Hitachi ZW 180-6 Operator'S Manual Download Page 8

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CONTENTS

B. Engine ..........................................................................................7-32

Check Engine Oil Level ..........................................................7-32

Change Engine Oil ..................................................................7-33

Replace Engine Oil Filter .......................................................7-35

Check Crankcase Breather Tube ........................................7-36

Replace Crankcase Air Breather Element .......................7-37

Check Vibration Damper ......................................................7-39

C. Power Train ................................................................................7-40

Check Transmission Oil Level ..............................................7-40

Change Transmission Oil and Transmission Oil

Filter........................................................................................7-41

Change Axle Oil .......................................................................7-44

Check Surroundings Around Axle and Covers for Oil

Leaks ......................................................................................7-46

Clean Axle Housing Air Breather .......................................7-46

D. Hydraulic System .....................................................................7-47

Inspection and Maintenance of Hydraulic Equipment ...7-47

Check Hydraulic Oil Level ....................................................7-49

Change Hydraulic Oil/Clean Hydraulic Oil Tank ...........7-50

Clean Suction Filter ................................................................7-52

Replace Pilot Oil Filter............................................................7-53

Replace Hydraulic Tank Oil Filter .......................................7-55

Replace Air Breather Element .............................................7-57

Check Pilot Circuit Accumulator Function,

Gas Leakage, Looseness, and Damage ......................7-58

Replace Pilot Circuit Accumulator ....................................7-59

Check Ride Control Accumulator Function,

Gas Leakage, Looseness, and Damage (Option) ....7-59

Check Gas Pressure in Ride Control Accumulator

(Option) .................................................................................7-59

Check Gas Pressure in Steering Accumulator ...............7-59

Check Hoses and Lines .........................................................7-60

E. Fuel System ................................................................................7-65

Check Fuel Level ......................................................................7-65

About Biodiesel Fuel ..............................................................7-65

Drain Water and Sediment from Fuel Tank ....................7-67

Drain Fuel Filter ........................................................................7-68

Replace Fuel Main Filter Element ......................................7-69

Replace Fuel Pre-Filter Element .........................................7-70

Clean Fuel Solenoid Pump Strainer ..................................7-71

Check Fuel Hoses ....................................................................7-73

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

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

Check Air Inlet System ..........................................................7-75

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

Check Coolant Level ..............................................................7-77

Check Drive Belt ......................................................................7-78

Check Drive Belt Tensioner ..................................................7-79

Change Coolant .......................................................................7-80

Clean Radiator/Oil Cooler and Other Cooling

System ...................................................................................7-81

H. Electrical System ......................................................................7-82

Batteries .....................................................................................7-82

Check Monitor Functions and All Other Instrument

Operation .............................................................................7-86

Check Work Lights ..................................................................7-87

Check Horn and Backup Alarm ..........................................7-87

Check Electrical Harnesses and Fuses .............................7-88

I. Brake System ...............................................................................7-90

Check Right and Left Brake Interlocking

Performance ........................................................................7-90

Check Parking Brake Force ..................................................7-91

Check Accumulator Function, Gas Leakage,

Looseness, and Damage .................................................7-92

Check Gas Pressure in Accumulator .................................7-93

Check Brake Disks (Service and Parking) ........................7-93

J. Tire ..................................................................................................7-94

Check and Replace Tire (Tire Pressure) ............................7-94

Check Tire for Damage ..........................................................7-94

Check Wheel Bolt Torque .....................................................7-95

K. Air Conditioner .......................................................................7-100

Clean/Replace Air Conditioner Circulation/Fresh

Air Filters .............................................................................7-100

Check Air Conditioner .........................................................7-104

Check Air Conditioner Piping ...........................................7-104

Check Air Conditioner Condenser ..................................7-105

Check Air Conditioner Drive Belt.....................................7-105

Check Refrigerant .................................................................7-106

Replace Air Conditioner Receiver Dryer .......................7-106

Check Compressor and Pulley ..........................................7-106

L. Miscellaneous ..........................................................................7-107

Check Bucket Teeth and Cutting Edge ..........................7-107

Check and Replace Seat and Seat Belt ..........................7-108

Check ROPS Cab, Resin Cab Roof, and Roof

Mounting Bolts .................................................................7-108

Check Windshield Washer Fluid Level ...........................7-108

Check Play Amount in Steering Wheel Movement ...7-109

Check Accelerator Pedal Operation, and Exhaust

Gas Color and Noise .......................................................7-110

Check Rearview Mirror and Inside Rearview

Mirror ...................................................................................7-111

Check Steps and Handrails for Damage and

Looseness ...........................................................................7-111

Clean Engine Compartment and Hood ........................7-112

Check Sound Absorbing Mat Around Engine ............7-112

Cleaning of Rear View Camera Lens ...............................7-112

Check and Adjust Valve Clearance ..................................7-113

Retighten Front Axle and Rear Axle Support

Mounting Bolts .................................................................7-113

Tightening and Retightening Torque of Nuts and

Bolts ......................................................................................7-114

M. Aftertreatment Device ........................................................7-125

Check and Clean Aftertreatment Device ......................7-125

N. Urea SCR System ....................................................................7-126

Check DEF/AdBlue® ..............................................................7-128

Replace DEF/AdBlue® Supply Module Main Filter ....7-131

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL

CONDITIONS ................................................................. 9-1
Maintenance Under Special Environmental Conditions ...9-1

Precautions for Maintenance During Cold Weather

Season ............................................................................................9-2

Summary of Contents for ZW 180-6

Page 1: ...NA1 3 ZW180 6 WHEEL LOADER OPERATOR S MANUAL PRINTED IN JAPAN E 2018 07 URL http www hitachi c m com ENMPD8 NA1 3 PART NO Wheel Loader Operator s Manual Serial No 005201 and up This book is printed on recycled paper ...

Page 2: ...rranty certificate which you should have received from your dealer This warranty provides you with the assurance that Hitachi will back its products where defects appear within the warranty period In some circumstances Hitachi also provides field improvements often without charge to the customer even if the product is out of warranty Should the equipment be abused or modified to change its perform...

Page 3: ...S NAME OPERATOR S STATION BREAK IN OPERATINGTHE ENGINE MOVINGTHE MACHINE OPERATINGTHEMACHINE TRANSPORTING MAINTENANCE MAINTENANCEUNDERSPECIALENVIRONMENTALCONDITIONS STORAGE OPTIONAL ATTACHMENTS SPECIFICATIONS INDEX INDEX ENMPD8 NA1 3 TROUBLESHOOTING ...

Page 4: ......

Page 5: ...r Hoses Periodically S 28 Avoid High Pressure Fluids S 28 Prevent Fires S 29 Evacuating in Case of Fire S 30 Beware of Exhaust Fumes S 31 Precautions for Welding and Grinding S 31 Avoid Heating Near Pressurized Fluid Lines S 31 Avoid Applying Heat to Lines Containing Flammable Fluids S 32 Precautions for Handling Accumulator and Gas Damper S 32 Precautions for Diesel Exhaust Fluid DEF S 32 Remove ...

Page 6: ...al Lever 1 83 Light Switch 1 84 High Low Beam Switch 1 85 Accelerator Pedal 1 86 Brake Pedal 1 86 Service Brake 1 86 Declutch Brake 1 86 Forward Reverse Lever Shift Switch 1 87 Forward Reverse Lever 1 87 Shift Switch 1 87 Wiper Switch 1 88 Wiper Operation 1 88 Front Rear Wiper Switch 1 89 Tilt Telescopic Lever Steering Column Tilt Pedal 1 90 Right Console Switches 1 91 Fingertip Control Type 1 91 ...

Page 7: ...orward Reverse Drive Direction 4 8 Steering Wheel 4 9 Secondary Steering Option 4 10 Emergency Stop and Restart of Operation 4 11 Precautions for Traveling 4 12 Operating in Water or on Soft Ground 4 13 Precautions for Driving on Slopes 4 14 Precautions to be Taken if Machine Failure Occurs 4 15 Stop 4 16 Parking 4 18 Emergency Stopping 4 19 OPERATING THE MACHINE 5 1 Loading Control Levers 5 1 Con...

Page 8: ...t Operation 7 86 Check Work Lights 7 87 Check Horn and Backup Alarm 7 87 Check Electrical Harnesses and Fuses 7 88 I Brake System 7 90 Check Right and Left Brake Interlocking Performance 7 90 Check Parking Brake Force 7 91 Check Accumulator Function Gas Leakage Looseness and Damage 7 92 Check Gas Pressure in Accumulator 7 93 Check Brake Disks Service and Parking 7 93 J Tire 7 94 Check and Replace ...

Page 9: ...ing the Machine 10 1 Precaution Items for Long Time Storage 10 1 TROUBLESHOOTING 11 1 Troubleshooting 11 1 SPECIFICATIONS 12 1 Specifications 12 1 OPTIONAL ATTACHMENTS 13 1 Hydraulic Type Quick Coupler Operation 13 1 INDEX 14 1 ...

Page 10: ...CONTENTS MEMO ...

Page 11: ...ach machine and hydraulic components These numbers 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 TYPE MACHINE SERIAL NUMBER Engine TYPE MFG NO MNEC 00 001 70MPD8 00 01 ...

Page 12: ...2 MACHINE NUMBERS Aftertreatment Device 1 SCR TYPE MFG NO 2 DOC TYPE MFG NO MNEK 00 003 MNEK 00 004 2 1 ...

Page 13: ... 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 do not use any of the designated signal word...

Page 14: ...chi Warranty Policy Never attempt to modify or disassemble the inlet exhaust parts and the aftertreatment device Avoid giving shocks on the aftertreatment device by striking elements with other objects or dropping the elements Failure to do so may affect the exhaust gas purifying device possibly damaging it or lowering its performance Do not use attachments and or optional parts or equipment not a...

Page 15: ...bers for doctors ambulance service hospital and fire department posted near your telephone Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job You may need A hard hat Safety shoes Safety glasses goggles or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and ...

Page 16: ... or earplugs to protect against objectionable or uncomfortably loud noises Inspect Machine Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury In the walk around inspection be sure to cover all points described in the Inspect Machine Daily Before Starting section in the operator s manual SA 435 SA 434 ...

Page 17: ...ndow decorations on the windowpanes as they may focus sunlight possibly starting a fire Refrain from using music headphones or mobile telephones in the cab while operating the machine Keep all flammable objects and or explosives away from the machine After using the ashtray always cover it to extinguish the match and or tobacco Do not leave cigarette lighters in the cab When the temperature in the...

Page 18: ... with tools in your hands Never Ride Attachment Never allow anyone to ride attachment or the load This is an extremely dangerous practice Adjust Operator s Seat A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperations The seat should be adjusted whenever changing the operator for the machine The operator should be able to fully de...

Page 19: ...tion Turn the parking brake switch ON and the key switch OFF to stop the engine Before leaving the machine close all windows doors and access covers and lock them up Fasten Your Seat Belt If the machine should overturn the operator may become injured and or thrown from the cab Additionally the operator may be crushed by the overturning machine resulting in serious injury or death Prior to operatin...

Page 20: ...operating the machine If any faulty illumination is present immediately repair it Ensure the cab door windows doors and covers are securely locked Check the mirrors and the monitor in the CAB for problems If there is replace the problem part s or clean the mirror camera and the monitor Refer to Rear View Monitor section on the cleaning of the camera and the monitor Handle Starting Aids Safely Star...

Page 21: ... neutral Before starting the engine confirm the safety around the machine and sound the horn to alert bystanders Jump Starting Battery gas can explode resulting in serious injury If the engine must be jump started be sure to follow the instructions shown in the OPERATING ENGINE chapter in the operator s manual The operator must be in the operator s seat so that the machine will be under control wh...

Page 22: ...orce ground edges and road shoulders as necessary Keep the machine well back from the edges of excavations and road shoulders When working on an incline or on a road shoulder employ a signal person as required Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist When the footing is weak reinforce the ground before sta...

Page 23: ...OPS and FOPS Any modification of the ROPS structure will modify its performances and its certification will be lost ROPS Roll Over Protective Structure FOPS Falling Object Protective Structure Provide Signals for Jobs Involving Multiple Machines For jobs involving multiple machines provide signals commonly known by all personnel involved Also appoint a signal person to coordinate the job site Make...

Page 24: ... of the possibility of slipping and or turning over the machine when driving on a slope When driving on level ground hold the bucket at mark A 300 mm 12 in above the ground as illustrated Avoid traveling over any obstacles Drive the machine slowly when driving on rough terrain Avoid quick direction changes Failure to do so may cause the machine to turn over If the engine stops while driving the st...

Page 25: ...pe keep the bucket facing the direction of travel approximately 200 to 300 mm approx 8 to 12 in A above the ground If the machine starts to skid or becomes unstable immediately lower the bucket to the ground and stop Before using the downshift switch DSS while driving down a slope apply the brake to decrease the machine speed enough Driving across the face of a slope or steering on a slope may cau...

Page 26: ... result in personal injury and or death Avoid rapid drive direction changes which could possibly cause personal injury and or death Drive on Snow Safely Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces The machine may slip more easily than expected on frozen snow surfaces even if the incline is small Reduce speed when driving Avoid fast starts ...

Page 27: ...ways Select level ground when possible to park machine Do not park the machine on a grade Lower the bucket to the ground Put the forward reverse lever switch in neutral Run the engine at low idle speed without load for 5 minutes to cool down the engine Turn the control lever lock switch to the lock position Turn the parking brake switch ON Stop the engine and remove the key from the key switch Blo...

Page 28: ...entangled in the machine Keep all personnel away from the machine by sounding the horn and or using hand signals Use extra care to be sure no one is in from the articulation area before turning the machine Keep windows mirrors and lights in good condition Reduce travel speed when dust heavy rain fog etc reducing the visibility In case good visibility is not obtained use a signal person to guide yo...

Page 29: ...HE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when operating on a grade possibly resulting in serious injury or death To avoid tipping Be extra careful before operating on a grade Prepare machine operating area flat Keep the bucket low to the ground and cl...

Page 30: ...lines If a fiber optic cable should be accidentally severed do not look into the end Doing so may result in serious eye injury Contact your local diggers hot line if available in your area and or the utility companies directly Have them mark all underground utilities Perform Truck Loading Safely Do not operate the machine involuntarily Unexpected machine movement may cause personal injury and or d...

Page 31: ... Lightning Lightning may strike the machine If lightning comes close immediately stop the operation and take the following action When you are around the machine or operating cab less machine evacuate to a safe place far away from the machine When you are in the cab stay in the cab until lightning has passed and safety is secured Close the cab doors and windows Lower the bucket to the ground and s...

Page 32: ...h Never attach a sling or chain to the bucket teeth or to the attachment fork or grapple for example They may come off causing the load to fall Protect Against Flying Debris If flying debris hit eyes or any other part of the body serious injury may result Guard against injury from flying pieces of metal or debris wear goggles or safety glasses Keep bystanders away from the working area before stri...

Page 33: ... for 3 minutes Turn key switch to OFF to stop engine Remove the key from the key switch Turn the control lever lock switch to the lock position Close windows roof vent and cab door Lock all access doors and compartments Store Attachments Safely Stored attachments such as buckets hydraulic hammers and blades can fall and cause serious injury or death Securely store attachments and implements to pre...

Page 34: ...s use a ramp or deck strong enough to support the machine weight 3 Use a low speed gear 4 Never steer the machine while being on the ramp If the traveling direction must be changed while being on the ramp unload the machine from the ramp reposition the machine on the ground then try loading again 5 After loading install the lock bar articulation stopper to securely hold the articulation mechanism ...

Page 35: ...ne while smoking or when near open flame or sparks Always stop the engine before refueling the machine Fill the fuel tank outdoors All fuels most lubricants and some coolants are flammable Store flammable fluids well away from fire hazards Do not incinerate or puncture pressurized containers Do not store oily rags they can ignite and burn spontaneously Securely tighten the fuel and oil filler caps...

Page 36: ...ey switch 8 Attach a Do Not Operate tag on the control lever 9 Connect the front and rear chassis with articulation stopper 10 Allow the engine to cool Refer to page 7 8 Preparations for Inspection and Maintenance If a maintenance procedure must be performed with the engine running do not leave machine unattended Never work under a machine raised by the lift arm Inspect certain parts periodically ...

Page 37: ...work on the machine attach a Do Not Operate tag on the control lever This tag is available from your authorized dealer Support Machine Properly Never attempt to work on the machine without securing the machine first Always lower the attachment to the ground before you work on the machine If you must work on a lifted machine or attachment securely support the machine or attachment Do not support th...

Page 38: ...to perform the job Have it done by your authorized dealer or a qualified repair service Always maintain the correct tire pressure DO NOT inflate tire above the recommended pressure When inflating tires use a chip on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly Use a safety cage if available Inspect tires and wheels daily Do no...

Page 39: ... Skin contact with escaping hot water or steam can cause severe burns Avoid possible injury from hot spraying water DO NOT remove the radiator cap until the engine is cool When opening turn the cap slowly to the stop Allow all pressure to be released before removing the cap The hydraulic oil tank is pressurized Again be sure to release all pressure before removing the cap Hot fluids and surfaces E...

Page 40: ...may result in severe burns gangrene or otherwise serious injury or death Avoid High Pressure Fluids Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury blindness or death Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of ...

Page 41: ...e or wires are loose kinked etc Never attempt to modify electric wirings Clean up Flammable Materials Spilled fuel and oil and trash grease debris accumulated coal dust and other flammable materials may cause fires Prevent fires by inspecting and cleaning the machine daily and by removing adhered oil or accumulated flammable materials immediately Check and clean high temperature parts such as the ...

Page 42: ...ged or missing heat shields must be repaired or replaced before operating the machine If hydraulic hoses are broken while the engine cover is open splattered oil on the high temperature parts such as mufflers may cause fire Always close the engine cover while operating the machine Evacuating in Case of Fire If a fire breaks out evacuate the machine in the following way Stop the engine by turning t...

Page 43: ...tarting welding Only qualified personnel should perform welding Never allow an unqualified person to perform welding Grinding on the machine may create fire hazards Store flammable objects in a safe place before starting grinding After finishing welding and grinding recheck that there are no abnormalities such as the area surrounding the welded area still smoldering Avoid Heating Near Pressurized ...

Page 44: ...as a consumable in selective catalytic reduction SCR to lower NOx concentration in the exhaust emissions from the engine It is a non flammable and non hazardous solution and harmful effects are not expected under normal conditions of use In case of a fire DEF AdBlue would decompose and generate ammonia gas when heated to 160 C 320 F or higher Ammonia gas may cause lung injury and potentially is fa...

Page 45: ... Asbestos and Silicon Dust and Other Contamination Take care not to inhale dust produced in the work site Inhalation of asbestos fibers may be the cause of lung cancer Inhalation of silicon dust and other contamination may cause sickness Depending on the work site conditions the risk of inhaling asbestos fiber silicon dust or other contamination may exist Spray water to prevent asbestos fibers sil...

Page 46: ...ly tighten all terminals Connect terminals to the correct electrical poles Failure to do so may cause damage to the electrical parts or fire Battery electrolyte is poisonous If the battery should explode battery electrolyte may be splashed into eyes possibly resulting in blindness Be sure to wear eye protection when checking electrolyte specific gravity Service Air Conditioning System Safely If sp...

Page 47: ...al products used with your machine Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with Hitachi equipment includes such items as oil fuel coolant brake fluid filters DEF AdBlue and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from ...

Page 48: ... of the aftertreatment device The water is mildly acidic by oxidation catalyst mounted in the aftertreatment device If filter water spills on your skin immediately flush it out with clean water Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices Inquire the device manufacturer for electrical wave distu...

Page 49: ...ng electrical waves Specific Absorption Rate SAR measured by 10 g per unit of communication terminal equipment Model A Model B E GSM900 0 573 W Kg 914 8 MHz 0 12 W Kg 897 6 MHz DCS 1800 0 130 W Kg 1710 2 MHz 0 06 W Kg 1748 0 MHz WCDMA Band I 0 271 W Kg 1950 0 MHz 0 05 W Kg 1950 0 MHz WCDMA Band VIII 0 10 W Kg 892 6 MHz fNOTE Please contact to your authorized representative if you want to know whic...

Page 50: ...fire to the base machine or to the communication terminal When required to remove or install the communication terminal consult your nearest authorized dealer Do not pinch or forcibly pull cables cords or connectors Failure to do so may cause a short or broken circuit that may result in damage and or fire to the base machine or to the communication terminal ...

Page 51: ... reviewing them on the machine and understanding them to ensure safe machine operation Always keep the safety labels clean In case a safety sign is lost or no longer readable immediately obtain a new replacement and affix it again in position on the machine Use the part No indicated under the bottom right corner of each safety label when placing an order for it to the authorized dealer S 39_180 ...

Page 52: ...S 40_70Z7B S 40 SAFETY LABELS 1 24 12 11 18 23 9 1 9 14 22 14 15 21 17 16 Battery Top 20 ...

Page 53: ...Tank Cover dCAUTION Sign indicates a fall hazard Do not step on or stand in this area 2 Both Sides of Lift Arm dDANGER Crush Hazard During operation loads may spill from the bucket and or the bucket may suddenly fall Never allow anyone to approach the machine with lift arms raised ...

Page 54: ...if machine is brought too near electric power lines Keep a safe distance from electric power lines 5 Cab Inside Right Front Column 3rd safety sign from the top dWARNING Runover or Entanglement Hazard If the parked machine starts moving unexpectedly personal injury or death due to entanglement in moving parts or running over by the machine may result Before leaving the machine set the park brake to...

Page 55: ...RNING Runover Hazard Be sure that the backup alarm is operable when the machine is put in reverse 8 Cab Inside Right Center Column dCAUTION Steering Hazard Unlock articulation stopper before operating machine 9 Both Sides of Oil Cooler and Hood dWARNING Burn Hazard Avoid skin contact with highly heated parts such as the engine muffler etc immediately after operation of the machine Severe burns may...

Page 56: ... if engine starts in gear could result in death or serious injury Do not start engine by shorting across starter terminals Do not start engine while standing on ground Make sure to start engine only from operator s seat with transmission in neutral and parking brake applied 12 Bottoms at Both Right and Left Side Covers of Rear Chassis dWARNING Entanglement Hazard Sign indicates a hazard of rotatin...

Page 57: ...umulator unless properly trained and equipped 14 Top of Coolant Reservoir Tank and Hydraulic Tank dWARNING Burn Hazard Pressurized system spray of hot fluid could result in death or serious injury Allow system to cool and vent pressure slowly before servicing 15 Top of Hydraulic Oil Tank dWARNING Burn Hazard Sign indicates a burn hazard from the pressurized tank spurting hot oil if the oil inlet i...

Page 58: ...afe and proper handling B dCAUTION Chemical Burn Hazard Skin contact with electrolyte will cause burns Splashed electrolyte into eyes will cause blindness Do not touch or come in contact with electrolyte solution C dWARNING Explosion Hazard Sign indicates an explosion hazard Keep fire and open flames away from this area 4478724350 4478724340 4478725000 ...

Page 59: ... 19 Both Sides of Front Chassis dDANGER Crush Hazard The articulation area becomes a pinch point when steering the machine Keep all personnel away from the articulation area during operation of the machine 20 Cab Inside Right Console To those persons fixed with any medical device Including implantable device such as a cardiac pacemaker Please read the instruction manual carefully and follow the in...

Page 60: ...anual 22 Use no starting fluid dWARNING Explosion Hazard Do not use ether This engine is equipped with electric heater starting aid Use of ether could cause explosion and could result in death or serious injury 23 Top of Battery Recycle Batteries Batteries contain lead and acid Obey all local and federal laws and regulation on disposal of batteries and electrolyte solution label 44774 23030 447872...

Page 61: ...S 49 SAFETY LABELS 24 Inside DEF AdBlue Tank Box IMPORTANT Avoid Contamination The DEF AdBlue tank should be filled with DEF AdBlue only Do not mix any other liquid like water oil fuel label 44774 27240 ...

Page 62: ...S 50 SAFETY LABELS MEMO ...

Page 63: ... DEF AdBlue Tank 11 Front Fender 12 Lift Arm Boom Cylinder 13 Lift Arm Boom 14 Rear Work Light 15 Aftertreatment Device 16 Exhaust Pipe 17 Hydraulic Oil Tank 18 Articulation Stopper Lock Bar 19 Rear Combination Light Turn Signal Hazard Light Tail Light Brake Light Backup Light 20 Battery 21 Counterweight 22 Towing Pin 23 Fuel Filler Port 24 Radiator Oil Cooler 1 2 3 4 5 6 7 8 9 10 11 12 13 MPD8 01...

Page 64: ...Other Cooling System 12 Work Light 13 Rear Combination Lamp 14 Fuel Tank 15 Engine 16 Rear Axle 17 Third Rear Propeller Shaft 18 Transmission 19 Second Center Propeller Shaft 20 Steering Cylinder 21 Lift Arm Boom Cylinder 22 Front Axle 23 Lift Arm Cylinder Rod Pin 24 Bell Crank Lever Pin 25 Bucket Link Pin 26 Bucket Hinge Pin 27 DEF AdBlue Tank 2 3 4 5 7 8 9 6 10 11 12 13 24 27 14 15 16 17 18 19 2...

Page 65: ... instructions below to prevent the aftertreatment device from being damaged IMPORTANT Refer to 1 31 for further information Exhaust gas from the aftertreatment device and exhaust piping becomes hotter during and right after engine running and regeneration of aftertreatment device Be careful not to let your skin contact any part of exhaust system or hot gas from the exhaust piping It may cause seve...

Page 66: ...al elements oil distillates or alcohol These items will permanently damage the aftertreatment device and are not covered by warranty Do not modify the machine without authorization Never attempt to modify the air inlet and exhaust parts such as the air duct aftertreatment device and the exhaust outlet Also never attempt to disassemble the aftertreatment device Avoid giving shocks on the aftertreat...

Page 67: ...your authorized dealer Auto regeneration may be terminated early inhibited when in the presence of flammable materials such as flammable airborne debris wood dust grain dust dried leaf debris or other flammable risks However when early termination inhibiting regeneration happens often the system will sense this and eventually call for a manual regeneration using manual regeneration switch 1 The re...

Page 68: ...mpanied by the aftertreatment device manual regeneration request It is required to perform manual regeneration as soon as requested fNOTE The manual regeneration request indicator remains ON until a regeneration process completes successfully When leaving machine without running aftertreatment device regeneration gradual derate will be applied to the engine refer to 1 35 If manual regeneration doe...

Page 69: ...ATION Cab Features 1 Front Defroster 2 Front Console 3 Operator s Seat 4 Right Console 5 Document Holder 6 Hot Cool Box 7 Rear Defroster 8 Glove Compartment 9 Cup Holder 10 Floor Mat MNEC 01 035 1 1 2 1 3 4 6 5 7 8 9 10 ...

Page 70: ... Pedal 10 Brake Pedal 11 Front Rear Window Wiper Switch 12 Forward Reverse Lever Shift Switch 13 Steering Column Tilt Pedal 14 Tilt Telescopic Lever 15 Turn Signal Lever Light Switch High Low Beam Switch 16 Key Switch 17 Multi Function Monitor Air Conditioner Switch Panel 18 Ash Tray 19 Cigar Lighter 20 Brake Declutch Pedal 21 Auxiliary MNEC 01 036 MNEC 01 037 MNEC 01 038 1 2 3 4 21 5 6 7 8 1 9 20...

Page 71: ...ctor Switch 10 Fan Reverse Rotation Switch 11 Auxiliary 12 Hydraulic Coupler Switch Option 13 Secondary Steering Operation Check Switch Option 14 Aftertreatment Device Regeneration Switch 15 Auxiliary 16 1st Speed Fixed Switch 17 Ride Control Switch Option 18 Armrest Adjust Handle 19 Armrest 20 Hold Switch 21 Right Console Slide Lever 22 DSS Down Shift Switch 23 Horn Switch 24 Quick Power Switch 1...

Page 72: ... Switch 10 Forward Reverse Selector Switch 11 Fan Reverse Rotation Switch 12 Auxiliary 13 Hydraulic Coupler Switch Option 14 Secondary Steering Operation Check Switch Option 15 Aftertreatment Device Regeneration Switch 16 Auxiliary 17 1st Speed Fixed Switch 18 Ride Control Switch Option 19 Armrest Adjust Handle 20 Armrest Adjustment 21 Right Console Slide Lever 22 Hold Switch Under the Lever 23 Ho...

Page 73: ...ommunication System Error Indicator 5 Parking Brake Indicator 16 Coolant Temperature Gauge 6 Brake Oil Low Pressure Indicator 17 Overheat Indicator 7 Hydraulic Oil Level Indicator 18 Engine Warning Indicator 8 Low Steering Oil Pressure Indicator Option 19 Engine Oil Low Pressure Indicator 9 Transmission Warning Indicator 20 Preheat Indicator 10 Control Lever Lock Indicator 21 Air Filter Restrictio...

Page 74: ...er will sound Immediately move the machine to a safe area set the machine in the park position and stop the engine Inspect the brake system for any abnormality When the brake oil pressure is recovered the buzzer stops and the indicator goes off fNOTE When the starter key is at ON position this indicator will light but no alarm sounds Hydraulic Oil Level Indicator Red dWARNING Stop machine operatio...

Page 75: ...urs in the transmission and or transmission related parts the red indicator will light If the transmission warning indicator and the service indicator light immediately move the machine to a safe area set the machine in the park position and stop the engine Contact your nearest authorized dealer for machine inspection Communication Error Indicator Yellow When communication system malfunction occur...

Page 76: ... engine at slow idle speed to lower the coolant temperature When required let engine cool check coolant level and add coolant if needed Engine Oil Low Pressure Indicator Red dWARNING If the engine is kept running with the engine oil pressure low damage to the engine may result Immediately stop machine operation and stop the engine if the indicator lights If the engine oil pressure becomes low the ...

Page 77: ... cleaner element Replace the element if necessary fNOTE This indicator may unexpectedly light when the coolant temperature gauge indicates the center or lower position It turns off automatically when the coolant temperature increases Preheat Indicator Yellow The engine is being preheated as long as the preheat indicator stays ON When the preheat indicator goes OFF engine preheating is completed M4...

Page 78: ...e coolant temperature lowers stop the engine for inspection Visually inspect coolant level in reservoir In case the needle does not move at all error in the electrical system is suspected Contact your nearest authorized dealer for machine inspection Fuel Gauge The fuel level is indicated by the needle Refuel before the needle reaches in the red range E When the needle reaches in the red range E th...

Page 79: ... the turn signal and the turn signal indicator start flashing High Beam Indicator Blue When the head lights are used at the high beam position the indicator will light Work Light Indicator Yellow When the work lights are turned ON this indicator will light M4GB 01 032 M4GB 01 033 MNDB 01 052 ...

Page 80: ...ht Indicator Green When the clearance lights are turned ON this indicator will light Control Lever Lock Indicator Red When the control lever lock switch is in ON position the control lever lock indicator will light M4GB 01 035 MNEC 01 004 ...

Page 81: ...eens There are 7 menus and a further 13 sub menus Basic Screen Main Menu Alarm List Dual Lift Arm Auto Leveler Setting Menu Ride Control Option Brightness Adjustment Mail Information Menu Date and Time Operation Transmission Setting Rear View Camera Monitor Troubleshooting Auto Shut Down Maintenance Parallel Tandem Switching Height Main Menu Sequence Change Display Item Selection Aftertreatment De...

Page 82: ...ment Device Regeneration Inhibit Inhibit regeneration OFF Shift Change Delay Mode Transmission Setting ON OFF of travel speed shift change delay mode OFF Parallel Tandem Switching Height Height at parallel or tandem circuit operation are switched Lift arm is level to the ground Warm Up Increases engine speed at engine start to help warm up in cold environment OFF fNOTE Typical functions are shown ...

Page 83: ...r 10 Declutch Indicator 11 Aftertreatment Device Indicator 12 Power Mode Indicator 13 Auto Idling Stop Indicator 14 Dual Lift Arm Auto Leveler Indicator 15 Clock Hour Meter Odometer 16 Fan Reverse Rotation Indicator 17 Shift HOLD Display 18 Transmission Auto shifting Indicator 19 F N R Shift Position Indicator 1 2 3 4 4 5 5 6 6 7 7 9 9 10 10 12 12 13 13 8 8 11 11 14 14 15 15 16 3 17 17 19 19 18 18...

Page 84: ...the basic screen is displayed When the key switch is turned to the ON position the starting screen displays for about two seconds and the basic screen displays Rear View Camera Sight When Rear View Monitor is Operative Basic Screen Basic Screen MNEK 01 103EN MNEK 01 104EN Starting Screen MNEK 01 102EN ...

Page 85: ... temperature as a gauge When the bar reaches the red range the oil temperature is abnormal If the oil temperature becomes abnormally high the alarm buzzer will sound and the warning indicator will be displayed DEF AdBlue Level Gauge 5 DEF AdBlue level gauge 5 displays the remaining DEF AdBlue amount When DEF AdBlue level becomes low the last segment turns yellow IMPORTANT If the engine runs with l...

Page 86: ... 13 When the auto idling stop is turned ON from the menu screen the auto idling stop indicator is displayed When the key switch is turned ON while the auto idling stop down is enabled the auto idling stop indicator blinks for 10 seconds Dual Lift Arm Auto Leveler Indicator 14 Clock Hour Meter Odometer 15 Clock Indicates the present time 24 h 12 h display can be selected Refer to Date and Time for ...

Page 87: ...n Auto shifting Indicator 18 Transmission auto shifting indicator 18 displays condition of the travel mode switch It is not displayed at manual mode F N R Shift Position Indicator 19 F N R Shift Position Indicator 19 displays machine operating condition status of the transmission F N R Display F N R indicator displays status of the transmission Forward F Neutral N Reverse R Shift Position Indicato...

Page 88: ...e basic screen is displayed the Main Menu Screen opens Push this switch after the menu screen the action is confirmed Rotate Cursor moves Return to Previous Screen 2 Push this switch to return to the previous screen Return to Basic Screen 3 Allows any screen to return to the basic screen MNEC 01 006 2 3 1 MNEC 01 078 MNEC 01 079 MNEC 01 080 1 2 3 ...

Page 89: ...alarms are generated the alarm symbols 1 can be scrolled by rotating selector knob 2 When the rear view monitor is operating service indicator 3 is displayed fNOTE When any of the warning indicators light on service indicator 3 also appears 2 MNEC 01 006 Basic Screen 1 3 MPD8 01 290EN Rear View Camera Display Operating Rear View Monitor Basic Screen 3 MPD8 01 291EN ...

Page 90: ...e alarm list and push selector knob 1 fNOTE The main menu displays the alarm list faults only when an alarm occurs 3 Rotate selector knob 1 to select a required alarm from the alarm list and push selector knob 1 fNOTE The alarm list contains only active faults or alarms 4 Detailed information of the selected alarm will be displayed 1 MNEC 01 006 MNEK 01 106EN MNEK 01 107EN MNEK 01 105EN MPD8 01 29...

Page 91: ...evice Alarm Blinking Red Aftertreatment device is abnormal Immediately set the machine in the park position stop the engine apply parking brake and contact your authorized dealer Aftertreatment Device Regeneration System Failure Aftertreatment device is abnormal Immediately set the machine in the park position stop the engine apply parking brake and contact your authorized dealer Aftertreatment De...

Page 92: ...y parking brake stop the engine and contact your authorized dealer Engine Trouble Alarm Red Engine or engine related parts are abnormal Immediately set the machine in the park position apply parking brake stop the engine and contact your authorized dealer Transmission Alarm Transmission or transmission related parts are abnormal Immediately set the machine in the park position apply parking brake ...

Page 93: ...n the DEF AdBlue level The engine speed and output level control is as follows fNOTE Set the FNR controller to neutral or apply the parking brake to show the alarm message on the monitor Level Gauge Alarm Indicator Status Inducement Yellow Red light DEF AdBlue level is low Refill DEF AdBlue Red Red slow blink DEF AdBlue is insufficient Refill DEF AdBlue Engine output is restricted Red Red slow bli...

Page 94: ...tus Inducement Red light Urea SCR system is broken Red slow blink Urea SCR system is broken Engine output is restricted Red slow blink Urea SCR system is broken Engine output and speed are restricted Contact your authorized dealer for service Red fast blink Red fast blink ...

Page 95: ...ys automatic regeneration abbreviated as auto regeneration manual regeneration and service regeneration Aftertreatment Device Regeneration Status Display Aftertreatment device display 1 displays the regeneration level of the aftertreatment device This symbol indicates that the exhaust temperature is higher than normal during the aftertreatment device regeneration It lights while auto regeneration ...

Page 96: ...tenance process and is not a malfunction Do not stop the engine or regeneration once auto regeneration has started unless it is absolutely necessary Auto regeneration may not be completed due to system limitations while operating the machine If this occurs the aftertreatment device regeneration request will appear on the monitor panel Refer to page 5 11 to perform manual regeneration This symbol i...

Page 97: ...to page 1 56 for more information Lighting Yellow The manual regeneration must be performed as soon as possible and it will take the loader out of service for about 10 20 minutes Refer to page 5 11 for the manual regeneration procedure fNOTE When the manual regeneration starts regeneration indicator 4 turns ON If it does not appear when pressing switch 3 the manual regeneration is not activated Co...

Page 98: ...osition while displaying the main menu screen the screen changes back to the basic screen Press selector knob 2 while displaying basic screen 1 to display Main Menu screen 3 The main menu screen contains the items shown in the figure to the right The alarm list is displayed only when an alarm is generated Ride control option and Mail option menus will not be displayed unless they are set beforehan...

Page 99: ...ess selector knob 2 to display Ride Control Drive Speed Setting screen 5 4 Press selector knob 2 once and then rotate it clockwise to increase set speed at 1 km h 0 6 mph interval Rotate the selector knob 2 counterclockwise to decrease set speed at 1 km h 0 6 mph interval The set vehicle speed can be changed within the set range fNOTE When the speed is at 0 km h 0 mph the ride control function is ...

Page 100: ... 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Dual Lift Arm Auto Leveler 4 3 Press selector knob 2 to display Dual Lift Arm Auto Leveler screen 5 4 Rotate selector knob 2 to select Height Kickout 6 or Lower Kickout 7 5 Press selector knob 2 1 5 6 7 3 4 MNEK 01 110EN MNEK 01 111EN MNEK 01 103EN ...

Page 101: ... indicates current set value of the height kickout Segment 11 indicates current height of the lift arm Setting Operation When the height kickout is ON enabled the lift arm stop height can be set When the lift arm height changes by operating the lift arm control lever the height is displayed on segment 11 When the lift arm height is within the setting range the mark 9 will be displayed Rotate selec...

Page 102: ...ment 10 indicates current set value of the lower kickout Segment 11 indicates current height of the lift arm Setting Operation When the lower kickout is ON enabled the lift arm stop height can be set When the lift arm height changes by operating the lift arm control lever the height is displayed on segment 11 When the lift arm height is within the setting range the mark 9 will be displayed Rotate ...

Page 103: ...ION Brightness Adjustment 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Brightness Adjustment 4 MNEC 01 006 2 3 4 1 MNEK 01 120EN MNEK 01 103EN ...

Page 104: ... clockwise to make the screen brighter counterclockwise to make the screen darker fNOTE When the machine s head light switch is turned ON the monitor screen changes to night mode and mark 6 is displayed Brightness can be adjusted for day mode and night mode respectively MNEC 01 006 2 5 6 MNEK 01 122EN MNEK 01 121EN ...

Page 105: ...playing Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Mail 4 3 Press selector knob 2 to display Mail screen 5 4 Rotate selector knob 2 to highlight desired request 5 Press selector knob 2 to send mail information to the communication terminal General Request Fuel Replenishment Request Service Maintenance Request Forwarding Request 2 MNEC 01 006 1 MNEK 01 103EN ...

Page 106: ...s Accepted is displayed on the screen Push back key 6 to return to the Mail screen 8 Then a mail is sent from the communication terminal to the central server fNOTE Depending on the machine s operating environment or signal strength the mail may not be sent fNOTE When the communication terminal could not receive the mail the message Failed is displayed on the screen 6 MNEC 01 006 MNEK 01 132EN MNE...

Page 107: ...ing option and rear view camera monitor setting 1 Press selector knob 2 while displaying basic screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 2 MNEC 01 006 3 4 1 MNEK 01 103EN MNEK 01 140EN 5 MPD8 01 141EN ...

Page 108: ...n the display setting Time Adjustment 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Date and Time 6 2 MNEC 01 006 3 4 MNEK 01 140EN 1 MNEK 01 103EN 5 6 MPD8 01 141EN ...

Page 109: ...selector knob 2 to highlight Hour or Minute and push selector knob 2 9 Rotate selector knob 2 to adjust the clock Rotate clockwise to adjust the number upwards and counterclockwise to decrease it 10 Push selector knob 2 to end the time setting procedure 11 Rotate selector knob 2 to highlight 11 Push selector knob 2 to make the change 2 MNEC 01 006 7 9 8 10 11 MNEK 01 143EN MNEK 01 144EN MNEK 01 14...

Page 110: ...ing Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Date and Time 6 2 MNEC 01 006 3 4 1 MNEK 01 103EN MNEK 01 140EN 5 6 MPD8 01 141EN ...

Page 111: ...elector knob 2 to highlight Year Month or Day and push selector knob 2 9 Rotate selector knob 2 to adjust the date Rotate clockwise to adjust the number upwards and counterclockwise to decrease it 10 Push selector knob 2 to end the date setting procedure 11 Rotate selector knob 2 to highlight 11 Push selector knob 2 to make the change 2 MNEC 01 006 7 9 8 10 11 MNEK 01 147EN MNEK 01 145EN MNEK 01 1...

Page 112: ...laying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Date and Time 6 2 MNEC 01 006 3 4 1 MNEK 01 103EN MNEK 01 140EN 5 6 MPD8 01 141EN ...

Page 113: ...e selector knob 2 to highlight Date 10 and push selector knob 2 Date Each time selector knob 2 is pushed the date format is changed as follows YYYY MM DD MM DD YYYY DD MM YYYY YYYY MM DD Time Each time selector knob 2 is pushed the time format is changed as follows 12 h 24 h 12 h 2 MNEC 01 006 7 9 8 10 MNEK 01 148EN MNEK 01 149EN MNEK 01 300EN MNEK 01 301EN MNEK 01 302EN MNEK 01 303EN MNEK 01 304E...

Page 114: ...s the monitor displays a message that the engine will be stopped and the indicator 7 starts flashing The buzzer also sounds The buzzer sounds once at 30 seconds before intermittently sounds from 15 seconds and then stops after 15 seconds When the machine is in the operating state or any of the above listed conditions is not satisfied before stopping the engine the auto idling stop is disabled and ...

Page 115: ...ayed in gray Acting Time Setting 1 On the Auto Shut Down screen rotate selector knob 2 to highlight Time 9 and push selector knob 2 2 Rotate selector knob 2 clockwise to extend idle time by 1 minute steps Rotate selector knob 2 counterclockwise to decrease idle time by 1 minute steps 3 Press selector knob 2 to make the change fNOTE The idle time can be set to 1 2 3 4 5 7 10 15 20 25 or 30 minutes ...

Page 116: ...ne pay thorough attention to the surroundings with use of mirrors and windows 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Rear View Camera Monitor 6 MNEC 01 006 2 3 4 1 Operating Rear View Monitor MNEK 01 103EN...

Page 117: ...mera monitor is OFF rear view image is not available IMPORTANT In order to obtain a clear image clean the camera lens and the monitor display before operating the machine In bad weather or extreme dust more frequent cleaning will be required fNOTE The monitor and camera lens surface is a resin plastic product Lightly wipe the surface with a wet clean cloth Never use an organic solvent IMPORTANT Ne...

Page 118: ...nt auto regeneration while operating the machine in a flammable area or indoors Setting Procedure 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 2 MNEC 01 006 3 4 1 MNEK 01 140EN MNEK 01 103EN 5 MPD8 01 141EN ...

Page 119: ...en ON is selected regeneration inhibit icon 11 will be displayed on the monitor fNOTE When the function is ON the mark is displayed in green When the function is OFF the mark is displayed in gray IMPORTANT This procedure will inhibit both automatic and manual regeneration When the machine is operated with the aftertreatment device regeneration inhibited the aftertreatment device becomes clogged mo...

Page 120: ... 4 6 for Shift Change Delay Mode 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 2 MNEC 01 006 3 4 1 MNEK 01 140EN MNEK 01 103EN 5 MPD8 01 141EN ...

Page 121: ...lector knob 2 to display Shift Change Delay Mode screen 9 8 Press selector knob 2 to turn ON enabled When ON enabled is selected background of the Speed Gear Stage display 10 turns blue Press selector knob 2 again to turn OFF disabled fNOTE When the function is ON the mark is displayed in green When the function is OFF the mark is displayed in gray 2 MNEC 01 006 7 9 8 10 MNEK 01 181EN MNEK 01 182E...

Page 122: ...peration when using this setting 1 Press selector knob 2 while displaying basic screen 1 to display main menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 2 MNEC 01 006 3 4 1 MNEK 01 103EN MNEK 01 140EN 5 MPD8 01 141EN ...

Page 123: ...s selector knob 2 to display Warm Up Setting screen 7 6 Press selector knob 2 to turn ON enabled Press selector knob 2 again to turn OFF disabled fNOTE When the function is ON the mark is displayed in green When the function is OFF the mark is displayed in gray 6 MPD8 01 200EN 7 MNEK 01 201EN ...

Page 124: ...ss selector knob 2 while displaying basic screen 1 to display main menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 3 Press selector knob 2 to display Setting Menu screen 5 4 Rotate selector knob 2 to highlight Display Item Selection 6 2 MNEC 01 006 1 MNEK 01 103EN 5 3 4 MNEK 01 140EN 70MPD8 01 220EN 6 ...

Page 125: ...Accumulated Operation Display Press selector knob 2 to set the display hour meter or ODO odometer 8 Before changing C and F turn the blower of the air conditioner ON Rotate selector knob 2 to highlight desired unit system C or F 8 Press selector knob 2 to set the unit When pressing selector knob 2 Wait will be will be displayed 9 and then the change will be completed MNEC 01 006 2 7 8 9 MNEK 01 22...

Page 126: ...Leveler Brightness Adjustment and Mail can be changed in this screen Frequently used menu can be located on top of the screen 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Setting Menu 4 2 MNEC 01 006 1 MNEK 01 103EN 3 4 MNEK 01 140EN ...

Page 127: ...b 2 to highlight Main Menu Sequence Change 6 5 Press selector knob 2 to display Main Menu Sequence Change screen 7 6 Rotate selector knob 2 to highlight a menu to be on the top of the screen Press selector knob 2 to set the menu to the top of the screen MNEC 01 006 2 5 6 70MPD8 01 230EN 7 MNEK 01 231EN ...

Page 128: ...ubleshooting and Monitoring 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 2 MNEC 01 006 1 MNEK 01 103EN 5 3 4 MNEK 01 240EN MNEK 01 241EN KC ...

Page 129: ... monitoring unit Fuel Consumption 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 4 Rotate selector knob 2 to highlight Operation 6 2 MNEC 01 006 1 MNEK 01 103EN 5 3 4 MNEK 01 240EN MNEK 01 241EN KC 6 ...

Page 130: ...ious screen To clear the fuel consumption and machine operation hours rotate selector knob 2 to highlight CLEAR 11 and then press selector knob 2 IMPORTANT Total fuel consumption and fuel consumption rate depend on the operating environment and the operation method of the machine The values shown on the screen are just for reference A difference could arise between actual fuel consumption and fuel...

Page 131: ...Fuel Filter Air Cleaner Filter Element Air Conditioner Filter DEF AdBlue Supply Module Main Filter Fuel Solenoid Pump Filter Oil Separator Crankcase Air Breather Element User Setting 1 User Setting 2 Maintenance Notice 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Inf...

Page 132: ...equired interval is reached an information message is displayed on the screen OFF No notification message is displayed fNOTE When the required interval for an item is reached screen 9 is displayed for 10 seconds when the key is switched ON Press back key 11 to delete the notification When checking the maintenance items from the menu an item where the set time has been reached are marked with a wre...

Page 133: ...displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 4 Rotate selector knob 2 to highlight Maintenance 6 2 MNEC 01 006 5 6 MNEK 01 245EN KC 3 4 1 MNEK 01 240EN MNEK 01 103EN ...

Page 134: ... 2 to highlight RESET 9 and then push selector knob 2 The value of the remaining hours is reset to that of the maintenance interval The previous change date hour is updated with the current date and time Maintenance Interval Setting To change the maintenance interval rotate selector knob 2 to highlight 11 and then press selector knob 2 The background color of Maintenance Interval 10 changes then t...

Page 135: ...ive fault code generated by the controller connected to the controller area network is displayed on this screen 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 3 Press selector knob 2 to display Information Menu screen 5 ...

Page 136: ...er troubleshooting 7 6 Active fault codes are displayed at the right side of each item Rotate selector knob 2 to highlight an item displaying the fault codes 7 Press selector knob 2 to display active fault code 8 Up to 20 fault codes can be displayed IMPORTANT Send the troubleshooting result to your nearest authorized service representative as soon as possible MNEC 01 261EN KC 90MNEC 01 262EN MNEC...

Page 137: ...R S STATION 2 MNEC 01 006 1 MNEK 01 103EN 3 4 MNEK 01 240EN Monitoring 1 Press selector knob 2 while displaying Basic Screen 1 to display Main Menu screen 3 2 Rotate selector knob 2 to highlight Information Menu 4 ...

Page 138: ... S STATION 3 Press selector knob 2 to display Information Menu screen 5 4 Rotate selector knob 2 to highlight Monitoring 6 5 Press selector knob 2 to display Monitoring screen 7 7 MNEK 01 271EN 5 6 MNEK 01 270EN KC ...

Page 139: ...verse Lever 5 Steering Wheel 6 Horn Switch 7 Key Switch 8 Turn Signal Lever Light Switch High Low Beam Switch 9 Accelerator Pedal 10 Brake Pedal 11 Forward Reverse Lever Shift Switch 12 Front and Rear Window Wiper Switch 13 Tilt Telescopic Lever 14 Steering Column Tilt Pedal 15 Brake Declutch Pedal MNEC 01 036 MNEC 01 037 1 2 3 4 5 6 7 8 11 12 13 14 10 9 15 ...

Page 140: ...d When a machine failure occurs use this switch to inform other vehicles that the machine is in an emergency situation When the on hazard switch 1 is pressed front and rear turn signals hazard light 2 on both right and left sides start flashing Press the opposite side of hazard switch 1 to turn the hazard signals OFF M4GB 01 065 1 MNEC 01 037 1 2 2 MNEC 01 523 2 2 MNEK 01 06US ...

Page 141: ...o turn front work lights 2 ON Rear work lights 3 stay OFF When the side with mark on switch 1 is pressed all front work lights 2 rear work lights 3 and rear cab lights 4 turn ON dCAUTION Do not turn the work lights ON while driving on a public road 1 MNFA 01 011 MNEC 01 037 1 2 2 MNEC 01 523 4 3 4 3 MNEK 01 06US ...

Page 142: ...g brake is applied parking brake indicator 2 will be shown Press the OFF side of parking brake switch 1 to release the parking brake Check that parking brake indicator 2 goes OFF by pressing the switch firmly clicks fNOTE The parking brake is released by hydraulic pressure only when the engine is running To ensure safe operation when the parking brake is applied with the forward reverse lever move...

Page 143: ...e lock position Pull Unlock Push Lock Steering Wheel dWARNING CRUSH HAZARD Keep personnel out of area of articulation joint IMPORTANT When steering wheel 5 is fully turned the front and the rear chassis come in contact with the stoppers so that the steering wheel does not rotate further If the steering wheel is forcibly turned moreover the engine may stall or malfunction of the steering system may...

Page 144: ... the descriptions in the OPERATING ENGINE section for the detail information dWARNING Never turn key switch 9 OFF while moving the machine Failure to do so will result in inoperable steering wheel and brake pedal functions and the parking brake will suddenly apply 1 OFF Engine Off 2 ACC Radio 3 ON Power ON 4 START Engine Start fNOTE Engine pre heating is controlled automatically by the engine cont...

Page 145: ...hange direction to persons and or other vehicles by operating turn signal lever 7 Return turn signal lever 7 to neutral manually L Left Turn R Right Turn fNOTE The lever does not return automatically when the steering wheel is returned to center 7 L R N MNEC 01 038 ...

Page 146: ... Signal Hazard Light 5 Brake Light Tail Light Light Switch Position Headlight Clearance Light Tail Light Monitor Panel Light OFF fNOTE The light switch position keeps lit even if the key switch is turned OFF It is used as a parking light when parking the machine by a public road IMPORTANT Do not hold the switch position at ON for a long time with the engine stopped The batteries will become discha...

Page 147: ... in the low beam position when other vehicles are present in the vicinity By bringing down the signal lever 7 with the headlight ON the headlight beam turns upward and the high beam indicator 8 comes ON By bringing up the signal lever 7 the headlight beam turns downward and the high beam indicator 8 goes OFF MNEC 01 038 7 8 9 MNEC 01 073 ...

Page 148: ...h from wearing out prematurely Keep the areas around the brake pedals clean to prevent dust and or grit from accumulating The brake may not be fully released and become inoperable Left and right brake pedals 1 2 can function as the service brake Left pedal 1 also functions as declutch brake by switching declutch position switch 4 Service Brake Brake pedals 1 2 function as normal brake by setting d...

Page 149: ...Also it may cause damage to the transmission fNOTE The engine will not be started unless the forward reverse switch 3 and forward reverse lever 1 are in the neutral position For safety turn the forward reverse selector switch 4 in the OFF position Refer to page 1 97 for forward reverse selector switch 4 Shift Switch Rotate shift switch 2 to shift the gear Forward 2nd 5th Speed Reverse 2nd 3rd Spee...

Page 150: ...eeze type washer fluid in freezing weather Squirt windshield washer fluid on the dry windshield before operating the wiper Besides continuous operation of the wiper with windshield at semiarid condition sprinkling of snow or rain may cause failure of the wiper Use wiper intermittently to protect it from damage In case of machine equipped with hot wire heater for windshield continuous operation of ...

Page 151: ...solvent that will not freeze The front windshield wiper operates at fast speed The front windshield wiper operates at slow speed INT The front windshield wiper intermittently operates OFF The front windshield wiper stops moving and the wiper blade is returned to the pre start position Washer fluid squirts from the front nozzle and the front windshield wiper operates Washer fluid squirts from the r...

Page 152: ... to the desired position Push lever 1 until it contacts the stopper ensuring the steering column is locked By depressing steering column tilt pedal 2 the steering column moves forward and the distance between the operator s seat and the steering wheel increases allowing operator to get in and out of the machine easily After moving the steering column forward pull the steering wheel toward the oper...

Page 153: ...ward Reverse Selector Switch 10 Fan Reverse Rotation Switch 11 Not used 12 Hydraulic Coupler Switch Option 13 Secondary Steering Operation Check Switch Option 14 Aftertreatment Device Regeneration Switch 15 Not used 16 1st Speed Fixed Switch 17 Ride Control Switch Option 18 Armrest 19 Hold Switch 20 Right Console Slide Lever 21 Quick Power Switch 22 DSS Down Shift Switch 23 Horn Switch 24 Armrest ...

Page 154: ...he bucket is tilted back also this is the transportation position G Detent When the bucket control lever is moved from the bucket dump position to the bucket tilt or roll back position the bucket control lever is held in this position with the detent fNOTE When applying the lift arm control lever 1 in the Raise position A the lever is moved F until the lift arm reaches the position set at the heig...

Page 155: ...ld in that position When the lift arm moves to the preset position the lift arm control lever automatically moves to Neutral N position fNOTE When operating the machine in the Float C position lower the bucket on the ground by setting the lift arm lower position B and then tilt the lever to the Float position M4GB 01 072 C B E N N A D MNEC 03 003 C B E N N A F G D ...

Page 156: ...r Mode Selector Switch 10 Forward Reverse Selector Switch 11 Fan Reverse Rotation Switch 12 Not used 13 Hydraulic Coupler Switch Option 14 Secondary Steering Operation Check Switch Option 15 Aftertreatment Device Regeneration Switch 16 Not used 17 1st Speed Fixed Switch 18 Ride Control Switch Option 19 Armrest 20 Right Console Slide Lever 21 Hold Switch Under the Lever 22 Horn Switch Under the Lev...

Page 157: ...ped and held in that position A Lift Arm Raise F Detent The lift arm is held in the raise position G Detent When the multi function joystick lever is moved from the bucket dump position to the bucket tilt position the multi function joystick lever is maintained in this position D Bucket Tilt The bucket is tilted back taking the transportation position N Hold The bucket is stopped and held in that ...

Page 158: ...use this lever Armrest Adjust Handle Armrest 2 is provided so that the operator can operate the lever with an arm on it for comfort and ease Loosen handle 3 and position the armrest height to fit the operator s preference tighten handle 3 to fix armrest 2 L Loosen R Tighten 1 MNEC 01 041 1 MNEC 01 043 Multi Function Joystick Type Fingertip Control Type 2 3 2 3 M4GB 01 077 L L R R 3 ...

Page 159: ...h OFF dWARNING At this time be sure to depress the brake pedal to ensure safety 2 When forward reverse selector switch 5 is turned ON while both forward reverse lever 22 and forward reverse switch 23 are in the neutral N position forward reverse indicator 24 is shown 3 Set forward reverse switch 23 to F or R fNOTE The forward reverse lever 22 has priority over the forward reverse switch 23 When th...

Page 160: ...ch Position Switch Declutch position switch 2 changes the function of left brake pedal Operating declutch position switch 2 turns the declutch function ON and OFF Declutch ON By depressing left brake pedal the clutch is disengaged and brake is applied without transmitting the drive power to the tires Clutch disengages while lightly depressing the left brake pedal Suitable for loading work on a lev...

Page 161: ...s according to the shift switch AUTO 1 Mode Starts out traveling at 2nd speed When traveling load increases it automatically shifts from 2nd to 1st speed Auto DSS function This mode is suited for heavy digging work or climbing a slope AUTO 2 Mode Starts out traveling at 2nd speed This mode shifts between 2nd 3rd 4th 5th speeds This mode is suited for loading loose material removing snow or a simil...

Page 162: ...le for heavy digging work prioritizing work effectiveness Under auto shifting mode the gear is shifted in regular engine RPM s min 1 and shift mapping Power mode OFF When the power mode is turned OFF the machine operates putting more emphasis on lowering fuel consumption Under auto shifting mode the gear is shifted with lower engine RPM s min 1 and shift mapping When the power mode is activated th...

Page 163: ...return to the normal direction Normal rotation Reverse rotation Normal rotation The fan rotates in the normal direction for 10 minutes for the first time After that it keeps normal rotation for 30 minutes The reverse rotation time is 60 seconds 1 minute 90 seconds 1 5 minutes at low temperature In case abnormal situation occurs such as engine coolant overheating or high refrigerant pressure of the...

Page 164: ...ng brake When the parking brake is released the fan reverse condition is automatically canceled after 1 minute In case abnormal situation occurs such as engine coolant overheating reverse rotation may forcibly be stopped or fan reverse rotation switch may be disabled 1 Close the side cover and the rear grille before operating the switch 2 Start the engine Be sure to confirm that the parking brake ...

Page 165: ...ile the ON side of switch 1 is being pressed secondary steering pump operates Secondary steering indicator 2 lights ON while the pump is operating After checking release switch 1 to turn it OFF IMPORTANT Conduct test only within 2 second Aftertreatment Device Regeneration Switch Use this switch to start the aftertreatment device manual regeneration procedures when it is requested Refer to page 5 1...

Page 166: ...ar to the 1st speed Be sure to stop the machine and set forward reverse lever 2 in the neutral N position before operating 1st speed fixed switch 1 1st Speed Fixed ON Set shift switch 3 to 2nd speed Push the ON side of 1st speed fixed switch 1 The transmission gear is fixed to 1st speed regardless of the position of travel mode selector 4 1st Speed Fixed OFF Push the OFF side of 1st speed fixed sw...

Page 167: ...ity is obtained As stable drive operation is achieved bucket load spill can be lessened AUTO When ride control switch 1 is turned to AUTO the drive speed sensor and the controller is activated Then when the drive speed increases above the preset travel speed the ride control system automatically operates When the drive speed decreases below the preset travel speed the ride control system becomes i...

Page 168: ...ress the hold switch again Change the gear range Change the travel mode or Press DSS down shift switch Right Console Slide Lever Adjust the position of the right console as follows 1 While tilting lever 2 to the right adjust the position of the right console by sliding it back or forth Holding and moving armrest 3 maybe easier to move the console Slide quantity 90 mm 3 5 in 2 After the adjustment ...

Page 169: ...eed while ascending on a slope When operating under low load or the forward reverse lever is in Neutral N position the mode will not change to power mode even if quick power mode switch is pressed The switch selection is ruled invalid Also even if the machine is in the power mode it is canceled when the following conditions are met When operating load is decreased while digging When the quick powe...

Page 170: ... reverse R the gear returns to 2nd speed Press DSS 2 when ECO indicator 5 turns OFF while operating on a slope or during snow removal In this case the gear temporarily shifts down to 1st speed by pressing DSS 2 but it automatically returns to 2nd speed when traveling load is reduced fNOTE When in auto shift mode or manual shift mode each time DSS 2 is pressed the gear down shifts to 1st speed When...

Page 171: ...the lighter knob 2 3 The cigar lighter knob will return to the original position when the lighter becomes hot Pull the cigar lighter out to use 4 After using the cigar lighter insert the cigar lighter into the panel until the knob is seated in the original position and not pressed in dCAUTION Do not connect accessories that use power other than 24 V DC MAX 5 A Damage to the batteries and accessori...

Page 172: ...cooling or heating can be obtained by rotating the temperature control switch clockwise 32 C 90 F or counterclockwise 18 C 64 F respectively Preheating During preheating the cab in winter with the foot vent selected the air volume is reduced to Low until the coolant temperature rises to prevent cool air from entering the cab fNOTE Even in the summer season the engine high idle speed may be higher ...

Page 173: ...Auto Switch Press 8 Defroster Vent 9 Rear Vent 10 Foot Vent 11 Air flows out of front vent and the defroster vents fNOTE Except for the foot vent 10 and defroster vent 8 all vents are provided with louvers to adjust the air flow direction In addition the louvers on front vent 11 and rear vent 9 can be completely opened and closed by hand MNEC 01 006 MNEC 01 035 MNEC 01 036 9 8 10 11 7 6 2 3 5 4 8 ...

Page 174: ...time mode switch 3 is pressed the vent location can be changed in 6 stages as illustrated below AUTO Press defroster switch 4 to change defroster vent mode AUTO mode The air vent location is automatically selected Temperature Control Switch 3 Sets temperature in the cab Temperature in the cab can be set from 18 0 to 32 0 C 64 to 90 F by rotating temperature control switch 3 Temperature can be set ...

Page 175: ...ill turn on and the air conditioner indicator will be displayed on the monitor when air conditioner ON OFF switch 6 is pressed Circulation Fresh Air Switch 5 It switches over the air intake port to recirculation mode and fresh air mode Icon of the selected mode will be displayed on the monitor Recirculation mode Fresh air mode IMPORTANT When running the air conditioner for a long time turn the lev...

Page 176: ...the temperature in the cab by using temperature control switch 3 3 Other Functions and Operations Operate Mode switch 3 to manually select the air vent Operate blower switch 7 to manually control the blower speed Operate circulation fresh air switch 5 to maintain the air vent in the fresh air mode or circulation mode Usually the cab heater turns the dehumidifier function OFF however it turns ON by...

Page 177: ...ports and air flow in temperature at the vent and controls the blower speed 2 Temperature Control Switch 3 Adjust the temperature in the cab by using temperature control switch 3 3 Other Functions and Operations Operate Mode switch 3 to manually select the air vent Operate blower switch 7 to manually control the blower speed Operate circulation fresh air switch 5 to maintain the air vent in the fr...

Page 178: ...adjust flow 4 Operate mode switch 3 to change foot defroster mode Cool Head Warm Feet Operation Cool and warm air is simultaneously supplied to the head vents and feet vents respectively 1 Rotate blower switch 7 to adjust the blower speed 2 Press MODE switch 3 to display the front and rear vent mark on the monitor Turn A C ON by using air conditioner ON OFF switch 6 Control air temperature inside ...

Page 179: ...umid days operate the air conditioner to aid in keeping the windows clear When the atmosphere is very damp and if the air conditioner has run excessively the outside of the windows may become fogged If this happens turn up the air temperature selection to adjust the temperature in the cab Off Season Air Conditioner Maintenance To protect each part of the compressor from a lack of lubricant operate...

Page 180: ...el with backrest when not in use 2 Turn adjustment knob 2 for desired lumbar support 3 Lift handle 3 and allow the back cushion to angle forward or lean backward into the cushion Release the handle at desired position 4 With the key turned ON push the knob 4 to increase the air pressure This will raise the seat and make a firmer ride Pull the knob 4 to reduce the air pressure air will be vented Th...

Page 181: ...volt electric power can be utilized Never connect accessories that use power other than 12 V Damage to the batteries and accessories may result Do not supply power to accessories for a long time without running the engine The batteries may be discharged 1 Remove the cover 2 Insert the socket of the accessory to be used into the electric power output port 3 Turn the key switch 6 ON Power is supplie...

Page 182: ... as a safety valve to prevent excess current from flowing through and to protect the electrical system The fuse capacity varies depending on its corresponding circuit Be sure to replace the blown fuses only with the specified one When checking fuses check the fuse A B and slow blow fuses in the battery box 1 and 2 in this order 1 70 A 140 A 2 45 A 65 A 2 used MNEK 07 017 1 2 MNEK 01 015 Fuse Box A...

Page 183: ...R SOCKET 10 A 13 SEAT HEATER 20 A 2 HEAD LAMP RH 5 A 12 OPTION 2 ACC1 20 A 1 FUEL PUMP 5 A 11 RADIO USA 10 A Fuse Box B 10 ECM 30 A 20 SECONDARY STEERING 5 A 9 TCU 10 A 19 HIGH BEAM 10 A 8 CONTROLLER 10 A 18 WIPER REAR 10 A 7 FLASHER 10 A 17 WORKING LAMP REAR 20 A 6 HORN 10 A 16 LOADER CONTROL 5 A 5 OPT C U 5 A 15 MC 10 A 4 OPTION 1 BT 15 A 14 TCU POWER 10 A 3 CAB DOME LAMP 5 A 13 POWER ON 10 A 2 ...

Page 184: ...he hot cool box If the A C is on cool air is sent into the box If the heater is on warm air is sent into the box Tray and Drink Holder IMPORTANT Tray 2 is not waterproof type Be careful not to spill liquid on the tray Place a bottle with a plug or cap on drink holder 3 Wipe up any spills with a damp cloth Secure anything stored in this area to avoid loose objects in the cab MNEC 01 048 1 MNEC 01 0...

Page 185: ...OPERATOR S STATION 1 123 ROPS Cab ROPS cab 1 is standard equipment 1 ROPS Cab 2 Speakers 3 Front Interior Light 4 Sun Visor MNEC 01 050 MNEC 01 051 2 3 4 MNEC 01 049 1 M4GF 01 010 ...

Page 186: ...OPERATOR S STATION 1 124 5 Radio 6 Cab Switch Panel Option 7 Inside Rear View Mirror 8 Rear Interior Light 9 Emergency Exit Hammer 10 Coat Hat Hook Z7_US_radio M4GB 01 117 5 7 8 9 6 MNEC 01 053 10 ...

Page 187: ...peration positions ON The light 2 comes and stays ON Neutral When the cab door is opened the light 2 comes ON When closed the light 2 goes OFF OFF The light 2 goes OFF Rear Interior Light Switch 3 ON Rear interior light 3 comes and stays ON Switch 3 OFF Rear interior light goes OFF M4GB 01 119 M4GB 01 117 M4GB 01 120 1 2 3 3 ON OFF MNEC 01 051 2 ...

Page 188: ... the cab top down to a desired place Emergency Exit Hammer In case the cab door becomes difficult or impossible to open if an emergency situation occurs exit machine by breaking the windowpane using the provided hammer Coat Hat Hook Use to hang your coat hat etc M4GB 01 117 M4GF 01 010 4 MNEC 01 053 ...

Page 189: ...ry Light Switch 2 Auxiliary 3 Auxiliary 4 Auxiliary 5 Auxiliary Rotary Light Switch Option Press either upper part or lower part of the switch to turn the rotary light ON Press middle part of the switch to turn OFF Z7_US_radio M4GB 01 125 ON ON OFF 4 2 1 5 3 ...

Page 190: ...mirrors so that persons standing on left and right back end of the machine or object with height of 1 m and 30 cm in diameter can be recognized from the operator s seat Always keep the mirrors clean fNOTE Optional extensions and other mirror types are available Inside Rear View Mirror Always keep room rear view mirrors 2 clean Cab Door dCAUTION When entering or leaving the cab securely close the d...

Page 191: ...le lifting door lock knob 5 pull lever 6 to disengage the door lock Window Open Close Levers When window open close levers 7 on both sides are simultaneously pressed the window is unlocked allowing the windowpanes to move When window open close levers 7 are released stoppers are engaged in the nearest steps so that the window is locked in that position M4GB 01 128 M4GB 01 129 5 6 M4EK 01 048 M4FJ ...

Page 192: ...tch may loose possibly causing an accident Push the door toward the outside of the cab to fully open the door 180 Cab Door Release Lever dCAUTION When keeping the door open open the door until latch 10 on the cab securely locks the door When disengaging the door lock push door lock disengage lever 8 or 9 downward M4GB 01 132 M4GB 01 133 M4GB 01 117 9 8 Left Door Lock Disengage Lever Right Door Loc...

Page 193: ... No current will flow through the entire electrical system Before turning the battery disconnect switch OFF be sure to turn the key switch OFF and wait 5 minutes or more after the engine stops before turning battery disconnect switch Because controllers communicate with each other and record information after the engine stops battery power is required for a minimum of 5 minutes Use the battery dis...

Page 194: ...erating the machine with battery disconnect switch 2 ON close the cover 2 When turning lever 1 90 counterclockwise the lever is lateral to the ground battery disconnect switch 2 turns OFF Lever 1 can be removed from battery disconnect switch 2 when it is in OFF position 3 Insert lever 1 removed from switch 2 into hole 3 of the holder 4 Close the cover ON ON OFF MNEK 01 016 MNEK 01 017 MNEK 01 346 ...

Page 195: ...1 Before operating the machine be sure to disengage lock bar 1 from front chassis 4 and fasten the lock bar to rear chassis 2 with β form lock clip 3 Articulation lock bar 1 locks the front and rear chassis to prevent articulation between the front and rear chassis when servicing or transporting the machine MNEK 01 019 MNEK 01 018 1 2 3 ...

Page 196: ...owing force and keep the specified speed during towing Available towing force 120 0 kN 26980 lbf Towing speed 10 km h 6 2 mph or less Towing pin 4 is located on the back end of the machine It is used for towing another machine being towed from the rear side or fastening the machine on a trailer deck for transportation Tie or loop the towing rope strap or cable and let it pass through the hole Secu...

Page 197: ...r close Take care not to pinch fingers when opening closing side cover 1 When side cover 1 is opened the cover may move suddenly Be careful not to come in contact with the cover Before inspecting around the engine be sure to secure side cover 1 with holding rod 4 When opening side cover 1 pull latch 3 fNOTE When servicing the machine for a long time with side cover 1 kept open lock side cover 1 us...

Page 198: ...ing the machine always check that the rear grille will not open Push rear grille 2 open close button 1 to allow the rear grille to open upward so that refilling the fuel tank or cleaning of the cooling fan can be conducted When closing rear grille 2 while supporting rear grille 2 slowly lower and push in the rear grille until a click sound is heard 1 2 MNEK 01 021 MNEK 01 020 ...

Page 199: ... accident Although the steps are provided on both sides of the machine only use the steps on the left side for cab entry The control levers are located on the right side obstructing easy access Right side steps are for emergency exit only Inspect the steps and handrails daily Immediately repair or replace any that are missing loosen or damaged Clean the steps of any mud snow or ice before entering...

Page 200: ...OPERATOR S STATION 1 138 Vandal Resistant Devices Locks can be installed to transmission oil inlet cap cover 1 tool box cover 2 and DEF AdBlue tank cover 3 M4GB 01 147 1 2 3 MNEK 01 022 MNEK 01 023 ...

Page 201: ...dal Resistant Devices continue from previous page Battery box cover 4 fuel tank cap 5 side covers 6 and air conditioner fresh air filter 7 can be locked with the starter key 7 MNEC 01 055 5 6 MNEK 01 014 MNEK 01 013 MNEK 01 024 4 ...

Page 202: ...nce Seat Belt 1 Confirm that seat belt 1 is not twisted Securely insert the end of seat belt 1 into buckle 2 Lightly pull on the belt to confirm that the buckle latches securely 2 Push button 3 on buckle 2 to unfasten seat belt 1 Replace seat belt 1 if it is damaged or worn or if the machine is involved in an accident which puts severe stress on the seatbelt Seat Pocket A pocket is provided on the...

Page 203: ...eration and burning friction material Running hydraulic system pressure over relief setting pressures too often and heating the oil excessively Tractively twisting the boom arms or chassis Running through impassible terrain Not decelerating while changing machine direction Scaling out heavy materials like heavy rock while in forward motion causing the bucket to catch and break free and catch mater...

Page 204: ...2 2 BREAK IN MEMO ...

Page 205: ...f the wheel disk is correct 4 Lights and Turn Signals They light up or flash normally with clear view and no lens damage 5 Outside Rear View Mirror and Inside Rear View Mirror Appropriate visibility 6 Reflectors and Registration Plate Clearly visible and no damage found 7 Previously reported damage Repaired 8 Engine 1 Oil level 2 Oil condition no antifreeze or contaminates present 3 Coolant level ...

Page 206: ...aks and contamination of the DEF AdBlue tank 9 DEF AdBlue leaks of pipe lines and hoses 10 Clean around the aftertreatment device 10 Loader 1 Oil leaks and damage to cylinders pipe lines and hoses 2 Loose worn and missing cutting edges 3 Wear and damage to the bucket 4 Lubrication of the loader parts 5 Damage to the pin lock bolts stoppers and links 6 Loose and missing mounting bolts nuts 11 Other...

Page 207: ...osition If your machine is not equipped with forward reverse switch 4 set only forward reverse lever 2 in the neutral N position fNOTE Unless forward reverse lever 2 and forward reverse switch are in neutral N the engine will not start 3 Check that parking brake switch 1 is in the ON position After the engine starts and checking indicator bulbs and display refer to page 3 5 check that parking brak...

Page 208: ...7 While seated on the operator s seat with your back in contact with the backrest adjust each function of the seat so that the brake pedal can be fully applied 8 Fasten seat belt 11 along your body without kinking or twisting it Be sure the buckle firmly snaps when coupled and works as it should and the retractor and anti synch mechanism work as designed 9 Inspect seat belt 11 9 10 11 8 MNEC 01 04...

Page 209: ...pressure 4 When the brake pressure is low and discharge warning indicator 5 will continue to stay ON and it will go OFF only after the engine is started and circuits are filled Preheating will automatically start with the key switch ON The preheat indicator 6 will automatically come ON when needed fNOTE When the key switch is turned ON the maintenance notification for the item whose maintenance in...

Page 210: ... is kept at low idle for maximum 35 seconds when the coolant transmission oil or hydraulic oil temperature is low or for 3 seconds if these temperatures are in the acceptable operation range After this period the engine RPM will increase by applying the accelerator pedal 3 dWARNING Do not operate the machine while the engine RPM is being kept at low idle otherwise the machine or the front attachme...

Page 211: ...eturn to the ON position Run the engine at low idle without applying accelerator pedal 3 IMPORTANT At starting the engine the engine RPM min 1 is kept at low idle for maximum 35 seconds to warm up the coolant hydraulic oil etc After this period the engine RPM will increase by applying the accelerator pedal 3 dWARNING Do not operate the machine while the engine RPM is being kept at low idle otherwi...

Page 212: ... that engine coolant temperature gauge 3 is within the normal green range fNOTE To check indicator bulbs and the buzzer function when the key switch is turned ON monitor indicators come ON and continue to stay ON for approx 2 seconds Check Engine Noise and Exhaust Gas Color Check that the engine noise and exhaust gas color is normal fNOTE Check the exhaust gas color as follows After warm up operat...

Page 213: ...level is lower than specified Explosion of the battery may result Park the machine and a machine with the booster batteries on a dry or concrete surface not on steel plates If the machine is parked on steel plates the machine is equivalent to a continuously grounded machine so that dangerous unexpected current flow may result Never connect a positive terminal to a negative terminal as a dangerous ...

Page 214: ...ounted machine 1 5 Start the engine on the machine 1 6 After the engine starts leave the booster batteries connected long enough so as not to overload alternator then disconnect booster cables 1 and 2 in the following steps 2 Disconnecting the booster cables 2 1 Disconnect black negative cable 2 from the bolt inside tool box 3 2 2 Disconnect the other end of black booster cable 2 from the negative...

Page 215: ...ponents from being damaged but also to ensure safe operation If the machine is operated with the hydraulic oil temperature below 20 C 68 F damage to the hydraulic components may result After starting the engine perform warm up as described below before operating the machine until the hydraulic temperature is above 20 C 68 F 1 While releasing accelerator pedal 3 run the engine at low idle speed for...

Page 216: ...minutes to warm up without stepping on accelerator pedal 3 If the Warm Up Operation in the multi monitor setting menu is set to ON enabled the engine speed automatically increases from slow idle to 1000 min 1 rpm and enters warm up mode when hydraulic oil temperature is 0 C 32 F or lower Further when either hydraulic oil temperature reaches 30 C 86 F or higher or engine coolant temperature reaches...

Page 217: ...n cold 4 Slowly and fully retract the bucket cylinder fNOTE Do not continuously operate the bucket control lever for more than 10 seconds at a time Do not bang linkage when cold 5 Repeat steps 2 to 4 above until the loading linkage speed is normal When the air temperature is lower than 0 C 32 F extend the warm up time by running the engine at about 1200 1500 min 1 RPM s 6 Slowly and fully turn the...

Page 218: ... turbocharger possibly damaging the turbocharger 2 Run the engine at low idle speed for 5 minutes to cool the engine 3 Turn the key switch 1 to OFF position to stop the engine 4 Press LOCK side of control lever lock switch 2 5 Make sure that the light switch is turned OFF fNOTE Do not idle for excessively long periods Observe local and federal engine idling regulations When stop the machine refer ...

Page 219: ...et the lift arms and bucket in the operating position 3 Before driving on public roads set the machine to the driving position as illustrated to the right 4 Be sure to press lock side of control lever lock switch 1 so that the linkage will not move even if the control levers are accidentally moved 5 After starting the engine be sure to run the engine at slow idle speed to warm up the machine befor...

Page 220: ...cket Avoid turning ride control switch 4 to ON position while moving the machine Failure to do so may automatically move the lift arm up or down fNOTE Refer to page 1 105 for detailed information of ride control switch 4 1 Check that none of the warning indicators except parking brake indicator 1 on the monitor panel are ON when engine is running 2 Set the front attachment in the driving position ...

Page 221: ...ng brake Check that at this time parking brake indicator 1 goes OFF fNOTE When starting to ascend a slope turn declutch switch 9 OFF clutch engaged and depress brake pedal 6 Gradually release brake pedal 6 while depressing accelerator pedal 10 to easily start ascending a slope MNEC 07 001 MNEC 01 036 9 8 10 7 6 1 MNEK 01 500 ...

Page 222: ... F or R Select the most appropriate transmission range position according to the operating conditions Select the most appropriate travel pattern by operating travel mode selector 13 AUTO 1 Mode This mode sets 1st range as the minimum speed gear stage Start traveling with 2nd range When driving load increases it automatically shifts to 1st range This mode is suited for heavy digging work or ascendi...

Page 223: ...ed 5th Speed 1st Speed 2nd Speed 3rd Speed 4th Speed 5th Speed 1st Speed 2nd Speed 3rd Speed AUTO 2 2nd Speed Only 2nd speed Only 2nd speed 3rd Speed 2nd Speed 3rd Speed 2nd Speed 3rd Speed 4th Speed 2nd Speed 3rd Speed 4th Speed 2nd Speed 3rd Speed 5th Speed 2nd Speed 3rd Speed 4th Speed 5th Speed 2nd Speed 3rd Speed fNOTE When AUTO 1 is selected the machine starts with 2nd speed and the gear aut...

Page 224: ... 5th range position the shift up timing in 2nd range 3rd range is delayed Loading work can be easily done in 2nd range position Shift Up Delay Forward movement The gear shifts up when moving the machine at high speed in 2nd range for 4 seconds or longer The gear will not shift while the lift arm is raising The shift up delay will operate only one time when the bucket is in the operating position W...

Page 225: ... stopping the machine on level ground fNOTE While running the engine when the parking brake is applied with forward reverse selector switch lever 3 in neutral parking brake indicator 2 comes ON 2 While running the engine when the parking brake is applied with forward reverse lever 3 in either the forward F or reverse R position parking brake indicator 2 comes ON and the alarm buzzer sounds F N R d...

Page 226: ...after reducing the travel speed by releasing the accelerator pedal Changing Forward Reverse Drive Direction dWARNING Before changing the forward reverse drive direction confirm that the direction of drive is clear To ensure operator s safety and ensure the longevity of the power train change the machine drive direction only after sufficiently slowing machine down to 13 km h 8 mph or slower 1 Pull ...

Page 227: ... extremely dangerous and may cause the machine to turn over IMPORTANT When the steering wheel is fully turned the front and the rear chassis come in contact with the stoppers so that the steering wheel does not rotate further If the steering wheel is forcibly turned further the engine may stall or steering system problems may result Turn the steering wheel toward the direction you intend to steer ...

Page 228: ...ng system is provided for an emergency use If continuously used for more than 60 seconds damage to the system may result Even though the machine is equipped with the secondary steering system if the steering function becomes inoperable while moving machine press secondary steering check switch 1 on the right console to activate the secondary steering system Then immediately park and stop the machi...

Page 229: ...machine for a long period of time return the forward reverse lever to neutral N turn the parking brake switch ON and apply the parking brake to ensure safety 4 During long load and carry applications the lift arm position may lower due to inner hydraulic oil leaks When required to adjust the lift arm position temporarily stop machine return the forward reverse selector switch lever to neutral appl...

Page 230: ...void running the engine at high RPM s min 1 under no load If any abnormal condition such as an abnormal noise vibration or smell is noticed while operating immediately stop the engine and inspect the machine for any trouble Avoid using sudden steering or braking as much as possible because your machine and other machines may become involved in a hazardous condition Road speeds of this machine are ...

Page 231: ...sion or front and rear propeller shafts in water or mud Avoid operating in water as much as possible If operating in water or mud is unavoidable do not allow the machine to be submerged deeper than allowable depth A up to the bottom of the axle housing Reduce the allowable depth in case the river bed is feared to be rugged or water is flowing fast When operating on muddy ground mud can easily accu...

Page 232: ...ximum travel speed Failure to do so may damage the machine and or a serious accident may result When steering on a slope lower the loader front to increase the machine stability Do not steer on a steep slope since this may cause the machine to turn over When descending a slope descend in a low drive range with engine resistance applied Do not operate the machine at a speed faster than the maximum ...

Page 233: ...is disabled by one or more of the following methods Use disabled machine triangles Turn the hazard lights ON Use an emergency signal instrument emergency signal light or reflective triangles dWARNING Do not spill oil on the road surface Oil spillage may cause another vehicle to slide possibly creating a serious accident In case of hydraulic oil leaks immediately repair the machine If oil gets on t...

Page 234: ...o neutral N Place neutral lever lock 4 to the lock position 3 Press the ON position of parking brake switch 5 4 Level the bucket with the surface of the ground and lower the bucket to the ground by operating bucket control lever 6 and lift arm control lever 7 5 Press lock side of control lever lock switch 8 MNEC 01 037 5 3 4 MNEC 01 036 MNEC 07 001 1 2 8 7 6 MPD8 04 001 Stop and Parking Position ...

Page 235: ... minutes to cool the engine fNOTE Do not idle for excessively long periods Observe local and federal engine idling regulations IMPORTANT Do not leave the machine with key switch 9 in ACC position This may discharge the batteries Be sure to turn key switch to OFF position before leaving the machine 7 Turn key switch 9 to OFF position to stop the engine Remove the key from the switch Place neutral l...

Page 236: ...at low RPM s the lubricant on the turbocharger bearing and seal surfaces may be dissipated due to the intense heat present inside turbocharger possibly damaging the turbocharger 3 Run the engine at low idle speed to cool the engine for a few minutes fNOTE Do not idle for excessively long periods Observe local and federal engine idling regulations 4 Turn key switch 2 to OFF position to stop the eng...

Page 237: ...ake pedal The brake oil pressure will be quickly reduced so that the brakes become inoperable If the machine does not stop even if the brake pedal is applied press the parking brake switch ON side to stop the machine The steering wheel will become hard to rotate as the hydraulic system becomes inoperable In the event any above mentioned symptom occurs immediately trace the cause of the problem In ...

Page 238: ...4 20 MOVING THE MACHINE MEMO ...

Page 239: ...A Lift Arm Raise F Detent The lift arm is held in the raise position with the detent Bucket Control Lever 2 Lever Position Bucket Operation E Bucket Dump The bucket is tilted forward to dump the bucket N Hold The bucket is stopped and held in that position D Bucket Tilt or Roll Back The bucket is tilted back also this is the transportation position G Detent When the bucket control lever is moved f...

Page 240: ...en the bucket reaches the preset position bucket control lever 2 automatically moves to the Neutral N position 3 When pushing down lift arm control lever 1 to the Float position C the lift arm moves to the position preset by lift arm auto leveler system and is held in that position When the lift arm moves to the preset position lift arm control lever 1 automatically moves to the Neutral N position...

Page 241: ...in that position A Lift Arm Raise F Detent The lift arm is held in the raise position with the detent G Detent When the multi function joystick lever is moved from the bucket dump position to the bucket tilt position the multi function joystick lever is held in this position with the detent D Bucket Tilt or Roll Back The bucket is tilted back taking the transportation position N Hold The bucket is...

Page 242: ...expected machine operation if the operator were to mistakenly come in contact with the bucket and or lift arm control lever when getting on or off the machine When control lever lock 1 is placed in unlock position the control lever becomes operable Control Lever Lock Operation When leaving the operator s seat 1 Park the machine on solid level ground Lower the bucket to the ground Return all levers...

Page 243: ...clutch ON when lightly depressing the left pedal 3 Suited to loading work on a level surface or on a gentle slope Declutch ON when firmly applying the left pedal 3 Suited to operate on a steep slope OFF Clutch Engaged By depressing brake pedals 3 or 4 brake is applied while power is transmitted to the drive train fNOTE When starting to ascend a slope turn declutch position switch 1 OFF clutch enga...

Page 244: ...e bucket is stopped with the bucket bottom parallel with the road surface For example after discharging material into a truck or a hopper when bucket control lever 4 is placed to detent position G the lever is held in that position Then when the bucket is returned to the preset angle position the bucket is automatically stopped and the lever is returned to neutral N The bucket auto leveler is pres...

Page 245: ...proximity switch Slide the end edge of leveler bar 3 up to the center of the sensitive area orange color Then tighten lock nut 2 3 The angle is able to be set to more than one position by setting the placement within the slot Loosen nuts of U bolts 1 2 used move the bracket and then tighten the nuts 4 After adjustment start the engine Check that the bucket can be stopped at the desired angle posit...

Page 246: ...position Height setting of lowering direction can not be done when the lift arm is above the horizontal position of the lift arms Also height setting of raising direction can not be done when the lift arm is below the horizontal position of the lift arms The lift arm auto leveler is a device that automatically stops the lift arm at the preset position while lowering or raising the lift arm It is c...

Page 247: ...xt page 30 seconds before the engine stop monitor 2 displays a message that engine will be stopped and indicator 1 starts flashing Also the buzzer sounds The buzzer sounds once at 30 seconds before intermittently sounds from 15 seconds and then stops after 15 seconds The auto idling stop is disabled and the engine will not stop if any of the conditions on the next page is not satisfied IMPORTANT E...

Page 248: ...smission temperature are not high The aftertreatment device manual regeneration is not operating IMPORTANT When the engine stops because of the auto idling stop function turn the key switch to ACC or OFF once and then turn it to START to restart the engine Do not leave the machine after auto idling stop This may discharge the batteries When the key switch is turned to OFF position while the auto i...

Page 249: ...nsmission in neutral Apply parking brake Lower the front attachment level to the ground 2 Verify that items are set as shown below Forward Reverse Lever N Neutral Forward Reverse Switch opt N Neutral Accelerator Pedal UP OFF Parking Brake Switch ON Loading Control Lock Switch 4 LOCK Aftertreatment Device Regeneration Inhibited Setting OFF Remaining fuel alarm does not light DEF AdBlue alarm does n...

Page 250: ...e key is turned to the OFF position the regeneration process will be aborted If the manual regeneration has been aborted start the process over again fNOTE The engine sound may change and the engine RPM may increase when the manual regeneration starts This is not a malfunction White smoke may temporarily be generated from the tail pipe during the regeneration process This is not a malfunction Cool...

Page 251: ...e is too high Run the engine at low idle to lower the oil temperature and restart the procedure fNOTE If aftertreatment device regeneration switch 3 is pressed when the ambient temperature is low it may take long to start the aftertreatment device regeneration process Before pressing aftertreatment device regeneration switch 3 increase the coolant temperature to about 70 C 158 F until the coolant ...

Page 252: ... away from the area of operation and machine movement Always be aware of all hazards within the area around the machine while operating Ensure Safety When Operating on Road Shoulders dCAUTION Stabilize the soil before operating the machine on soft road shoulders Avoid Overloading dWARNING Do not penetrate the bucket into piles of soil and or gravel at fast travel speed Avoid excavating or scooping...

Page 253: ...t ahead position when entering the material 2 Lower the bucket parallel to the ground Drive the bucket straight into the material fNOTE Use approximately 1 2 full engine speed 3 Raise the lift arm while running the machine forward slowly in 1st or 2nd speed Use 2nd speed for loose materials 4 Move the bucket control lever to the Roll Back and the Hold position several times to get more material in...

Page 254: ...cribed below Always take care not to apply loads to only to one side of the bucket 1 Position the bucket edge slightly downward dump forward 10 degrees or less 2 While moving the machine forward in 1st or 2nd speed roll the bucket forward so that the ground surface is gradually lifted Increase engine speed as the bucket digs deeper 3 Adjust the digging depth by operating the lift arm or bucket 4 W...

Page 255: ...s performed by moving the machine forward severe loads are applied to the front attachment possibly creating cracks or damage to the front attachment 1 After filling the bucket dump the bucket gradually to spread soil while moving the machine in reverse 2 Lower the bucket edge onto the ground Grade and level the ground surface while driving the machine in reverse with the bucket edge dragging 3 Af...

Page 256: ...dump truck method Select either method depending on the work site conditions while taking the cost and safety into account Load and Carrying Method dWARNING Be sure to provide a tire stopper 1 in front of the hopper Before raising the lift arm slightly tilt the bucket back and forth to stabilize the load in the bucket to avoid injury or damage to the machine from falling of loose material Avoid ra...

Page 257: ...t a right angle Then travel forward to carry material onto the dump truck 2 Position the wheel loader so that the material can be loaded around the center of the dump body In case the dump body is longer than twice the bucket width load from the front to rear position of the dump body in order 3 When dumping sticky material such as clay move the bucket lever back and forth to lightly hit the bucke...

Page 258: ...ly in neutral and the lift arm rises faster 3 Return the lift arm control lever to the Hold position when the bucket reaches the enough height to clear the truck or hopper sideboards If the lift arm is equipped with the kickout device the lift arm will automatically stop and the lift arm control lever will return to the Hold position when the bucket reaches the preset height Holding the lift arm c...

Page 259: ...o the working tools Keep bucket or attachment bottom parallel to ground Dozing with a wheel loader means a working method performed by a wheel loader using the wheel loader bucket in place of a bulldozer blade This operation method is employed when reclaiming land or dumping material into a hopper that is below ground level Set the bucket bottom parallel with the ground surface and move the wheel ...

Page 260: ...id steering of the machine Use tire chains on all four wheels Pay attention to the presence of the utility facilities such fire hydrants manholes curbs roadside drains etc The facilities or the machine may be damaged Lifting Wheel Loader dWARNING Be sure to use lifting tools and set the articulation stopper lock bar in the LOCK position Refer to page 1 133 Never allow any person to ride on the mac...

Page 261: ...ACHINE chapter 2 Refill the fuel tank dCAUTION Wash the machine when needed In areas of exposed metal spray a light coat of rust preventive oil to protect the machine from rusting If the machine continues to be used with rust developing in areas like cylinder rods oil leaks may occur IMPORTANT If hard rain is expected or the machine is to be stored wrap the muffler with a tarpaulin to prevent wate...

Page 262: ...d connectors Most lights such as the headlights work lights and turn signal lights are water resistant 4 1 Clean the machine thoroughly Clean each cylinder rod plated areas and the radiator with extra care 4 2 After positioning the machine for storage carefully coat each cylinder rod plated areas with rust preventive oil 4 3 Lubricate all pins while referring to A Greasing Section in the Maintenan...

Page 263: ...weight limits and traffic regulations Take any detours that may be needed into account In some cases getting approval from the authority concerned disassembling the machine to bring it within dimensional limits or weight limits of local regulations may be necessary Selecting a Trailer Provide an appropriate trailer while referring to the weight and dimensions shown in the specifications When trans...

Page 264: ... and flatbed Dirty ramps loading docks and flatbeds with oil mud or ice on them are slippery and dangerous 2 Chock 1 the truck and trailer wheels while using a ramp or loading dock 3 Ramps must be the right size and able to bear the load Be sure that the incline of the ramp is less than 15 4 Loading docks must be the right size and able to bear the load to support the machine and have an incline o...

Page 265: ...ual shifting Loading 1 Load the machine so that the centerline of the machine aligns with the centerline of the trailer flatbed 2 Slowly move the machine on the ramp 3 Lower the bucket onto the trailer deck 4 Stop the engine Remove the key from the key switch 5 Operate the control lever several strokes to relieve pressure in the cylinders 6 Move the control lever lock switch in the lock position 7...

Page 266: ...pply the parking brake Slowly rest the bucket on the trailer deck or load carrying platform 2 Place blocks 1 in front of and behind the tires to prevent the machine from moving 3 Securely fasten the machine and the front attachment to the truck or trailer platform with heavy chains or wire cables The machines for export are provided with lifting eyes Use these eyes for securing the machine 1 MNEC ...

Page 267: ...he wheel loader by driving on roads Observe the rules and regulations associated to this wheel loader and travel carefully Recommended tire pressures and traveling speeds may vary depending on the type of tires used and the road conditions Consult your nearest authorized dealer Check the tire pressure before self traveling when the tires are cool After driving the wheel loader for 30 minutes allow...

Page 268: ...ing and brake system are operable Release the parking brake If the engine is inoperable Removing the propeller shafts When the parking brake cannot be released manually release the parking brake Refer to the Releasing Parking Brake on page 6 7 Then disconnect the front and rear propeller shafts At this time wedge wheel stoppers at all tires to prevent the machine from moving The steering system is...

Page 269: ...rking brake be sure to chock tires with wheel stoppers dCAUTION As soon as towing is completed connect the parking brake Towing only when moving the machine to a place where the machine is inspected and or serviced Avoid towing to move the machine over a long distance Release the parking brake manually only when the parking brake switch becomes inoperable due to any abnormality or failure in the b...

Page 270: ... Rotate cap 1 counterclockwise and remove cap 1 2 Rotate lock nut 2 counterclockwise by using tool 3 and remove lock nut 2 Wrench Size 24 mm 3 Rotate set bolt 4 counterclockwise by using hexagon wrench 5 until brake disk 7 becomes completely free Torque to be applied to hexagon wrench 5 is 70 N m Wrench Size 8 mm 4 Install and tighten lock nut 2 until it contacts to piston 6 5 Install cap 1 and li...

Page 271: ...ropes to the machine using eye plates on the front chassis as indicated in the illustration Always use soft material at the corners between the front chassis and wire cables to prevent damage to the wire cables Towing from the rear end of the machine Attach wire ropes to the machine using the towing pin on the rear chassis as indicated in the illustration Always use the lock pin after completely i...

Page 272: ...amage and or injury of personnel Do not lift the machine quickly Excessive load will be applied to the wire cables and or lifting tools and may cause them to break Do not allow anyone to come close to or under the raised machine Lifting 1 Straighten the machine and lower the front attachment as illustrated to the right 2 Move the control lever lock switch in the lock position 3 Rigidly secure the ...

Page 273: ...chine breakdown Failure to use recommended coolant fuel DEF AdBlue lubricants and genuine Hitachi parts will result in loss of Hitachi product warranty Never adjust engine governor Never adjust hydraulic system relief valve Protect electrical parts from water and steam Never spray high pressure water or steam to the transmission oil filler port transmission air breather and vicinity of the axle ai...

Page 274: ...this device Communication Terminal Operation Option It is not necessary to check or operate the communication terminal however if any abnormality is found consult your nearest authorized dealer Before installing any covering attachment such as a head guard consult your nearest authorized dealer Never spray water on the communication terminal and wiring Inquire on the proper way to recycle or dispo...

Page 275: ...s grouping the intervals into three categories as follows Daily Check To be conducted daily before operation every 10 hours Monthly Check To be regularly conducted once per month every 250 hours Annual Check To be regularly conducted once per year every 2000 hours Check and maintenance intervals shown in this manual are those for the machines to be operated under normal conditions In case the mach...

Page 276: ...Cooler and Other Cooling System 12 Work Light 13 Rear Combination Lamp 14 Fuel Tank 15 Engine 16 Rear Axle 17 Third Rear Propeller Shaft 18 Transmission 19 Second Center Propeller Shaft 20 Steering Cylinder 21 Lift Arm Cylinder 22 Front Axle 23 Lift Arm Cylinder Pin 24 Bell Crank Lever Pin 25 Bucket Link Pin 26 Bucket Pin 27 DEF AdBlue Tank 2 3 4 5 7 8 9 6 10 11 12 13 24 27 14 15 16 17 18 19 20 21...

Page 277: ...7 5 MAINTENANCE MEMO ...

Page 278: ...ks The following marks are used in the maintenance guide table Grease Front Joint Pin Cylinder Pin Propeller Shaft Hydraulic Oil Engine Oil Hydraulic Oil Filters Pilot Filter Hydraulic Oil Tank Filter Suction Filter Air Breather Element Engine Oil Filter Gear Oil Final Drive Differential Gear Coolant Long Life Coolant Fuel Transmission Oil Transmission Torque Converter Fuel Filter Fuel Main Filter...

Page 279: ...6 Hydraulic Oil Filter Pilot 7 52 6 Air Breather Element 7 56 17 Grease Steering Cylinder Pin 7 25 7 Hydraulic Oil 7 48 18 Grease Propeller Shaft 7 29 8 Coolant Long Life Coolant 7 79 19 Grease Propeller Shaft Center Support 7 29 9 Fuel Filter Fuel Pre Filter 7 68 to 69 20 Grease Propeller Shaft Universal 7 29 21 Grease Brake Pedal 7 30 10 Fuel Diesel Fuel 7 69 22 DEF AdBlue 7 127 11 Engine Oil 7 ...

Page 280: ...switch 3 OFF 4 Place forward reverse lever 4 and forward reverse switch to neutral and place neutral lever lock 6 to lock position 5 Apply the parking brake Turn parking brake 5 ON 6 Wedge the tires 7 Run the engine at low idle speed for 5 minutes to cool the engine Turn key switch 7 OFF to stop the engine Again turn key switch 7 ON and place control lever lock switch 2 to the unlock position Full...

Page 281: ...g parts is unavoidable pay special attention to ensure that hands feet and clothing do not become entangled If parts or tools are dropped or inserted into the fan or the belt they may fly off or be cut off Do not drop or insert parts and tools into the moving parts Move control lever lock switch 2 to lock position so that the front attachment will not move Never touch the control levers and pedals...

Page 282: ...expected movement of the machine 1 Align the front and rear chassis centers with each other 2 Remove β form pin 5 to remove set pin 1 from the rear chassis hole 3 Pull out and rotate articulation stopper 2 to align it with the front chassis hole 3 4 Install set pin 1 into the front chassis hole 3 and the articulation stopper tip end hole Install β form pin 5 to lock the articulation stopper 2 in p...

Page 283: ...d the cover may move suddenly Be careful not to come in contact with the cover Before inspecting around the engine be sure to secure side cover 1 with holding rod 4 If the machine is equipped with the fenders 2 on side covers 1 never ride on the fenders 2 When opening side cover 1 pull latch 3 fNOTE When required to inspect the machine for a long time with side cover 1 kept open lock side cover 1 ...

Page 284: ...s check that rear grille 2 is not open Rear grille 2 may spring open Take care not to come in contact with the rear grille Opening the rear grille Push open close Button 1 laterally to open rear grille 2 upward allowing the fuel tank to be refilled and or the cooling fan to be cleaned Closing the rear grille While holding the rear grille slowly close the rear grille downward until a click sound is...

Page 285: ...gine to oil filter Heater hose Heater to engine Fuel hose Engine to fuel tank Coolant filter hose Engine to DCA coolant filter Heater hose Engine to dosing module DEF AdBlue hose Aftertreatment device Brakes Brake valve seals Rubber parts Every 1 year Wet type brake D ring for piston Every 4 years Accumulator Every 2 years Stop light switch Every 2 years Brake hose Every 2 years or 4000 hours whic...

Page 286: ...heck Sound Absorbing Mat Around Engine 7 112 Check Crankcase Breather Tube 7 36 Check Air Inlet System 7 75 Replace Engine Oil and Oil Filter Cartridge 7 33 7 35 Clean Radiator Oil cooler Cores and Other Cooling System 3 7 81 Replace Fuel Main Filter Element 7 69 Replace Fuel Pre Filter Element 7 70 Drain Water and Sediment from Fuel Tank 7 67 Clean Fuel Pump Strainer 7 71 Check Drive Belt Tention...

Page 287: ...reasing Second Front Propeller Shaft Every 12000 hours 3 7 28 Greasing Second Center Propeller Shaft Every 12000 hours 3 7 29 Greasing Third Rear Propeller Shaft Every 12000 hours 3 7 30 Steering system Check Steering Wheel Play 7 109 Greasing Steering Cylinder 1 7 26 Check Gas Pressure in Steering Accumulator 7 59 Brake system Check Parking Brake Force 7 91 Check Right and Left Brake Interlocking...

Page 288: ... and Roof Mounting Bolts 7 108 Check and Replace Seat Belt and Lower Tether Replace every 3 years 7 108 Clean Engine Room and Hood 7 112 Check Steps Grab Handles and Handrails 7 111 Check Windshield Washer Fluid Level 7 108 Greasing Center Pin 7 27 Electrical system Check Monitor Functions and Instrument Operation 7 86 Check Horn and Back Up Alarm 7 87 Check Work Lights 7 87 Clean Rear View Camera...

Page 289: ...t 7 105 Check Refrigerant Level 7 106 Check Air Conditioner Condenser 7 105 Check Air Conditioner 7 104 Check Air Conditioner Piping 7 104 Check Compressor and Pulley 7 106 Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours 7 106 Others Check Tightening Torque of Bolts and Nuts 7 114 fNOTE 3 Shorten maintenance intervals when the machine is operated under severe conditions or when ...

Page 290: ...eratures and some auto lube systems Use NLGI No 1 or No 0 grease for extremely low temperature Engine Oil IMPORTANT Use engine oil equivalent to DH 2 specified in JASO or CJ 4 API Failure to do so may reduce the engine performance and or shorten the engine service life Please be noted that all engine failures caused by using engine oil other than specified are excluded from Hitachi Warranty Policy...

Page 291: ...Hitachi High Gear Oil TKTT15150 4th Alternative Product TO 4 SAE50 Fluid with 6 friction modifier fNOTE When using TO 4 SAE50 Fluid other than the listed recommended products add 6 friction modifier or anti chatter additive to prevent or eliminate service brake application noise Recommended additive package for universal tractor fluid HCM 9990A or Afton Hitec8703 or equivalent The acceptable ambie...

Page 292: ...OTE Never mix hydraulic oils containing zinc with zinc free hydraulic oils as hydraulic system component damage could result Use appropriate oil of viscosity depending on the temperature Low temperature viscosity will differ depending on each product Contact each hydraulic oil manufacture directly Recommended Coolant Kind of Coolant Long Life Coolant Application Radiator Standard ASTMD 6210 Manufa...

Page 293: ...nt Engine Oil 25 6 6 Engine Coolant 33 8 7 Transmission 30 7 9 Axle Front Rear 34 34 9 9 Hydraulic Oil 150 39 6 DEF Tank 25 6 6 fNOTE Refill quantity when the level gauge indicates empty The other shows the maximum refill quantity to be required during level check and may differ from the whole system quantity ...

Page 294: ...ement outer YA00018804 Air Cleaner Element inner YA00018805 Suction Filter 263F752091 Hydraulic Tank Oil Filter 4448401 Pilot Oil Filter 2655742471 Transmission Oil Filter YA00049017 Crankcase Air Breather Element YA00018806 DEF AdBlue Supply Module Main Filter YA00058284 Hydraulic Tank Air Breather Element 4437838 2 Drive Belts Part No Air Conditioner Drive Belt 263F672001 ...

Page 295: ...434678 Turn Signal Light Turn Signal Light Assembly 2640242432 Bulb Clearance Light 24V 5W 2640247301 Turn Signal Light 24V 25W 2640247291 Rear Combination Light Rear Combination Light Assembly 44881 60490 Work Light Work Light Assembly 4336570 Bulb 24V 70W 4285648 4 Slow Blow Fuses Part No 45A 4315323 65A 263G244421 70A 4315073 140A YA00021809 ...

Page 296: ...mination around the grease fitting add grease After greasing thoroughly remove the old grease that was pushed out from the seals 1 One point each to right and left bucket pins 1 every 500 hours 250 hours at first time only 2 One point each to bucket link pins 2 and 3 every 500 hours 250 hours at first time only 3 One point to bucket cylinder pin 4 every 500 hours 250 hours at first time only One p...

Page 297: ... every 500 hours 250 hours at first time only 6 One point each to right and left lift arm pivot pins 8 every 500 hours 250 hours at first time only 7 One point each to right and left lift arm cylinder pins 9 every 500 hours 250 hours at first time only MNEC 07 006 9 8 M4GB 07 005 7 ...

Page 298: ...d left steering cylinder pins 10 and 11 every 250 hours 10 Cylinder left front 11 Cylinder right front 9 One point each to right and left steering cylinder rod pins 12 and 13 every 250 hours Left rear 12 Right rear 13 11 10 MNEC 07 007 M4GB 07 008 12 13 ...

Page 299: ...7 27 MAINTENANCE 10 One point each to upper and lower center hinge pins 14 and 15 every 250 hours Upper 14 Lower 15 M4GB 07 010 15 MNEC 07 008 14 ...

Page 300: ...s 16 and 17 every 10 hours Front 16 Rear 17 12 One point to second front propeller shaft universal 18 every 12000 hours fNOTE When the machine is continuously operated under severe conditions for a long time shorten the greasing intervals M4GB 07 013 18 MNEC 07 009 16 17 ...

Page 301: ...enter support pillow unit 19 every 250 hours 14 One point to second center propeller shaft universal front 20 every 12000 hours One point to second center propeller shaft universal rear 22 every 12000 hours M4GB 07 014 20 19 MNEC 07 007 22 MNEC 07 010 ...

Page 302: ...econd center propeller shaft splines 21 every 2000 hours 16 Two points to third rear propeller shaft universal 23 every 12000 hours 17 One point to third rear propeller shaft splines 24 every 2000 hours M4GB 07 014 M4GB 07 017 21 24 23 ...

Page 303: ...7 31 MAINTENANCE 25 18 Two points to brake pedal 25 every 1000 hours 19 One point to brake pedal linkage 26 every 1000 hours 26 M4FC 07 014 M4FC 07 015 ...

Page 304: ...vel gauge 1 If oil level is below the lower limit mark add the recommended engine oil via oil filler 2 If oil level exceeds the upper limit mark remove drain plug 3 and then drain oil Recheck oil level Specified Range fNOTE Level the engine when adding oil or inspecting oil level When required to check oil level after operating the machine first stop the engine Wait for more than 15 minutes Then c...

Page 305: ...oil at the same time 1 Park the machine following the same procedures as described on page 7 8 for preparation of inspection maintenance work 2 Clean the areas around the drain plug and the oil filter 3 Arrange a 40 liter 11 gallons capacity container to receive the drain oil 4 Remove drain plug 3 provided on the fuel tank side to allow oil to drain 5 Drain oil from the oil filter cartridge 6 Allo...

Page 306: ...ck for looseness of other oil filler caps 4 12 Check that the oil level is between the maximum and minimum level scales on oil level gauge 1 Then start the engine 13 After starting the engine check the sealing surfaces for any oil leakage 14 Keep the engine running at low idle speed for 5 minutes and stop the engine About 15 minutes later recheck the oil level If necessary add oil 4 4 1 2 MNEK 07 ...

Page 307: ...ter such as dirt to enter the oil filter Be careful not to damage the filter body when removing or installing the filter Never reuse a cartridge type element 4 Remove cartridge type element 1 by turning it counterclockwise with a filter wrench 5 Pour new oil into new element 1 being careful not to let it overflow 6 After coating a new cartridge gasket with engine oil turn the cartridge clockwise u...

Page 308: ...described on page 7 8 for preparation of inspection maintenance work 2 Check tube 1 for sludge debris or ice in the tube 3 If sludge debris or ice is found clean the tube with detergent and warm water or a solvent Dry the tube with compressed air 4 Visually check the tube for cracks or damage If damage is found replace the crankcase breather tube 5 Check for any oil leakage or loose clamps at the ...

Page 309: ... of inspection maintenance work 2 Remove oil filler cap 1 3 Remove bolts 2 from crankcase air breather cover 3 fNOTE Make a note of bolt 2 position for reference at assembling work 4 Remove crankcase air breather cover 3 5 Remove air breather element 4 from rocker lever cover 5 Do not remove gasket from the rocker lever cover IMPORTANT If gasket 6 sticks out from the rocker lever cover 5 groove in...

Page 310: ...essary 10 If gasket 6 is removed install new gasket on the groove of rocker lever cover 5 fNOTE Install gasket 6 in the order from A to E shown in the right illustration Softly push gasket 6 when installing it Gasket 6 will not fit inside the groove if it is pushed hard with the fingers 11 Apply engine oil on the O ring on air breather element 4 Install air breather element 4 on rocker lever cover...

Page 311: ... following the same procedure as described on page 7 8 for preparation of inspection maintenance work 2 Check damper on the fan end of the engine crankshaft 3 If any cracks dent or deformation is found consult your authorized dealer for check and repair MNEC 07 116 MNEC 07 117 ...

Page 312: ...ult Before starting the engine check the transmission oil level with oil level gauge 2 When the oil level is correct the float in the oil level gauge shall be in the center with the oil cooled Refill the oil as necessary from transmission oil filler port 1 When checking oil level before operating the machine normally the float in gauge 2 must be higher than the COLD MIN position If the float is lo...

Page 313: ...xpected machine movement Avoid accidents due to unexpected movement of the machine IMPORTANT Do not use transmission oils other than those listed in the Transmission Oil fNOTE Be sure to replace the transmission oil filter when changing the transmission oil at the same time 1 Operate the machine until the transmission oil is heated to the appropriate temperature 50 C to 60 C 122 F to 140 F 2 Park ...

Page 314: ... to the turbocharger 4 Turn the key switch OFF to stop the engine Leave the machine untouched for 10 minutes 5 Prepare a container of more than 50 liters 13 gallons capacity to receive the drain oil fNOTE Drain plug 5 is magnetized If excessive amount of metal pieces are found adhered to drain plug 5 contact your authorized dealer 6 Remove drain plug 5 from the transmission bottom to drain the oil...

Page 315: ...filter wrench Take care not to excessively tighten the cartridge filter Be careful not to damage filter cartridge by overtightening 11 Refill the specified amount of oil through transmission oil filler port 7 Oil amount 30 liters 7 9 gallons 12 Start the engine and keep it running for two minutes 13 Check that the oil level is within the specified range in oil level gauge 8 If necessary add oil fN...

Page 316: ...ing the same procedures as described on page 7 8 for preparation of inspection maintenance work 2 Install articulation lock bar 1 to the front and rear of the frame by following the procedures described on page 7 10 3 Clean the vicinity of oil level plug 2 4 Remove oil level plug 2 Clean the tip of dipstick 3 connected to oil level plug 2 with a clean cloth 5 Make the plug lower surface contact to...

Page 317: ...0 liters capacity to receive the drain oil 5 Remove drain plug 1 to drain the oil 6 Securely tighten drain plug 1 7 Refill the specified amount of oil through oil level plug 2 hole Oil amount Front Axle Rear Axle 34 liters 9 0 gallons 34 liters 9 0 gallons IMPORTANT It takes time for oil to fully lubricate the overall front axle After installing the plug allow the machine to drive for several minu...

Page 318: ...ther Open the machine front cover Front axle air breather 1 is located at the right side Open the machine side cover Rear axle air breather 2 is located at the left side 2 Put a cover on the air breather port to prevent foreign matter from entering dCAUTION Be sure to wear safety glasses when cleaning the air breather with compressed air 3 Clean the air breather using compressed air If completely ...

Page 319: ...aulic components only after components hydraulic oil and lubricants are completely cooled and after releasing residual pressure 2 1 Release internal pressure 2 2 Be sure to relieve the air pressure from the hydraulic oil tank by pressing air bleed valve 1 2 3 Allow the machine to cool down Note that servicing heated and pressurized hydraulic components may cause hot parts and or oil to fly off or ...

Page 320: ...when connecting them The life of twisted hoses will be shortened considerably Carefully tighten low pressure hose clamps Do not overtighten them When adding hydraulic oil always use the same brand of oil do not mix brands of oil As the machine is filled with Hitachi Super EX 46HN or Genuine Hydraulic Oil 5000 when it is shipped from the factory use it as a general rule When selecting to use anothe...

Page 321: ...oil level is higher than the level gauge drain oil down to the appropriate level using a pump 1 Park the machine following the same procedures as described on page 7 8 for preparation of inspection maintenance work 2 Check oil level with level gauge 1 on hydraulic oil tank Oil must be between marks on the gauge If necessary add oil fNOTE During cold weather season check the oil level after warming...

Page 322: ...pressure from the hydraulic oil tank 3 by pressing air bleed valve 2 IMPORTANT When changing hydraulic oil take care not to permit foreign matter such as dirt water and or sand to enter into the hydraulic oil tank 4 Carefully pressure wash the area around the breather filter cover and around the hydraulic tank Dry the area before removing any other covers 5 Arrange a container of approx 150 liters...

Page 323: ...and or sand to enter into the hydraulic oil tank 11 After changing hydraulic oil or replacing the return filter pilot filter and or suction filter bleed air from the hydraulic system following the procedures below Bleed Air from the Hydraulic System 11 1 After supplying oil start the engine 11 2 Move the bucket and lift arm cylinders several times to bleed air mixed in the hydraulic circuit Do not...

Page 324: ...all particles in the strainer is normal Large metal rubber pieces or a large amount of fine particles is abnormal If found contact your authorized dealer 2 Clean the suction filter and the hydraulic oil tank inside with cleaning oil 3 Supply the specified volume of oil through the oil supply port while checking the oil level with the oil gauge 4 Securely insert the suction filter into pipe 3 when ...

Page 325: ...edures described on page 7 10 3 Before replacing the filter element be sure to relieve the air pressure from the hydraulic oil tank by pressing air bleed valve 1 4 Remove the inspection cover for left side rear frame 5 Rotate the hexagonal section on the bottom of case 2 counterclockwise using a spanner to remove case 2 from head 3 6 While turning element 5 remove the element downward 7 Replace O ...

Page 326: ... air from the hydraulic pump and check the oil level in the hydraulic oil tank Refer to the descriptions for Bleed air from the hydraulic system in item If the machine is operated without bleeding the air mixed in the hydraulic circuit damage to the hydraulic pump may result fNOTE Replace the element at the regular intervals to maintain clean hydraulic oil and extend the service life of the hydrau...

Page 327: ...lowing the procedures described on page 7 10 3 Clean the vicinity around cover plate 1 4 Arrange a container and workshop towels to receive the spilled oil and the element Relieve the air pressure from the hydraulic oil tank by pressing air bleed valve 2 5 Loosen bolts 3 6 used to remove cover 1 and O ring 4 When removing cover 1 slowly remove the cover while pressing the cover downward so that sp...

Page 328: ...fer to the descriptions for Bleed air from the hydraulic system in item If the machine is operated without bleeding the air mixed in the hydraulic circuit damage to the hydraulic pump may result fNOTE Replace the element at the regular intervals to maintain clean hydraulic oil and extend the service life of the hydraulic components ...

Page 329: ... oil tank by pressing air bleed valve 1 3 Rotate cover 3 clockwise approx 1 4 turn Remove cap 2 by rotating it counterclockwise 4 Rotate cover 3 counterclockwise and remove it Remove element 4 5 Install new element 4 Tighten cover 3 clockwise After cover 3 come in contact with the inside element tighten the cover by 1 4 turn further 6 Manually tighten cap 2 clockwise to the end Hold cap 2 in posit...

Page 330: ...s 1 Park the machine following the same procedures as described on page 7 8 for preparation of inspection maintenance work 2 Raise the lift arm at the maximum height and then set the lift arm control lever in the Neutral N position 3 Turn the key switch OFF to stop the engine 4 Turn the key switch ON but do NOT start the engine 5 Confirm the safety around the machine 6 Place the lift arm control l...

Page 331: ...itch turned AUTO and OFF to compare the machine s vertical vibration during travel Travel the machine at a speed faster than Ride Control Drive Speed Setting displayed on the multi monitor If the machine s vertical vibration is not dampened when letting the machine travel with the ride control function activated the accumulator may be faulty Consult your authorized dealer for check and repair Chec...

Page 332: ...d this hazard Park the machine on a solid level surface Lower the bucket to the ground Stop the engine Remove key from the key switch Push the control lever lock switch to the lock position Check for missing or loose clamps kinked hoses lines or hoses that rub against each other damaged oil cooler and loose oil cooler flange bolts for leaks Check hoses lines and oil cooler at the check points indi...

Page 333: ...covers Exposed reinforcement 6 Replace Hose covers Blister 7 Replace Hose Bend 8 Replace Use proper bend radius Hose Collapse 9 Replace Use proper bend radius Hose ends and fittings Deformation or Corrosion 10 Replace fNOTE Refer to the illustrations in Fig 1 for each check point location or for a description of the abnormality Use genuine Hitachi parts M137 07 008 M115 07 145 M115 07 146 M115 07 ...

Page 334: ... 11 Replace Bolts Loose or leak 11 Retighten or replace O ring Welded surfaces on flange joints Leak 12 Replace Every 250 hours Flange joint neck Crack 13 Replace Welded surfaces on flange joints Crack 12 Replace Clamps Missing or deformation Loose bolts Replace or retighten M4GB 07 059 M4GB 07 060 12 13 12 Fig 2 13 11 ...

Page 335: ...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 replace O ring 1 and check for correct O ring...

Page 336: ...10 1 Tighten fitting 7 by hand 2 Tighten fitting 7 or nut 8 to the torque values shown Do not allow hose 5 to twist when tightening fittings Tightening torque Tighten fittings to the torque values shown below Width across flats mm 17 19 22 27 36 Tightening torque N m lbf ft 25 18 30 22 40 30 80 59 180 133 7 9 8 10 5 M202 07 051 ...

Page 337: ...ftertreatment device which may result in malfunction About Biodiesel Fuel Biodiesel fuel is made by refining various vegetable oils or animal fats IMPORTANT When blended with Ultra Low Sulfur Diesel ULSD fuel it may be used only if It is used in blends of B5 5 biodiesel 95 ULSD It is supplied by a BQ9000 Certified Marketer check www bq9000 org It meets the ASTM D6751 standard for B100 biodiesel be...

Page 338: ... before fueling Do not smoke while you fill the fuel tank or work on fuel system 2 Check fuel gauge 1 of the monitor panel Add fuel if necessary IMPORTANT Keep all dirt dust water and other foreign materials out of the fuel system 3 To avoid condensation fill the tank at the end of each day s operation Take care not to spill fuel on the machine or ground Fuel tank capacity 245 liters 64 gallons 4 ...

Page 339: ... every 1000 hours Before starting to operate the machine remove plug 2 from the tip of drain valve 1 on the fuel tank bottom and open drain valve 1 to drain water and or sediment from the fuel tank fNOTE Drain valve 1 has vandal proof plug 2 2 1 MNEK 07 002 ...

Page 340: ... Air in the fuel system may make the engine hard to start or make it run rough or not run at all After running the fuel tank dry draining water from fuel filter or fuel pre filter 1 or replacing the fuel filter be sure to bleed the air from the fuel system If fuel contains high water content check the fuel filter earlier than the normal interval and drain water if necessary 1 Loosen air bleed plug...

Page 341: ...r shorten the engine service life Make sure that debris water steam or cleaning solution does not get inside the fuel system 1 Remove cartridge filter 2 from fuel filter 1 by using a filter wrench Arrange a container to receive fuel for safety and to prevent ground from contamination 2 Apply a thin film of clean fuel to the gasket of new cartridge filter 2 3 Turn cartridge filter 2 clockwise by ha...

Page 342: ...r shorten the engine service life Make sure that debris water steam or cleaning solution does not get inside the fuel system 1 Remove cartridge filter 1 by using a filter wrench Arrange a container to receive fuel for safety and to prevent ground from contamination 2 Apply a thin film of clean fuel to the gasket of new cartridge filter element 2 3 Turn cartridge filter element 2 clockwise by hand ...

Page 343: ...iner every 1000 hours Cleaning When the strainer is disassembled be sure to replace the gasket Install the cover and the magnet only after sufficiently cleaning them After being assembled closely check the air tightness of the strainer MNEK 07 002 ...

Page 344: ... replace the strainer as well as gaskets 2 and 4 while servicing the fuel pump Never attempt to disassemble other parts Gasket 4 can get caught in the bore of pump 5 making it difficult to remove the gasket but do not disassemble the cylinder of pump 5 If the gasket is difficult to remove do not disassemble other parts but stretch gasket 4 to remove it Use a new gasket 4 for assembling 2 1 3 4 5 M...

Page 345: ...oses According to the check points shown below check hoses for oil leaks and damage If any abnormality is found replace or retighten as instructed in the table Hose Interval hours Check Points Abnormalities Remedies Every 10 hours daily Hose ends Leak 1 Retighten or replace Hose covers Wear crack 2 Every 250 hours Hose covers Crack 3 Replace Hose ends Crack 4 Replace Hose Bend 5 Collapse 6 Replace...

Page 346: ...oreign matter such as dirt to enter the engine when cleaning or replacing elements 2 Remove clip band 3 and remove cover 2 3 Hold the outer element release knob 6 Pull out outer element 4 from the air cleaner to remove it 4 Clean inside the air cleaner 1 with a wet cloth 5 Hold inner element 5 release knob 7 Pull out inner element 5 from air cleaner 1 to remove it 6 Install inner element 5 and out...

Page 347: ...09 MNEK 07 010 Check Air Inlet System every 10 hours daily Check pipes and hoses of the air inlet system for wear damage or loose connections and clamps Replace damaged pipes and hoses Retighten loose clamps Tightening torque 8 N m 6 lbf ft ...

Page 348: ...Mixing ratio Coolant Capacity 33 liter 8 7 gallons LLC liter gallon Soft Water liter gallon 50 16 5 4 35 16 5 4 35 dWARNING Antifreeze is poisonous if ingested it can cause serious injury or death Induce vomiting and get emergency medical attention immediately When storing antifreeze be sure to keep it in a clearly marked container with a tight lid Always keep ANTIFREEZE out of the reach of childr...

Page 349: ...xpansion tank 1 If the coolant level is below the FULL 3 mark remove cap 2 from expansion tank 1 and refill coolant If expansion tank 1 is empty add coolant to the radiator and then to expansion tank 1 When refilling a long life coolant LLC use the same brand product and the same mixture ratio as already used in the machine If only water is refilled the mixture ratio in the long life coolant LLC i...

Page 350: ...MAINTENANCE 7 78 Check Drive Belt every 10 hours daily Check the drive belt for any abnormality If any cracks are found replace the belt with a new one OM0099 ...

Page 351: ...rm stops are still in contact with the spring case stop the belt tensioner must be replaced 5 Check tensioner 2 for cracks on arm pulley and stops If any cracks are observed the drive belt tensioner must be replaced fNOTE Consult your nearest authorized dealer for the drive belt tensioner replacement 6 Check belt tensioner pulley 3 for any dirt or damage If ir is dirty or damaged contact your near...

Page 352: ...ion lock bar to the front and rear of the frame by following the procedures described on page 7 10 3 Remove expansion tank cap 1 Open radiator drain cock 2 and drain the coolant 4 Close radiator drain cock 2 Supply low impurity soft water or tap water together with the specified LLC up to the radiator filler port When adding coolant do so slowly to avoid mixing in the system Start the engine and s...

Page 353: ...zzle away from the core surface more than 500 mm 20 in Over the Side Cover Check and clean air conditioner condenser 2 and torque converter oil cooler 3 Over the Rear Grille Check and clean radiator 4 hydraulic oil cooler 5 and intercooler 6 and hydraulic driven fan 7 by releasing lock 8 and opening the hydraulic driven fan If dirt or dust is accumulated on them cooling system performance decrease...

Page 354: ...of such components is required contact your authorized dealer Batteries dWARNING Battery gas can explode Keep sparks and flames away from batteries Do not keep tools metals or flammable materials around the battery or inside the battery room If a metal tool is placed across the battery terminal and a vehicle component such as the engine block sparks may be created possibly resulting in fire and or...

Page 355: ...y IMPORTANT Add water to batteries when cool weather before you begin operating your machine for the day or else charge the batteries IMPORTANT If the battery is used with the electrolyte solution level lower than the specified level the battery performance may deteriorate quickly IMPORTANT Do not refill electrolyte solution more than the specified upper level Electrolyte solution may spill damagi...

Page 356: ... L and L L immediately refill with distilled water or commercial battery fluid Be sure to refill with distilled water before recharging operating the machine After refilling securely tighten the filler caps 3 2 When impossible to check the level from the battery side or no level check mark is indicated on the side After removing the filler plug from the top of the battery Check the electrolyte lev...

Page 357: ...res If you spill acid on yourself call 911 then 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 If splashed in eyes flush with water for 10 to 15 minutes Get medical attention immediately If acid is swallowed call 911 then 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately IMPO...

Page 358: ... maintenance free battery Different types of batteries may have different rates of charge This difference could overload one of the batteries and cause it to fail Check Monitor Functions and All Other Instrument Operation every 10 hours daily Run the engine at low idle when checking the instruments The monitor indicates alarm caution and confirmation status in red orange and normal operative condi...

Page 359: ...the parking brake and clear the machine s vicinity of other personnel Horn 1 is located on the front chassis The horn switch button is located at the steering wheel center and on the right console If the machine is equipped with a multi function joystick lever the horn switch is located on the multi function joystick lever Backup alarm 2 is located at the left side of the rear grille Check that ba...

Page 360: ... if necessary If any burned mark or an abnormal smell is noticed at a harness consult your nearest authorized dealer Replace Fuse 1 If any electrical equipment becomes inoperable first check the fuses in the fuse boxes A B located in the left console in the operator s station 2 One spare fuse for each respective fuse capacity is provided in the fuse boxes A B 3 Finally check slow blow fuses 1 2 lo...

Page 361: ...CKET 10 A 13 SEAT HEATER 20 A 2 HEAD LAMP RH 5 A 12 OPTION 2 ACC1 20 A 1 FUEL PUMP 5 A 11 RADIO USA 10 A Fuse Box B 10 ECM 30 A 20 SECONDARY STEERING 5 A 9 TCU 10 A 19 HIGH BEAM 10 A 8 CONTROLLER 10 A 18 WIPER REAR 10 A 7 FLASHER 10 A 17 WORKING LAMP REAR 20 A 6 HORN 10 A 16 LOADER CONTROL 5 A 5 OPT C U 5 A 15 MC 10 A 4 OPTION 1 BT 15 A 14 TCU POWER 10 A 3 CAB DOME LAMP 5 A 13 POWER ON 10 A 2 LIGH...

Page 362: ...ates in vicinity 3 of the brake pedal remove the accumulated dust and or soil Check Brake Performance The machine must be stopped within 5 m 16 4 ft range after the brake is applied while driving at the speed of 20 km h 12 4 mph on a flat dry paved surface road Check Play in Brake Pedal Stroke Measure the pedal stroke at pedal tip 2 by pressing the pedal with your hand until you feel an intermitte...

Page 363: ...mally test the parking brake 1 Move the machine to a safe open place on a 20 11 3 degrees inclining dry surface slope 2 Stop the machine with the service brake 3 Turn ON parking brake switch 1 4 Release the service brakes 5 The machine should not move IMPORTANT If machine moves when parking brake switch is ON there is some problem with parking brake Consult your nearest authorized dealer Do not op...

Page 364: ...r indicators come ON 2 Note that alarm function is deactivated Start the engine Run the engine at middle speed to pressurize the accumulator Check that when the pressure builds in the accumulator the alarm buzzer stops sounding and the brake oil pressure indicator goes OFF 3 Note how many times the brake pedal is stepped Check that the brake pedal can be stepped more than 5 strokes before the brak...

Page 365: ...on and or loading operation may not be achieved possibly creating very hazardous situations Ask your nearest authorized dealer for checking Check Brake Disks Service and Parking every 2000 hours Service brake 1 is a closed wet type brake Parking brake 2 is a dry type disk brake Parking brake 2 is mounted on the transmission side Consult your nearest authorized dealer for checking M4GB 06 004 M4GB ...

Page 366: ...s maintain the correct tire pressure Even if only one tread pattern has worn out replace the tire with new one Tires must be evenly sized Before operating the machine check the tires for damage When replacing one tire use a new tire having the same tread pattern and specification as the other tires Tires must be evenly sized Check Air Pressure 1 Measure air pressure when the tires are cool before ...

Page 367: ...es 1 Park the machine following the same procedures as described on page 7 8 for preparation of inspection maintenance work 2 Install articulation lock bar to the front and rear of the frame by following the procedures described on page 7 10 3 Loosen all wheel bolts one turn Note which way the tread pattern is facing 4 After jacking up the machine securely support the machine with blocks 5 Remove ...

Page 368: ...dealer or tire manufacturer for more detailed information Driving on Public Roads Standard Pressure Loading excavation on normal ground surface Standard or slightly higher than standard pressure Heavy duty excavation Higher pressure in the standard pressure range Operation on soft or sandy terrain Slightly lower than standard pressure fNOTE Apply the same air pressure to snow tires For radial tire...

Page 369: ...een the machine parts and top of tire A may become narrower interference can occur between the tire and the machine parts When size and tread pattern of tires are changed install the correct oscillation stopper 1 by referring the list below Tire Size Tread Pattern Oscillation Stopper 20 5 25 12 16PR L 3 L 4 20 5 R 25 L 5 Use Not use fNOTE The oscillation stopper is available at your nearest author...

Page 370: ...n tread design pattern optional will affect not only economy of tire but also safety of operation How to Check Wear Amount Tread Design Groove Depth Measure the groove depth at 1 4 tread width position shown with mark 1 in the figure Use limit of the groove depth shall be approx 85 of the new tire groove depth If extreme uneven wear or exposed rubbing strips are found replace the tire even before ...

Page 371: ...ry When one axle is raised off the ground block the tires at the axle that is still in contact with the ground After the machine is raised off ground be sure to block the machine using rigid supports If wooden blocks are used for cribbing support use only hard wood blocks Never use soft wood for support Never leave the machine to be supported only by jacks The rear wheels oscillate Insert wooden b...

Page 372: ...th the starter key Loosen wing nuts 3 and remove plate 2 Remove fresh air filter 4 dCAUTION When using compressed air pressure wear safety glasses or goggles IMPORTANT If compressed air delivery pressure is high damage to the filter fins may result Always use compressed air at the lower pressure than 0 2 MPa 30 PSI Keep the nozzle more than 500 mm 20 in away from the core surface 2 Clean fresh air...

Page 373: ...er causing malfunction or breakdown of the air conditioner Before installing the filter element clean off dust around the mounting area install the filter element with extra care 3 Install the cleaned fresh air filter or a new filter by following the filter removal procedure described in step 1 in the reverse order ...

Page 374: ...re is high damage to the filter fins may result Always use compressed air at the lower pressure than 0 2 MPa 30 PSI Keep the nozzle more than 500 mm 20 in away from the core surface 2 Clean double filter 7 Clean double filter 7 using compressed air or by washing with water Washing procedure with water is as follows 2 1 Use tap water 2 2 Submerge the filter in water containing a neutral detergent f...

Page 375: ... filter 8 using compressed air or by washing with water Washing procedure with water is as follows 2 1 Use tap water 2 2 Submerge the filter in water containing a neutral detergent for about 5 minutes 2 3 Clean the filter with water again 2 4 Sufficiently dry the filter IMPORTANT Inappropriate installation of the filter may cause dust to enter into the air conditioner causing malfunction or breakd...

Page 376: ...e the air conditioner in the cooling mode once a week to prevent lack of lubrication dWARNING Do not clean the compressor and receiver tank with steam The refrigerant gas pressure will increase possibly causing the hoses to break Check Air Conditioner Piping every 6 months dCAUTION If any leakage is found repair or replace the corresponding pipes Tighten the joint bolts to specification Do not ove...

Page 377: ... fins Check Air Conditioner Drive Belt every 6 months Check the belt for abnormal deflection and damage Check drive belt tension by depressing the midpoint shown with mark in the illustration with the thumb Deflection must be as follows with a depression force of approximately 98 N 22 lbf Deflection approx 6 mm 0 24 in Belt Tension Adjustment Procedure 1 Loosen lock nut 2 of tension pulley 4 2 Mov...

Page 378: ...Receiver Dryer every 6000 hours or three years IMPORTANT Do not release refrigerant into the atmosphere as this is illegal Comply with refrigerant regulations Before charging refrigerant all the refrigerant must be recovered from the system Consult your nearest authorized dealer to replace receiver dryer 1 or to charge the refrigerant Check Compressor and Pulley once a year Check the compressor an...

Page 379: ... much use it again with the face reversed If both sides are worn out replace it with a new one 4 Tighten nuts 2 Tightening torque Cutting edge 1068 N m 788 lbf ft 5 Retighten mounting nuts 2 after a few hours of operation Bucket Teeth 1 Lift the bucket so its bottom is level Lift the bucket to an appropriate height and wedge a block under it so the bucket will not come down Stop the engine 2 Inser...

Page 380: ... large play or damage Replace it if necessary Check ROPS Cab Resin Cab Roof and Roof Mounting Bolts every 10 hours daily Check the appearance of ROPS cab 3 and resin cab roof 4 for any abnormal damage or deformation Check Windshield Washer Fluid Level every 10 hours daily IMPORTANT Keep all dirt dust and other foreign materials out of the tank Use anti freeze type washer fluid in cold weather Chec...

Page 381: ...per when the steering wheel is fully turned and that the steering cylinders operate normally 1 Start the engine Turn the parking brake switch ON 2 Slightly lift the bucket above the ground Place the control lever lock in the lock position 3 While running the engine at slow speed slightly rotate the steering wheel clockwise and counterclockwise Measure the beginning movement distance along the stee...

Page 382: ...Ventilate the shop with fresh air when carrying out warm up operation indoors Failure to do so may cause intoxication by exhaust gas possibly resulting in personal death accident IMPORTANT This machine is equipped with an engine that meets Tier 4 emission requirements Never attempt to modify the inlet and exhaust system Exhaust gas color is normally transparent or light blue Although exhaust gas c...

Page 383: ...eeded Check Steps and Handrails for Damage and Looseness every 10 hours daily Check steps 3 and handrails 4 for damage looseness and contamination If oil grease or mud are on the steps and or handrails 4 remove it If the steps 3 and or handrails 4 become damaged or loosened immediately replace Do not repair handrails or steps Repairs can fail unexpectedly Be sure to replace damaged steps or handra...

Page 384: ...daily dCAUTION If the sound absorbing mat in the engine compartment becomes unglued the mat may come in contact with high temperature sections of the engine possibly resulting in fires Check if the sound absorbing mat around the engine is unglued If any part of the mat is found unglued immediately contact your nearest Hitachi dealer for repair Cleaning of Rear View Camera Lens every 10 hours Oil d...

Page 385: ...Front Axle and Rear Axle Support Mounting Bolts every 2000 hours 50 hours at first time only Check front and rear axle support mounting bolts for looseness Tightening torques of the front axle and rear axle support mounting bolts Front Axle Mounting Bolt Rear Axle Support Mounting Bolt 785 150 N m 579 111 lbf ft 890 170 N m 656 125 lbf ft ...

Page 386: ...5 Propeller shaft support bearing mounting bolt 20 2 30 206 152 6 Transmission mounting bolt Bracket 20 4 30 401 296 7 Transmission mounting bolt Cushion rubber 18 2 27 315 232 8 Engine mounting bolt Bracket 12 10 19 110 82 9 Engine mounting bolt Cushion rubber 18 2 27 315 232 10 Aftertreatment device mounting nut Double 10 16 17 20 14 8 11 Counterweight mounting bolt 30 4 46 1510 1114 12 Top cent...

Page 387: ...79 550 406 400 295 170 125 30 400 295 17 22 0 87 750 553 550 406 220 162 32 24 0 94 950 700 700 516 280 207 36 27 1 06 1400 1033 1050 774 400 295 41 30 1 18 1950 1438 1450 1069 550 406 46 33 1 30 2600 1918 1950 1438 750 553 50 36 1 42 3200 2360 2450 1807 950 700 55 dCAUTION If counterweight mounting bolts are loosened consult your nearest authorized dealer IMPORTANT Apply lubricant to bolts and nu...

Page 388: ...16 1 Front axle mounting bolt Bolt dia mm 24 Quantity 8 2 Rear axle support mounting bolt Bolt dia mm 24 Quantity 8 3 Wheel rim mounting bolt Bolt dia mm 24 Quantity 60 M4GB 07 124 M4GB 07 125 M4GB 07 127 MNEC 07 052 ...

Page 389: ...ty 12 Transmission side Bolt dia inch 1 2 20 UNF 2A Quantity 8 fNOTE Apply LOCTITE 263 5 Propeller shaft support bearing mounting bolt Bolt dia mm 20 Quantity 2 6 Transmission mounting bolt Bracket Bolt dia mm 20 Quantity 4 fNOTE Apply LOCTITE 263 M4GB 07 017 MNEC 07 053 MNDB 07 010 ...

Page 390: ...on mounting bolt Cushion rubber Bolt dia mm 18 Quantity 2 8 Engine mounting bolt Bracket Bolt dia mm 12 Quantity 10 fNOTE Apply LOCTITE 263 9 Engine mounting bolt Cushion rubber Bolt dia mm 18 Quantity 2 MNEC 07 093 9 MNEC 07 054 8 ...

Page 391: ...e mounting nut Double Bolt dia mm 10 Nut Quantity 16 11 Counterweight mounting bolt Bolt dia mm 30 Quantity 4 12 Top center pin upper flange lock Bolt dia mm 16 Quantity 7 fNOTE Apply LOCTITE 263 MNEK 07 023 MNEK 07 024 MNEK 07 040 MNEK 07 047 ...

Page 392: ...120 13 Bottom center pin lock Bolt dia mm 16 Quantity 1 14 Loader front pin lock Bolt dia mm 16 12 Quantity 9 4 15 Steering cylinder pin lock Bolt dia mm 12 Quantity 4 MNEC 07 006 M4GB 07 137 MNEK 07 043 MNEK 07 043 ...

Page 393: ...MAINTENANCE 7 121 16 Radiator frame mounting bolt Bolt dia mm 16 Quantity 6 fNOTE Apply LOCTITE 263 17 Radiator mounting bolt Bolt dia mm 8 Quantity 2 MNEK 07 025 MNEK 07 026 ...

Page 394: ...ia mm 8 Quantity 1 19 Oil cooler mounting bolt Bolt dia mm 10 Quantity 2 20 Torque converter cooler mounting bolt Bolt dia mm 10 Quantity 4 21 Air conditioner condenser mounting bolt Bolt dia mm 8 Quantity 4 MNEK 07 027 MNEK 07 027 MNEK 07 029 MNEK 07 028 ...

Page 395: ...MAINTENANCE 7 123 22 Air conditioner compressor mounting bolt Bolt dia mm 8 Quantity 4 23 Cab cushion rubber mounting bolt Bolt dia mm 16 Quantity 4 fNOTE Apply LOCTITE 263 MNEC 07 066 MPD8 07 001 ...

Page 396: ...MAINTENANCE 7 124 24 Cutting edge mounting bolt Bolt dia inch 1 Quantity 12 25 Wear plate mounting bolt Bolt dia inch 1 Quantity 4 M4GB 07 116 M4GB 07 150 ...

Page 397: ... is not a malfunction Do not disassemble the base machine support parts and sensors When the machine is operated in dusty areas refer to the page 9 1 Maintenance Under Special Environmental Conditions 1 Open the right and left side cover 2 Check exhaust pipe 1 for cracks Check the aftertreatment device units for loose or disconnection 3 Check the connectors and harnesses of NOx sensors 2 temperatu...

Page 398: ...AdBlue at temperature between 10 and 40 C 14 and 104 F In some cases specified urea solution is referred to by one or more of these names Aqueous Urea Solution 32 AUS 32 NOx Reduction Agent Catalyst Solution fNOTE AdBlue is produced from suppliers which are licensed by the VDA Verband der Automobilindustrie e V Diesel Exhaust Fluid DEF is certified by the API American Petroleum Institute Diesel Ex...

Page 399: ...n fire occurs Wash out spilled DEF AdBlue with clean water Seal the container and store it in a well ventilated place If DEF AdBlue freezes the quality does not change just after freezing As long as sealed by an airtight stopper unless water evaporates DEF AdBlue will not deteriorate within the guarantee period Do not pour waste DEF AdBlue and its containers onto the ground and do not allow waste ...

Page 400: ...te to the job Wash DEF AdBlue with clean water when it contacts on the skin If DEF AdBlue is accidentally splashed into eyes flush with water for 15 minutes or longer and get emergency medical attention 1 Park the machine according to the instruction on Preparations for Inspection and Maintenance 7 8 2 DEF AdBlue tank 2 is located in the cover at left rear of the machine Open the DEF AdBlue tank c...

Page 401: ...er fNOTE Wipe spilled DEF AdBlue and wash spilled area with plenty of water The sound of flowing water may be heard from the tank after the engine stops It is the sound of returning DEF AdBlue from piping to the tank not a malfunction DEF AdBlue will freeze at low temperature and deteriorate ammonification at high temperature It is recommended storing DEF AdBlue at temperature between 10 and 40 C ...

Page 402: ...d DEF AdBlue is used malfunction may result Change DEF AdBlue periodically to keep cleanliness in the tank 1 Remove bolts 1 and washers and remove cover 2 2 Place a 50 liter 13 gallons or larger capacity container under drain plug 3 3 Slowly loosen drain plug 3 to drain DEF AdBlue 4 Tighten drain plug 3 after draining DEF AdBlue Wrench size 6 mm Tightening torque 5 to 7 N m 3 7 to 5 lbf ft 5 Fix c...

Page 403: ...sition may be observed when DEF AdBlue is dried naturally it is normal Wash out DEF AdBlue deposition with clean water Never use a high pressure washer 1 Park the machine according to the instruction on Preparations for Inspection and Maintenance 7 8 2 Open the side cover 3 Remove cap 1 from the DEF AdBlue supply module by using a 27 mm bihexagon wrench 4 Pull out filter 2 inside the supply module...

Page 404: ...MAINTENANCE 7 132 MEMO ...

Page 405: ...uitable for low temperature Check the fuel tank breather pipe freezing Lubricant Use high quality low viscosity hydraulic oil and engine oil Engine Coolant Be sure to use antifreeze Battery Fully charge the batteries regularly at shorter service intervals If not charged fully electrolyte may freeze Tires and Chassis Keep fires and chassis clean Park the machine on a hard surface to prevent the tir...

Page 406: ...is supplied 3 Change the engine oil to cold weather type oil 4 Use fuel 1 diesel fuel To prevent condensation on the inside wall in the fuel tank fully refill the fuel tank with 1 diesel fuel after each shift 5 If the electrolyte solution in the battery case freezes damage to the battery case may result Keep the batteries fully charged After completing work turn all lights OFF When finished with w...

Page 407: ...zen Use tire chains on all four wheels 9 Take anti freeze measures after completing operation Spray keyholes with light oil Cover the keyhole by sticking a tape on Rubber parts such as wiper blades may freeze Keep other parts away from the rubber parts Warm up cab prior to use of wipers Remove packed snow from around the axles articulation joint and inside the machine with a bar or brush Be carefu...

Page 408: ...9 4 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ...

Page 409: ... inhibitor Thoroughly wash the radiator by water and then dry it DEF AdBlue Make sure to store DEF AdBlue at 30 C 86 F or lower When stored for a month or more at around 40 C 104 F DEF AdBlue may decompose If it smells like ammonia when opening the storage container do not use it DEF AdBlue starts freezing at 10 C 12 F Freezing does not affect its performance once thawed Never use a container used...

Page 410: ...aulic equipment transmission axle etc due to insufficient lubrication or coolant If lubrication running is not performed for more than three months start the engine by following the procedure below 1 Crank the engine operate starter motor without running the engine for three seconds and stop 10 seconds Repeat this process three times 2 Start the engine Run the engine at low idle for three minutes ...

Page 411: ...he disconnect switch ON 7 Start the engine Run the engine at less than 1 000 RPM s for several minutes before full load operation 8 Repeat the process several times 9 Stop the engine Check each device for oil leaks 10 Replace the fuel filter and engine oil filter with new one as needed Change engine oil 11 Check clamps of the suction hoses air cleaner hoses and radiator hoses Retighten them as nee...

Page 412: ...10 4 STORAGE MEMO ...

Page 413: ...ng 2 Engine Auxiliaries Problem Cause Solution Batteries will not charge Broken battery separator Replace Faulty regulator Adjust and replace Faulty ground line Repair Faulty alternator Repair and replace Batteries discharge quickly after being charged Shorted cable Repair and replace Shorted battery separator Repair and replace Increased sediment in battery Clean Coolant temperature is too high L...

Page 414: ...ity fuel Faulty intake air heater Replace intake air heater Air mixed in the fuel supply line Bleed air Faulty injection pump or nozzle Repair or replace Reduced compression pressure Repair or replace Engine speed does not increase During fan reversing operation the F R or parking switch was deactivated or the Fan reverse rotation switch was turned OFF Rotate the fan in normal direction Refer to t...

Page 415: ... level increases Faulty hydraulic pump Repair Replace Lack of hydraulic oil Refill Broken suction pipe and or hose Repair Replace All actuators have no power Malfunction due to worn hydraulic pump Replace Decrease in set pressure of main relief valve in control valve Clean Adjust Lack of hydraulic oil Refill Trapped foreign matter in hydraulic oil tank suction filter Clean Aeration in suction side...

Page 416: ...bles in area of brake pedals Remove clean area Service brake fluid loss hydraulic oil Oil leak from brake line and or hose connector Retighten or repair Oil leak due to brake piston seal inside axle Repair Transmission is noisy Lack or deterioration of gear oil Refill replace Worn inner parts in transmission Repair Replace Broken gear or bearing Repair Replace Oil temperature increases Faulty fan ...

Page 417: ...nd rear tires mm in 2050 81 F Ground Clearance mm in 395 16 G Bucket Hinge Height mm in 3920 154 H Dumping Clearance 45 mm in 2760 109 I Dumping Reach 45 mm in 1110 44 R1 Minimum Rotation Radius mm in 5580 220 R2 Minimum Rotation Radius mm in 6230 245 Travel Speed Forward Reverse at Power mode km h mph 38 5 38 5 26 5 28 3 23 9 23 9 16 5 17 6 Transmission Speeds F R 5 3 Articulation Angle Left Righ...

Page 418: ...12 2 SPECIFICATIONS MEMO ...

Page 419: ...r information on hydraulic hose connection and disconnection Put the bucket attachment to be removed on a support such as a pallet if available 1 Horizontally lift the bucket by approx 20 cm above the pallet dWARNING Before leaving the machine apply the parking brake 2 Operate the quick coupler cylinder with hydraulic coupler switch 1 to remove pin 4 3 While pulling to slide lock switch 2 continue...

Page 420: ...ly bring the machine close to bucket attachment hook 3 and install the quick coupler to the hook 2 Slightly raise lift arm 4 Slowly tilt the bucket attachment backward by operating the bucket cylinder until stopper 5 comes in contact with the coupler 3 While pulling to slide lock switch continue to press switch installation position to install coupler cylinder pin 1 fNOTE In case the newly install...

Page 421: ... 31 Brake Oil Low Pressure Indicator Red 1 12 Brake Pedal 1 86 Brake System 7 90 Break in Period for New Machine 2 1 Brightness Adjustment 1 41 C COMPONENTS NAME 1 1 Cab Door 1 128 Cab Door Release Lever 1 130 Cab Features 1 7 Cab Heater Operation 1 114 Change Axle Oil 7 44 Change Coolant 7 80 Change Engine Oil 7 33 Change Hydraulic Oil Clean Hydraulic Oil Tank 7 50 Change Transmission Oil and Tra...

Page 422: ...clutch Position Switch 1 98 5 5 DEF AdBlue Level Alarm 1 31 DEF SCR System Alarm 1 31 Default Setting 1 20 Defroster Operation 1 116 Dig with Caution S 18 Discharge Warning Indicator Red 1 13 Display Item Selection 1 62 Display Mode Setting 1 50 Displaying Basic Screen 1 22 Dispose of Waste Properly S 35 Door Lock Knob 1 129 Door Open Close Lever 1 129 Dozing 5 21 Drain Fuel Filter 7 68 Drain Wate...

Page 423: ...ance Under Special Environmental Conditions 9 1 Manual Operation 1 102 Manual Regeneration 1 35 Miscellaneous 7 107 Monitor Operation 1 26 Monitor Panel 1 11 Monitoring 1 75 Move and Operate Machine Safely S 8 Multi Function Monitor 1 19 Multi Function Joystick Type 1 10 1 94 N Neutral Lever Lock for the Forward Reverse Lever 1 81 Never Ride Attachment S 6 Never Undercut a High Bank S 18 Notes for...

Page 424: ...eat Belt 1 140 Seat Pocket 1 140 Secondary Steering Option 4 10 Secondary Steering Operation Check Switch Option 1 103 Selecting a Trailer 6 1 Service Air Conditioning System Safely S 34 Service Brake 1 86 Setting Menu 1 45 Setting Procedure 1 56 Shift Change Delay Mode Setting 1 58 Shift Switch 1 87 Specifications 12 1 Starting Engine 3 5 Starting in Cold Weather 3 7 Starting to Move 4 2 Stay Cle...

Page 425: ...Service Work S 25 Wear Protective Clothing S 3 When Fully Opening the Door 1 130 When Windows Become Fogged 1 117 Window Open Close Levers 1 129 Wiper Operation 1 88 Wiper Switch 1 88 Work Light Indicator Yellow 1 17 Work Light Switch 1 79 Work Mode for Break in 2 1 ...

Page 426: ...14 6 INDEX MEMO ...

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Hitachi ZW 180-6, Operator'S Manual

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