe machine operation Always keep the safety signs clean In case a safety sign is broken or lost immediately obtain a new replacement and affix it again in position on the machine Use the part No indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer SS3079466 SS 2866 SS 259 SS 2867 SS 024 SS 2868 ...

Page 41: ...SAFETY SIGNS S 32 SS4387344 SS 2901 SS3090482 SS 2869 SS3088058 SS 2870 ...

Page 42: ...SAFETY SIGNS S 33 SS4433590 SS 2871 SS4604981 SS 2872 SS4642517 SS 2873 ...

Page 43: ...SAFETY SIGNS S 34 SS4430516 SS 2902 2Way Multi Lever Equipped Machines SS4605065 SS 2875 SS3110371 SS 2876 ...

Page 44: ...ure s protective structure Damaged Roll Over Protective Structure ROPS Tip Over Protective Structure TOPS Falling Object Protective Structure FOPS must be replaced not repaired or revised Any alternation to the ROPS or TOPS or FOPS must be approved by the manufacturer ROPS FOPS SS3109771 SS 2877 ...

Page 45: ...SAFETY SIGNS S 36 MEMO ...

Page 46: ...unterweight 2 Canopy 3 Boom 4 Work Light 5 Arm Cylinder 6 Bucket Cylinder 7 Arm 8 Bucket 9 Boom Cylinder 10 Blade 11 Blade Cylinder 12 Front Idler 13 Boom Swing Cylinder 14 Track Shoe 15 Track Frame 16 Travel Device 2 5 6 7 4 8 10 14 1 15 16 3 13 11 12 9 ...

Page 47: ... Travel Lever 5 Right Travel Lever 6 Right Control Lever Horn Switch 7 Boom Swing Pedal 8 Blade Lever 9 Key Switch 10 Engine Control Lever 11 Switch Panel Monitor Panel 12 Operator s Seat 13 Operator s Manual Box 14 Travel Mode Pedal 15 Fuse Box 16 Side Frame Extend Retract Lever M1MS 01 002 M1MS 01 003 2 3 14 6 8 10 9 11 1 4 5 7 12 13 15 16 ...

Page 48: ...ngine Start 4 HEAT Engine Preheat SWITCH PANEL 5 Work Light Switch Press the switch 5 to turn work lights 9 located on the boom ON 6 Travel Alarm Deactivation Switch Push the travel alarm deactivation switch 6 to stop the alarm M1M7 01 007 M1MS 01 011 M1MS 01 001 3 2 1 4 6 5 9 ...

Page 49: ...the ma chine is operating on level ground the remaining fuel amount in the fuel tank is 4 5 L 1 2 US gal Refill the fuel as soon as possible Preheat Indicator When the key switch is turned to the HEAT position or ange indicator will light Light will turn off after approx 3 seconds have passed Overheat Indicator If the coolant temperature rises extremely high this in dicator operates If the red lig...

Page 50: ...l accumulated machine operation hours counted since the machine started working are displayed in the unit of HOUR h One digit after the decimal point indi cates the tenths of an hour 6 minutes Fuel Gauge The gauge needle position indicates the fuel level Refill the fuel before only the E marked segment comes ON Coolant Temperature Gauge The gauge needle position indicates the engine coolant temper...

Page 51: ... Seat fore aft posi tion can be adjusted at the interval of 20 mm in 6 steps 120 mm in total TOOL AND OPERATOR S MANUAL BOXES Tool box 2 is located under the operator s seat and op erator s manual box 3 is located behind the backrest of the operator s seat respectively M1MS 01 009 M1MS 01 009 M1MS 01 010 1 2 3 ...

Page 52: ...they are damaged or worn Replace seat belt 1 every three years regard less of appearance Seat Belt 1 Confirm that seat belt 1 is not twisted and securely insert the end of seat belt 1 into buckle 2 Lightly pull on the belt to confirm that the buckle latches securely 2 Adjust tightness of the seat belt 1 so that the belt is snug but comfortable 3 Push button 3 on buckle 2 to unfasten seat belt 1 M5...

Page 53: ...OPERATOR S STATION 1 8 MEMO ...

Page 54: ...equently affecting the service life of the machine Thoroughly perform break in operation The service life and performance of the machine can be greatly affected by operation and maintenance of the ma chine during the initial stage of operation Perform break in operation with the engine output less than 80 of the maximum output for the first 50 hours ...

Page 55: ...BREAK IN 2 2 MEMO ...

Page 56: ...ll not be displayed even if any abnormality occurs on the machine Accordingly in case any of the indicator bulbs or the warning lamps do not come ON imme diately contact your nearest Hitachi dealer for repair If any of alternator 3 or engine oil pressure 4 fails to light after indicator light check is completed the machine may have trouble Immediately contact your nearest Hitachi dealer for repair...

Page 57: ...rge Never run the starter for more than 20 seconds at a time If the engine fails to start return the key switch to OFF Wait for more than 30 seconds then try again 5 Release key switch 2 immediately after the engine has started It will automatically return to the ON po sition NOTE The horn sounds even though the key switch is turned OFF The engine does not start unless the pilot control shut off l...

Page 58: ...tion to run the starter IMPORTANT Prevent starter damage and or battery over discharge Never run the starter for more than 20 seconds at a time If the engine fails to start return the key switch to OFF Wait for more than 30 seconds then try again 6 Release key switch 2 immediately after the engine has started It will automatically return to the ON po sition NOTE Set the engine control lever to the...

Page 59: ...lowing points through the monitor 1 Check that alternator indicator 3 is OFF In case alternator indicator 3 stays ON immediately stop the engine Then check the alternator and or battery system for any abnormality 2 Check that engine oil pressure indicator 2 is OFF In case engine oil pressure indicator 2 stays ON immediately stop the engine Then check the engine oil pressure system and or the oil l...

Page 60: ...y and the other end to the positive terminal of the booster battery 3 After connecting one end of the black cable 2 to the negative terminal of the booster battery connect the other end to upperstructure frame 3 on the ma chine Be alert to sparks that may be produced in the last connection to the hydraulic oil tank cover hinge 4 After securely connecting the booster cables start the engine of the ...

Page 61: ...wer the bucket and blade to the ground unless specified 2 Return the engine control lever to the slow idle posi tion and keep the engine running at slow idle speed for 5 minutes 3 Turn the key switch 2 OFF to stop the engine 4 Pull up pilot control shut off lever 1 to the LOCK po sition M1M7 01 007 M1MS 03 001 2 1 ...

Page 62: ... are provided for smooth control In extremely cold weather lower than 20 C the travel lever will become heavy to operate This is caused by increase in oil viscosity which is not abnormal Forward Reverse Travel Move both levers forward together to travel forward Pull the levers back together to travel in reverse The travel speed can be controlled by adjusting the lever operating stroke Ascending De...

Page 63: ...posite directions each other Move one lever forward and pull the other back at the same time CAUTION During pivot or spin turn machine operations the base machine may shake When turning the machine in a tight area slowly operate the machine while taking care not to allow the machine to come in contact with the surrounding objects M1MF 04 001 M104 04 005 M1MF 04 001 M104 04 007 Pivot Turn Spin Turn...

Page 64: ...LARM The travel alarm functions to alert co workers and or bystanders to movement of the machine both forward and reverse The travel alarm sounds when any travel lever is operated and will continue to sound as long as the tracks are moving WARNING If the travel alarm does not sound when traveling immediately stop the engine and contact your authorized dealer for repair Operating the machine with a...

Page 65: ...w the machine to ride on only the rails Check that the machine can pass under a bridge and electric lines before driving the machine When crossing a river drive the machine slowly while measuring the depth of the river using the bucket Do not cross the river when the depth of the river is deeper than the upper track shoe surface Reduce the engine speed when traveling on rough terrains Select slow ...

Page 66: ...into the undercarriage the machine may become impossible to travel Raise one side track above the ground with the boom and arm extended remove mud and or grabbles from the track Then evacuate the machine Rotate the raised track in forward or reverse directions alternately to remove the packed rocks and or mud from the track Tow the machine with other machine if the machine becomes stuck in soft gr...

Page 67: ...e machine using another machine Be sure to attach the wire ropes around the track frames To prevent the wire ropes from being damaged place pieces of soft protective material between the wire ropes and the edge corners if the frame IMPORTANT Do not tow the machine using the light weight part towing holes provided on the blade Damage to the towing holes may result M585 05 035 Wire Ropes ...

Page 68: ...ars and or center joint in water or mud 2 The machine may enter deeper areas gradually Check the machine s position often Reposition the machine if necessary IMPORTANT If the swing bearing swing gears and center joint are submerged in water or mud by mistake premature wearing on parts such as the swing bearing may result Grease must be changed or overhauling will be required immediately Stop opera...

Page 69: ...skids or becomes unstable immediately lower the bucket to the ground to stop traveling Traveling across the face of slope or steering on a slope may cause the machine to skid or turnover If the direction must be changed move the machine to level ground then change the direction to ensure safe operation Avoid swinging the upperstructure downhill The machine may tip over If swinging uphill is unavoi...

Page 70: ... Also put blocks at the downhill end of the tracks PARKING ON SLOPES 1 Park the machine on a level solid surface Position the arm vertically and lower the bucket and blade to the ground 2 Turn the engine control dial or the engine control lever to the slow idle position Run the engine at the slow idle speed for approx 5 minutes to cool the engine 3 Turn the key switch to OFF to stop the engine Rem...

Page 71: ...DRIVING THE MACHINE 4 10 MEMO ...

Page 72: ... not to come into contact with the control levers when turning and looking behind the machine Labels showing the lever control pattern are provided on the operator s right As illustrated below the labels indicate the ISO Excavator Pattern M588 05 050 When a control lever is released it automatically returns to neutral stopping the function in that position 1 Arm Roll Out 2 Arm Roll In 3 Swing Left...

Page 73: ...t with the control levers when looking back Labels displaying the available lever control patterns are provided at the right of the operator As illustrated below the labels with H pattern mark at the right bottom corner indicate the HITACHI Excavator Pattern M1LA 05 014 When a control lever is released it automatically returns to neutral stopping the function in that position 1 Swing Right 2 Swing...

Page 74: ...he control levers when looking back Labels showing the SAE BACKHOE pattern are provided on the operator s right Whenever changing the pattern stop the engine rotate the selector valve 9 and set to the pattern position M1M7 05 028 When a control lever is released it automatically returns to neutral stopping the function in that position 1 Boom Lower 2 Boom Raise 3 Swing Left 4 Swing Right 5 Arm Rol...

Page 75: ... located at the operator s right foot as illustrated to the right Boom Swing Operation 1 Turn cover 2 for boom swing pedal 1 forward 2 Step on the left side of boom swing pedal 1 to swing left Step on the right side of the pedal to swing right 3 Turn cover 2 backward over boom swing pedal 1 when boom swing operation is no longer required 3 Swing Left 4 Swing Right M1MS 05 004 M1MS 05 003 M571 01 0...

Page 76: ...ight to operate hydraulic breaker crusher etc Operation 1 Turn auxiliary pedal cover 1 forward 2 Step on the right or the left side of the auxiliary pedal 2 to operate the front end attachment such as a hydraulic breaker 3 When the auxiliary pedal 2 is not used turn cover 1 backward on the pedal M1MS 05 005 M1MS 05 003 2 1 1 ...

Page 77: ...he operator s right to raise and lower the blade When the lever is released it automatically returns to neutral holding the blade in the present position until the lever is operated again 2 Blade Raise 3 Blade Lower M1MS 05 001 M1MS 04 001 2 3 3 2 1 ...

Page 78: ... do so may result in damage to the blade and the undercarriage When jacking up the machine with this blade the surface beneath the blade comes under high pressure increasing the risk of surface collapse Always be sure that the surface is strong enough to support the weight of the machine before jacking up the machine Avoid dangerous uneven distribution of weight to the blade by maintaining even co...

Page 79: ...retracted only when traveling through a flat narrow work site Except for this condition whenever traveling the machine performing excavation or operating the blade be sure to fully extend the side frames Failure to do so may cause the machine to turn over IMPORTANT Before extending or retracting the side frames park the machine on a level surface with no obstructions and remove packed mud or grave...

Page 80: ... engine When extending the blade width 1 Remove blade pins 5 2 Turn over the extension blade 4 and align the two pin holes 3 Install blade pins 5 4 Extend the left side following steps 1 to 3 above When retracting the blade width 1 Remove blade pins 5 2 Turn over the extension blade 4 so that the cutting edge side may turn to the track shoe side Align the two pin holes 3 Install blade pins 5 4 Ret...

Page 81: ...fter each shift Pilot Control Shut off Lever Operation Before Leaving the Machine 1 Park the machine on a firm level surface Lower the bucket and blade to the ground Return all control levers to neutral Stop the engine 2 To deactivate control lever 3 function be sure to pull pilot control shut off lever 1 and raise console 2 to the fully locked position Before Starting Operation WARNING Never atte...

Page 82: ... and lightly operate the swing and travel motors to warm up them WARMING UP IN COLD WEATHER IMPORTANT In case the hydraulic oil temperature is low never operate the machine until all actuator speeds become normal after warming up operation 1 Run the engine at intermediate speed for 5 minutes longer if the air temperature is extremely low 2 Do not run the engine at either slow or fast speed during ...

Page 83: ...m tipping over and from being involved in a ground collapse Take the following necessary precautions Make sure the work site ground has sufficient strength to firmly support the machine When working close to an excavation or on road shoulders operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear and with the blade at the front so that the mac...

Page 84: ...backward to continue the trench Operate each cylinder with a slight allowance left at both stroke ends IMPORTANT Do not dig the ground in the diagonal direction toward the track frame Failure to do so may cause the bucket teeth to come in contact with the crawler When lowering the boom avoid sudden stops that may create shock load damage to the machine Always smoothly lower the boom so that shock ...

Page 85: ...above AVOID DRIVING BUCKET TEETH INTO GROUND WARNING If the bucket teeth are forcedly driven into the ground crushed material may spatter possibly resulting in injury of the operator and or co workers around the machine Furthermore the service lifetimes of all front attachment parts may be shortened If the bucket teeth are forcedly driven into the ground the service lifetime of all front attachmen...

Page 86: ...the front attachment or shortening of the service life of the swing systems may result USE CORRECT TRACK SHOE Never use rubber crawlers or wide track shoes on rough terrain with scattered rocks gravel or boulders Failure to do so may cause breakages of rubber crawlers shoe bending looseness of shoe bolts or damage to track parts such as track links or rollers Refer to the table for Types and Appli...

Page 87: ... become unstable possibly resulting in tipping accident When lifting a load carefully swing the machine not to cause the lifting load to come in contact with personnel working near the machine Reduce the engine speed to slowly swing the machine Failure to do so may cause the machine to tip over by swing centrifugal force If traveling the machine with a load lifting is unavoidable reduce the engine...

Page 88: ...ucket hook To prevent wire rope from coming off the hook never allow the wire rope to slacken by operating the front attachment as slowly as possible Do not allow anyone to enter below the lifted load or in the vicinity of the lifted load Control the bucket angle so that the bucket hook mounting face remains vertical as illustrated to the right BOOM CYLINDER MAY HIT BLADE When digging deeply with ...

Page 89: ...not attempt to allow the blade to collide with rocks Premature damage to the blade and the blade cylinders may result AVOID COLLIDING BOOM CYLI NDER WITH TRACK When digging deeply with the front attachment positioned at an angle as illustrated the boom cylinder may accidentally collide with the track causing damage Take extra care to prevent this from happening M586 05 017 M586 05 035 M586 05 018 ...

Page 90: ...iding 3 Do not travel the machine while raising one side crawler off the ground with the front attachment Shear or damage to the rubber crawler may result Precautions for Using Rubber Crawlers WARNING The rubber crawler machine is less stable than the steel crawler machine as the edge of the rubber crawler is easier to deform more than steel crawler Pay attention when operating the machine at an a...

Page 91: ...as a thin rubber film shown in doted line on its roller tread During operation of a new machine or immediately after the rubber crawlers are replaced the rubber film may come off due to contact with the rollers This is not abnormal See the right illustration 6 If the rubber crawler is damaged and the rubber crawler core wire rusts the service lifetime of the rubber crawler will become short If dam...

Page 92: ...he caps and plugs Always keep the auxiliary parts in the tool box Check that the pipe clamp bolts are tight and no oil is leaking from the pipe and hose joints before operating the hydraulic breaker Precautions for Hydraulic Breaker Operation WARNING When the hydraulic breaker is installed machine stability is reduced as the breaker is much heavier than the bucket In addition soil broken pieces of...

Page 93: ...of the breaker possibly allowing rust dust and or water to enter the hydraulic circuit so that damage to the hydraulic components on the base machine may result 5 Do not use the breaker to lift objects Serious accidents may result due to tipping over of the machine and or coming off of the lifted load 6 Do not operate the breaker over the side of the machine The machine stability is reduced possib...

Page 94: ...il and replace the full flow filter element at the intervals as shown in the table below to especially extend the service life of the hydraulic pump Refer to the Hydraulic System group in the Inspection and Maintenance Section Hydraulic Oil change and Full Flow Filter Element Replacement Intervals Hours M1M7 05 027 9 Greasing Front Attachment When using a hydraulic breaker grease all lubrication p...

Page 95: ...oken pieces of rock or metals may be scattered during crusher operation potentially creating hazardous situation Take protective measures to prevent machine tipping over and or scattering of hard materials and observe the precautions described below to ensure safe operation Do not raise the base machine off the ground with the bucket cylinder fully retracted or extended Damage to the front attachm...

Page 96: ...ome contaminated Change the hydraulic oil and replace the full flow filter element at the same intervals as applied to the hydraulic breaker Before transporting the machine on a trailer remove the crusher from the front attachment Position the bucket cylinder so that the cylinder is not fully extended during transportation During transportation the machine may be raised off the trailer deck floor ...

Page 97: ...OPERATION 5 26 MEMO ...

Page 98: ...DING UNLOADING Always load and unload the machine on a firm level surface WARNING Be sure to use a loading dock or a ramp when loading unloading the machine Ramp Loading Dock 1 Thoroughly clean the ramp and flatbed Dirty flatbed ramps contaminated with oil mud or ice can be slippery and dangerous 2 Wedge the trailer wheels with blocks so that the trailer does not move 3 Ramps must be sufficient in...

Page 99: ...ith the centerline of the flatbed 2 Drive the machine onto the ramp slowly 3 Position the bucket above the flatbed Operate the front attachment so that the angle between the boom and the arm is maintained at 90 to 110 4 The machine tips forward when the machine travels over the top end of the ramp Lower the bucket onto the flatbed before the machine begins to tip forward 5 After the machine reache...

Page 100: ... the base machine and the front attachment to the flatbed with wire ropes Transporting the machine equipped with rubber crawlers When securing the machine to the flatbed do not directly tighten the rubber crawler with wire ropes As illustrated below place soft protectors against left right side frame respectively to securely tighten the machine to the flatbed before transporting the machine M1MS 0...

Page 101: ...le between the boom and the arm at 90 to 110 If the machine is unloaded with the arm fully rolled in damage to the base machine may result 1 Before moving the machine from the flatbed rear end to the ramp position the front attachment so that the angle between the boom and the arm becomes into the range of 90 to 110 While allowing the bucket to be contacted on the ground slowly move the machine IM...

Page 102: ...lade is positioned at the rear of the counterweight 2 Fully retract the blade cylinder 3 Fully extend the boom arm and bucket cylinders as illustrated to the right Pull the pilot control shut off lever to LOCK position 4 Position the boom straight ahead of the upperstructure Apply the boom swing pedal lock 5 Attach shackles to the boom and blade hooks Securely thread wire ropes through the shackle...

Page 103: ...TRANSPORTING 6 6 MEMO ...

Page 104: ...and lines Walk around machine checking general appearance noise heat etc Check for loose or missing parts If there is any problem with your machine repair it before operating or contact your authorized dealer IMPORTANT Use only recommended fuel and lu bricants Use only genuine HITACHI parts Failure to use recommended fuel lu bricants and genuine Hitachi parts will result in loss of Hitachi product...

Page 105: ... slow idle speed without load for approx 5 minutes to cool down the engine 4 Turn the key switch OFF Remove the key from the switch If inspection maintenance must be performed with the engine running be sure to place a lookout to prevent the machine from being operated mistakenly by other personnel 5 Be sure to place pilot control shut off lever 1 in the LOCK position 6 Attach an UNDER INSPECTION ...

Page 106: ...se the cover After checking that stopper 4 provided on the left link is placed in LOCK position 5 remove your hand from the cover Cover 1 will be locked in place When closing cover 1 while raising cover 1 push stopper 4 at the arrowed position Ö to disengage the lock While pushing stopper 4 lower the cover When the cover is lowered by the 1 4 stroke leave stopper 4 Then lower cover 1 further to co...

Page 107: ...opening closing the right side cover take care not to allow your fingers to be pinched with the cover 1 Unlock key 1 and open fuel refueling cover 2 2 Release the lock 3 in the fuel refueling cover 2 3 Unlock key 4 and open right side cover 5 Take stopper 6 out of holder 7 Install stopper 6 into the lock position 4 When close right side cover 5 follow the reverse order of the above procedure M1MS ...

Page 108: ...ks from travel devices 4 Loose or missing nuts and bolts Front Attachment 1 Damage to or oil leak from cylinders hoses and pipes 2 Damage to or wear on bucket and blade 3 Loose worn or missing bucket teeth 4 Lubrication at greasing points 5 Damage to lock pins stoppers fastener rings and lock bolts for front joint pins 6 Loose or missing nuts and bolts Miscellaneous 1 Malfunction of gauges switche...

Page 109: ...commended intervals Consult your nearest Hitachi dealer for correct replace ment Periodic Replacement Parts Replacement Interval Fuel hose Fuel tank to filter Every 2 years or 4000 hours Fuel hose Fuel tank to injection pump Every 2 years or 4000 hours Engine rubber vibration insulator Every 5 years or 3000 hours Engine Pump coupling Every 5 years or 3000 hours Pump suction hose Every 2 years or 4...

Page 110: ...l filter 1 ÌÌ NOTE Ì The oil life is shortened more than normal under high temperature operating shorten the mainte nance interval ÌÌ For the first time only C TRANSMISSION See Page 7 19 Interval hours Parts Quantity 8 50 100 250 500 1000 2000 Oil Level Check 1 Travel Reduction Gear Change 0 25 L 2 0 26 US qt 2 D HYDRAULIC SYSTEM See Page 7 21 Interval hours Parts Quantity 8 50 100 250 500 1000 20...

Page 111: ...Ì or clogged 1 Air Cleaner Element Replacement 1 NOTE Ì Shorten the interval in a dusty work site G COOLING SYSTEM See Page 7 39 Interval hours Parts Quantity 8 50 100 250 500 1000 2000 1 Check Coolant Level 1 2 Check and Adjust Fan Belt Tension 1 ÌÌ 3 Change Coolant 2 7 L 2 9 US qt Once every two years in autumn or 2000 hours Outside 1 Ì 4 Clean Radiator Core Interior 1 When changing coolant NOTE...

Page 112: ...heck and Replace Seat Belt 1 Every 3 years Replace 7 Check bucket hook Optional 8 Check Fuel Injection Nozzles 9 Adjust Value Clearance 10 Check and Clean Injection Device 11 Measure Engine Compression Pressure As required 12 Check Starter and Alternator As required 13 Check Radiator Cap As required 14 Check Tightening Torque of Bolts and Nuts ÌÌ NOTE Consult your nearest Hitachi dealer for inspec...

Page 113: ...super wide 15W 40 Apoll oil gear HE90 Mobil Delvac Exxon Mobil Mobilux EP2 1310 1330 1340 Mobilube HD80W 90 Hi diesel S3 Eneos Epinoc Grease Ap2 20 to 35 C 6 to 95 F 10W 30 10 to 40 C 14 to 104 F 15W 40 Hypoid gear 90 Rymla D Shell Oil Shell Alvania EP Grease 2 10W 30 40 Shell Spirax EP 90 Remarks API CD CLASS API GL4 class Hydraulic Oil Fuel Oil Change Interval 2000 hours 1000 hours Air Temp Manu...

Page 114: ...ion machine with the arm cylinder fully retracted and the bucket cylinder fully extended Lower bucket to the ground the front attachment inspection posi tion All greasing points can be lubricated from the ground 2 Grease all grease fittings illustrated below 1 Boom cylinder rod end 2 Boom cylinder bottom Greasing Point M1M7 05 024 M1M7 07 020 M1MS 07 007 ...

Page 115: ...MAINTENANCE 7 12 3 Boom foot 4 Arm cylinder rod end and bucket cylinder bottom 5 Boom and arm joint pin and arm cylinder bottom 6 Swing cylinder M1MS 07 007 M571 07 006 M585 07 046 M1M7 07 023 ...

Page 116: ...MAINTENANCE 7 13 7 Swing post M1MS 07 008 ...

Page 117: ...ach ment or blade do not attempt to clean the bore in sides of the bushings 2 Before installing the front attachment or the blade apply grease sufficiently to the pin boss ends or the dust seals of the cylinders 3 Be sure to install at least one shim on both sides of front joint pins 4 When the swing post is disassembled coat the pins and the thrust plates with grease before reinstalling them M503...

Page 118: ...no per sonnel are present around the machine before starting to work Grease via grease fittings 1 Lower the bucket and the blade to the ground stop the engine and place the pilot control shut off lever to the LOCK position Add grease with a grease gun by two to three strokes Lower the bucket and blade to the ground 2 Raise the bucket approx 200 mm 8 in above the ground While rotating the upperstru...

Page 119: ... or dirt 2 Apply grease via grease fittings by the quantity shown in the table 3 In order to apply grease evenly to the swing gear raise the bucket approximately 200 mm 8 in above the ground While swinging the upperstruc ture at approximately 90 intervals until one full turn is made add grease at each interval Greasing Quantity Total Grease Capacity ZAXIS17U 2 0 2 L 0 2 US qt 0 6 L 0 6 US qt Contr...

Page 120: ...RNING Each component of the engine may be hot immediately after operation Allow com ponents to cool before starting to work on them 1 Prepare a 10 liter 2 6 US gal container to receive the drain oil 2 Remove drain plug 4 from engine oil pan 3 to drain the oil 3 Allow oil to drain through a clean cloth to check if any debris such as small pieces of metal are pre sent on the cloth 4 After all oil ha...

Page 121: ...ly tightened NOTE Tightening torque 19 6 to 23 5 N m 2 0 to 2 4 kgf m 14 5 to 17 lbf ft 8 Remove oil filler cap 6 Refill the engine NOTE Refer to the recommended oil and grease chart on page 7 10 for the brand names of oils 9 Check that oil level is between the upper and lower limit marks on the dipstick 7 Start the engine 10 Check that no oil is leaking from the sealing joints 11 Run the engine a...

Page 122: ... gear oil to fly out possibly resulting in personal injury Keep body and face away from the air bleed plug Check Oil Level every 250 hours 1 Park the machine on a level surface 2 Rotate the travel motor until plugs are positioned as illustrated on the right Stop the engine 3 Slowly loosen plug 1 to release pressure 4 Remove plugs 1 and 2 Check that oil flows out of the thread hole for plug 2 If no...

Page 123: ...tely clean plug 1 Install plug 1 Tightening torque 34 3 4 9 N m 3 5 0 5 kgf m 25 3 3 6 lbf ft 5 Supply oil through the thread hole for plug 2 NOTE Refer to the recommended oil and grease chart on page 7 10 for the brand names of oils 6 Add oil until oil flows out of the tread hole for plug 2 Oil Quantity 0 25L 0 26US qt 7 After cleaning plugs 2 reinstall the plugs Tightening torque 34 3 4 9 N m 3 ...

Page 124: ...Remove plugs and screws only after thoroughly releasing the residual pres sure 3 3 Never attempt to service or inspect the travel and swing motor circuits on slopes Even after air pressure is released from the hydraulic oil tank the machine on a slope will create force to pressurize hydraulic oil in the travel and swing circuit by its own weight IMPORTANT Take special care to keep seal surfaces of...

Page 125: ... Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended Lower the bucket and blade to the ground Stop the engine 2 Check oil level gauge 1 on the side of the hydraulic oil tank Oil must be at the specified level on the gauge M1M7 05 024 M1MS 07 011 1 ...

Page 126: ...chine on a solid level surface Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended Lower the bucket and blade to the ground Stop the engine 2 Leave the machine without operating the machine until hydraulic oil becomes cool Then bleed air pressure from the hydraulic oil tank 3 Slowly loosen drain plug 1 on the bottom of the hy draulic oil tank to drain ...

Page 127: ...ucket cylinder fully extended Lower the bucket and blade to the ground Stop the engine 2 Open the left side cover Loosen filler cap 1 on the hydraulic oil tank to release air pressure from the hy draulic oil tank 3 Remove cap 1 4 Arrange a container with the capacity approximately 40 liter 11 US gal Drain oil using a suction pump 5 Slowly loosen drain plug 2 on the bottom of the hy draulic oil tan...

Page 128: ...e position 4 Start the engine Wait 5 to 10 seconds Stop the en gine 5 Check the hydraulic oil level at the level gauge 1 located on the side of the hydraulic oil tank Add hy draulic oil if necessary 6 Restart the engine Confirm that hydraulic oil level in the hydraulic oil tank is sufficient Run the engine for approximately 1 minute 7 This is the end of the hydraulic pump air bleeding procedure NO...

Page 129: ...hydraulic oil 1 After draining hydraulic oil remove suction filter 2 together with cover 1 2 Clean the hydraulic oil tank interior and the suction filter 2 3 Install suction filter 2 together with cover 1 to the hydraulic oil tank 4 Bleed air from the hydraulic system Refer to Bleed Air from Hydraulic System Wrench Size 17 mm Tightening Torque 49 N m 5 kgf m 36 lbf ft M503 07 027 1 2 ...

Page 130: ...ressing cover 2 down slowly remove cover 2 so that spring 4 doesn t fly out 4 Remove spring 4 valve 5 and element 6 5 Take care not to allow water and or dirt to enter the filter case 6 Be careful not to damage element 6 and O ring 3 Don t use a broken element 7 Install new element 6 and O ring 3 in the hydraulic oil tank 8 Install cover 2 with four bolts 1 Wrench Size 17 mm Tightening torque 49 N...

Page 131: ...n the machine with the arm cylinder fully retracted and the bucket cylinder fully extended Lower the bucket and blade to the ground Stop the engine 2 Before replacing the element be sure to loosen the hydraulic oil tank cap to release the air pressure from the hydraulic oil tank 3 Remove bolts 3 to remove under cover 2 from the rear left bottom side of the base machine Wrench size 17 mm Tightening...

Page 132: ... 4 while rotating filter element 7 taking care not to damage the filter element 9 Take care not allow dust and or water enter the filter case 10 Install case 6 into head cover 5 while rotating the case clockwise Wrench size 17 mm Tightening Torque 25 to 34 N m 2 5 to 3 5 kgf m 18 to 26 lbf ft 11 After replacing the filter element bleed any remaining air from the hydraulic circuit while running the...

Page 133: ...void this hazard search for leaks with a piece of cardboard Take care to protect hands and body from high pressure fluids If an accident occurs see a doctor familiar with this type of injury immediately Repair or replace any missing loose or dam aged clamps hoses and lines Do not bend or strike high pressure lines Never install bent or damaged hoses or lines Check hoses and lines for oil leaks and...

Page 134: ...replace hose or O ring Every 250 hours Hose surface Hose end Hose surface Hose surface Hose Hose and hose fitting Oil leak 4 Oil leak 5 Exposed reinforcement 6 Blister 7 Acute bend 8 Collapse 9 Deformation or Corrosion 10 Replace Replace Replace Replace Replace Replace M137 07 008 M115 07 145 M115 07 146 M117 07 147 M117 07 148 M117 07 149 1 2 3 2 3 3 2 1 2 3 9 10 8 7 8 4 5 ...

Page 135: ...e O ring and or retighten bolt Replace Every 250 hours Flange type fitting neck Weld joint surfaces On flange type fitting Clamp Crack 13 Crack 12 Omission Deformation Loose Replace Replace Replace Replace Retighten Oil cooler Interval Hours Check Point Abnormality Remedy Every 250 hours Hose and hose connection Oil cooler Oil leak 14 Oil leak 15 Retighten or replace Replace M137 07 001 M137 07 00...

Page 136: ...tal flare 5 on hose 2 ends seal pressure oil Precaution for Application Take care not to damage flare seat 4 and flare 5 when disconnecting or connecting them Tightening Torque Tighten adapter 1 and nut 3 to the torque values shown in the table below 10 Width across flats mm 17 19 22 27 N m 24 5 29 5 39 64 kgf m 2 5 3 4 6 5 Tightening torque lbf ft 18 21 5 29 47 M202 07 051 1 4 3 5 2 ...

Page 137: ... cover 4 Be sure to lock the cover to prevent vandalism NOTE Take care not to allow water and or dirt to enter the fuel system when refilling fuel Bleed Air from Fuel System Air in the fuel system will cause the engine to start hard and or run roughly Be sure to bleed air from the system after replacing the fuel filter or draining the tank Automatic bleeding device is provided on this machine 1 Co...

Page 138: ...uel Tank Sump as required Park the machine on a solid level surface Loosen bolts 5 to remove drain valve cover 6 from right front under cover 7 Rotate drain valve cover 6 to open the checking port Open drain valve 1 on the bottom of the fuel tank and allow the water and sediments to drain from the fuel tank sump M1MS 07 017 M1MS 07 018 M1MS 07 019 2 7 5 6 1 ...

Page 139: ... cap 4 4 Install new filter element 2 filter cap 4 and retighten ring nut 3 securely 5 Open fuel cock 6 6 Loosen plug 5 to bleed air 7 Tighten plug 5 when fuel flows from the plug hole 8 Turn the key switch ON and hold for 10 to 15 seconds to engage automatic bleeding 9 Start the engine and check for fuel leakage M1MS 07 017 M503 07 038 5 2 4 3 6 1 ...

Page 140: ...and or damage while referring to the following tables If any abnormality is found repair it as instructed in the remedy column Hoses Interval Hours Check Point Abnormality Remedy Daily Hose fittings Soutache braid hose surface Leak 1 Rubbed marks 2 Crack 2 Retighten or replace Replace Replace Every 250 hours Soutache braid Hose surface Hose fittings Hose Hose ends and fittings Crack 3 Crack 4 Acut...

Page 141: ...ing the air cleaner suction port If water enters the air cleaner suction port damage to the engine may result When cleaning do not hit element 1 or force the element to collide against other object 3 Clean element 3 by blowing compressed air pressure less than 0 2 MPa 2 kgf cm 2 29 psi from the inside of the element After cleaning be sure to check element 1 for damage If any damage is found replac...

Page 142: ...tween 30 and 60 If the ratio is below 30 the system may develop rust and if it is above 60 the engine may overheat LLC Mixing Ratio Mixing ratio 30 35 40 45 50 Air temperature C F 10 14 15 5 20 4 25 13 30 22 Precautions for Handling LLC WARNING LLC is poisonous 1 If ingested Induce vomiting and immediately get emergency medical attention 2 If antifreeze is accidentally splashed in the eyes suffici...

Page 143: ...gh radiator cap 1 Check and Adjust Fan Belt Tension every 100 hours first time after 50 hours IMPORTANT Loose fan belt tension may result in insufficient battery charging engine overheating as well as a rapid abnormal belt wear Belts that are too tight however can damage both water pump and alternator bearings and belts Check Check fan belt tension by depressing the fan belt mid point with the for...

Page 144: ...o locking position 8 3 Loosen mounting bolts 6 of alternator 5 4 Move alternator 5 to correctly adjust the fan belt tension 5 Securely tighten bolts 6 6 Reverse order of the above procedure Return the seat base to previous position reassemble the unites NOTE When a new belt is installed the new belt is difficult to be correctly seated from the beginning Be sure to readjust the tension after operat...

Page 145: ...acket Fill the radiator with fresh water including less impurity and a radiator cleaner agent Start the engine and run it at a speed slightly higher than slow idle to raise the coolant temperature until the needle of the temperature gauge reaches the white zone Then run the engine further for about ten minutes 3 Stop the engine and open radiator drain cock 1 to allow the coolant to drain Flush out...

Page 146: ...entry of dust and water while cleaning the radiator High pressure air less than 0 2 MPa 2 kgf cm 2 29 psi or water can damage radiator fins Keep the pressure nozzle 500 mm 19 7 in or more away from the core face The radiator and the oil cooler are arranged in series In case dust or dirt should become stuck to the radiator core clean the radiator with compressed air and or water to maintain the coo...

Page 147: ... to use or charge the battery when the electrolyte level is lower than specified Explosion of the battery may result Charge battery in a well ventilated area Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed into eyes IMPORTANT If the battery is used with the electrolyte level lower than the specified low level ...

Page 148: ...e filler port It is difficult to judge the accurate electrolyte level in this case Check if the electrolyte surface touches the bottom end of the sleeve or not according to the right illustrations When the electrolyte surface is lower than the bottom end of the sleeve refill with distilled water or commercial battery fluid up to the bottom end of the sleeve After refilling securely tighten the fil...

Page 149: ...parks to fly near the batteries Perform battery maintenance only after turning the key switch OFF and removing the battery caps Touching the batteries soon after operation is hazardous Wait for the batteries to cool During charging batteries generate flammable hydrogen gas Remove the batteries from the base machine Then charge the batteries in a well ventilated area only after removing the caps Wh...

Page 150: ...NANCE 7 47 Replacing Fuses 1 If any electrical equipment fails to operate first check the fuses in the fuse box 2 One each capacity of spare fuses are provided in the fuse box M1MS 01 003 M1MS 07 035 Fuse Box ...

Page 151: ...d hat and safety glasses 1 Use hammer 2 and drift 3 to drive out locking pin 5 Be careful not to damage rubber pin lock 4 while removing locking pin 5 2 Inspect locking pin 5 and rubber pin lock 4 for any damage Replace short or damaged locking pins as illustrated below with new ones M104 07 056 M589 07 017 M104 07 118 M104 07 058 M104 07 059 4 WRONG WRONG RIGHT WRONG 5 Level the bottom surfaces L...

Page 152: ...ce 4 Install rubber pin lock 4 into shank 6 hole as shown M104 07 060 5 Position new tooth 1 over shank 6 M104 07 061 6 Drive locking pin 5 fully into the hole as shown M104 07 062 1 5 6 1 6 4 RIGHT WRONG WRONG WRONG WRONG WRONG RIGHT RIGHT ...

Page 153: ...ground and position it with the flat surface resting on the ground Be sure the bucket will not roll when the pins are removed 2 Slide the O rings out of the specified position to the bucket boss side 3 Remove bucket pins A and B to separate the arm and bucket Installation 1 Clean the removed pins and pin bores Apply sufficient grease to the pins and pin bores 2 Place a new bucket in a stabilized p...

Page 154: ...39 to 0 59 Adjusting Track Sag 1 If track sag is not within specifications loosen or tighten the track following the procedures shown on the next page 2 Before adjusting track sag lower the bucket and blade to the ground to raise both tracks off the ground Be sure to place blocks under machine frame to support the machine 3 After adjusting track sag of both tracks run the tracks back and forth sev...

Page 155: ...ther 3 If grease does not drain smoothly raise the track to be loosed off the ground and slowly rotate the track 4 When proper track sag is obtained turn valve 1 clockwise and tighten it to 88 N m 9 kgf m 65 lbf ft Tighten Track Rubber Crawler WARNING In case the track sag is not adjustable this is a very hazardous situation Since the track adjuster spring is excessively loaded the grease pressure...

Page 156: ... the rubber track only after taking appropriate measures to prevent the front idler from coming off Removing Rubber Track 1 Lower the bucket and blade to raise both tracks off ground as shown Place blocks under machine frame to support the machine 2 Slowly turn valve 1 counterclockwise to allow grease to escape from the grease outlet 3 Insert two or three steel pipes into the gaps among lower roll...

Page 157: ...al force to the rubber track to seat it on the idler 5 Insert a steel pipe into gaps among lower rollers track frame and rubber track and rotate the rubber track slowly to correctly seat the rubber track on the idler 6 Confirm that the rubber track is correctly engaged with the sprocket and idler 7 Adjust track sag See page 7 51 8 After checking that the rubber track is correctly engaged with the ...

Page 158: ...ials may easily become packed into the undercarriage adjust the track sag so that it is slightly loose Adjusting Track Sag 1 If track sag is not within specifications loosen or tighten the track following the procedures shown on the next page 2 When adjusting track sag lower the bucket to the ground to raise one track off the ground Repeat this procedure to raise the other track Every time be sure...

Page 159: ...ther 3 If grease does not drain smoothly raise the track to be loosed off the ground and slowly rotate the track 4 When proper track sag is obtained turn valve 1 clockwise and tighten it to 88 N m 9 kgf m 65 lbf ft Tighten Track Steel Crawler WARNING In case the track sag is not adjustable this is a very hazardous situation Since the track adjuster spring is excessively loaded the grease pressure ...

Page 160: ...ter the rubber track is removed the front idle will become free to remove If the front idle comes off unexpectedly personal injury and or death may result Be sure to remove the rubber track only after taking an appropriate measure to prevent the front idler from coming off Consult your nearest authorized dealer for converting the track Change the track adjuster whenever converting the steel or rub...

Page 161: ...ace the damaged or worn item s before operating the machine Replace seat belt 1 every three years regardless of its apparent condition Check Bucket Hook Optional daily Perform lifting work only after checking hook 1 for wear cracks and deformations the hook joint for cracks and rope guide 2 latch spring pin and spring pin for damage and malfunction M1MS 07 026 M107 07 129 ２１ Hook Spring Spring Pi...

Page 162: ...for inspection and repair Check and Clean Injection Device every 1500 hours Consult your authorized dealer for inspection and repair Measure Engine Compression Pressure As required Consult your authorized dealer for inspection and repair Check Starter and Alternator As required Consult your authorized dealer for inspection and repair Check Radiator Cap As required Consult your authorized dealer fo...

Page 163: ...se mounting bolt 10 4 17 49 5 36 8 Swing device mounting bolt 12 4 19 88 9 65 9 Battery mounting nut 6 4 10 5 0 5 3 5 10 3 17 49 5 36 10 Canopy mounting bolt 12 4 19 88 9 65 Upperstructure 10 16 17 49 5 36 11 Swing bearing mounting bolt Undercarriage 10 18 17 49 5 36 12 Travel device mounting bolt 10 16 8 Socket 64 6 5 47 13 Sprocket mounting bolt 10 18 8 Socket 64 6 5 47 14 Steel crawler guide mo...

Page 164: ...0 5 8 29 5 3 0 19 5 2 0 9 8 1 13 19 5 2 0 6 10 64 6 5 49 5 19 5 2 17 49 5 8 12 108 11 88 9 34 3 5 19 88 9 10 14 175 18 137 14 54 5 5 22 137 14 12 16 265 27 205 21 78 8 24 205 21 14 18 390 40 295 30 118 12 27 295 30 14 20 540 55 390 40 167 17 30 390 40 17 22 740 75 540 55 215 22 32 24 930 95 690 70 275 28 36 27 1370 140 1030 105 390 40 41 30 1910 195 1420 145 540 55 46 33 2550 260 1910 195 740 75 5...

Page 165: ...MAINTENANCE 7 62 MEMO ...

Page 166: ...868 3 Tooth Lock Rubber 4339867 3 Side Cutter R 4626441 1 Side Cutter L 4626442 1 Bolt J921440 6 Spring Washer A590914 6 Side Cutter Nut J950014 6 O ring 4275463 4 Shim 4354264 2 NOTE The quantities shown in the above tables are those required for the one standard bucket The quantities for an optional bucket may differ The figures in in the O ring columns include the O ring quantities used at the ...

Page 167: ...CONSUMABLE PARTS LIST 8 2 MEMO ...

Page 168: ...e 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 Freezing Weather Fuel Use high quality fuel suitable for low temperature Lubricant Use high quality low viscosity hydraulic oil and engine oil Engine Coolant Be ...

Page 169: ...MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 9 2 MEMO ...

Page 170: ...negative battery cable from the ter minal 8 Add an antirust agent to the coolant In cold weather add an antifreeze or drain the coolant completely Be sure to attach a No Water in Radiator tag on a clearly visible location if the system is drained 9 Loosen the alternator belt and fan belt 10 Paint necessary areas to prevent rust 11 Store the machine in a dry protected place If stored outside cover ...

Page 171: ...ydraulic functions several cycles 6 Carefully check all systems before operating the ma chine with a full load NOTE When the machine has been stored for a long time be sure to perform the following steps as well a Check the condition of all hoses and con nections b Warm up the engine c Stop the engine d Install new fuel filters Replace the engine oil filter and fill the engine with oil IMPORTANT I...

Page 172: ...nsufficient engine oil Oil leak at connections Oil pressure switch failure Add oil Repair Replace Engine knocks or runs irregularly Fuel filter restriction Air in the fuel system Air cleaner restriction Clean or replace the filter Re tighten connections and bleed Clean or replace the element Engine overheats Insufficient coolant and or cool ant leak Loose fan belt or oil on fan belt Radiator fins ...

Page 173: ...y Too tight track sag Foreign matter such as rocks stuck in the tracks Counterbalance valve failure Travel motor performance drop Adjust track sag Remove foreign matter Replace Replace Machine mistracks Track sag is not equal on both sides Hydraulic pump performance drop Oil leak inside control valve Adjust track sag properly and equally on both sides Replace Replace the control valve Insufficient...

Page 174: ...Swing Radius mm ft in 675 2 3 D Minimum Ground Clearance mm ft in 165 6 E Counterweight Height mm ft in 435 1 5 F Engine Cover Height mm ft in 1230 4 0 G Undercarriage Length mm ft in 1570 5 2 H Undercarriage Width mm ft in 970 3 2 1280 4 2 I Sprocket Center to Idler Center mm ft in 1210 3 12 J Track Shoe Width mm ft in 230 9 Rubber Crawler Ground Pressure kPa kgf cm 2 psi 28 0 0 29 4 1 Swing Spee...

Page 175: ...400 7 11 F Overall Transport Length mm ft in 3590 11 9 3640 11 11 G Minimum Swing Radius mm ft in 1540 5 1 1630 5 4 H Boom Swing Pivot Offset Distance mm ft in 100 4 I Blade Bottom Highest Position above ground level 282 11 J Blade Bottom Lowest Position above ground level mm ft in 240 9 K Offset Distance mm ft in L520 L 1 9 R550 R1 10 Maximum Boom Swing Angle Degree L70 R50 NOTE The dimensions do...

Page 176: ...onal Operating Weight kg lb 1770 3900 1820 4010 Minimum Ground Clearance mm ft in 165 6 160 6 Undercarriage Length mm ft in 1570 5 2 1550 5 1 Undercarriage Width mm ft in 970 3 2 1280 4 2 970 3 2 1280 4 2 Ground Pressure kPa kgf cm 2 psi 28 0 28 4 0 29 0 29 4 1 NOTE The specifications for the front end attachment are for 0 93 m 3 ft 1 in arm with ISO 0 044 m 3 0 058 yd 3 bucket ...

Page 177: ...8 NOTE 1 Symbols in the above table have the following meanings General excavating Light duty excavating Loading work 2 Hoe bucket is applicable to the following types of work General excavating For digging and loading operation of sand gravel clay ordinary earth and so on Light duty excavating For digging loading operation of dried loosened earth sand mud so on Their bulk density shall be less th...

Page 178: ...t doesn t fall Wire rope 2 2 Breaking load more than 7 kN Pin Shackle 3 2 JIS Nominal size 8 or more Eye bolt 4 2 M16 2 Remove mounting bolts 5 WARNING Take care if the additional counterweight is eccentrically lifted the lifted counterweight may widely sway Place the removed additional counterweight on a level surface Installation 1 Lift the additional counterweight using the lifting tools descri...

Page 179: ...REFERENCE 13 2 MEMO ...

Page 180: ...t Hook Optional 7 58 Check Bucket Teeth for Looseness and or Wear 7 48 Check Coolant Level 7 40 Check Fuel Hoses 7 37 Check Hoses and Lines 7 30 Check Hydraulic Oil Level 7 22 Check Injection Nozzle 7 59 Check Machine After Starting Engine 3 4 Check Radiator Cap 7 59 Check Starter and Alternator 7 59 Check Tightening Torque of Bolts and Nuts 7 60 Check Track Sag steel crawler 7 55 Check Water Sepa...

Page 181: ...peration 5 7 Precautions for Operations 5 12 Precautions for Traveling 4 4 Precautions for Traveling On Slopes 4 8 Precautions for Using Bucket Hook 5 17 Precautions for Welding and Grinding S 27 Preheat Indicator 1 4 Prepare Machine for Inspection Maintenance 7 2 Prepare for Emergencies S 2 Prevent Battery Explosions S 28 Prevent Burns S 22 Prevent Fires S 24 Prevent Parts from Flying S 21 Proced...

Page 182: ...ad 6 1 Travel Alarm 4 3 Travel Levers 4 1 Travel Mode Pedal 4 3 Travel Reduction Gear 7 19 Traveling On Soft Ground 4 5 U Understand Signal Words S 1 Unloading 6 4 Use Correct Track Shoe 5 15 Use Handholds and Steps S 4 Using Booster Batteries 3 5 Using Rubber Crawler 5 19 W Warming Up In Cold Weather 5 11 Warming Up Operation 5 11 Warn Others of Service Work S 20 Wear Protective Clothing S 3 Work...

Page 183: ...INDEX 14 4 MEMO ...

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