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Hitachi ZW 550-6, Operator'S Manual

The Hitachi ZW 550-6 is a robust and efficient construction machine designed for heavy-duty work. To harness its full potential, it is imperative to utilize the Operator's Manual. Get the comprehensive manual for this product, available for free download at manualshive.com, and optimize your productivity and performance on the field.

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INDEX

14-2

ZW550-6 US

Change Axle Oil.............................................................................7-37

Change Coolant ............................................................................7-76

Change Differential Gear Oil ....................................................7-37

Change Engine Oil  ......................................................................7-26

Change Hydraulic Oil ..................................................................7-44

Change Parking Brake Gear Oil ...............................................7-91

Change Planetary Gear Oil ........................................................7-38

Change Transmission Oil ...........................................................7-31

Change Transmission Oil Filter ................................................7-31

Changing Forward/Reverse Drive Direction ..........................4-8

Check Accelerator Pedal Operation .....................................7-114

Check Accumulator Function, Gas Leakage,  

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

Check After Starting .......................................................................3-9

Check Air Conditioner...............................................................7-101

Check Air Conditioner Compressor Belt ............................7-102

Check Air Conditioner Condenser ........................................7-102

Check Air Conditioner Piping .................................................7-101

Check Air Pressure ........................................................................7-94

Check Axle Oil Level ....................................................................7-35

Check Backup Alarm ...................................................................7-85

Check Before Starting ....................................................................3-3

Check Brake Performance .........................................................7-88

Check Bucket Teeth ...................................................................7-111

Check Cab .....................................................................................7-112

Check Compressor .....................................................................7-103

Check Compressor and Pulley ...............................................7-103

Check Coolant Level ....................................................................7-73

Check DEF Level ..........................................................................7-106

Check Differential Gear Oil Level ............................................7-35

Check Dosing Module ..............................................................7-110

Check Drive Belt ............................................................................7-74

Check Electrical Harnesses ........................................................7-86

Check Electrolyte Specific Gravity ..........................................7-83

Check Engine Compression Pressure ..................................7-116

Check Engine Noise ........................................................................3-9

Check Engine Oil Level  ..............................................................7-25

Check Exhaust Gas Color ................................................ 3-9, 7-114

Check Fuel Hoses ..........................................................................7-69

Check Fuel Injector ....................................................................7-117

Check Fuel Level ...........................................................................7-57

Check Fuses ....................................................................................7-86

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

Check Gas Pressure in Ride Control Accumulator  

(Option) ......................................................................................7-52

Check Gas Pressure in Steering Accumulator ....................7-52

Check Handrails ..........................................................................7-115

Check Horn .....................................................................................7-85

Check Hoses and Lines ...............................................................7-53

Check Hydraulic Oil Level ..........................................................7-43

Check Instrument Operation ...................................................7-84

Check Monitor Functions ..........................................................7-84

Check Monitor Operation .............................................................3-9

Check Noise ..................................................................................7-114

Check Parking Brake Disks ........................................................7-93

Check Parking Brake Force ........................................................7-89

Check Parking Brake Gear Oil Level .......................................7-90

Check Pilot Circuit Accumulator Function, Gas Leakage, 

Looseness, and Damage.......................................................7-51

Check Planetary Gear Oil Level ................................................7-36

Check Play Amount in Joystick Steering Movement .....7-113

Check Play in Brake Pedal Stroke ............................................7-88

Check ROPS ..................................................................................7-112

Check ROPS Mounting Bolts ..................................................7-112

Check Rearview Mirror and Inside Rearview Mirror ......7-115

Check Refrigerant .......................................................................7-103

Check Ride Control Accumulator Function, Gas Leakage, 

Looseness, and Damage (Option) .....................................7-52

Check Right and Left Brake Interlocking Performance ...7-88

Check Service Brake Disks .........................................................7-93

Check Sound Absorbing Mat Around Engine ..................7-116

Check Steps ..................................................................................7-115

Check Tightening Torque of Nuts and Bolts .....................7-119

Check Tire Pressure ......................................................................7-94

Check Tire for Damage ...............................................................7-95

Check Transmission Oil Level ...................................................7-30

Check Turbocharger ..................................................................7-117

Check Urea SCR System ...........................................................7-117

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

Check Windshield Washer Fluid Level .................................7-113

Check Work Lights ........................................................................7-85

Check and Adjust Engine Controller (ECM) ......................7-117

Check and Adjust Valve Clearance .......................................7-116

Check and Clean Aftertreatment Device ...........................7-104

Check and Clean Alternator ....................................................7-116

Check and Clean EGR Cooler ..................................................7-117

Check and Clean EGR Valve ....................................................7-117

Check and Clean Starter ..........................................................7-116

Check and Replace Lower Tether ..........................................7-112

Check and Replace Seat Belt ..................................................7-112

Check the Hour Meter Regularly ................................................7-3

Cigar Lighter (24 V DC Electrical Outlet) ............................1-114

Circulation Air Filter, Clean ......................................................7-100

Circulation/Fresh Air Switch ...................................................1-118

Clean Axle Oil Cooler Fins (Option) ........................................7-40

Clean Circulation Air Filter .......................................................7-100

Clean DEF Strainer......................................................................7-107

Clean Engine Compartment ...................................................7-116

Clean Fresh Air Filter ....................................................................7-99

Clean Fuel Priming Solenoid Pump Strainer ......................7-67

Clean Fuel Pump Strainer ..........................................................7-66

Clean Hood ...................................................................................7-116

Clean Pilot Oil Filter .....................................................................7-47

Clean Radiator/Oil Cooler Cores and Other Cooling  

System.........................................................................................7-79

Clean Suction Filter ......................................................................7-46

Clean Suction Strainer ................................................................7-31

Clean Torque Converter Air Breathers...................................7-34

Clean Transmission Air Breathers ...........................................7-34

Clean/Replace Air Conditioner Circulation/Fresh Air  

Filters ...........................................................................................7-99

Cleaning of Rear View Camera Lens ....................................7-118

Summary of Contents for ZW 550-6

Page 1: ...NA1 1 ZW550 6 WHEEL LOADER OPERATOR S MANUAL PRINTED IN JAPAN T 2018 03 URL http www hitachi c m com ENMNHK NA1 1 PART NO Wheel Loader Operator s Manual Serial No 005201 and up This book is printed on recycled paper ...

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

Page 3: ...S COMPONENTS NAME OPERATOR S STATION BREAK IN OPERATINGTHE ENGINE MOVINGTHE MACHINE OPERATINGTHEMACHINE TRANSPORTING MAINTENANCE MAINTENANCEUNDERSPECIALENVIRONMENTALCONDITIONS STORAGE SPECIFICATIONS INDEX INDEX ENMNHK NA1 1 TROUBLESHOOTING ...

Page 4: ......

Page 5: ... 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 Paint Before Welding or Heating S 33 Beware of Asbes...

Page 6: ...ont Console Switches Pedals and Joystick Steering 1 85 Hazard Switch 1 86 Work Light Switch 1 87 Parking Brake Switch 1 88 Key Switch 1 89 Accelerator Pedal 1 90 Brake Pedal 1 90 Service Brake 1 90 Declutch Brake 1 90 Joystick Steering 1 91 Joystick Steering Lever 1 91 Forward Reverse Switch 1 91 Joystick Steering System Switch 1 91 Shift Switch 1 92 Light Switch 1 93 Wiper Switch 1 94 Wiper Opera...

Page 7: ...arm Up 3 12 Cold Weather Warm Up 3 13 Stopping Engine 3 15 MOVING THE MACHINE 4 1 Driving the Machine 4 1 Precautions for Starting to Move 4 1 Starting to Move 4 2 Shift Range of Auto Transmission 4 5 Power Mode Selector 4 6 Shift Change Delay Mode 4 6 Parking Brake Switch 4 7 Drive Speed Change Manual Shift 4 8 Changing Forward Reverse Drive Direction 4 8 Steering 4 9 Secondary Steering Option 4 ...

Page 8: ...eplace Axle Oil Cooler Line Filter Option 7 39 Clean Axle Oil Cooler Fins Option 7 40 D Hydraulic System 7 41 Inspection and Maintenance of Hydraulic Equipment 7 41 Check Hydraulic Oil Level 7 43 Change Hydraulic Oil 7 44 Bleed Air from the Hydraulic System 7 45 Clean Suction Filter 7 46 Clean Pilot Oil Filter 7 47 Line Filter in Steering Circuit 7 47 Line Filter in Brake Circuit 7 48 Replace Hydr...

Page 9: ...r 7 103 L Aftertreatment Device 7 104 Check and Clean Aftertreatment Device 7 104 M Urea SCR System 7 105 Specified DEF AdBlue 7 105 Check DEF Level 7 106 Refill DEF 7 106 Clean DEF Strainer 7 107 DEF Exchange Procedure 7 108 Replace DEF Supply Module Main Filter 7 109 Check Dosing Module 7 110 Replace DEF Tank Inlet Filter 7 110 N Miscellaneous 7 111 Check Bucket Teeth 7 111 Check and Replace Sea...

Page 10: ...CONTENTS SPECIFICATIONS 12 1 Specifications 12 1 Intended Use 12 1 INDEX 14 1 ...

Page 11: ...chine 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 Model type Product Identification Number Engine TYPE MFG NO 550SN_plate_US 6WG1_SN ...

Page 12: ...MACHINE NUMBERS 2 Aftertreatment Device SCR TYPE MFG NO DOC TYPE MFG NO 95Z7B SCR4 95Z7B SCR4 ...

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

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: ...ment 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 depress the pedals and to correctly operate t...

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 545 mm 21 5 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 s...

Page 25: ...turn possibly resulting in serious injury or death When driving up or down a slope keep the bucket facing the direction of travel approximately 545 mm 21 5 in A above the ground If the machine starts to skid or becomes unstable immediately lower the bucket to the ground and stop Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn If the direction mus...

Page 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: ...aways 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 Bl...

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: ...EL LEVER OR ANY FIXED EQUIPMENT 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...

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: ...ion Precautions for Lightning The machine is vulnerable to lightning strikes In the event of an electrical storm immediately stop operation and take the following actions If you are around the machine evacuate to a safe place far away from the machine If 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 groun...

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 6 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 t...

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: ...or missing or damaged terminal caps DO NOT OPERATE MACHINE if cable 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 flammables may cause fires Prevent fires by inspecting and cleaning the machine daily and by removing adhered oil or accumulated flammables immediately Che...

Page 42: ...ing 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 the key switch to the OFF position if there is time Use a fire extingui...

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

Page 44: ...solution used 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 would decompose and generate ammonia gas when heated to 160 C 320 F or higher Ammonia gas may cause lung injury and potentiall...

Page 45: ...ware of 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 silica dust or other contamination may exist Spray water to prevent asbestos fibe...

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: ... 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 DEF AdBlue brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from th...

Page 48: ...y but is not a trouble Do not touch water coming directly out of the aftertreatment device The water is mildly acidic by oxidation catalyst mounted in the aftertreatment device If filter 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 devi...

Page 49: ...on terminal type A or type B Consult your authorized dealer for the type of communication terminal Specific Absorption Rate SAR measured by 10 g per unit of communication terminal equipment Type A Type B E GSM900 0 573 W kg 914 8 MHz 0 12 W kg 897 6 MHz DCS 1800 0 130 W kg 1710 2 MHz 0 06 W kg 1748 0 MHz WCDMA Band I 0 271 W kg 1950 0 MHz 0 05 W kg 1950 0 MHz WCDMA Band VIII 0 10 W kg 892 6 MHz fN...

Page 50: ...Refer to page 7 8 To lock 1 Align the front and rear chassis straight ahead 2 Remove lock bolt 2 to release articulation stopper 1 from the rear chassis 3 Turn the link and fix the end to the bracket on the front chassis as shown 4 Insert the pin and clip pin This is the LOCKED position To unlock 1 Remove the clip pin and pin from the end of articulation stopper 1 on the front chassis bracket 2 Tu...

Page 51: ...n hold lever 2 and lift armrest 1 to the fully raised position before getting off the machine 2 When armrest 1 is fully raised the joystick steering system is turned off automatically 3 Then indicator lamp 3 on the monitor display goes out To turn ON 1 Before operating the machine lower armrest 1 back to the operating position 2 When armrest 1 is completely lowered the joystick steering system is ...

Page 52: ... following Whenever seated fasten the seat belt Do not modify ROPS such as drilling or welding Do not use ROPS deformed If any damage or loose bolts 1 are found do not operate until repaired Never repair or modify ROPS without manufacturer s approval and instructions Be sure the ROPS is in place properly attached no bolts loose or missing not damaged not modified Periodically check the ROPS bolts ...

Page 53: ...ng 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 115Z7B S 41US 22 18 19 20 21 23 17 8 14 13 15 2 2 3 6 24 ...

Page 54: ...SAFETY LABELS S 42 2 25 7 4 1 26 1 8 9 5 6 11 12 10 24 115Z7B S 42US ...

Page 55: ...hazard Nitrogen accumulator contains compressed gas and fluid which could result in death or serious injury Release the oil pressure from all brake circuits before removing any oil lines or piping Do not attempt to service or repair an accumulator unless properly trained and equipped 115Z7B S 43 label 44787 24470 label 44787 24370 115Z7B S 53 115Z7B S 44 115Z7B S 49 ...

Page 56: ... such as the engine muffler etc immediately after operation of the machine Severe burns may result 4 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 label 44787 24990 label 44787 24460 115Z7B S 46 115Z7B S 45 ...

Page 57: ...capped during or right after operation Read manual for safe and proper handing 6 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 label 44787 25030 label 44787 24331 115Z7 S 43K 115Z7 S 43K 115Z7B S 45 ...

Page 58: ...a pinch point when steering the machine Keep all personnel away from the articulation area during operation of the machine 9 Top of Right Rear Chassis Articulation Stopper dWARNING Crush Hazard The articulation area becomes a pinch point when steering the machine Be sure to install the articulate lock bar stopper during inspection maintenance work and transportation of the machine label 44787 2493...

Page 59: ...such as belt Turn off before inspection and maintenance 12 Bottoms at Both Right and Left Side Covers of Rear Chassis dWARNING Runover Hazard Machine movement 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 n...

Page 60: ...RNING Explosion Hazard Sign indicates an explosion hazard Keep fire and open flames away from this area 15 Inside Battery Box 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 115Z7B S 44 115Z7B S 44 label 44787 24350 label 44787 24340 label 44787 25000 115Z7B S ...

Page 61: ...nd regulation on disposal of batteries and electrolyte solution 17 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 label 44774 23030 115Z7B S 54 label 44787 24420 115Z7 S 47G1 ...

Page 62: ...ar electric power lines Keep a safe distance from electric power lines 20 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 parking position lower the...

Page 63: ...n the seat belt prior to operating the machine 22 Cab Inside Left Rear Column dWARNING Runover Hazard Be sure that the backup alarm is operable when the machine is put in reverse 23 Cab Inside Right Rear Column dCAUTION Steering Hazard Unlock articulation stopper before operating machine label 44787 24970 label 44841 20650 label 44787 24680 115Z7B S 51 115Z7B S 50 115Z7B S 50 ...

Page 64: ...n off before inspection and maintenance 25 EGR Cooler 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 26 Radiator Cap Cover Coolant Replacement Instruction label 44787 24380 115Z7B S 46 115Z7B S 47 115Z7B S 52 label 44787 25880 label 44787 25890 ...

Page 65: ... Front Fender 11 Lift Arm Cylinder 12 Lift Arm 13 Battery Two on the left side 14 Fuel Filler Port 15 Rear Work Light 16 Aftertreatment Device Inside the cover 17 Exhaust Pipe 18 Hydraulic Oil Tank 19 Articulation Lock Bar 20 Rear Combination Light Turn Signal Hazard Light Tail Light Brake Light Backup Light 21 Counterweight 22 Towing Pin 23 Cooling Unit 24 DEF Tank 115Z7B 1 1 1 115Z7B 1 1 2 1 9 1...

Page 66: ...14 Rear Axle 15 Engine 16 Third Rear Propeller Shaft 17 Transmission 18 Second Front and Center Propeller Shaft 19 Steering Cylinder 20 Front Axle 21 Lift Arm Cylinder 22 Lift Arm Cylinder Rod Pin 23 Bell Crank Lever Pin 24 Bucket Link Pin 25 Bucket Hinge Pin 26 First Main Propeller Shaft 27 Torque Converter 28 Cab 29 ROPS Roll Over Protective Structure 30 DEF Tank 31 DEF Supply Module 115Z7B 1 2 ...

Page 67: ...uctions below to prevent the aftertreatment device from being damaged IMPORTANT Refer to 1 35 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 severe bur...

Page 68: ...ill 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 aftertreatment device by hitting elements with other objects o...

Page 69: ...nsult 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 ...

Page 70: ...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 36 If manual regeneration doe...

Page 71: ...TOR S STATION 1 7 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 115Z7 1 7 1 ...

Page 72: ... 4 Parking Brake Switch 5 Monitor Panel 6 Accelerator Pedal 7 Brake Pedal 8 Front Window Wiper Switch 9 Rear Window Wiper Switch 10 Light Switch 11 Key Switch 12 Multi Function Monitor Air Conditioner Switch Panel 13 Ash Tray 14 Cigar Lighter 15 Brake Declutch Pedal 115Z7 1 8 1 115Z7 1 8 2 115Z7 1 8 3 ...

Page 73: ...tick 23 Shift Up Switch 24 Shift Down Switch 25 Hold Switch Under the Joystick 26 Horn Switch Under the Joystick 27 Joystick Steering System Switch 28 Armrest Lock Release Button 29 Armrest Adjust Handle 30 Support Bar 31 Armrest 115Z7B 1 10 3 30 22 21 25 26 27 28 29 31 23 24 ...

Page 74: ...liary 10 Fan Reverse Rotation Switch 11 Hydraulic Coupler Switch Option 12 Auxiliary 13 Aftertreatment Device Regeneration Switch 14 Secondary Steering Operation Check Switch Option 15 Auxiliary 16 2nd 3rd Speed Limit Switch Option 17 Ride Control Switch Option 19 Armrest 20 Hold Switch 21 Right Console Slide Lever 22 DSS Down Shift Switch 23 Horn Switch 24 Quick Power Switch 12 13 14 21 20 19 17 ...

Page 75: ... Selector Switch 10 Auxiliary 11 Fan Reverse Rotation Switch 12 Hydraulic Coupler Switch Option 13 Auxiliary 14 Secondary Steering Operation Check Switch Option 15 Aftertreatment Device Regeneration Switch 16 Auxiliary 17 2nd 3rd Speed Limit Switch Option 18 Ride Control Switch Option 19 Armrest Adjust Handle 20 Armrest 21 Right Console Slide Lever 22 Hold Switch Under the Lever 23 Horn Switch Und...

Page 76: ...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 77: ...and the service indicator will light and the alarm buzzer will sound Immediately move the machine to a safe area set the machine in the park position and stop the engine Inspect the brake system for any abnormality When the brake oil pressure is recovered the buzzer stops and the indicator goes off Hydraulic Oil Level Indicator Red dWARNING Stop machine operation if the hydraulic oil level lowers ...

Page 78: ...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 79: ... 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 80: ... 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 81: ...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 82: ...gh beam position the indicator will light Work Light Indicator Yellow When the work lights are turned ON this indicator will light Clearance Light 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 01 032 M4GB 01 033 M4GB 01 035 MNEC ...

Page 83: ...eens There are 7 menus and a further 13 sub menus Basic Screen Main Menu Alarm List Dual Lift Arm Auto Leveler Mail Ride Control Option Brightness Adjustment 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 Device Regenera...

Page 84: ...ration OFF Shift Change Delay Mode Transmission Setting ON OFF of shift travel speed change delay mode OFF Lockup ON OFF of transmission lock up function ON Traction Control ON OFF of traction control 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...

Page 85: ... 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 20 Auto Brake Indicator 21 Joystick Steering Indicator 22 Traction Control Indicator 23 Torque Converter Lock Up Indicator When Rear Vie...

Page 86: ...he 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 When Rear View Monitor is Operative MNEK 01 102EN Starting Screen Rear View Camera Display Basic Screen Basic Screen MNHG 01 103EN MNHG 01 104EN ...

Page 87: ...icts transmission oil 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 Level Gauge 5 DEF level gauge 5 displays the remaining DEF amount When DEF level becomes low the last segment turns yellow IMPORTANT If the engine runs with low DEF ...

Page 88: ...ling 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 When the height kickout is ON enabled is displayed When the lower kickout is ON is displayed Clock Hour Meter Odometer 15 Clock Indicates the p...

Page 89: ...Indicator It displays currently engaged gears It is not displayed at neutral position Forward 1st 4th Reverse 1st 3rd Auto Brake Indicator 20 Auto brake indicator 20 appears when the auto brake works due to excessive machine speed or when direction is changed while running at the specified speed or faster It automatically turns off when the machine speed decreases below within the safety speed lim...

Page 90: ...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 91: ...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 Basic Screen 1 3 MNHG 01 290EN 2 MNEC 01 006 Operating Rear View Monitor Basic Screen Rear View Camera Display 3 MNHG 01 291EN ...

Page 92: ...e alarm list and push selector knob 1 fNOTE The main menu displays the alarm list faults only when an alarm occurs 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 Detailed information of the selected alarm will be displayed 1 MNEC 01 006 MNHG 01 290EN MNHG 01 105EN MNHG 01 106EN MNHG 01 107EN ...

Page 93: ...hine 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 Device Regeneration Request Blinking Yellow The aftertreatment device needs regenera...

Page 94: ...e park position apply parking brake stop the engine and contact your authorized dealer Engine Oil Pressure Alarm Engine oil pressure has decreased Immediately stop the engine and apply parking brake Check the engine oil system and oil level Boost Temperature Rise Alarm Intake air temperature is abnormally high Stop operation Check intercooler for clogging and intake air piping connections Auto Bra...

Page 95: ...rge is abnormal Inspect the alternator and the battery system Fuel Temperature Alarm Fuel temperature is abnormally high Stop machine operation and apply parking brake Run the engine at slow idle speed to lower the fuel temperature Air Cleaner Clogging Air filter elements are clogged Clean or replace air cleaner element Fuel Filter Restriction Alarm Fuel filter is clogged Replace fuel filter eleme...

Page 96: ... of the DEF gauge changes depending on the DEF 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 level is low Refill DEF Red Red slow blink DEF is insufficient Refill DEF Engine output is restricted Red Red fast b...

Page 97: ...m Indicator Status Inducement Red light Urea SCR system is broken Red slow blink Urea SCR system is broken Engine output is restricted Red fast blink Urea SCR system is broken Engine output and speed are restricted Contact your authorized dealer for service ...

Page 98: ...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 99: ...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 16 to perform manual regeneration This symbol i...

Page 100: ...o page 1 57 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 13 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 Con...

Page 101: ...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 102: ...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 103: ... 1 Press selector knob 2 while displaying basic screen 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 ...

Page 104: ... 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 105: ...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 106: ... 42 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 1 MNHG 01 103EN 3 4 MNHG 01 120EN ...

Page 107: ... 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 MNHG 01 121EN MNHG 01 122EN ...

Page 108: ...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 3 5 4 1 MNHG 01 ...

Page 109: ...as 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 MNHG 01 132EN MN...

Page 110: ...etting 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 5 4 1 MNHG 01 103EN MNHG 01 140EN MNHG 01 141EN ...

Page 111: ...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 5 4 6 1 MNHG 01 103EN MNHG 01 140EN MNHG 01 141EN ...

Page 112: ...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 MNHG 01 142EN MNHG 01 143EN MNHG 01 14...

Page 113: ...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 5 4 6 1 MNHG 01 103EN MNHG 01 140EN MNHG 01 141EN ...

Page 114: ...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 MNHG 01 145EN MNHG 01 146EN MNHG 01 1...

Page 115: ...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 5 4 1 6 MNHG 01 103EN MNHG 01 140EN MNHG 01 141EN ...

Page 116: ...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 300EN MNEK 01 301EN MNEK 01 302EN MNEK 01 303EN MNEK 01 304EN MNHG 01 148EN MNHG 01 149E...

Page 117: ...he engine stops 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...

Page 118: ... in gray Acting Time Setting 1 On the Auto Shut Down screen rotate selector knob 2 to highlight Setting 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 minu...

Page 119: ...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 5 3 4 6 1 MNHG 01 140EN MNHG 01 160EN MNHG 01 1...

Page 120: ...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 121: ...ent 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 5 4 1 MNHG 01 140EN MNHG 01 141EN MNHG 01 103EN ...

Page 122: ...F When ON is selected regeneration inhibited 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 clog...

Page 123: ... 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 5 4 1 MNHG 01 103EN MNHG 01 140EN MNHG 01 141EN ...

Page 124: ...ress selector 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 9 6 10 7 8 MNHG 01 180EN MNHG 01 182EN MNH...

Page 125: ...the lockup shifting refer to page 4 5 fNOTE The lock up control directly links the transmission to the engine when the Auto Shift Mode 1 or 2 is selected 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 5 4 1 MNHG 01 140EN MNHG 01 141EN ...

Page 126: ... Press selector knob 2 to display Lockup setting screen 9 8 Press selector knob 2 to turn ON When ON is selected L UP indicator 10 turns ON when the lockup clutch is engaged 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 10 95Z7B 1 60 4 7 9 8 6 MNHG 01 180EN MNHG 01 184EN MNHG 01 1...

Page 127: ...d is temporarily slowed down and tire spin is reduced This increases tire life 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 5 4 MNEK 01 140EN MNEK 01 141EN 1 MNEK 01 103EN ...

Page 128: ... Traction Control 8 7 Press selector knob 2 to display Traction Control screen 9 8 Press selector knob 2 to turn ON When ON is selected traction control indicator 10 appears on the monitor Press selector knob 2 again to turn OFF fNOTE When the function is ON the mark is displayed in green When the function is OFF the mark is displayed in gray MNEK 01 180EN 95Z7 01 05 7 8 6 9 10 MNHG 01 187EN ...

Page 129: ...erated at the same time under a set height This setting is adjustable 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 5 4 1 MNHG 01 140EN MNHG 01 141EN MNHG 01 103EN ...

Page 130: ...nt 8 7 When the lift arm height is within the setting range mark 9 will be displayed 8 Press selector knob 2 to change parallel tandem control height setting value 9 When the parallel tandem control height setting value changes the value will be displayed on segment 10 fNOTE Under the set value the lift arm and bucket can be operated at the same time parallel operation circuit Over the set value t...

Page 131: ...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 5 4 1 MNHG 01 141EN MNHG 01 140EN MNHG 01 103EN ...

Page 132: ...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 7 6 MNHG 01 201EN MNHG 01 200EN ...

Page 133: ...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 5 6 3 4 1 MNHG 01 140EN MNHG 01 103EN MNHG 01 220EN KC ...

Page 134: ...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 MNHG 01 22...

Page 135: ...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 3 4 1 MNHG 01 103EN MNHG 01 140EN ...

Page 136: ...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 7 6 MNHG 01 230EN KC MNHG 01 231EN ...

Page 137: ...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 5 3 4 1 MNHG 01 240EN MNHG 01 103EN MNHG 01 241EN KC ...

Page 138: ... 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 5 6 MNHG 01 241EN KC 3 4 1 MNHG 01 240EN MNHG 01 103EN ...

Page 139: ...vious 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 fue...

Page 140: ...ar Axle Oil Air Cleaner Filter Element Fuel Filter Air Conditioner Filter DEF AdBlue Supply Module Main Filter Fuel Solenoid Pump Filter Oil Separator Filter 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 Information Men...

Page 141: ...uired 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 Return button 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 ...

Page 142: ...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 MNHG 01 245EN KC 3 4 1 MNHG 01 240EN MNHG 01 103EN ...

Page 143: ... 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 144: ...nerated 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 MNHG 01 260EN KC ...

Page 145: ...ng 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 MNHG 01 260EN KC 95MNEC 01 261EN 95MNEC 01 262EN 95MN...

Page 146: ...nitoring 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 Monitoring 6 MNHG 01 270EN KC ...

Page 147: ...Monitoring screen 7 fNOTE When the PM Accumulation bar reaches the right end auto regeneration takes place However auto regeneration may not be performed depending on the machine condition The PM Accumulation is not displayed during regeneration 7 MNHG 01 271EN ...

Page 148: ...OPERATOR S STATION 1 84 MEMO ...

Page 149: ...iper Switch 8 Rear Window Wiper Switch 9 Light Switch 10 Brake Declutch Pedal 11 Forward Reverse Switch 12 Shift Up Switch without steering wheel Quick Power Switch with steering wheel 13 Shift Down Switch without steering wheel Down Shift Switch DSS with steering wheel 14 Joystick Steering System Switch 15 Horn Switch 16 Hold Switch 115Z7B 1 81 1 95Z7 1 85 1 11 12 15 16 13 14 5 6 7 8 9 10 1 4 2 3...

Page 150: ...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 2 2 2 2 115Z7_front 115Z7_rear 115Z7B 1 81 1 1 ...

Page 151: ...work lights 2 ON Rear work lights 3 stay OFF fNOTE Refer to page 1 91 for the light switch position When the side with mark on switch 1 is pressed both front work lights 2 and rear work lights 3 are turned ON dCAUTION Do not turn the work lights ON while driving on a public road 1 M4GB 01 067 2 2 3 3 115Z7_front 115Z7_rear 115Z7B 1 81 1 1 ...

Page 152: ... turned ON the parking 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 the machine should not travel when the parking b...

Page 153: ...descriptions in the OPERATING ENGINE section for the detail information dWARNING Never turn key switch 1 OFF while moving the machine Failure to do so will result in inoperable steering and brake pedal functions and the parking brake will suddenly apply OFF Engine Off ACC Radio ON Power ON START Engine Start fNOTE Engine pre heating is controlled automatically by the engine control system M4GB 01 ...

Page 154: ...aring 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 declutch p...

Page 155: ...o reverse and vice versa Set forward reverse switch 2 to the F position to travel the machine forward Set forward reverse switch 2 to the R position to drive the machine in reverse IMPORTANT Never attempt to shift forward reverse switch 2 while letting the machine travel at high speed 3 or 4 speed Failure to do so will cause engine to have excessively high RPM s leading to hazardous situation Also...

Page 156: ...ear Press shift switch 4 to shift down the gear Select a proper shift for the work IMPORTANT The joystick steering lever and switches are designed to operate with low effort Do not press and twist the lever and switches firmly Damage to them may result 115Z7B 4 4 1 F N R 2 3 4 ...

Page 157: ...Position Headlight Clearance Light Tail Light Monitor Panel Light High Low OFF I Tail Low High fNOTE The light switch position I Tail 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 discharged 115Z7 AK Light SW 1 2 ...

Page 158: ...frozen over defrost them Use anti freeze 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...

Page 159: ...ot freeze Front Window Wiper Switch HI The front windshield wiper operates at fast speed LO 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 Push Washer fluid squirts from the front nozzle and the front windshield wiper operates Rear Window W...

Page 160: ...r 9 Auxiliary 10 Fan Reverse Rotation Switch 11 Hydraulic Coupler Switch Option 12 Auxiliary 13 Aftertreatment Device Regeneration Switch 14 Secondary Steering Operation Check Switch Option 15 Auxiliary 16 2nd 3rd Speed Limit Switch 17 Ride Control Switch Option 19 Armrest 20 Hold Switch 21 Right Console Slide Lever 22 DSS Down Shift Switch 23 Horn Switch 24 Quick Power Switch 12 13 14 21 20 19 17...

Page 161: ...cket 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 height ki...

Page 162: ...t 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 fNOTE Be advised that the turn signal switch has been changed on S N 5101 and thereafter M4GB 01 072 C B E N N A D MNEC 03 003 1 C B E N N A F G ...

Page 163: ...wer Mode Selector Switch 10 Auxiliary 11 Fan Reverse Rotation Switch 12 Hydraulic Coupler Switch Option 13 Auxiliary 14 Secondary Steering Operation Check Switch Option 15 Aftertreatment Device Regeneration Switch 16 Auxiliary 17 2nd 3rd Speed Limit Switch 18 Ride Control Switch Option 19 Armrest Adjust Handle 20 Armrest 21 Right Console Slide Lever 22 Hold Switch Under the Lever 23 Horn Switch Un...

Page 164: ...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 165: ...ent how to use this lever 1 MNEC 01 043 1 115Z7 1 9 4a Turn Signal Switch Indicates the drive change direction to persons and or other vehicles by operating turn signal switch 4 L Left Turn R Right Turn 4 Multi Function Joystick Type MNEC 01 043 4 L R 115Z7B 4 9 1 Joystick steering lever Fingertip Control Type fNOTE This switch 4 does not return automatically to neutral when the joystick steering ...

Page 166: ...ction 5 4 for details Control lever lock switch 1 is provided to prevent unexpected machine operation if the operator mistakenly comes in contact with the bucket and or lift arm control lever when getting on or off the machine When control lever lock switch 1 is placed to unlock position the loading control lever becomes operable Armrest Adjust Handle The armrest is provided so that the operator c...

Page 167: ... lightly depressing the left brake pedal Suitable for loading work on a level surface Clutch disengages while deeply depressing the left brake pedal Suitable for work on a slope Declutch OFF When depressing left or right brake pedal brake is applied while driving power is transmitting to the tires fNOTE When starting to ascend a slope turn declutch position switch 2 OFF neutral depress the left br...

Page 168: ...ine and set forward reverse switch 3 in the neutral N position before operating travel mode selector switch 1 Manual Mode Manual gear shift The gear shifts 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...

Page 169: ...ping 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 the symbol is displayed on the power mode indicator of the monitor screen 2nd 3rd Speed Limit Switch Option A three position switch 1 is provided to...

Page 170: ...on for 10 minutes for the first time Then the fan automatically reverses rotation and again return to the normal direction Normal rotation Reverse rotation Normal rotation 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 refrigera...

Page 171: ...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 172: ...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 3 to start the aftertreatment device manual regeneration procedures when it is requested Refer to page 5 13 for det...

Page 173: ... the front attachment during operation so that comfortable machine ride quality 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 spe...

Page 174: ...onitor Operate one of the following to release the hold function Press the hold switch again Change the gear range Change the travel mode or Press DSS down shift switch fNOTE Lockup clutch does not function while holding the speed range Loading Control Lever Joystick Steering Lever Fingertip Control Type Multi Function Joystick Type Option MNEC 01 041 MNEC 01 044 1 1 95Z7 1 85 1 1 Upper one ...

Page 175: ...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 power mode switch is pressed The forward reverse switch is operated While driving in the auto shift mode the gear shifts up to the selected gear stage Right Console Slide Lever Adjust the position of the right co...

Page 176: ...oval 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 1 is pressed the gear down shifts to 1st speed When in auto shift mode press and hold DSS 1 to down shift from 4th speed 3rd speed 2nd speed and then to 1st speed fNOTE When DSS 2 ...

Page 177: ... the horn The horn switches are provided on the control lever and the joystick steering to improve operator comfort Loading Control Lever Joystick Steering Lever Fingertip Control Type Multi Function Joystick Type 115Z7 1 92 1 1 MNEC 01 044 1 95Z7 1 85 1 1 Lower one ...

Page 178: ... 2 Press and release 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 ba...

Page 179: ...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 180: ...to 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 9 8 10 8 8 MNEC 01 006 115Z7 1 115 3 7 6 2 3 5 4 115MNEC 01 37...

Page 181: ... 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 182: ...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 183: ...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 184: ...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 185: ...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 186: ...mid 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 187: ...bar support 2 Lift handle 2 and allow the back cushion to angle forward or lean backward into the cushion Release the handle at desired position 3 With the key turned ON push the knob 3 to increase the air pressure This will raise the seat and make a firmer ride Pull the knob 3 to reduce the air pressure air will be vented This will lower the seat and make a softer ride When properly adjusted the ...

Page 188: ...tric 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 supplied to the ...

Page 189: ...ve 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 1 140 A x 2 2 70 A x 2 Front attachment side Fuse box A Battery box Fuse box B FuseBox...

Page 190: ... A 2 Head lamp right 5 A 12 Option 2 ACC1 20 A 1 CONTROLLER SUB 10 A 11 Radio USA 10 A Fuse Box B 10 ECM 30 A 20 Secondary steering option 5 A 9 CONTROLLER SUB 10 A 19 High beam 10 A 8 Main controller DSZ Monitor Load dump relay GPS GSM OPT C U 10 A 18 Rear wiper 10 A 7 Flasher unit 10 A 17 Working lamp rear 20 A 6 Horn 10 A 16 Loader control 5 A 5 Option CAN 5 A 15 MC solenoid power 10 A 4 Option...

Page 191: ...e 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 3 2 115Z7 ...

Page 192: ... STATION 1 128 Cab The ROPS Roll Over Protective Structure is attached to Cab 1 as standard equipment 1 Cab 2 Speakers 3 Front Interior Light 4 Sun Visor 115Z7B 1 128 1 115Z7B 1 128 2 2 3 ROPS 1 4 115Z7B 1 128 3 ...

Page 193: ...ERATOR S STATION 1 129 5 Radio 6 Cab Switch Panel Option 7 Inside Rear View Mirror 8 Rear Interior Light 9 Emergency Exit Hammer 10 Coat Hat Hook 115Z7B 1 129 2 8 9 115Z7B 1 129 3 10 115Z7B 1 129 1 5 7 6 ...

Page 194: ... closed the light 2 goes OFF OFF The light 2 remains OFF Rear Interior Light Slide to ON side of switch 1 to turn the interior light ON The rear interior light switch has three operation positions ON The light 3 turns and stays ON Neutral When the cab door is opened the light 3 turns ON When closed the light 3 goes OFF OFF The light 3 remains OFF 115Z7B 1 130 2 115Z7B 1 129 2 115Z7B 1 130 2 1 1 Ce...

Page 195: ...4 by hanging its edge from 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 4 115Z7B 1 128 3 ...

Page 196: ...y 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 M4GB 01 125 ON ON OFF 115Z7B 1 129 1 4 2 1 5 3 ...

Page 197: ...ors so that persons standing on left and right back end of the machine or object with height of 1 m 3 ft and 30 cm 12 in 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 clos...

Page 198: ...w 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 115Z7B 1 134 3 115Z7B 1 134 2 7 7 Lock Unlock 115Z7B 1 134 1 5 6 ...

Page 199: ... from the battery 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 Us...

Page 200: ...ating the machine with battery disconnect switch 3 ON close cover 1 3 When turning lever 2 90 counterclockwise the lever points down to the ground battery disconnect switch 3 turns OFF Lever 2 can be removed from battery disconnect switch 3 when it is in OFF position 4 Insert lever 2 removed from switch 3 into hole 4 of the holder 5 Close cover 1 115Z7 BatterySW1 1 115Z7 batterySW 115Z7 batterySW ...

Page 201: ... sure to disengage the lock bar 1 from the front chassis and fasten the lock bar to the rear chassis with lock bolt 2 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 Refer to page S 38 for details LOCKED position STORED position MNHE 07 005 MNHE 07 004 1 2 1 ...

Page 202: ...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 Pull up the front end or push down the rear end of stopper 1 to pull out towing pin 2 Tie or loop the towing rope strap or cable and let it pass through the hole IMPORTANT DO NOT use eye plate 3 on the rear chassis when pull out or rescue this machine fr...

Page 203: ...tedly move or close Take care not to pinch fingers when opening closing side cover 1 and or top cover 3 When fully opening side cover 1 lock lever 5 automatically slides and is positioned in the lock position Make sure that lock bar 5 is firmly positioned to lock the cover To release the lock pull wire 4 and release the end of lock bar 5 from the lock position Never attempt to stand on fender 2 if...

Page 204: ...rear grille is well latched fNOTE The starter key cannot be removed from latch 3 while rear grille 4 is being opened Remove bolt caps 1 and bolts 2 Release latch 3 with the starter key to unlock rear grille 4 The rear grille opens and the cooling fan can be cleaned After closing rear grille 4 turn and remove starter key 3 to lock rear grille 4 Tighten bolts 2 and install caps 1 1 2 3 4 4 115Z7B 7 ...

Page 205: ...th 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 or exiting the cab Tool Box There is a grease ...

Page 206: ...OPERATOR S STATION 1 142 Vandal Resistant Devices Locks can be installed to transmission oil inlet cap cover 1 battery box cover 2 and relay and fuse box cover 3 1 2 3 115Z7 Vandal 1 115Z7 Vandal 4 ...

Page 207: ...ION 1 143 Vandal Resistant Devices continue from previous page Fuel tank cap 4 side covers 5 and air conditioner fresh air filter 6 can be locked with the starter key 6 MNEC 01 055 115Z7B 1 146 1 5 115Z7B 1 146 2 5 4 ...

Page 208: ...OPERATOR S STATION 1 144 MEMO ...

Page 209: ...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 210: ...BREAK IN 2 2 MEMO ...

Page 211: ...Wheel Disk Mounting condition of 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 contam...

Page 212: ...el leaks and contamination of the DEF tank 9 DEF 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 Others 1 Opera...

Page 213: ...g position until it is locked Hold support bar 2 when moving armrest 3 The joystick steering system is automatically turned on and indicator lamp 3 on the monitor display turns on 4 Check that forward reverse switch 4 is in the neutral N position fNOTE Unless forward reverse switch 4 is in neutral N the engine will not start 115Z7 3 3 1 115Z7B 1 10 3 Lowered position 1 2 ON OFF 4 95Z7B 3 7 1 3 ...

Page 214: ...and display refer to page 3 6 check that parking brake indicator is ON 6 Check that bucket control lever 6 and lift arm control lever 7 are in the neutral N position 7 Check that control lever lock switch 8 is in the locked position 8 6 7 Multi Function Joystick Type MNEC 01 043 8 Fingertip Control Type 7 6 115Z7B 1 9 4 115Z7B 1 81 1 5 ...

Page 215: ...rator 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 9 10 11 115Z7 3 4 3 115Z7 01 126 ...

Page 216: ...the indicators for brake oil 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 ...

Page 217: ...ANT At starting the engine the engine RPM min 1 is kept at low idle for maximum 35 seconds when the coolant 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...

Page 218: ...forward reverse 4 As soon as preheat indicator 2 turns OFF turn key switch 1 to START position to rotate the starter As soon as the engine starts release the key switch The key switch will automatically return to the ON position Run the engine at low idle without applying accelerator pedal 5 IMPORTANT At starting the engine the engine RPM min 1 is kept at low idle for maximum 35 seconds to warm up...

Page 219: ...em and the oil level 4 Check that engine coolant temperature gauge 4 is within the blue 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 ...

Page 220: ...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 221: ...the machine batteries as far away as possible from the bracket 1 4 After securely connecting the booster cables start the engine on the booster battery mounted machine 1 5 Start the engine on the machine 1 6 After the engine starts 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 boo...

Page 222: ...om 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 about 3 5...

Page 223: ... the engine and hydraulic components Be sure to perform warm up not only to protect the hydraulic components from being damaged but also to ensure safe operation 1 Run the engine at slow idle speed for more than 5 minutes to warm up 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 wa...

Page 224: ...er fNOTE Do not continuously operate the bucket control lever for more than 10 seconds at a time Do not bang linkage when cold 4 Repeat steps 1 to 3 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 fNOTE Headlights working lights or room light may become dim during engine pre...

Page 225: ...urbocharger 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 stopping the machine refer to page 4 16 for further procedur...

Page 226: ...OPERATING THE ENGINE 3 16 MEMO ...

Page 227: ...RATING THE ENGINE Precautions for Starting to Move 1 Perform a thorough walk around inspection Conduct correct start up procedure 2 After raising the lift arm set 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 ...

Page 228: ...et 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 Refer to page 1 109 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 operating position by ope...

Page 229: ...the parking 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 the brake pedal 6 Gradually release the brake pedal while depressing the accelerator pedal to easily start ascending a slope 8 10 7 6 115MNEC 07 01 9 1 MNEK 01 500 ...

Page 230: ...st 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 ascending on a slope AUTO 2 Mode This mode sets 2nd range as the minimum speed gear stage This mode is suited for removing...

Page 231: ...rd L UP 4th range 4th L UP f f f f f f Reverse 2nd range 2nd L UP 3rd range 3rd L UP f f f fNOTE Start traveling with 2nd range L UP stands for lock up and indicates lockup clutch is used When lockup setting is turned OFF the L UP shift ranges are skipped during shift change Refer to page 1 61 for the lockup setting L UP shift ranges are skipped during shift down When AUTO 1 is selected the gear a...

Page 232: ... 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 8 seconds or longer The gear will not shift while the lift arm is raising The forward shift up delay will operate only one time when the bucket is in the operating position When the bucket is lower at digging position the shift delay always operates Revers...

Page 233: ...pping the machine on level ground fNOTE While running the engine when the parking brake is applied with forward reverse switch 3 in neutral parking brake indicator 2 comes ON 2 While running the engine when the parking brake is applied with forward reverse switch 3 in either the forward F or reverse R position parking brake indicator 2 comes ON and the alarm buzzer sounds F N R display 4 of the mo...

Page 234: ... by releasing the accelerator pedal Refer to item 5 on page 4 4 for the auto shifting mode 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 down the machine 1 Pres...

Page 235: ...ese indicators Turn joystick steering 3 toward the direction you intend to steer the machine during operation When joystick steering 3 is moved from the neutral centered position to the right or left the machine steer to the right or left When joystick steering 3 is returned to the neutral position the machine stops steering The further joystick steering 3 is moved to the side the faster the machi...

Page 236: ...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 237: ...rk the machine for a long period of time return the forward reverse switch 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 switch to neutral apply the p...

Page 238: ...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 239: ...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 240: ...e maximum 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 maxi...

Page 241: ...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 242: ...ock switch 7 IMPORTANT This machine is equipped with a turbocharged engine Therefore if the engine is stopped without first cooling down 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 6 Run the engine at slow idle speed for 5 minutes to cool the engine fNOTE Do not idl...

Page 243: ...ving the machine 7 Turn key switch 8 to OFF position to stop the engine Remove the key from the switch 8 Push lock button 9 and lift armrest 10 to the fully raised position 9 Before leaving the machine turn OFF the light switch close and lock all the windows cab doors and covers M4GB 01 089 8 8 Stop and Parking Position 115Z7B BKT 115Z7B 1 81 1 Raised position 115Z7B 1 10 3 10 9 ...

Page 244: ...g 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 engine Remove the key from the switch 5 Press lock side ...

Page 245: ...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 246: ... 3 mph 14 9 km h 9 3 mph 2 21 6 km h 13 4 mph 23 8 km h 14 8 mph 2L 15 4 km h 9 6 mph 17 0 km h 10 6 mph 3 35 8 km h 22 3 mph 35 8 km h 22 3 mph 3L 26 0 km h 16 2 mph 28 7 km h 17 8 mph 4 35 8 km h 22 3 mph 4L 35 8 km h 22 3 mph fNOTE When the machine speed reaches the specified machine maximum speed at the 4th speed range the engine speed automatically reduces before the auto brake is applied to ...

Page 247: ...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 248: ...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 249: ...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 250: ...xpected 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 251: ...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 252: ...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 253: ... end edge of rod 3 up to the center of proximity switch 4 orange color Then tighten bolt 2 to fix bracket 1 3 Loosen the proximity switch mounting nut and adjust the clearance between rod 3 and proximity switch 4 to 5 2 mm 0 2 0 08 in After adjusting securely tighten the mounting nut 4 After adjustment start the engine Check that the bucket can be stopped at the desired angle position 4 3 95Z7B 5 ...

Page 254: ...Chock wheels with blocks Keep bystanders away from the vicinity of the machine The bucket angle switch detects the bucket angle during operation for the judgment of the lock up or digging power control activation When the machine is shipped from the factory the bucket roll back angle is 30 degree from the road surface When required to roll back the bucket beyond this preset level position adjust t...

Page 255: ...e end edge of rod 3 up to the center of proximity switch 4 orange color Then tighten bolt 2 to fix bracket 1 3 Loosen the proximity switch mounting nut and adjust the clearance between rod 3 and proximity switch 4 to 5 2 mm 0 2 0 08 in After adjusting securely tighten the mounting nut 4 After adjustment start the engine Check that the bucket can be stopped at the desired angle position 95Z7B 5 8 1...

Page 256: ...wering 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 convenient to change the setti...

Page 257: ...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 258: ...ansmission temperature are not high The exhaust filter 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 idling...

Page 259: ...rganic man made debris plastics paper refuse etc Any other loose flammable debris Manual Regeneration Procedure 1 Park the machine in a safe and open place Place the transmission in neutral Apply parking brake Lower the front attachment level to the ground 2 Verify that items are set as shown below Forward Reverse Switch N Neutral Accelerator Pedal UP OFF Parking Brake Switch ON Loading Control Lo...

Page 260: ...he 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 Coo...

Page 261: ...e 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 temperature gauge needle st...

Page 262: ...ed with FOPS and ROPS if the machine is to be operated in the areas where the possibility of rollover or falling stones exists If operation on excessively soft ground is required operate the machine only after stabilizing the soil Be sure to wear close fitting clothing and safety equipment appropriate for the job such as a hardhat etc when operating the machine Clear all persons and obstacles away...

Page 263: ...or attachment to receive loads at only one side Damage to the machine may result Avoid Rapid Steering Changes and or Sudden Braking dWARNING Always maintain a flat work site surface Avoid rapid steering changes and sudden braking while raising the lift arm with the bucket loaded to prevent the machine from turning over Avoid Operation with Loads on Only One Side dWARNING Avoid machine abuse by all...

Page 264: ...e in a straight 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 mo...

Page 265: ...described below Always take care not to apply loads to only to one side of the bucket 1 Position the bucket teeth 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...

Page 266: ...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 267: ...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 268: ...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 269: ...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 270: ...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 271: ... 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 1 137 Never allow any person to ride on the machine to be ...

Page 272: ...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 273: ...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 Maintenance Guide List dCAU...

Page 274: ...OPERATING THE MACHINE 5 28 MEMO ...

Page 275: ...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 276: ... 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 277: ...l shifting Loading 1 Load the machine so that the center line of the machine aligns with the center line 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 278: ... 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 Option Use these eyes for securing the machine 1 11...

Page 279: ...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 280: ...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 281: ...rking brake be sure to chock tires with wheel stoppers dCAUTION As soon as towing is complete 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 br...

Page 282: ...nual release bolt 2 3 Install the flange nuts which were removed at step 1 to manual release bolt 2 4 Tighten flange nuts 4 alternately and evenly until contacting with housing 1 5 Then tighten flange nuts 4 until you feel the nuts are rather tight the brake is released fNOTE After contacting with housing 1 approximately 3 or 4 additional turns of the flange nuts will release the parking brake 6 A...

Page 283: ... 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 inserting the drawbar...

Page 284: ...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 285: ...e breakdown Failure to use recommended coolant fuel DEF 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 air breather ...

Page 286: ... of 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 d...

Page 287: ...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 288: ...Rear Axle 15 Engine 16 Third Rear Propeller Shaft 17 Transmission 18 Second Front and Center Propeller Shaft 19 Steering Cylinder 20 Front Axle 21 Lift Arm Boom Cylinder 22 Lift Arm Boom Cylinder Rod Pin 23 Bell Crank Lever Pin 24 Bucket Link Pin 25 Bucket Hinge Pin 26 First Main Propeller Shaft 27 Torque Converter 28 Cab 29 ROPS Roll Over Protective Structure 30 DEF Tank 31 DEF Supply Module 115Z...

Page 289: ...nd add if necessary GO Gear oil TO Engine oil Oil replacement EO Engine oil 115Z7 44794 24380 Lubrication Guide The lubrication chart is affixed on the left side of the front chassis Lubricate and or service the parts at the intervals as instructed in the chart so that all necessary maintenance can be performed regularly Lubrication Chart ...

Page 290: ...s unexpectedly moved a serious accident may result Be sure to apply the parking brake when parking the machine Unless specified otherwise park the machine by following the procedures below before beginning the inspection and or maintenance work 1 Park the machine on a solid level surface 2 Lower the working tools such as the bucket level to the ground 3 Turn ride control switch 3 OFF 4 Set forward...

Page 291: ...g an UNDER INSPECTION MAINTENANCE tag in a highly visible place such as on the cab door or the control lever dWARNING Never attempt to maintain the machine when the engine is running If the engine must be run while working do the following One person should be in the operator s seat and ready to stop the engine while communicating with other workers When working around moving parts is unavoidable ...

Page 292: ...tion To lock 1 Align the front and rear chassis straight ahead 2 Remove lock bolt 2 to release articulation stopper 1 from the rear chassis 3 Turn the link and fix the end to the bracket on the front chassis as shown 4 Insert the pin and clip pin This is the LOCKED position To unlock 1 Remove the clip pin and pin from the end of articulation stopper 1 on the front chassis bracket 2 Turn the link t...

Page 293: ...top cover 3 In case the machine is equipped with the fenders 2 on side covers 1 never ride on the fenders 2 1 When opening side cover 1 pull latch 6 2 When fully opening side cover 1 lock lever 5 automatically slides and is positioned in the lock position Make sure that lock bar 5 is firmly positioned to lock the cover 3 To release the lock pull wire 4 and release the end of lock bar 5 from the lo...

Page 294: ... grille is well latched fNOTE The starter key cannot be removed from latch 3 while rear grille 4 is being opened Remove bolt caps 1 and bolts 2 Release latch 3 with the starter key to unlock rear grille 4 The rear grille opens and the cooling fan can be cleaned After closing rear grille 4 turn and remove starter key 3 to lock rear grille 4 Tighten bolts 2 and install caps 1 1 2 3 4 4 115Z7B 7 10 1...

Page 295: ...d Other Cooling System 3 7 79 Replace Fuel Main Filter 7 62 Replace Fuel Pre Filter 7 64 Clean Fuel Supply Pump Strainer 7 66 Clean Fuel Priming Solenoid Pump Strainer 7 67 Drain Fuel Tank Sump 7 58 Check and Adjust Valve Clearance 7 116 Check Engine Compression Pressure 7 116 Check and Clean Starter and Alternator 7 116 Check Sound Absorbing Mat Around Engine 7 116 Replace DEF Supply Module Filte...

Page 296: ...ft Every 12000 hours 3 7 22 Greasing Front 2nd Propeller Shaft Every 12000 hours 3 7 22 Greasing Center 2nd Propeller Shaft Every 12000 hours 3 7 23 Greasing Rear 3rd Propeller Shaft Every 12000 hours 3 7 23 Clean Axle Oil Cooler Fins Option As required 7 40 Steering system Check Play Amount in Joystick Steering 7 113 Greasing Steering Cylinder 1 7 20 Clean Pilot Oil Filter 7 47 Check Gas Pressure...

Page 297: ...ab 7 112 Check and Replace Seat Belt and Lower Tether Every 3 years 7 112 Clean Engine Room and Hood 7 116 Check Steps Grab Handles and Handrails 7 115 Check Windshield Washer Fluid Level 7 113 Greasing Center Pin 7 21 Electrical system Check All Monitor Functions and Instrument Operation 7 84 Check Horn and Back Up Alarm Operation 7 85 Check Work Lights 7 85 Check Electrical Harnesses and Fuses 7...

Page 298: ... if needed 7 102 Check Refrigerant Level 7 103 Check Air Conditioner Condenser 7 102 Check Air Conditioner 7 101 Check Air Conditioner Piping 7 101 Check Compressor and Pulley 7 103 Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours 7 103 Others Check Tightening Torque of Bolts and Nuts 7 119 fNOTE 3 Shorten maintenance intervals when the machine is operated under severe conditions...

Page 299: ...gine 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 Consult your nearest authorized dealer for the unclear points Kind of Oil Engine Oil Application Engine Crank Case Air Te...

Page 300: ...n the range 15 to 45 C 5 to 113 F The acceptable ambient temperature when using TO 4M Fluid should fall within the range 30 to 45 C 22 to 113 F Hydraulic Oil Kind of Oil Hydraulic Oil Application Hydraulic System Hydraulic Oil Tank Air Temperature 20 to 45 C 4 to 113 F Change Interval 4000 hours 2000 hours Recommended Product Hitachi Super EX 46HN Alternative Product JCMAS HK VG46W fNOTE Never mix...

Page 301: ...0610 Pilot Oil Filter Steering Circuit 3098170720 Transmission Oil Filter 3098170620 Oil Tank Air Breather Valve Element 3098170990 Air Conditioner Circulating Air Filter YA00001490 Air Conditioner Fresh Air Filter 4251527 Air Conditioner Receiver Dryer 4552070070 Axle Oil Filter option 4034470090 DEF AdBlue Supply Module Main Filter YA00047054 DEF AdBlue Tank Inlet Filter YA60050027 2 Drive Belts...

Page 302: ...34 Bulb 3848070930 Work Light Front Work Light Assembly 4336570 Bulb 3848071100 Lens 4570171270 Rear Work Light Assembly 4489060370 Bulb 3848071120 Lens 4570171280 Rear Combination Light Rear Combination Light Assembly 4488160490 Lens Amber 4570171160 Clear 4570171170 Red 4570171180 4 Slow Blow Fuses Part No 70A 4315073 140A YA00021809 fNOTE The part numbers are subject to change without notice Re...

Page 303: ...emove the old grease that was pushed out from the seals and grease at the grease zerk nipple 1 One point each to right and left bucket hinge pins 1 every 100 hours 2 One point each to right and left bucket link pins 2 and 3 every 100 hours 3 One point to bucket cylinder pin 4 every 100 hours One point to bucket cylinder rod pin 5 every 100 hours 4 One point to bell crank pin 6 every 100 hours 5 On...

Page 304: ... steering cylinder pins 10 and 11 every 250 hours Cylinder right front 10 Cylinder right rear 11 8 Two points to left steering cylinder rod pins 12 and 13 every 250 hours Cylinder left front 12 Cylinder left rear 13 MNHE 07 010 12 10 11 13 ...

Page 305: ...21 9 One point each to upper and lower center hinge pins 14 and 15 every 250 hours Upper 14 Lower 15 10 One point each to front and rear axle support pins 16 and 17 every 10 hours MNHE 07 012 MNHE 07 010 15 14 16 17 ...

Page 306: ...ntinuously operated under severe conditions for a long time shorten the greasing intervals 12 One point to front second 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 MNHE 07 017 MNHE 07 013 18 26 ...

Page 307: ...y 2000 hours fNOTE When greasing spline 21 steer the machine fully to the right or left and stop the engine Lubricate the fitting start the engine and slowly turn the machine from side to side 2 or 3 times after greasing to lubricate the spline enough IMPORTANT When greased with the machine positioned in straight remove the fitting on the sleeve yoke before starting the engine 16 Two points to rea...

Page 308: ...reather nipple 25 Fill grease from grease nipple 24 until it spills out of breather nipple 25 hole Wipe the spilled grease and install breather nipple 25 fNOTE Breather nipple 25 is located on the top opposite position of grease nipple 24 MNHE 07 016 MNHE 07 013 Front axle Rear axle 24 25 24 ...

Page 309: ... it out again The oil level should be between the HIGH and LOW marks on oil level gauge 1 If oil level is below the LOW mark add the recommended engine oil via oil filler 2 If oil level exceeds the HIGH mark loosen drain plug 3 to drain excess oil m Plug 3 78 5 N m 8 0 kgf m 58 lbf ft fNOTE Level the machine when adding oil or inspecting oil level When required to check oil level after operating t...

Page 310: ... waste oil in accordance with the local regulation and or law Be sure to replace the engine oil filter when changing the engine oil at the same time 1 Park the machine following the same procedures as described on page 7 6 for preparation of inspection maintenance work 2 Clean the areas around the drain plug and the oil filler 3 Arrange a 60 liter 16 gallons capacity container to receive the drain...

Page 311: ...n page 7 15 57 liters 15 gallons IMPORTANT When filling oil take care not to allow foreign matter to enter Do not spill oil Wipe off spilled oil if any as it may cause fires 10 Securely tighten oil filler cap 2 11 Check that the oil level is between the maximum and minimum level scales on oil level gauge 1 12 Wait 5 minutes after refueling and start the engine 13 Keep the engine running at low idl...

Page 312: ...il filter make sure that the gasket is not caught at the rim This could cause oil leakage Any dirt on the cock or plug must be wiped off before installing it Do not perform abrupt engine idling which may cause an engine failure After replacement run the engine and confirm that there is no oil leakage from the area around the filter 2 Clean around the oil filler cap so that foreign matter does not ...

Page 313: ... one more turn using the tool oil filter wrench 8 Replace the other filter element in the same manner 9 Confirm that the oil pan drain cock or plug is securely tightened 10 Remove the oil level gauge and carefully supply the specified amount of engine oil from the oil filler 11 Install the oil level gauge and the filler cap 12 Start the engine 5 minutes after refueling 13 While running the engine ...

Page 314: ...Transmission Oil Never spray high pressure water to the cap and vicinity of the cap Water may enter into the transmission damage to the transmission may result 1 Park the machine on level ground apply the parking brake and lower the attachment onto the ground 2 Check the oil level with engine at low idle 3 At low oil temperature check if the oil surface level is within the COLD window of sight gau...

Page 315: ... parking brake and stop the engine dWARNING Before changing oil install articulation stopper lock bar 3 to securely hold the front and rear chassis to avoid an accident due to unexpected machine movement IMPORTANT Do not use transmission oils other than those listed in the Kind of Oils Transmission Oil 1 Operate the machine until the transmission oil is heated to the appropriate temperature 2 Park...

Page 316: ...om to drain the oil Dispose of the oil in accordance with local regulations 7 Loosen four bolts 6 with a 14 mm wrench 8 Remove flange 7 together with the pipe and suction strainer 8 9 Remove set screw 9 using a 2 5 mm 0 1 in hex allen wrench from strainer 8 10 Remove suction strainer 8 from flange 7 Brush off any debris and clean with solvent fNOTE It is normal for a few fine particles to be on st...

Page 317: ...oating the new filter gasket surface with new oil reinstall the filter on the filter head m 98 9 8 N m 10 1 kgf m 72 3 7 2 lbf ft 20 Clean and install the oil drain plug m 59 5 N m 6 0 5 kgf m 43 4 3 6 lbf ft 21 Refill the specified amount of oil through transmission oil filler port 12 90 liters 24 gallons 22 Start the engine and keep it running for two minutes 23 Check that the oil level is withi...

Page 318: ...ING Be sure to wear safety glasses when cleaning the air breather with compressed air 3 Clean the air breather using compressed air If completely contaminated wash the air breather with a cleaning solvent blow it dry and reinstall it 4 Take care not to allow foreign matter to enter when reinstalling the air breather 5 Close covers 1 and tighten bolts 2 dWARNING Be sure to tighten bolts 2 to preven...

Page 319: ...See the illustration on the next page 2 Install articulation stopper lock bar 1 to the front and rear of the chassis by following the procedures described on page 7 8 Check Differential Gear Oil Level 3 Clean the vicinity of oil level plug 2 4 Remove oil level plug 2 from the axle housing 5 If the oil level is lower than the plug add the specified oil through the level plug hole Front Axle MNHE 07...

Page 320: ...op the engine 9 Remove oil level plug 4 on the housing 10 If the oil level is lower than the plug add the specified oil through the level plug hole 11 Magnetic plugs are used for the planetary gear housing Wipe off the small amount of fine metallic powder that normally sticks to the plugs If abnormal debris is found determine the cause and correct it 12 If there is any sign of water in the oil dra...

Page 321: ...hange Differential Gear Oil 3 Clean the vicinity around drain plug 1 and the oil drain plug hole 4 Arrange a container of 120 liters 32 gallons 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 Front differential 115 liters 30 4 gallons Rear differential 115 liters 30 4 gallons...

Page 322: ... drain oil fNOTE Plug 5 can be also used to drain oil when accessible 14 Securely tighten drain plugs 5 15 Refill the specified amount of oil through oil level plug 4 Supplied oil amount 32 5 liters 8 6 gallons gear IMPORTANT It takes time for oil to fully lubricate the overall front axle After installing the plug operate the machine slowly for several minutes Then stop the engine and check the ax...

Page 323: ...ters 2 for axle oil cooler 1 Using a filter wrench turn the oil filter cartridge counterclockwise to remove it Properly dispose of them 3 Clean the oil filter head gasket surface 4 Fill the new filter cartridges with clean axle oil 5 Apply a light film of gear oil to the gasket surface of the new filter cartridge 6 Install and tighten the filter clockwise by hand until the gasket contacts filter h...

Page 324: ...s the pressure of compressed air should be at 196 kPa 28 psi or less When using high pressure water keep the nozzle a distance of at least 500 mm 20 in away from the core surface applying the water jet perpendicular to the core Move nozzle from side to side not up and down 2 Blow off mud dirt or clogging debris from the axle oil cooler 1 fins with compressed air Use a pressure washer to remove har...

Page 325: ...nts hydraulic oil and lubricants are completely cooled and after releasing residual circuit pressures 2 1 Release internal pressure 2 2 Be sure to relieve the air pressure from the hydraulic oil tank by pressing air bleed valve 1 2 3 Allow the machine to cool down Note that servicing heated and pressurized hydraulic components may cause hot parts and or oil to fly off or escape suddenly possibly r...

Page 326: ...pressure hoses to twist 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 compatible oils do not mix brands of oil The machine is filled with Super EX 46HN when it is shipped from the factory When selecting to use another brand of oil listed in the table Kind of Oils ...

Page 327: ...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 6 for preparation of inspection maintenance work 2 Check oil level with level gauge 1 on the hydraulic oil tank Float 2 must be seen on the gauge If necessary add oil fNOTE During cold weather season check the oil level after warming up the hydraulic oil by refer...

Page 328: ... procedures described on page 7 8 3 Before changing the hydraulic oil be sure to relieve the air pressure from the hydraulic oil tank 4 by pressing air bleed valve 2 IMPORTANT When changing hydraulic oil take care not to permit foreign matters such as dirt water and or sand to enter into the hydraulic oil tank 4 Remove air bleed valve 2 Arrange a container of approx 500 liters 130 gallons Remove d...

Page 329: ...oreign matter such as dirt water and or sand to enter into the hydraulic oil tank Bleed Air from the Hydraulic System 9 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 9 1 After supplying oil start the engine Do not exceed 1000 RPM min 1 Move the bucket and lift arm cylinders several t...

Page 330: ...s 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 solvent Swab out cleaning oil with a lint free cloth 3 Install cleaned suction filters 4 to the oil pipe and tighten lock nuts 2 with washers 3 m 38 N m 3 9 kgf m 28 lbf ft 4 Install ...

Page 331: ...ck bar to the front and rear of the chassis by following the procedures described on page 7 8 3 Before removing the filter element be sure to relieve the air pressure from the hydraulic oil tank by pressing air bleed valve 1 Line Filter in Steering Circuit Reducing Valve Unit 2 4 Remove plug 4 with O ring 5 dWARNING Be sure to wear safety glasses when cleaning the air breather with compressed air ...

Page 332: ...aned filter 11 with washer 12 and O ring 13 and tighten adapter 10 11 After replacing the return filter element bleed 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 2 dCAUTION If the machine is operated without bleeding the air mixed in the hydraulic circuit damage to the hydraulic pump may res...

Page 333: ...m the hydraulic oil tank by pressing air bleed valve 6 5 Loosen bolts 2 6 used to remove cover 1 and O ring 3 When removing cover 1 slowly remove the cover while pressing the cover downward so that spring 4 does not fly off Slowly permit cover to rise then carefully remove 6 Remove spring 4 and element 5 7 Replace element 5 and O ring 3 with new ones Install new element and new O ring in the hydra...

Page 334: ... tank by pressing air bleed valve 1 3 Remove cap 2 and remove nut 3 by rotating it counterclockwise 4 Rotate cover 4 counterclockwise and remove it Remove element 5 5 Install new element 5 Tighten cover 4 clockwise After cover 4 comes in contact with the inside element tighten the cover 1 4 turn further 6 Install and tighten nut 3 Install cap 2 m 3 8 10 N m 0 8 1 0 kgf m 6 7 4 lbf ft 7 Take care n...

Page 335: ...ration 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 to ON position Do not start the engine 5 Confirm the safety around the machine 6 Place the lift arm control lever to FLOAT position C and lower the bucket 1 m 3 ft off the ground within ...

Page 336: ...eed 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 nearest authorized dealer for check and repair Check Gas Pressure in Ride Control Accumulator Option every 2000 hours Check the gas pressure at a regula...

Page 337: ... injury To avoid 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 ch...

Page 338: ...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 339: ...Welded surfaces on joints Leak 12 Replace Every 250 hours Joint neck Crack 13 Replace Welded surfaces on joints Crack 12 Replace Clamps Missing Replace Deformation Replace Loose Retighten fNOTE Refer to the illustrations in Fig 2 for each check point location or for a description of the abnormality Use genuine Hitachi parts M4GB 07 059 M4GB 07 060 12 13 12 Fig 2 13 11 ...

Page 340: ...re O ring 1 remains in place and is not damaged 5 Tighten fitting 2 or nut 4 to the torque values shown Do not allow hose 5 to twist when tightening fittings 6 Check for leaks If oil leaks from a loose connection do not tighten fitting 2 Open the connection replace O ring 1 and check for correct O ring position before tightening the connection Metal Face Seal Fittings Fittings are used on smaller ...

Page 341: ...eatment 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 before b...

Page 342: ...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 from filler port 2 Take care not to spill fuel on the machine or ground Fuel tank capacity 648 liters 171 gallons Drain Water and Sediment from Fuel Tank every 1000 hours Before starting to operate the machine loosen drain plug on the fuel tank bottom and drain wat...

Page 343: ...goes to the bottom of case Draining Procedures Pre Filter 1 Remove two bottom plates 4 of the pre filter box by removing the flanged bolt 2 Connect transparent drain hose 2 stored in the tool box to drain 1 3 Place 0 5 liters or larger capacity container under drain hose 2 to collect the drained water 4 Rotate drain 1 on the bottom of the filter counterclockwise Drain the water accumulated in the ...

Page 344: ...hard to start or make it run rough or not run at all After draining water and sediment from the fuel filter replacing the fuel filter cleaning the fuel pump strainer or running the fuel tank dry be sure to bleed the air from the fuel system according to the following procedure Air Bleeding Procedure This machine is equipped with a fuel priming solenoid pump 6 dCAUTION Fuel leaks may lead to fires ...

Page 345: ...return the key switch to the OFF position Then after waiting for more than 30 seconds turn the key switch ON again Failure to do so may cause damage to fuel priming solenoid pump 5 and or discharging the batteries If Air Mixed After Common Rail dWARNING INJECTION HAZARD Fuel under high pressure High pressure common rail high pressure lines fuel lines and high pressure fuel injection lines contain ...

Page 346: ...ris water steam or cleaning solution does not get inside the fuel system 1 Prepare 1 liter 1 quart or larger capacity container to hold the drained fuel 2 Loosen and remove fuel main filter 1 using the provided filter wrench fNOTE Make sure the filter gasket 2 does not stick to the filter head 3 Apply a light film of clean engine oil to gasket surface of the new filter IMPORTANT Do not fill fuel m...

Page 347: ...epeat for the other filter 7 Turn the starter key to the ON position IMPORTANT Do not start the engine 8 Allow the fuel lift pump to prime the fuel system while leaving the starter key to the ON position for 30 seconds Then turn OFF the key to OFF position for 30 seconds It can be necessary to repeat this process two or three times 9 Turn the starter key to the START position If the engine does no...

Page 348: ...l until the filter is empty After draining fuel remove drain 5 and replace the gasket at drain 5 4 Remove transparent filter case 11 using the provided filter wrench 5 When transparent filter case 11 is removed the element and O ring for transparent filter case 11 is exposed Remove the element by hand IMPORTANT When cleaning transparent filter case 11 use clean diesel oil DO NOT use acid or alcoho...

Page 349: ... start the engine 10 Allow the fuel priming solenoid pump to prime the fuel system while leaving the starter key to the ON position for 30 seconds Then turn OFF the key to OFF position for 30 seconds It can be necessary to repeat this process two or three times 11 Turn the starter key to the START position If the engine does not start repeat above steps 9 and 10 Refer to Bleed Air from the Fuel Sy...

Page 350: ... the joint bolt clean it while being assembled 1 Loosen joint bolt 1 and take out fuel strainer 2 being assembled with joint bolt 1 from the fuel pipe on the supply pump 2 Clean the strainer in clean diesel fuel and blow off dust with high pressure air IMPORTANT After cleaning the fuel strainer bleed air from the fuel supply system 3 Reinstall strainer 2 tighten joint bolt 1 and closely check the ...

Page 351: ... every 1000 hours Cleaning When the strainer is disassembled be sure to replace the gasket Install the cover and the magnet only after thoroughly cleaning them After being assembled closely check the air tightness of the strainer 115Z7B 7 61 3 Machine RH Side ...

Page 352: ... with solvent 3 Install the strainer in the reverse order of disassembling At that time install gasket 2 into cover 1 first Then securely tighten cover 1 to pump 5 using a wrench fNOTE Wrench size 17 mm IMPORTANT Only clean and 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 ...

Page 353: ...stall bent or damaged hoses According to the check points shown below check hoses for oil leaks and damage If any problem is found replace or retighten as instructed in the table Hose Interval hours Check Points Problems Remedies Daily Hose ends Leak 1 Retighten or replace Hose covers Wear crack 2 Replace Every 250 hours Hose covers Crack 3 Replace Hose ends Crack 4 Replace Hose Bend 5 Collapse 6 ...

Page 354: ...MAINTENANCE 7 70 MEMO ...

Page 355: ...engine when replacing elements 2 Remove clip band 3 and remove cover 2 Clean out dust from inside cover 2 thoroughly 3 Remove outer element 6 by slowly pulling it out Replace outer element with new one IMPORTANT Do not reuse inner and outer element 5 6 4 In case the air filter restriction indicator lights soon after replacing outer element 6 replace both outer and inner elements with new ones Inne...

Page 356: ...s LLC liter gallon Soft Water liter gallon 15 5 0 33 29 0 7 7 59 0 15 5 20 4 0 38 33 4 8 8 54 6 14 4 25 13 43 37 8 10 0 50 2 13 2 30 22 48 42 2 11 1 45 8 12 1 fNOTE To avoid water impurity and minerals a premixed coolant is recommended to use dWARNING Antifreeze is poisonous if ingested it can cause serious injury or death Induce vomiting and get emergency medical attention immediately When storin...

Page 357: ...lant mixture via cap hole 2 on reservoir 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 is diluted so that anti rust and antifreeze effect in the coolant will become diluted and less affective IMPORTANT If the coolant level is low EGR cooler i...

Page 358: ... the value is not within the range adjust the tension 3 Check the belt for a damage such as a scratch and crack 4 When the belt adjusting allowance is no longer available when crack damage or abnormal wear is found or when the belt squeaks during driving even after the belt tension has been adjusted replace the belt Adjusting Drive Belt 1 Loosen idler pulley s lock nut 1 Lock nut 1 137 157 N m 14 ...

Page 359: ...the specified torque Lock nut 1 137 157 N m 14 16 kgf m 101 116 lbf ft 6 After the adjustment run the engine at the idling speed for approx 5 minutes and then stop the engine to recheck the belt tension dCAUTION When the generator is fixed the belt tension slightly changes so check the belt tension again after the generator is fixed If the lock nut that is fixing the idler pulley is not tightened ...

Page 360: ...aler for the replacement interval 1 Park the machine following the same procedures as described on page 7 6 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 12 3 Prepare a container to capture approx 88 liters 23 2 gallons of drained coolant Recycle or properly dispose of the used coola...

Page 361: ...out of outlet 8 Tighten valve 7 after the bleeding is complete Tightening torque 23 5 N m 17 3 lbf ft 11 Refill the coolant to the bottom level 4 of the radiator filler port fNOTE The drained coolant in the above step 9 can be used 12 Tighten radiator cap 1 firmly 13 Supply the LLC up to FULL level line 5 of the radiator sub tank 14 Start the engine and run the engine at low idle for about 5 minut...

Page 362: ...6 F keep running the engine at high idle for at least 6 minutes This opens the engine thermostat and releases the air between the radiator and the engine Keep the coolant temperature at 80 C 176 F or higher during this high idle operation IMPORTANT Failure to keep the engine at high idle and the coolant temperature at 80 C 176 F or above for at least 6 minutes may result in air remaining in the EG...

Page 363: ... nozzle away from the core surface more than 500 mm 20 inch Over the Side Cover Check and clean engine charge air cooler 1 HVAC condenser 2 and fuel cooler 3 Over the Rear Grille dWARNING Make sure the fan is not rotating before opening the rear grill Check and clean hydraulic oil cooler 4 radiator 5 torque converter oil cooler 6 and hydraulic driven fan 7 In case dirt or dust sticks to the radiat...

Page 364: ... of such components is required contact your authorized dealer Batteries dWARNING Battery gas can explode Keep sparks and flames away from batteries Check batteries only when cool Use a flashlight to check the battery electrolyte level Do not continue to use or charge the battery when electrolyte level is lower than specified Explosion of the battery may result Sulfuric acid in battery electrolyte...

Page 365: ...tteries 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 damaging painted surfaces and or corroding other machine parts fNOTE In case electrolyte solution is filled above the specified uppe...

Page 366: ...t and a mirror to do this It is difficult to accurately judge the electrolyte solution level in this case Therefore when the electrolyte solution level is flush with the U L the level is correct Referring to the illustrations to the right check the level When the electrolyte solution level is lower than the bottom end of the sleeve refill with distilled water or commercial battery fluid up to the ...

Page 367: ...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 368: ...e This difference could overload one of the batteries and cause it to fail fNOTE When replacing batteries 1 remove bolts 2 5 used and remove box 3 surrounding the batteries j 17 mm m 53 N m 5 4 kgf m 39 lbf ft Box 3 weight 25 kg 55 lb 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 ...

Page 369: ...rea of other personnel The horn switch button is located at the steering wheel center and on the right console In case the machine is equipped with a multi function joystick lever the horn switch is located on the multi function joystick lever fNOTE Refer to page 1 8 through 1 11 for the location of these switches Horn 1 is located on the front chassis Backup alarm 2 is located at the left side of...

Page 370: ... burning odor 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 or two each spare fuse for respective fuse capacities is provided in the fuse boxes A B 3 Finally check slow blow fuses 1 2 located on the left side of the m...

Page 371: ... Head lamp right 5 A 12 Option 2 ACC1 20 A 1 CONTROLLER SUB 10 A 11 Radio USA 10 A Fuse Box B 10 ECM 30 A 20 Secondary steering option 5 A 9 CONTROLLER SUB 10 A 19 High beam 10 A 8 Main controller DSZ Monitor Load dump relay GPS GSM OPT C U 10 A 18 Rear wiper 10 A 7 Flasher unit 10 A 17 Working lamp rear 20 A 6 Horn 10 A 16 Loader control 5 A 5 Option CAN 5 A 15 MC solenoid power 10 A 4 Option 1 b...

Page 372: ...n OFF the declutch switch 2 Firmly step on the left hand brake pedal 3 Release the parking brake 4 Select the transmission shift lever 2nd and FORWARD 5 Slowly accelerate the engine to full speed 6 The machine should not move IMPORTANT If machine moves when firmly step on right hand brake with transmission in 2nd and FORWARD there is some problem with service brake Do not operate until problem has...

Page 373: ...rmally test the parking brake 1 Move the machine to a safe open place on a 15 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 operat...

Page 374: ...inspection maintenance work 2 Install articulation stopper lock bar 1 to the front and rear of the chassis by following the procedures described on page 7 8 3 Clean the vicinity of oil plugs 2 3 4 Remove oil level plugs 2 3 for oil level check 5 Fill the oil from plug 2 until oil comes out of plug 3 6 Install and tighten plugs 2 3 115Z7 7 91 2 MNHE 07 005 1 3 2 ...

Page 375: ... Adjust so that the TOP mark on the planetary gear housing comes top See the illustration on the next page 2 Install articulation stopper to the front and rear of the chassis by following the procedures described on page 7 8 3 Clean the vicinity around plugs 1 2 3 and the oil drain plug holes 4 Arrange a container of 3 liters 0 8 gallons capacity to receive the drain oil 5 Remove drain plug 1 to d...

Page 376: ...tor indicators come ON 2 Note that alarm function is deactivated Start the engine Run the engine at 1 200 RPM min 1 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 3 strokes before the...

Page 377: ...st authorized dealer for checking Check Gas Pressure in Accumulator every 2000 hours Check the gas pressure at a regular interval If the machine is operated with the gas pressure lower than specified value normal brake performance and or loading performance may not be to specifications achieved possibly creating very hazardous situations Ask your nearest authorized dealer for checking fNOTE Check ...

Page 378: ...he 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 Check Air Pressure 1 Measure air pressure when the tires are cool before operating the machine Radial tire stand...

Page 379: ...chine by using unauthorized tire sizes 1 Park the machine following the same procedures as described on page 7 6 for preparation of inspection maintenance work 2 Install the articulation stopper to the front and rear of the chassis by following the procedures described on page 7 8 3 Loosen all wheel bolts one turn Note which way the tread pattern is facing 4 After jacking up the machine securely s...

Page 380: ... in conformity with the work mode the machine is engaged in Tire Sizes to be Used Consult your nearest authorized 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 s...

Page 381: ...al positions Align the tire rotation direction with the tire tread design pattern Tread design pattern direction option 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 X mark 1 in the figure Use limit of the groove depth shall be approx 85 of the new tire groove dept...

Page 382: ...necessary 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 w...

Page 383: ...PORTANT If compressed air delivery pressure is high damage to the filter fins may result Always use compressed air at the lower pressure than 0 2 MPa 2kgf cm2 30 PSI Keep the nozzle more than 500 mm 20 in away from the core surface 4 Clean fresh filter 4 using compressed air IMPORTANT Incorrect installation of the filter may cause dust to enter into the air conditioner causing malfunction or break...

Page 384: ...m clean or lightly tapping to dust the filter IMPORTANT Inappropriate installation of the filter may cause dust to enter into the air conditioner causing malfunction or breakdown of the air conditioner Before installing the filter element clean off dust around the mounting area install the filter element with extra care Keep cab doors closed when operating machine 4 Install the cleaned circulation...

Page 385: ...cooling mode once a week to prevent lack of lubrication dCAUTION Avoid steam cleaning Do not clean the compressor and receiver tank with steam The high temperature will cause the refrigerant gas pressure to increase possibly causing the hoses to break This could injure personnel Check Air Conditioner Piping every 6 months dIMPORTANT If any leakage is found repair or replace the corresponding pipes...

Page 386: ...onditioner Compressor Belt every 6 months Check the belt for abnormal deflection and damage Check HVAC belt tension by using tension gauge Belt tension 412 49 N 42 5 kgf 93 11 Ibf fNOTE The belt tension should be 588 98 N 60 10 kgf 132 22 lbf when the belt is replaced with new one Compressor Belt Tension Adjustment Procedure 1 Loosen lock nuts 2 6 of tension pulley 4 2 Remove plate 5 and tension p...

Page 387: ...mosphere 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 fNOTE This machine uses new refrigerant R134a Type Refrigerant No Quantity kg HFC R134a 1 00 0 05 Check Compressor and Pulley once a year Check the compressor...

Page 388: ...operated in dusty areas refer to 9 1 Maintenance Under Special Environmental Conditions 1 Open the left side cover 2 Check exhaust pipe 1 and pipe 2 for cracks Check the aftertreatment device units for loose or disconnection Check the lagging cover for breaks fNOTE Do not remove the lagging cover 3 Check the connectors and harnesses of NOx sensors 3 temperature sensors 4 and dosing module 5 for ab...

Page 389: ...er when it contacts on the skin If you swallow DEF by mistake drink 1 or 2 cups of water or milk and seek immediate medical attention If DEF is accidentally splashed into eyes flush with water for 15 minutes or longer and get emergency medical attention IMPORTANT Use dedicated container recommended by the business entity who is handling DEF to store DEF Do not use general container a container use...

Page 390: ... clean water when it contacts on the skin 1 Park the machine following the same procedures as described on page 7 6 for preparation of inspection maintenance work 2 DEF tank 2 is located in the cover at left rear of the machine Open and secure the cover 3 by turning stopper plate 4 downward 3 Clean dust and mud around the filler port of DEF tank with clean cloth 4 Remove cap 5 from DEF tank 2 and ...

Page 391: ...DEF Or use polyethylene resin tank or stainless tank Clean DEF Strainer Check strainer 6 installed at the inlet of DEF tank and clean it as needed dCAUTION Use rubber gloves and goggles or safety glasses for protection during operation Wash DEF with clean water when it contacts on the skin If splashed in eyes flush with water for 10 to 15 minutes Get medical attention immediately IMPORTANT Take ca...

Page 392: ...esult Change DEF periodically to keep cleanliness in the tank 1 Remove bolts 1 with washers and remove cover 2 2 Place 60 liter 16 gal or larger capacity container under drain plug 3 3 Slowly loosen drain plug 3 to drain DEF 4 Tighten drain plug 3 after draining DEF l 13 mm m 19 5 4 N m 2 0 0 4 kgf m 14 4 3 lbf ft 5 Fix cover 2 with bolts 1 with washers 6 Remove the cap from DEF tank and refill DE...

Page 393: ... engine the DEF pump keeps operating Wait for 3 minutes or more after turning OFF the key switch until the pump stops running 1 Park the machine following the same procedures as described on page 7 6 for preparation of inspection maintenance work fNOTE The DEF supply module DEF pump is located on the frame left rear of the machine 2 Remove bolts 1 nuts 5 6 with washers and covers 7 8 9 3 Remove ca...

Page 394: ... or when DEF spills out while filling IMPORTANT Do not clean or reuse DEF tank inlet filter 1 Locate filter 1 inside the DEF tank covering DEF tank inlet cap 2 Replacement of filter 1 is required regularly or if DEF spills out while pouring it from the tank inlet port Contact your nearest authorized dealer for assistance 115Z7B 7 104 2 95Z7B 7 126 2 1 2 ...

Page 395: ... or safety glasses hard hat and face shield 1 Raise the bucket to an appropriate height with the bucket bottom parallel to the ground Insert hard wood support blocks under the bucket to support it Stop the engine 2 Remove lock pin 1 and remove bucket teeth 2 from adapter nose 4 using tool 3 3 Install new teeth 2 onto adapter 4 4 Install lock pin 1 with the guide rib 5 facing back 115Z7 7 95 1 95ZV...

Page 396: ...ttaching hardware 2 and seat belt web Replace the seat belt web buckle or attaching hardware if they are damaged or worn Also check the wind up condition of the seat belt Replace seat belt and lower tether every 3 years regardless of appearance Check ROPS ROPS Mounting Bolts and Cab every 10 hours daily Check the appearance of ROPS 1 and Cab 3 for any abnormal damage or deformation Check the condi...

Page 397: ...linders operate normally 1 Start the engine Turn the parking brake switch ON 2 Slightly lift the bucket above the ground Place control lever lock 2 in the lock position 3 While running the engine at slow speed slightly and slowly move the joystick steering right and left Measure the beginning movement distance from the center neutral position of steering lever until both right and left steering cy...

Page 398: ... air when carrying out warming up warm up operation indoor Failure to do so may cause asphyxiation from exhaust gas resulting in death or severe injury IMPORTANT This machine is equipped with the engine that meets Interim 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 color slightly beco...

Page 399: ...s Clean if needed Check Steps and Handrails for Damage and Looseness every 10 hours 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 ...

Page 400: ...rs daily dCAUTION If the sound absorbing mat in the engine compartment loosens 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 has loosened If any part of the mat is found loose immediately contact your nearest authorized dealer for repair Check and Adjust Valve Clearance every 1000 hours Consul...

Page 401: ...k and Adjust Engine Controller ECM every 4500 hours Consult your nearest authorized dealer for check and repair Check and Clean EGR Valve every 4500 hours Consult your nearest authorized dealer for check and repair Check and Clean EGR Cooler every 4500 hours Consult your nearest authorized dealer for check and repair Check Urea SCR System every 4500 hours Consult your nearest authorized dealer for...

Page 402: ...by gently wiping surface of the camera lens with a damp cloth IMPORTANT Never use organic solvent Do not apply excessive force as it may damage the camera Retighten Front Axle and Rear Axle Support Mounting Bolts every 2000 hours Maintenance required only during first time 50 operating hours Check front and rear axle support mounting bolts for looseness Refer to page 7 120 for details ...

Page 403: ... 400 40 295 300 30 221 120 12 88 5 27 14 20 0 79 550 55 406 400 40 295 170 17 125 30 27 17 22 0 87 750 75 553 550 55 406 220 22 162 32 24 0 94 950 95 700 700 70 516 280 28 207 36 32 19 27 1 06 1400 140 1033 1050 105 774 400 40 295 41 30 1 18 1950 195 1438 1450 145 1069 550 55 406 46 33 1 30 2600 260 1918 1950 195 1438 750 75 553 50 36 1 42 3200 320 2360 2450 245 1807 950 95 700 55 dCAUTION If coun...

Page 404: ...145 kgf m 1045 lbf ft 2 Rear axle support mounting bolt Bolt diameter 24 mm 0 95 in Quantity 14 Wrench size 36 mm Tightening torque 721 N m 73 5 kgf m 532 lbf ft 3 Wheel rim mounting bolt Bolt diameter 24 mm 0 95 in Quantity 124 Wrench size 32 mm Tightening torque 892 N m 91 kgf m 658 lbf ft MNHE 07 058 MNHE 07 057 115Z7B 7 114 2 ...

Page 405: ...aent Second propeller shaft Bolt diameter 14 mm 0 55 in Quantity 8 Wrench size 22 mm Tightening torque 221 N m 22 5 kgf m 163 lbf ft fNOTE Apply Loctite 262 or equivaent Third propeller shaft Bolt diameter 12 mm 0 47 in Quantity 8 Wrench size 19 mm Tightening torque 142 N m 14 5 kgf m 105 lbf ft fNOTE Apply Loctite 262 or equivaent 115Z7 7 114 1 View from Top Open Deck 115Z7B 7 32 1 115Z7B 7 135 2...

Page 406: ...diameter 20 mm 0 8 in Quantity 8 Wrench size 30 mm Tightening torque 400 N m 40 kgf m 295 lbf ft fNOTE Apply Loctite 262 or equivaent Bolt B Bolt diameter 20 mm 0 8 in Quantity 2 Wrench size 30 mm Tightening torque 550 N m 55 kgf m 406 lbf ft fNOTE Apply lubrication oil Bolt C Bolt diameter 16 mm 0 63 in Quantity 8 Wrench size 24 mm Tightening torque 210 N m 21 kgf m 155 lbf ft fNOTE Apply Loctite...

Page 407: ...ench size 30 mm Tightening torque 550 N m 55 kgf m 406 lbf ft Bolt D Bolt diameter 16 mm 0 63 in Quantity 2 Wrench size 24 mm Tightening torque 210 N m 21 kgf m 155 lbf ft fNOTE Apply lubrication oil both C and D 9 Engine mounting bolt Bolt A Bracket Bolt diameter 14 mm 0 55 in Quantity 8 Wrench size 22 mm Tightening torque 142 N m 14 5 kgf m 105 lbf ft fNOTE Apply Loctite 262 or equivaent Bolt B ...

Page 408: ...eter 10 mm 0 4 in Quantity 20 Wrench size 17 mm Tightening torque 50 N m 5 kgf m 37 lbf ft Bolt C Bolt diameter 16 mm 0 63 in Quantity 6 Wrench size 24 mm Tightening torque 210 N m 21 kgf m 155 lbf ft 11 Counterweight mounting bolt Bolt diameter 24 mm 0 95 in Quantity 8 Wrench size 36 mm Tightening torque 721 N m 73 5 kgf m 531 lbf ft 115Z7B 7 137 1 A C A B B B A 115Z7B 7 137 4 ...

Page 409: ...0 mm 0 8 in Quantity 6 Wrench size 30 mm Tightening torque 675 N m 69 kgf m 498 lbf ft fNOTE Apply lubrication oil 14 Bottom center pin lock Bolt diameter 20 mm 0 8 in Quantity 1 Wrench size 30 mm Tightening torque 550 N m 55 kgf m 406 lbf ft 15 Steering cylinder pin lock Bolt diameter 16 mm 0 63 in Quantity 4 Wrench size 24 mm Tightening torque 210 N m 21 kgf m 155 lbf ft 115Z7B 7 137 3 MNHE 07 0...

Page 410: ...s Bolt diameter 20 mm 0 8 in Quantity 18 Wrench size 30 mm Tightening torque 550 N m 55 kgf m 406 lbf ft Bolt B Bolt diameter 24 mm 0 95 in Quantity 16 Wrench size 36 mm Tightening torque 700 N m 70 kgf m 516 lbf ft 115Z7B 7 138 1 MNHE 07 010 MNHE 07 011 B A A A A A A A A A ...

Page 411: ...orque 210 N m 21 kgf m 155 lbf ft Bolt B Radiator core Bolt diameter 10 mm 0 39 in Quantity 4 Wrench size 17 mm Tightening torque 44 N m 4 5 kgf m 32 5 lbf ft 18 T C oil cooler mounting bolt Bolt diameter 10 mm 0 39 in Quantity 2 Wrench size 17 mm Tightening torque 50 N m 5 kgf m 37 lbf ft 115Z7B 7 139 1 A X View X B 18 ...

Page 412: ... lbf ft Bolt B Hydraulic oil cooler Bolt C Fuel cooler Bolt D Air cooler Bolt diameter 12 mm 0 47 in Quantity 12 Wrench size 19 mm Tightening torque 90 N m 9 kgf m 66 4 lbf ft 20 Air conditioner compressor mounting bolt Bolt diameter 8 mm 0 3 in Quantity 4 Wrench size 13 mm Tightening torque 24 5 29 4 N m 2 5 3 kgf m 18 21 7 lbf ft 115Z7B 7 140 2 115Z7B 7 140 3 C A A A B 115Z7B 7 140 1 C C D D ...

Page 413: ...Bolt diameter 16 mm 0 63 in Quantity 4 Wrench size 22 mm Tightening torque 210 N m 21 kgf m 155 lbf ft 22 ROPS mounting bolt Bolt diameter 30 mm 0 63 in Quantity 22 Wrench size 46 mm Tightening torque 1421 N m 145 kgf m 1048 lbf ft MNHE 07 070 MNHE 07 066 ...

Page 414: ...02 N m 245 kgf m 1772 lbf ft 24 Wear plate mounting bolt Bolt diameter 7 8 9UNC in Quantity 8 Wrench size 36 mm Tightening torque 834 N m 85 kgf m 615 lbf ft 25 Combination valve mounting bolt Bolt diameter 10 mm 0 39 in Quantity 4 Wrench size 14 mm Tightening torque 50 N m 5 kgf m 37 lbf ft 115Z7 7 95 1a 90Z7 7 113 2 115Z7B 1 142 4 ...

Page 415: ...lity fuel suitable for low temperature Check the fuel tank breather pipe freezing Lubricant Use high quality low viscosity hydraulic oil and engine oil Engine Coolant Be sure to use antifreeze Battery Fully charge the batteries regularly at shorter service intervals If not charged fully electrolyte may freeze Tires and Chassis Keep fires and chassis clean Park the machine on a hard surface to prev...

Page 416: ...e oil in the engine crankcase 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 work ru...

Page 417: ...l be frozen Use tire chains on all four wheels 10 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 ...

Page 418: ...9 4 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ...

Page 419: ... do not use it DEF may start freezing at 10 C 12 F Freezing does not affect its performance once thawed Never use a container used for any other liquid or oil Contaminated DEF will cause the SCR system to work incorrectly resulting in a vehicle operating illegally Prevention of Dust and Moisture Store the machine in a dry garage and cover it Tools Inspect and repair then store Periodic Operation O...

Page 420: ...eration Failure to do so may cause damage to the engine hydraulic 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 St...

Page 421: ...e 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 need...

Page 422: ...10 4 STORAGE MEMO ...

Page 423: ...ne 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 Low coolan...

Page 424: ...ange fuel Refill tank with good quality fuel Faulty glow plug Replace glow plug 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 ...

Page 425: ...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 426: ...o page 3 3 F R switch failure Repair Replace Armrest switch failure Repair Replace Controller failure Repair Replace Joystick steering system does not turn off when the armrest is fully raised Armrest switch failure Repair Replace Controller failure Repair Replace Defective wiring Repair Replace Joystick steering lever movement is hard or stiff or does not return to neutral when released Defective...

Page 427: ...haft is noisy Excessively worn spline Replace Worn or seized spider bearing Replace Loosened parts Retighten Insufficient greasing Grease Front and or rear axle is noisy Worn or broken gears Replace Lack or deterioration of gear oil Refill Replace Worn bearings Excess play Replace Excess play on shaft spline Repair Replace Front and or rear axle does not transmit power Broken axle Repair Broken ge...

Page 428: ...11 6 TROUBLESHOOTING MEMO ...

Page 429: ...ght mm in 5040 200 H Dumping Clearance 45 mm in 3270 130 I Dumping Reach 45 mm in 2045 81 R1 Minimum Rotation Radius mm in 7545 295 R2 Minimum Rotation Radius mm in 8835 348 Travel Speed Forward Reverse km h mph 35 1 24 6 21 8 15 3 Transmission Speeds F R 4 3 Articulation Angle Left Right deg 37 Tire Size 35 65R33 L5 fNOTE These specifications are subject to change without notice Specifications In...

Page 430: ...SPECIFICATIONS 12 2 MEMO ...

Page 431: ...on Lock 7 8 Articulation Stopper 1 137 S 38 Asbestos S 33 Ash Tray 1 114 Auto Air Conditioner 1 115 Auto Brake 4 20 Auto Idling Stop 1 53 5 11 Auto Idling Stop Acting Time Setting 1 54 Auto Idling Stop ON OFF 1 53 Auto Idling Stop Operating Condition 5 12 Auto Transmission Shift Range 4 5 Automatic Regeneration 1 5 Automatic regeneration Auto regeneration 1 35 Auxiliary Control Lever Option 1 101 ...

Page 432: ...lot Circuit Accumulator Function Gas Leakage Looseness and Damage 7 51 Check Planetary Gear Oil Level 7 36 Check Play Amount in Joystick Steering Movement 7 113 Check Play in Brake Pedal Stroke 7 88 Check ROPS 7 112 Check ROPS Mounting Bolts 7 112 Check Rearview Mirror and Inside Rearview Mirror 7 115 Check Refrigerant 7 103 Check Ride Control Accumulator Function Gas Leakage Looseness and Damage ...

Page 433: ...ank 7 58 Draining Procedures Pre Filter 7 59 Drink Holder 1 127 Drive Belt Adjusting 7 74 Drive Belt Check 7 74 Drive Belt Replace 7 75 Drive Function Troubleshooting 11 4 Drive Machine Safely Work Site S 13 Drive Safely S 12 Drive Safely with Bucket Loaded S 14 Drive Speed Change Manual Shift 4 8 Drive on Snow Safely S 14 Driving On Roads Precaution 6 5 Driving on Public Roads Standard Pressure 7...

Page 434: ...Height Kickout ON OFF Stop Height Setting 1 40 High Beam Indicator Blue 1 18 Hold Switch 1 110 Hood Clean 7 116 Horn Switch 1 113 Horn Check 7 85 Hoses and Lines Check 7 53 Hot Cool Box 1 127 Hour Meter Check Regularly 7 3 How to Check Wear Amount Tread Design Groove Depth 7 97 How to Use Screens 1 22 Hydraulic Coupler Switch Option 1 107 Hydraulic Oil 7 16 Hydraulic Oil Level Indicator Red 1 13 H...

Page 435: ...side Rear View Mirror 1 133 Overheat Indicator Red 1 15 P Parallel Tandem Switching Height Setting 1 65 Park Machine Safely S 21 Parking 4 18 Parking Brake Disks Check 7 93 Parking Brake Force Check 7 89 Parking Brake Gear Oil Level Check 7 90 Parking Brake Gear Oil Change 7 91 Parking Brake Indicator Red 1 13 Parking Brake Switch 1 88 4 7 Pedals 1 85 Perform Truck Loading Safely S 18 Pilot Circui...

Page 436: ...ting Option 1 38 Ride Control Switch Option 1 109 Ride Control Switch AUTO 1 109 Ride Control Switch OFF 1 109 Right Console 1 10 1 96 Right Console Slide Lever 1 111 Right Console Switches 1 99 Right and Left Brake Interlocking Performance Check 7 88 Roll Over Protective Structure ROPS S 40 ROPS Check 7 112 ROPS Roll Over Protective Structure S 11 S 40 ROPS Mounting Bolts Check 7 112 Rotary Light...

Page 437: ...nt Situation 6 5 Transporting by Road 6 1 Travel Mode Selector Switch 1 104 Travel on Public Roads Safely S 15 Traveling Precaution 4 12 Tray 1 127 Troubleshooting 1 80 11 1 Turbocharger Check 7 117 Turn Signal Indicator Green 1 18 Turn Signal Switch 1 101 U Understand Signal Words S 1 Upper Switch Panel Option 1 132 Urea SCR System 7 105 Urea SCR System Malfunction 1 33 Urea SCR System Check 7 11...

Page 438: ...INDEX 14 8 ZW550 6 US MEMO ...

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