Руководство по эксплуатации погрузчиков hitachi

• Page 1
  PART NO. ENMNFB-NA1-2 Operator’s Manual Wheel Loader URL:http://www.hitachi-c-m.com Serial No. 005201 and up This book is printed on recycled paper. PRINTED IN JAPAN (T) 2018, 06…
• Page 2
  INTRODUCTION Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support service your machine correctly. Failure to do so could program for customers who operate and maintain their result in personal injury or machine damage.
• Page 3
  INDEX MACHINE NUMBERS SAFETY SAFETY LABELS COMPONENTS NAME OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE MOVING THE MACHINE OPERATING THE MACHINE TRANSPORTING MAINTENANCE MAI N TENANCE UNDER SPECI A L ENVI R ONMENTAL CONDI T I O NS STORAGE TROUBLESHOOTING SPECIFICATIONS OTHER ATTACHMENTS INDEX ENMNFB-NA1-2…
• Page 4
  MEMO …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..

• Page 5: Table Of Contents

  CONTENTS MACHINE NUMBERS …………1 Prevent Parts from Flying …………S-27 Prevent Burns …………….. S-27 Machine ………………..1 Replace Rubber Hoses Periodically ……..S-28 Engine ………………….1 Avoid High-Pressure Fluids …………S-28 Aftertreatment Device ……………2 Prevent Fires ………………. S-29 Evacuating in Case of Fire …………S-30 SAFETY …………….

• Page 6
  CONTENTS Fuel Gauge ………………1-16 Hazard Switch …………….1-82 Turn Signal Indicator (Green) ……….. 1-17 Work Light Switch ……………. 1-83 High Beam Indicator (Blue) …………1-17 Parking Brake Switch …………..1-84 Work Light Indicator (Yellow) ……….. 1-17 Neutral Lever Lock (for the Forward/Reverse Lever) ..1-85 Clearance Light Indicator (Green) ……….
• Page 7
  CONTENTS OPERATING THE ENGINE ……….3-1 Components Name …………..1-115 Controller Part Name and Function …….1-116 Inspect Machine Daily Before Starting ……..3-1 Mode/Temperature Control Switch ……1-116 Check Before Starting …………..3-3 Fan/AUTO Switch ………….1-117 Starting Engine …………….3-5 Air Conditioner ON/OFF Switch ………1-117 Starting in Cold Weather……………3-7 Circulation/Fresh Air Switch ……..1-117 Preheating ………………3-7…
• Page 8
  CONTENTS Excavation ………………5-17 Check Vibration Damper …………7-32 Loading Accumulated Soil……….. 5-17 C. Power Train …………….7-33 Digging and Loading Level Ground ……… 5-18 Check Transmission Oil Level ……….7-33 Grading ……………….. 5-19 Change Transmission Oil …………7-34 Loading ……………….. 5-20 Change Transmission Oil Filter ………..
• Page 9
  CONTENTS Replace DEF/AdBlue® Supply Module Main Filter ..7-109 Precautions for Using DCA4 ……….7-71 N. Miscellaneous ……………..7-110 Check Coolant Level ………….. 7-72 Check Bucket Teeth and Cutting Edge ……7-110 Check Drive Belt …………..7-73 Check and Replace Seat Belt and Lower Tether ..7-111 Replace DCA4 Coolant Filter Cartridge ……
• Page 10
  CONTENTS Operating Procedures …………13-7 Descriptions of Warnings ………..13-10 Axle Oil Cooler …………….13-12 Axle Oil Cooler (Optional) ……….13-12 Maintenance Guide of the Axle Oil Cooler ….13-12 Axle Oil ………………13-12 Check Axle Oil Level ………….13-13 Change Axle Oil …………..13-14 Replace Axle Oil Cooler Line Filter (Option) ….13-15 Clean Axle Oil Cooler Fins (Option) ……..13-16 INDEX …………….

• Page 11: Machine Numbers

  MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.

• Page 12: Aftertreatment Device

  MACHINE NUMBERS Aftertreatment Device TYPE MFG. NO. 90Z7B_SCR_SN TYPE MFG. NO. 90Z7B_SCR_SN…

• Page 13: Safety

  SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices. SA-2644 Understand Signal Words …

• Page 14: Follow Safety Instructions

   Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Carefully read and follow all instructions for use and safety in the operator’s manual for the attachment. Failure to do so may deteriorate the safety, function, and/or service life of the machine.

• Page 15: Prepare For Emergencies

  SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly. …

• Page 16: Protect Against Noise

  SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine …

• Page 17: General Precautions For Cab

  SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and / or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and / or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.

• Page 18: Use Handrails And Steps

  SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as handholds. …

• Page 19: Ensure Safety Before Rising From Or Leaving Operator’s Seat

  SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position.

• Page 20: Move And Operate Machine Safely

  SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Be advised that there may be blind spots with rear view camera. Confirm the location of bystanders before moving, swinging, or operating the machine by sight and mirrors as well as the rear view monitor.

• Page 21: Operate Only From Operator’s Seat

  SAFETY Operate Only from Operator’s Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator’s seat.  NEVER start the engine while standing on the tire or on ground.

• Page 22: Investigate Job Site Beforehand

  SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.

• Page 23: Equipment Of Head Guard, Rops, Fops

  SAFETY Equipment of Head Guard, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) Any modification of the ROPS structure will modify its performances and its certification will be lost.

• Page 24: Keep Riders Off Machine

  SAFETY Keep Riders Off Machine  Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

• Page 25: Drive Machine Safely (Work Site

  SAFETY Drive Machine Safely (Work Site)  Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions. …

• Page 26: Drive Safely With Bucket Loaded

  SAFETY Drive Safely with Bucket Loaded  If the machine is operated incorrectly while driving with the bucket loaded, the machine may turn over. Be sure to follow all of the instructions indicated below.  When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.

• Page 27: Travel On Public Roads Safely

  SAFETY Travel on Public Roads Safely  This machine is not allowed to drive on public roads with the bucket loaded.  Be sure to empty the bucket.  Hold the bucket at mark (A) 500 mm (20 in) above the road surface as illustrated.

• Page 28: Avoid Accidents From Backing Up And Turning

  SAFETY Avoid Accidents from Backing Up and Turning  Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and / or death by being run over or entangled in the machine.

• Page 29: Avoid Positioning Bucket Or Attachment Over Anyone

  SAFETY Avoid Positioning Bucket or Attachment Over Anyone  Never allow the bucket or attachment to pass over co- workers and / or the dump truck operator’s cab. Falling material from the bucket or contact with bucket or attachment may cause serious personal accidents and / or damage to the machine.

• Page 30: Never Undercut A High Bank

  SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death. SA-519 Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and / or fire, possibly resulting in serious injury or death.

• Page 31: Avoid Power Lines

  SAFETY Avoid Power Lines Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length. SA-455 Precautions for Operation …

• Page 32: Object Handling

  SAFETY Object Handling CRANING OPERATION USING THE MACHINE IS NOT ALLOWED.  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example).

• Page 33: Park Machine Safely

  SAFETY Park Machine Safely To avoid accidents:  Park the machine on a firm, level surface.  Lower bucket to the ground.  Put the forward / reverse lever (switch) in neutral, and turn the parking brake switch (lever) ON (parking brake) position.

• Page 34: Transport Safely

  SAFETY Transport Safely  Be careful because the machine may turn over when loading or unloading the machine on or off of a truck or trailer.  Observe the related regulations and rules for safe transportation. Less than 15 ° …

• Page 35: Handle Fluids Safely−Avoid Fires

  SAFETY Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and / or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.

• Page 36: Practice Safe Maintenance

  SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving. …

• Page 37: Warn Others Of Service Work

  SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

• Page 38: Stay Clear Of Moving Parts

  SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. SA-026 Support Maintenance Properly …

• Page 39: Prevent Parts From Flying

  SAFETY Prevent Parts from Flying  Travel reduction gears are under pressure.  As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.  GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

• Page 40: Replace Rubber Hoses Periodically

  SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Page 41: Prevent Fires

  SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.

• Page 42: Evacuating In Case Of Fire

  SAFETY Check Key Switch:  If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at low idle. 2.

• Page 43: Beware Of Exhaust Fumes

  SAFETY Beware of Exhaust Fumes  Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.  If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

• Page 44: Avoid Applying Heat To Lines Containing Flammable Fluids

  SAFETY Avoid Applying Heat to Lines Containing Flammable Fluids  Do not weld or flame cut pipes or tubes that contain flammable fluids.  Clean them thoroughly with nonflammable solvent before welding or flame cutting them. Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper.

• Page 45: Remove Paint Before Welding Or Heating

   Keep bystanders out of the work site during operation.  Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. S-33…

• Page 46: Prevent Battery Explosions

  SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. …

• Page 47: Handle Chemical Products Safely

   Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Hitachi equipment includes such items as oil, fuel, coolant, brake fluid, filters, DEF/AdBlue®, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

• Page 48: Notes For Aftertreatment Device

  SAFETY Notes for Aftertreatment Device Urea SCR System The aftertreatment device removes particulate matter (PM) and nitrogen oxide (NOx) from the exhaust gas. Follow the instructions below to prevent the aftertreatment device from being damaged. WARNING: Exhaust gas from the aftertreatment device, muffler, exhaust piping and tail piping becomes hot during and just after engine running and regeneration of aftertreatment device.

• Page 49: Precaution For Communication Terminal Equipment

  SAFETY Precaution for Communication Terminal Equipment This machine may have a communication terminal equipment emitting electrical waves installed in the right rear corner within the cab. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment.

• Page 50: Articulation Stopper (Lock Bar

  SAFETY Articulation Stopper (Lock Bar) WARNING: With articulation stopper in LOCKED position, machine will not steer; which, while operating, could cause an accident, injury or death. Do not lock Articulation Stopper during normal operation. Articulation stopper locks the front and rear chassis to prevent them from sudden articulation during inspection or transportation.

• Page 51: Safety Labels

  SAFETY LABELS All safety signs and their locations on the machine are illustrated in this group. Become familiar with the contents of the safety labels by reviewing them on the machine and understanding them, to ensure safe machine operation. Always keep the safety labels clean. In case a safety sign is lost or no longer readable, immediately-obtain a new replacement and affix it again in position on the machine.

• Page 52
  SAFETY LABELS 90Z7B-S-40USa S-40…
• Page 53
  SAFETY LABELS 1. Bucket and Hood CAUTION: Sign indicates a fall hazard.  Do not step on or stand in this area. label 44787-24370 90Z7B-S-43-1US 2. Accumulator residual pressure WARNING: Oil injection hazard.  Nitrogen accumulator contains compressed gas and fluid which could result in death or serious injury.
• Page 54
  SAFETY LABELS 3. Both Sides of Oil Cooler and Engine Housing WARNING: Burn Hazard  Avoid skin contact with highly heated parts such as the engine, muffler, etc. immediately after operation of the machine. Severe burns may result. label 44787-24990 90Z7B-S-44-1US 4.
• Page 55
  SAFETY LABELS 5. Top of Hydraulic Oil Tank label 44787-25030 WARNING: Burn Hazard  Sign indicates a burn hazard from the pressurized tank spurting hot oil if the oil inlet is uncapped during or right 90Z7-S-43K1 after operation. Read manual for safe and proper handing. 6.
• Page 56
  SAFETY LABELS 7. Side of Engine Starter label 44787-24930 DANGER: Runover Hazard  If the engine is not started correctly the machine may suddenly start to move. Start the engine from the operator’s seat only. 90Z7B-S-46-1US 8. Both Sides of Front Chassis DANGER: Crush Hazard …
• Page 57
  SAFETY LABELS 10. Both Sides of Counterweight WARNING: Runover Hazard  Avoid injury or fatality from being run over with the machine. Keep everyone away from the machine when operating. 90Z7B-S-47-1US label 44787-24400 11. Bottoms at Both Right and Left Side Covers of Rear Chassis WARNING: Entanglement Hazard …
• Page 58
  SAFETY LABELS 13. Inside Battery Box CAUTION: Shock Hazard  Sign indicates a possible shock hazard from handling battery terminals. Read manual for safe and proper handling. label 44787-24350 90Z7B-S-48-1US 14. Inside Battery Box WARNING: Explosion Hazard  Sign indicates an explosion hazard. Keep fire and open flames away from this area.
• Page 59
  SAFETY LABELS 16. Top of Battery Recycle Batteries  Batteries contain lead and acid. Obey all local and federal laws and regulation on disposal of batteries and electrolyte solution. label 44774-23030 90Z7B-S-48-1US 17. Top of Battery label 44787-25010 DANGER: Explosion Hazard …
• Page 60
  SAFETY LABELS 19. Cab Inside Right Front Column (First safety sign from the top) WARNING  Prior to operation, maintenance, disassembling, and transportation of the machine, be sure to read and understand the Operator’s Manual. label 44787-24940 90Z7-S-48B1 20. Cab Inside Right Front Column (2nd safety sign from the top) DANGER: Electrocution Hazard…
• Page 61
  SAFETY LABELS 22. Cab Inside Right Front Column (4th safety sign from the top) WARNING: Rollover Hazard  To minimize the injury due to an overturning accident, be sure to fasten the seat belt prior to operating the machine. label 44787-24970 90Z7-S-49B 23.
• Page 62
  SAFETY LABELS 25. Both Right and Left Side of Engine Housing Frame WARNING: Entanglement Hazard  Sign indicates a hazard of rotating parts, such as fan. Turn it off before inspection and maintenance. label 44787-24380 90Z7B-S-47-1US 26. DEF/AdBlue® Tank IMPORTANT: Avoid Contamination …

• Page 63: Components Name

  COMPONENTS NAME Components Name 1- Cutting Edge (BOC) 2- Bucket 3- Bell Crank (Lever) 4- Bucket Cylinder 5- Front Combination Light (Headlight/Turn Signal/Clearance Light/Hazard Light) 6- Outside Rear View Mirror 7- Front Work Light 8- ROPS Cab 90Z7B-1-1-1 9- Rear Fender 10- Front Fender 11- Lift Arm (Boom) Cylinder 12- Lift Arm (Boom)

• Page 64
  COMPONENTS NAME 90Z7B-7-4-1 1- Bolt on Cutting Edge 17- Transmission 2- Bucket 18- Second (Front and Center) Propeller Shaft 3- Bucket Cylinder Rod Pin 19- Steering Cylinder 4- Bucket Cylinder 20- Front Axle 5- Head Light 21- Lift Arm (Boom) Cylinder 6- Hydraulic Oil Tank 22- Lift Arm Cylinder Rod Pin 7- Air Cleaner…

• Page 65: Operator’s Station

  OPERATOR’S STATION Aftertreatment Device The machine is equipped with the aftertreatment system combining Diesel Oxidation Catalyst (DOC) block (1) with Selective Catalytic Reduction (SCR) block (2) to remove nitrogen oxide (NOx) from the exhaust gas in order to meet governmental emissions regulations. The DOC reduces harmful substances in exhaust gas by chemical reaction, then DEFAdBlue®…

• Page 66
  OPERATOR’S STATION  Refill DEF/AdBlue® which meets JIS or ISO (International Organization for Standardization). If improper liquid (diesel oil, kerosene or gasoline) is refilled in the DEF/AdBlue® tank, fire or system failure may result.  Use only recommended engine oil. Using engine oil other than the recommended may result in malfunction of the aftertreatment device.

• Page 67: Automatic Regeneration

  OPERATOR’S STATION Automatic regeneration White deposition may accumulate inside the aftertreatment device. An automatic regeneration (Auto-regeneration) mode is designed to automatically clean the aftertreatment device at regular intervals. The auto-regeneration may start during operation of the machine; you can continue to operate the machine.

• Page 68: Repeated Inhibiting Of Aftertreatment Device Cleaning

  OPERATOR’S STATION Repeated inhibiting of aftertreatment device cleaning IMPORTANT: When the machine is operated without performing manual regeneration, the aftertreatment device may be damaged. Immediately move the machine to a safe area and perform manual regeneration.  If auto-regeneration is inhibited or interrupted, the following auto-regeneration will be accompanied by the aftertreatment device manual regeneration request.

• Page 69: Cab Features

  OPERATOR’S STATION Cab Features 1- Front Defroster 2- Front Console 3- Operator’s Seat 4- Right Console 5- Document Holder 6- Hot/Cool Box 7- Rear Defroster 8- Glove Compartment 9- Cup Holder 10- Floor Mat MNEC-01-035…

• Page 70: Front Console

  OPERATOR’S STATION Front Console 1- Air Conditioner Front Vent 2- Hazard Switch 3- Work Light Switch 4- Parking Brake Switch 5- Neutral Lever Lock (Forward/Reverse Lever) 6- Steering Wheel 7- Monitor Panel 8- Horn Switch 9- Accelerator Pedal MNEC-01-036 10- Brake Pedal 11- Front/Rear Window Wiper Switch 12- Forward/Reverse Lever/ Shift Switch 13- Steering Column Tilt Pedal…

• Page 71: Right Console

  OPERATOR’S STATION Right Console Fingertip Control Type 1- Auxiliary Control Lever (Option) 2- Bucket Control Lever 3- Lift Arm Control Lever 4- Forward/Reverse Switch 5- Control Lever Lock Switch 6- Declutch Position Switch 7- Travel Mode Selector 8- Power Mode Selector MNEC-01-041 9- Forward/Reverse Selector Switch 10- Fan Reverse Rotation Switch…

• Page 72: Multi-Function Joystick Type

  OPERATOR’S STATION Right Console Multi-Function Joystick Type 1- Forward/Reverse Switch 2- Multi-Function Joystick Lever 3- Quick Power Switch 4- DSS (Down Shift Switch) 5- Auxiliary Control Lever (Option) 6- Control Lever Lock Switch 7- Declutch Position Switch 8- Travel Mode Selector Switch MNEC-01-043 9- Power Mode Selector Switch 10- Forward/Reverse Selector Switch…

• Page 73: Monitor Panel

  OPERATOR’S STATION Monitor Panel MNEC-01-001 1- Left Turn Signal Indicator 12- Discharge Warning Indicator 2- High Beam Indicator 13- Fuel Gauge 3- Work Light Indicator 14- Multi Function Monitor 4- Right Turn Signal Indicator 15- Communication System Error Indicator 5- Parking Brake Indicator 16- Coolant Temperature Gauge 6- Brake Oil Low Pressure Indicator 17- Overheat Indicator…

• Page 74: Parking Brake Indicator (Red)

  OPERATOR’S STATION Parking Brake Indicator (Red) The parking brake indicator will light when the parking brake is applied. If the forward/reverse lever is moved to either the forward (F) or the reverse (R) position when the parking brake is applied, the alarm buzzer will sound. Return the forward/ M4GB-01-012 reverse lever to neutral (N) and release the parking brake.

• Page 75: Low Steering Oil Pressure Indicator (Red)(Option)

  OPERATOR’S STATION Low Steering Oil Pressure Indicator (Red) (Option) IMPORTANT: The secondary steering system shall only be used temporarily when the steering oil pressure has dropped. If continuously used, it may damage the system. If the steering oil pressure decreases, the low steering oil pressure indicator and the service indicator will light, and the alarm buzzer will sound.

• Page 76: Engine Warning Indicator (Red)

  OPERATOR’S STATION Engine Warning Indicator (Red) If any serious abnormality occurs in the engine and/or engine related parts, the red indicator will light. If the engine 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.

• Page 77: Air Filter Restriction Indicator (Red)

  OPERATOR’S STATION Air Filter Restriction Indicator (Red) If the air cleaner element becomes clogged,, the air filter restriction indicator and the service indicator light. Immediately stop the engine and inspect the air cleaner element. Replace the element, if necessary. NOTE: This indicator may unexpectedly light when the coolant temperature gauge indicates the center or lower position.

• Page 78: Coolant Temperature Gauge

  OPERATOR’S STATION Coolant Temperature Gauge The engine coolant temperature is indicated with a needle. When the needle stays in the range (1) during operation, the coolant temperature is normal. If the engine coolant temperature becomes abnormally high, the service indicator will flash and the alarm buzzer will sound.

• Page 79: Turn Signal Indicator (Green)

  OPERATOR’S STATION Turn Signal Indicator (Green) When the turn signal lever is operated, the turn signal and the turn signal indicator start flashing. M4GB-01-032 High Beam Indicator (Blue) When the head lights are used at the high beam position, the indicator will light. M4GB-01-033 Work Light Indicator (Yellow) When the work lights are turned ON, this indicator will light.

• Page 80: Clearance Light Indicator (Green)

  OPERATOR’S STATION Clearance Light Indicator (Green) When the clearance lights are turned ON, this indicator will light. M4GB-01-035 Control lever lock indicator (Red) When the control lever lock switch is in ON position, the control lever lock indicator will light. MNEC-01-004 1-18…

• Page 81: Multi Function Monitor

  OPERATOR’S STATION Multi Function Monitor Feature The multi function monitor displays various meters, indicators, operation mode selection and maintenance screen. Screen Configuration The multi function monitor consists of the following screens. There are 7 menus, and a further 13 sub menus. Basic Screen Main Menu Alarm List…

• Page 82: Default Setting

  OPERATOR’S STATION Default Setting Function Item Default Auto Shut-Down ON/OFF of auto idling-stop function Time period for auto idling-stop activation 5 min Rear View Camera Monitor ON (Constant display) OFF (No display) AUTO AUTO (Display at reverse operation only) Aftertreatment Device Regeneration Inhibit regeneration Inhibit Shift Change Delay Mode…
• Page 83
  OPERATOR’S STATION Basic Screen 1- Engine Tachometer 2- Economy (ECO) Indicator 3- Speedometer 4- Transmission Oil Temperature Gauge 5- DEF/AdBlue® Level Gauge 6- Air Conditioner Display MNFB-01-100EN 7- Ride Control Indicator (Option) 8- Seat Belt Indicator 9- Forward/Reverse Selector Switch Indicator 10- Declutch Indicator 11- Aftertreatment Device Indicator 12- Power Mode Indicator…

• Page 84: Basic Screen

  OPERATOR’S STATION How to Use Screens Displaying Basic Screen IMPORTANT: Start the engine after the basic screen is displayed. When the key switch is turned to the ON position, the starting screen displays for about two seconds and the basic screen displays. Starting Screen MNEK-01-102EN Basic Screen…

• Page 85
  OPERATOR’S STATION  Engine Tachometer (1) Engine tachometer (1) indicates the speed of currently running engine in a gauge form. (200 min step or «RPM») If the engine overspeeds, the color of the gauge changes.  ECO Indicator (2) ECO indicator (2) lights when the engine runs in energy efficient condition.
• Page 86
  OPERATOR’S STATION  Forward/Reverse Selector Switch Indicator (9) The forward/reverse indicator lights when the forward/ reverse switch on the right console or on the multi- function lever is usable.  Declutch Indicator (10) The declutch indicator lights when the declutch position switch on the right console is in ON position.
• Page 87
  OPERATOR’S STATION  Fan Reverse Rotation Indicator (16) Displays rotating direction of the fan. Normal Rotation  The icon is not displayed. Changing  The icon blinks. Rotational Direction Reverse Rotation  The icon lights ON.  HOLD Display (17) Hold display (17) is displayed when the hold switch on MNFB-01-100EN the side console is in ON position.

• Page 88: Monitor Operation

  OPERATOR’S STATION Monitor Operation  Select/Confirm Knob (1) Push Push this switch while the basic screen is displayed, the Main Menu Screen opens. Push this switch after the menu screen, the action is confirmed. Rotate : Cursor moves. MNEC-01-006 Multi Function Monitor/Air Conditioner Switch Panel MNEC-01-078 …

• Page 89: Alarm Occurrence Screen

  OPERATOR’S STATION Alarm Occurrence Screen In case any abnormality occurs, alarm symbols (1) and service indicator (3) are displayed on the basic screen. MNFB-01-290EN Basic Screen If 8 or more 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.

• Page 90
  OPERATOR’S STATION Follow the procedure below to display detailed information for an alarm. 1. Push selector knob (1) on the basic screen to display the main menu. MNFB-01-290EN 2. Rotate selector knob (1) to select the alarm list, and push selector knob (1).

• Page 91: Remedy

  OPERATOR’S STATION Remedy Display Contents of Alarms Remedy System Failure Alarm Communication system is abnormal. Consult your nearest authorized dealer. Brake Oil Pressure Alarm Brake oil pressure has decreased. Immediately stop the machine and check the brake system. Low Steering Oil Pressure Steering oil pressure has decreased.

• Page 92
  OPERATOR’S STATION Display Contents of Alarms Remedy Engine Overheat Alarm Coolant temperature is above normal. Stop operation. Run the engine at slow idle speed to lower the coolant temperature. When needed, add coolant. Hydraulic Oil Overheat Alarm Hydraulic oil temperature is above normal. Stop operation. Run the engine at slow idle speed to lower the oil temperature.

• Page 93: Def/Scr System Alarm

  OPERATOR’S STATION DEF/SCR System Alarm When the DEF/AdBlue® level becomes low and/or the Urea SCR system malfunctions, the engine performance is controlled depending on the status. The operator is alerted with alarm indicators. Move and park the machine in a safe place and follow the displayed message, or troubleshooting guide for the accompanied alarms.

• Page 94: Urea Scr System Malfunction

  OPERATOR’S STATION Urea SCR System Malfunction Alarm Indicator Status/Inducement Urea SCR system is broken. (Red, light) Urea SCR system is broken. Engine output is restricted. (Red, slow blink) (Red, slow blink) Urea SCR system is broken. Engine output and speed are restricted. (Red, fast blink) Contact your authorized dealer for service.

• Page 95: Aftertreatment Device Regeneration

  OPERATOR’S STATION Aftertreatment Device Regeneration To keep the system working correctly, periodically, the collected deposit is removed by purging it at a high temperature. This process is known as «regeneration». The regeneration is done in three ways; automatic regeneration (abbreviated as auto-regeneration), manual regeneration, and service regeneration.

• Page 96: Automatic Regeneration (Auto-Regeneration)

  OPERATOR’S STATION Automatic regeneration (Auto-regeneration) The machine automatically increases the exhaust temperature during normal operation to purge the deposit. There are no actions on the part of the operator when auto-regeneration is performed.  Auto-regeneration may start while operating the machine, and there is no need to stop the machine when this happens.

• Page 97: Manual Regeneration

  OPERATOR’S STATION Manual Regeneration When the deposit level increases to a level that is more than an auto-regeneration can remove, a manual regeneration is required. The yellow regeneration symbol (shown below)(1) and service indicator (2) appear to make the operator aware that this is required.

• Page 98: Main Menu

  OPERATOR’S STATION Main Menu IMPORTANT: If the forward/reverse lever is in the forward or reverse position, the basic screen is displayed. (You can not change to the other screen.) When the forward/reverse lever is changed to forward or reverse position while displaying the main menu screen, the screen changes back to the basic screen.

• Page 99: Ride Control Drive Speed Setting (Option)

  OPERATOR’S STATION Ride Control Drive Speed Setting (Option) 1. Press selector knob (2) while displaying basic screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Ride Control (4). 3. Press selector knob (2) to display Ride Control Drive Speed Setting screen (5).

• Page 100: Dual Lift Arm Auto-Leveler

  OPERATOR’S STATION Dual Lift Arm Auto-Leveler 1. Press selector knob (2) while displaying basic screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Dual Lift Arm Auto- Leveler (4). MNEK-01-110EN 3. Press selector knob (2) to display Dual Lift Arm Auto- Leveler screen (5).

• Page 101: Height Kickout On/Off, Stop Height Setting

  OPERATOR’S STATION Height Kickout ON/OFF, Stop Height Setting  Rotate selector knob (2) to highlight ON (8).  ON/OFF Selection Press selector knob (2) to turn ON (enabled). (A box next to ON turns green.) This enables the setting of the lift arm height. Press selector knob (2) again to turn OFF (disabled).

• Page 102: Lower Kickout On/Off, Stop Height Setting

  OPERATOR’S STATION Lower Kickout ON/OFF, Stop Height Setting  Rotate selector knob (2) to highlight ON (8).  ON/OFF Selection Press selector knob (2) to turn ON (enabled). (A box next to ON turns green.) This enables the setting of the lift arm height. Press selector knob (2) again to turn OFF (disabled).

• Page 103: Brightness Adjustment

  OPERATOR’S STATION Brightness Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Brightness Adjustment (4). MNEK-01-120EN 1-41…

• Page 104
  OPERATOR’S STATION 3. Press selector knob (2) to display Brightness Adjustment screen (5). MNEC-01-006 4. Rotate selector knob (2) clockwise to make the screen brighter, counterclockwise to make the screen darker. MNEK-01-121EN NOTE: When the machine’s head light switch is turned ON, the monitor screen changes to night mode and mark (6) is displayed.

• Page 105: Mail (Option)

  OPERATOR’S STATION Mail (Option) IMPORTANT: This function is available only to a machine equipped with a communication terminal. When using the mail function, consult your nearest authorized dealer. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2.

• Page 106
  OPERATOR’S STATION 6. While mail information is sent to the communication terminal, the message «Wait.» is displayed on the screen. MNEK-01-132EN 7. When the communication terminal completes receiving mail information, the message «Request Was Accepted.» is displayed on the screen. Push back key (6) to return to the Mail screen.

• Page 107: Setting Menu

  OPERATOR’S STATION Setting Menu Setting menu consists of date and time setting, auto idling stop setting (option), and rear view camera monitor setting. 1. Press selector knob (2) while displaying basic screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2.

• Page 108: Date And Time

  OPERATOR’S STATION Date and Time Time, date and display mode can be set on this screen. Year- month-day format and 24h/12h display mode are selected in the display setting. Time adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).

• Page 109
  OPERATOR’S STATION 5. Press selector knob (2) to display Date and Time screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight Time Setting (8). 7. Press selector knob (2) to display Time Setting screen (9). 8. Rotate selector knob (2) to highlight Hour or Minute and push selector knob (2).

• Page 110: Date Adjustment

  OPERATOR’S STATION Date Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNEK-01-140EN 3. Press selector knob (2) to display Setting Menu screen (5).

• Page 111
  OPERATOR’S STATION 5. Press selector knob (2) to display Date and Time screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight Date Setting (8). 7. Press selector knob (2) to display Date Setting screen (9). 8. Rotate selector knob (2) to highlight Year, Month or Day MNEK-01-145EN and push selector knob (2).

• Page 112: Display Mode Setting

  OPERATOR’S STATION Display Mode Setting 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNEK-01-140EN 3. Press selector knob (2) to display Setting Menu screen (5).
• Page 113
  OPERATOR’S STATION 5. Press selector knob (2) to display Date and Time screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight Display Form (8). MNEK-01-148EN 7. Press selector knob (2) to display Display Form screen (9). 8. Rotate selector knob (2) to highlight Date (10) and push selector knob (2).

• Page 114: Auto Idling Stop

  OPERATOR’S STATION Auto Idling Stop WARNING: This function automatically idles, then stops the engine. Take extra care on the work and environment when using this function. The auto idling stop function can be set in this screen. Set the auto idling stop time and enable the function beforehand (set to ON).

• Page 115: Acting Time Setting

  OPERATOR’S STATION 5. Press selector knob (2) to display Auto Shut-Down screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight ON (8). 7. Press selector knob (2) to set the auto shut-down function ON and indicator (11) will be lit. Press selector knob (2) again to set the auto shut-down function OFF and indicator (11) goes off.

• Page 116: Rear View Camera Monitor

  OPERATOR’S STATION Rear View Camera Monitor IMPORTANT: The image displayed on the rear view monitor is meant only as an aid. Actual position and distance of people and objects in the rear view monitor will be different from the actual view. When operating the machine, pay thorough attention to the surroundings with use of mirrors and windows.

• Page 117
  OPERATOR’S STATION 5. Press selector knob (2) to display Rear View Camera Monitor screen (7). MNEC-01-006 6. Press selector knob (2) to turn the rear view camera monitor ON/OFF/AUTO. 7. When the rear view camera monitor is ON, rear view image is continuously displayed on the basic screen.

• Page 118: Aftertreatment Device Regeneration Inhibit

  OPERATOR’S STATION Aftertreatment Device Regeneration Inhibit IMPORTANT: The aftertreatment device regeneration can be inhibited at this screen to prevent auto regeneration while operating the machine in a flammable area or indoors. Setting Procedure MNEK-01-103EN 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).

• Page 119
  OPERATOR’S STATION 4. Rotate selector knob (2) to highlight Aftertreatment Device Regeneration Inhibit (6). MNEC-01-006 5. Press selector knob (2) to display Aftertreatment Device Regeneration Inhibit screen (7). 6. Rotate selector knob (2) to highlight (8), and press MNEK-01-170EN selector knob (2) to display Aftertreatment Device Regeneration Inhibit screen (9).

• Page 120: Transmission Setting

  OPERATOR’S STATION Transmission Setting Shift Change Delay Mode Setting Refer to page 4-6 for Shift Change Delay Mode. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNEK-01-140EN 3.

• Page 121
  OPERATOR’S STATION 4. Rotate selector knob (2) to highlight Transmission Setting Menu (6). MNEC-01-006 5. Press selector knob (2) to display Transmission Setting screen (7). MNEK-01-180EN 6. Rotate selector knob (2) to highlight Shift Change Delay Mode (8). MNFB-01-181EN 7. Press selector knob (2) to display Shift Change Delay Mode screen (9).

• Page 122: Lockup Setting

  OPERATOR’S STATION Lockup Setting Lock-up clutch is provided for efficient power transmission from the engine, that helps to improve fuel efficiency and have higher ground speed. Use this setting to activate the lockup shifting (refer to page 4-5). NOTE: The lock-up control directly links the transmission to the engine when the Auto Shift Mode 1 or 2 is selected.

• Page 123
  OPERATOR’S STATION 4. Rotate selector knob (2) to highlight Transmission Setting Menu (6). MNEK-01-180EN 5. Press selector knob (2) to display Transmission Setting screen (7). 6. Rotate selector knob (2) to highlight Lockup (8). MNFB-01-184EN 7. Press selector knob (2) to display Lockup setting screen (9).

• Page 124: Parallel/Tandem Switching Height Setting

  OPERATOR’S STATION Parallel/Tandem Switching Height Setting With parallel/tandem circuits, the boom and bucket can be operated 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). MNEK-01-103EN MNEC-01-006 2.

• Page 125
  OPERATOR’S STATION 4. Rotate selector knob (2) to highlight Parallel/Tandem Switching Height (6). MNEC-01-006 MNEK-01-190EN 5. Press selector knob (2) to display Parallel/Tandem Switching Height screen (7). 6. When the lift arm height changes by operating the lift arm control lever, the height is displayed on segment (8). 7.

• Page 126: Warm Up Operation

  OPERATOR’S STATION Warm Up Operation Refer to «Cold Weather Warm Up» (page 3-12) for the operation when using this setting. 1. Press selector knob (2) while displaying basic screen (1) to display main menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNEK-01-140EN 3.

• Page 127
  OPERATOR’S STATION 4. Rotate selector knob (2) to highlight Warm Up (6). MNEC-01-006 5. Press selector knob (2) to display Warm Up Setting screen (7). 6. Press selector knob (2) to turn ON (enabled). MNEK-01-200EN Press selector knob (2) again to turn OFF (disabled). NOTE: When the function is ON, the mark «»…

• Page 128: Display Item Selection

  OPERATOR’S STATION Display Item Selection Unit system displayed on the monitor can be selected in this screen. 1. Press selector knob (2) while displaying basic screen (1) MNEK-01-103EN to display main menu screen (3). MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNEK-01-140EN 3.

• Page 129
  OPERATOR’S STATION 5. Press selector knob (2) to display Display Item Selection screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight Unit. Press selector knob (2) to set the unit (Metric or US system). 7. Rotate selector knob (2) to highlight Accumulated Operation Display.

• Page 130: Main Menu Display Order Change

  OPERATOR’S STATION Main Menu Display Order Change Menu sequence of «Ride Control» (option), «Dual Lift Arm Auto 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) MNEK-01-103EN to display Main Menu screen (3).
• Page 131
  OPERATOR’S STATION 3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Main Menu Display Order Change (6). MNEK-01-230EN-KC 5. Press selector knob (2) to display Main Menu Display MNEC-01-006 Order Change screen (7). 6.

• Page 132: Information Menu

  OPERATOR’S STATION Information Menu The information menu includes Operation, Maintenance, Troubleshooting and Monitoring. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Information Menu (4).

• Page 133: Operation Condition

  OPERATOR’S STATION Operation Condition The Operation screen displays fuel consumption, operating hours, and fuel consumption rate from resetting of the monitoring unit. Fuel Consumption MNEK-01-103EN 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEC-01-006 2.

• Page 134
  OPERATOR’S STATION 5. Press selector knob (2) to display Operation screen (7). 6. Rotate selector knob (2) to highlight Fuel Consumption (8) or Machine Information (9). MNEC-01-006 7. Press selector knob (2) while selecting Fuel Consumption MNEK-01-242EN-KC (8) to display Fuel Consumption screen (10). The Machine Operation Hours, Fuel Consumption, and Average Fuel Consumption Rate can be checked on Fuel Consumption screen (10).

• Page 135: Maintenance

  OPERATOR’S STATION Maintenance The maintenance screen includes maintenance notice, remaining hours until the next maintenance, and maintenance intervals. Maintenance Items  Engine Oil  Engine Oil Filter MNEK-01-103EN  Hydraulic Oil  Hydraulic Oil Pilot Filter  Hydraulic Oil Return Filter …

• Page 136
  OPERATOR’S STATION 5. Press selector knob (2) to display Maintenance screen (7). 6. Rotate selector knob (2) to highlight Maintenance Notice MNEC-01-006 (8). 7. Press selector knob (2) to turn the Maintenance Notice ON. Press selector knob (2) again to turn the Maintenance Notice OFF.

• Page 137: Time Remains And Maintenance Interval

  OPERATOR’S STATION Time Remains and Maintenance Interval 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Information Menu (4). MNEK-01-240EN 3. Press selector knob (2) to display Information Menu screen (5).

• Page 138
  OPERATOR’S STATION 5. Press selector knob (2) to display Maintenance screen (7). 6. Rotate selector knob (2) to highlight a maintenance item to be checked (8). (In the right example, Engine Oil is MNEC-01-006 selected.) 7. Press selector knob (2) to display the time remaining for the selected maintenance item.

• Page 139: Troubleshooting

  OPERATOR’S STATION Troubleshooting An active fault code generated by the controller connected to the controller area network is displayed on this screen. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2.

• Page 140
  OPERATOR’S STATION 4. Rotate selector knob (2) to highlight Troubleshooting (6). MNEK-01-260EN-KC MNEC-01-261EN-KC 5. Press selector knob (2) to start troubleshooting. After displaying «Wait.» message, the screen displays controller troubleshooting (7). 6. Active fault codes are displayed at the right side of each 90MNEC-01-262EN item.

• Page 141: Monitoring

  OPERATOR’S STATION Monitoring 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEK-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Information Menu (4). MNEK-01-240EN 1-79…

• Page 142
  OPERATOR’S STATION 3. Press selector knob (2) to display Information Menu screen (5). 4. Rotate selector knob (2) to highlight Monitoring (6). MNEK-01-270EN-KC 6. Press selector knob (2) to display Monitoring screen (7). MNEK-01-271EN 1-80…

• Page 143: Switches, Steering Wheel And Pedals

  OPERATOR’S STATION Switches, Steering Wheel and Pedals 1- Hazard Switch 2- Work Light Switch 3- Parking Brake Switch 4- Neutral Lever Lock (for the Forward/Reverse Lever) 5- Steering Wheel 6- Horn Switch 7- Key Switch 8- Turn Signal Lever/ Light Switch/ High-Low Beam Switch 9- Accelerator Pedal MNEC-01-036 10- Brake Pedal…

• Page 144: Hazard Switch

  OPERATOR’S STATION Hazard Switch IMPORTANT: Do not leave the hazard switch (1) in the » » or «ON» position for a long time with the engine stopped. The batteries will become discharged. When a machine failure occurs, use this switch to inform other vehicles that the machine is in an emergency situation.

• Page 145: Work Light Switch

  OPERATOR’S STATION Work Light Switch Press the mark on switch (1) while the light switch is in » » or » » position to turn front work lights (2) ON. Rear work lights (3) stay OFF. MNEC-01-037 When the side with mark on switch (1) is pressed, all front work lights (2), rear work lights (3), and rear cab lights (4) turn ON.

• Page 146: Parking Brake Switch

  OPERATOR’S STATION Parking Brake Switch WARNING:  To prevent accidents due to rolling away of the machine, after parking the machine or before leaving the machine, be sure to apply the parking brake.  Never apply the parking brake while the machine is moving except in an emergency.

• Page 147: Neutral Lever Lock (For The Forward/Reverse Lever)

  OPERATOR’S STATION Neutral Lever Lock (for the Forward/Reverse Lever) Unlock ( ) WARNING: When the machine is parked or serviced, be sure to place the neutral lever lock (red lever) in the lock ( ) position. Lock ( ) The neutral lever lock makes the forward/reverse lever immovable so that the machine does not start moving even if a body part comes in contact with the forward/ reverse lever by mistake.

• Page 148: Key Switch

  OPERATOR’S STATION Key Switch WARNING: Before starting the engine, return the forward/reverse lever and forward/reverse switch to neutral (N), apply the parking brake, lock the neutral lever lock, and lock the control lever. Refer to the descriptions in the OPERATING ENGINE section for the detail information.

• Page 149: Turn Signal Lever

  OPERATOR’S STATION Turn Signal Lever Indicates the drive change direction to persons and/or other vehicles by operating turn signal lever (7). Return turn signal lever (7) to neutral manually. L- Left Turn R- Right Turn NOTE: The lever does not return automatically when the steering wheel is returned to center.

• Page 150: Light Switch

  OPERATOR’S STATION Light Switch Light switch (1) has three positions, OFF, Small, and Main. As shown below, each light comes ON ( ) or OFF ( according to the selected position of the light switch. 2- Headlight 3- Turn Signal / Hazard Light / Clearance Light 4- Turn Signal/Hazard Light 5- Brake Light/Tail Light 6- License Plate Light…

• Page 151: High-Low Beam Switch

  OPERATOR’S STATION High-Low Beam Switch Shifts the headlight beam between high and low. CAUTION: Travel the machine with the headlight in the low beam position when other vehicles are present in the vicinity. By bringing down the signal lever (7) with the headlight ON, the headlight beam turns upward, and the high beam indicator (8) comes ON.

• Page 152: Accelerator Pedal

  OPERATOR’S STATION Accelerator Pedal When accelerator pedal (3) is applied, the engine speed increases. When released, the engine speed decreases. NOTE: The engine speed may change due to the machine control regardless of the operation of the accelerator pedal. Brake Pedal MNEC-01-036 WARNING: …

• Page 153: Forward/Reverse Lever/ Shift Switch

  OPERATOR’S STATION Forward/Reverse Lever/ Shift Switch 1, 2 Forward/Reverse Lever Changes the machine drive direction from forward to reverse and vice versa. Move forward/reverse lever (1) to the F position to travel the machine forward. Move forward/reverse lever (1) to the R position to drive the machine in reverse.

• Page 154: Wiper Switch

  OPERATOR’S STATION Wiper Switch Wiper Operation IMPORTANT: The windshield surface, the wiper blade, the wiper motor and the relay may be damaged due to dry or frozen condition of the wiper blade and the windshield.  Before operating the windshield wiper, remove snow, ice or dust heavy debris from the windshield surface.

• Page 155: Front/Rear Wiper Switch

  OPERATOR’S STATION Front/Rear Wiper Switch Operate wiper switch (1) to move the front and rear windshield wipers. IMPORTANT: The washer motor may become damaged if washer fluid is continuously used for more than 20 seconds or the washer motor pump switch is operated with no fluid in the washer tank.

• Page 156: Tilt, Telescopic Lever/Steering Column Tilt Pedal

  OPERATOR’S STATION Tilt, Telescopic Lever/Steering Column Tilt Pedal WARNING:  Before operating the machine, be sure that the steering wheel is locked.  Do not operate the tilt, telescopic lever (1) and steering column tilt pedal (2) during operation.  Before operating the machine, adjust the steering column inclination so as to match the operator’s needs.

• Page 157: Right Console / Switches

  OPERATOR’S STATION Right Console / Switches Fingertip Control Type 1- Auxiliary Control Lever (Option) 2- Bucket Control Lever 3- Lift Arm Control Lever 4- Forward/Reverse Switch 5- Loading Control Lever Lock Switch 6- Declutch Position Switch 7- Travel Mode Selector Switch 8- Power Mode Selector Switch MNEC-01-041 9- Forward/Reverse Selector Switch…

• Page 158: Loading Control Levers

  OPERATOR’S STATION Loading Control Levers The lift arm control lever and the bucket control lever are used to operate the lift arm and/or bucket. Lift Arm Control Lever (1) Lever Lift Arm Operation Position Float (Detent): The lift arm free falls and can be moved as loads are applied.

• Page 159
  OPERATOR’S STATION  When pushing down the lift arm control lever to the «Float» position (C), the lift arm moves to the position preset at lower kickout and is held in that position. When the lift arm moves to the preset position, the lift arm control lever automatically moves to «Neutral»…

• Page 160: Right Console / Switches

  OPERATOR’S STATION Right Console / Switches Multi-Function Joystick Type 1- Forward/Reverse Switch 2- Multi-Function Joystick Lever 3- Quick Power Switch 4- DSS (Down Shift Switch) 5- Auxiliary Control Lever (Option) 6- Loading Control Lever Lock Switch 7- Declutch Position Switch 8- Travel Mode Selector Switch MNEC-01-043 9- Power Mode Selector Switch…

• Page 161: Loading Multi-Function Joystick Lever (Option)

  OPERATOR’S STATION Loading Multi-Function Joystick Lever (Option) The multi-function joystick lever is used to operate the lift arm and/or bucket. Lever Bucket Operation Position Float (Detent): The lift arm free falls and can be moved as loads are applied. The lever is held in this position.

• Page 162: Auxiliary Control Lever (Option)

  OPERATOR’S STATION Auxiliary Control Lever (Option) An optional control lever (1) can be installed to control the attachment. Refer to the operator’s manual for the attachment how to use this lever. MNEC-01-041 Fingertip Control Type MNEC-01-043 Multi-Function Joystick Type 1-100…

• Page 163: Forward/Reverse Selector Switch

  OPERATOR’S STATION Forward/Reverse Selector Switch Forward/reverse selector switch (5) is a switch that activates forward/reverse switch (23). When forward/ reverse selector switch (5) is in ON position, the machine travels in the forward or reverse direction by selecting the (F) or (R) side of forward/reverse switch (23). Operational Procedure 1.

• Page 164: Loading Control Lever Lock Switch

  OPERATOR’S STATION Loading Control Lever Lock Switch WARNING:  Before leaving the operator’s seat, be sure to stop the engine. Place the boom and bucket in a level, safe position. Then, set control lever lock switch (1) to the lock ( ) position. …

• Page 165: Travel Mode Selector Switch

  OPERATOR’S STATION Travel Mode Selector Switch Travel mode selector switch (1) selects the travel mode. Selecting the manual mode » » by using travel mode selector switch (1) switch 1 sets the transmission to manual mode, which allows manual shift change by using shift switch (2).

• Page 166: Power Mode Selector Switch

  OPERATOR’S STATION Power Mode Selector Switch Two operation modes are available and can be selected by power mode selector switch (3) depending on the applications. Each time the switch is pressed, the power mode is activated (ON) and deactivated (OFF) alternately. Power : The power mode is suitable for heavy digging mode…

• Page 167: Fan Reverse Rotation Switch

  OPERATOR’S STATION Fan Reverse Rotation Switch Fan reverse rotation switch (1) reverses the hydraulic driven fan. In case the radiator is clogged, rotate the hydraulic driven fan in reverse direction to blow out the clogged dust. It is recommended to carry out the fan reverse rotation regularly to prevent the cooling system from clogging.

• Page 168: Manual Operation

  OPERATOR’S STATION Manual Operation IMPORTANT:  Fan rotating direction can be manually changed when the engine is running. Each time the ON side of fan reverse rotation switch (1) is pressed, the fan’s rotating direction switches alternatively. While switching the fan rotating direction, fan reverse rotation indicator (2) flashes.

• Page 169: Secondary Steering Operation Check Switch (Option)

  OPERATOR’S STATION Secondary Steering Operation Check Switch (Option) Use this switch to check if the secondary steering pump is operable. While the ON side of switch (1) is being pressed, secondary steering pump operates. Secondary steering indicator (2) lights ON while the pump is operating.

• Page 170: Ride Control Switch (Option)

  OPERATOR’S STATION Ride Control Switch (Option) WARNING:  To ensure safety, operate the ride control switch only after parking the machine with the bucket lowered to the ground.  When operating the machine with the front attachment in the float position (scooping, grading, or snow removal), always turn the ride control switch OFF.

• Page 171: Auto

  OPERATOR’S STATION AUTO When ride control switch (1) is turned to AUTO, the drive speed sensor and the controller is activated. Then, when the drive speed increases above the preset travel speed, the ride control system automatically operates. When the drive speed decreases below the preset travel speed, the ride control system becomes inoperable.

• Page 172: Hold Switch

  OPERATOR’S STATION Hold Switch Press hold switch (1) while letting the machine travel in the auto shift mode, and the machine holds the speed gear range that is currently displayed on the monitor. 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).

• Page 173: Quick Power Switch

  OPERATOR’S STATION Quick Power Switch By pressing quick power switch (4) when the power mode is OFF, the power mode is temporarily activated. (The power mode indicator on the monitor shows symbol ( NOTE: The quick power switch is operable only in the following cases.

• Page 174: Dss (Down Shift Switch)

  OPERATOR’S STATION DSS (Down Shift Switch) Press DSS (2) to down shift the gear. Set the shift gear to 2nd speed for normal operation. By pressing DSS (2) while digging with the machine in forward, the gear automatically shifts to 1st speed, which increases drive force and digging force.

• Page 175: Cigar Lighter (24 V Dc Electrical Outlet)

  OPERATOR’S STATION Cigar Lighter (24 V DC Electrical Outlet) Using Cigar Lighter WARNING: Never touch other than insulated the knob part. Otherwise, it may result in severe burns. IMPORTANT: In case the cigar lighter does not pop out automatically after 30 seconds after pushing the cigar lighter in, pull out the cigar lighter manually.

• Page 176: Auto Air Conditioner

  OPERATOR’S STATION Auto Air Conditioner Feature  Full Auto-Temperature Control: Automatically controls the cab temperature to maintain the temperature set by the temperature control switch regardless of outside air temperature and insolation.  Max. Cooling and Heating: Maximum cooling or heating can be obtained by rotating the temperature control switch clockwise (32 °C)(90°F) or counterclockwise (18 °C)(64°F) respectively.

• Page 177
  OPERATOR’S STATION Components Name 1- Monitor 2- Control Panel 3- Temperature Control Switch (Rotate)/Mode Switch (Press) 4- Defroster Switch MNEK-01-103EN 5- Circulation/Fresh Air Switch 6- Air Conditioner ON/OFF Switch 7- Fan (Rotate)/Auto Switch (Press) MNEC-01-006 8- Defroster Vent 9- Rear Vent 10- Foot Vent 11- Air flows out of front vent and the defroster vents.
• Page 178
  OPERATOR’S STATION Controller Part Name and Function Mode/Temperature Control Switch  Mode Switch (3) Selects the air vent. The selected air vent is indicated on monitor (1). Front Vent Mode Front/Rear Vent Mode MNEC-01-006 Front/Rear/Foot Vent Mode Foot Vent Mode Foot/Defroster Vent Mode MNEK-01-103EN Defroster Vent Mode…
• Page 179
  OPERATOR’S STATION Fan/AUTO Switch  Blower Switch (7)  When the AUTO indicator (8) is ON, the blower speed is automatically controlled.  When AUTO indicator (8) is OFF, the blower speed is controlled in 6 steps. Rotate blower switch (7) clockwise to increase blower speed.
• Page 180
  OPERATOR’S STATION Cab Heater Operation 1. AUTO switch (7): According to signals sent from various sensors, the air conditioner amplifier automatically selects the air flow inlet ports, and air temperature, and controls the blower speed. 2. Temperature Control Switch (3): Adjust the temperature in the cab by using temperature control switch (3).
• Page 181
  OPERATOR’S STATION Cooling Operation 1. AUTO switch (7): Press AUTO switch (7) to set the air conditioner AUTO mode. According to signals sent from various sensors, the air conditioner amplifier automatically selects the air flow-in vents, air suction ports, and air flow- in temperature at the vent, and controls the blower speed.
• Page 182
  OPERATOR’S STATION Defroster Operation 1. Press defroster switch (4) to change defroster vent mode; the fresh air mode and air conditioner will turn ON. 2. Temperature in the cab can be adjusted by operating temperature control switch (3). 3. Operate fan switch (7) to adjust flow. 4.
• Page 183
  OPERATOR’S STATION Tips for Optimal Air Conditioner Usage For Rapid Cooling Temperature in the cab may rise over 80 °C (176 °F) when the machine is exposed to sun light in the summer. In this case, ventilate air in the cab first by opening the windows for rapid cooling.
• Page 184
  OPERATOR’S STATION Adjusting Operator’s Seat (Air Suspension Type Seat) Adjust the seat for comfort and so that the pedals may be pushed fully down when the operator’s back is fully against the seat back. Components Name 1- Armrest Angle Adjustment 2- Lumbar Support Adjustment 3- Reclining Angle Adjustment 4- Damper Adjustment…
• Page 185
  OPERATOR’S STATION Rear Tray 1- Document Holder 2- Hot/Cool Box 3- Electric Power Output (12 VDC, 15 A) 4- Glove Compartments 5- Fuse Box 6- Cup Holder MNEC-01-046 Electric Power Output Use the electric power output (Max. 15A) such as electric power to an instrument used for inspection/ maintenance work such as an illumination light.
• Page 186
  OPERATOR’S STATION Fuse Box IMPORTANT: If a fuse blows, turn the key switch OFF. Fuse box A After checking and correcting the cause of the Fuse box B trouble, replace the fuse with a new one. The slow blow fuses (fusible links) (1 and 2) function as a «safety valve»…
• Page 187
  OPERATOR’S STATION Fuse Box A 10- Parking solenoid 20- Option 4 10 A (Joystick steering) 5 A 9- Air conditioner 1 19- Option 3 (ACC2) 10 A (15 A) 8- Stop lamp, Turn signal 18- DEF line heater 15 A 7- Back lamp, Back buzzer 17- DEF supply module 15 A…
• Page 188
  OPERATOR’S STATION Hot/Cool Box Cool or warm air from the air conditioner or heater is routed to hot & cool box (1) so that food or a drink can be temporarily stored. Use a container with a tight cap in the hot/cool box. …
• Page 189
  OPERATOR’S STATION ROPS Cab ROPS cab (1) is standard equipment. 1- ROPS Cab 90Z7B-1-124-1 2- Speakers MNEC-01-050 3- Front Interior Light MNEC-01-051 4- Sun Visor M4GF-01-010 1-127…
• Page 190
  OPERATOR’S STATION 5- Radio 6- Cab Switch Panel (Option) 7- Inside Rear View Mirror Z7_US_radio 8- Rear Interior Light 9- Emergency Exit Hammer M4GB-01-117 10- Coat/Hat Hook MNEC-01-053 1-128…
• Page 191
  OPERATOR’S STATION Front Interior Light Press ON side of switch (1) to turn the interior light ON. The front interior light switch has three operation positions.  ON: The light (2) comes and stays ON.  Neutral: When the cab door is opened, the light (2) comes ON.
• Page 192
  OPERATOR’S STATION Sun Visor When sunlight is strong, use sun visor (4) by hanging its edge from the cab top down to a desired place. M4GF-01-010 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.
• Page 193
  OPERATOR’S STATION Upper Switch Panel (Option) 1- Rotary Light Switch 2- Auxiliary 3- Auxiliary 4- Auxiliary 5- Auxiliary Z7_US_radio 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.
• Page 194
  OPERATOR’S STATION Outside Rear View Mirror WARNING: Do not move the machine in reverse by relying on only the range of vision the rear view mirror (1) provides. Use the rear view mirror only as a visual aid during travel. Be sure to confirm safety by looking to the rear when moving the machine in reverse.
• Page 195
  OPERATOR’S STATION Door Lock Knob CAUTION: After closing the door, always check that the door lock is securely engaged. Depress door lock knob (5) to engage the door lock. M4GB-01-128 Door Open/Close Lever When opening the door, while lifting door lock knob (5), pull lever (6) to disengage the door lock.
• Page 196
  OPERATOR’S STATION When Fully Opening the Door WARNING: Before getting in or out the cab while using the handrails, check that the cab door is securely latched. If entering the cab without latching the door securely, the door latch may loose, possibly causing an accident.
• Page 197
  OPERATOR’S STATION Battery Disconnect Switch IMPORTANT: Never attempt to turn the battery disconnect switch OFF while engine running. Failure to do so may damage the electrical system. WARNING: After stopping the engine, the DEF/ AdBlue® pump keeps operating to return the DEF/ AdBlue®…
• Page 198
  OPERATOR’S STATION Switch Operation 1. Open battery box cover (1). When lever (2) is vertical to the ground, battery disconnect switch (3) turns ON. The lever can not be removed when lever (2) points downward. When operating the machine with battery disconnect switch (3) ON, close cover (1).
• Page 199
  OPERATOR’S STATION Articulation Stopper (Lock Bar) WARNING:  Before servicing or transporting the machine, be sure to engage lock bar (1).  Before operating the machine, be sure to disengage lock bar (1) from front chassis (4) and fasten the lock bar to rear chassis (2) with β-form lock clip (3).
• Page 200
  OPERATOR’S STATION Towing Pin WARNING: Since towing is a potentially dangerous operation, perform only when there is an emergency or crisis situation. IMPORTANT: To prevent excessive wear of tires and for safety, avoid towing requiring more than the available towing force, and keep the specified speed during towing.
• Page 201
  OPERATOR’S STATION Inspection/Maintenance Side Access Cover CAUTION:  Never attempt to stand on fender (2) if side cover (1) is provided with fender (2).  Always close side covers (1) when moving and/or operating machine.  Do not keep the side cover open on a slope or when a strong wind is blowing.
• Page 202
  OPERATOR’S STATION Rear Grille WARNING: Open or close rear grille (4) only after stopping the engine. It is very dangerous if you are entangled in the cooling fan. Before operating the machine, always check that the rear grille is well 1, 2 latched.
• Page 203
  OPERATOR’S STATION Steps WARNING: When getting on and off the machine, use steps and handrails to support your body with at least three points of contact. Getting on and off the machine with less than three support points may cause you to slip, possibly resulting in a falling accident.
• Page 204
  OPERATOR’S STATION Vandal-Resistant Devices Locks can be installed to transmission oil inlet cap cover (1), radiator inlet cover (2), fuel inlet cover (3), and DEF/AdBlue tank cover (4). 90Z7B-1-141-1 90Z7B-1-139-2 90Z7B-1-142-2 90Z7B-1-142-3 1-142…
• Page 205
  OPERATOR’S STATION Vandal-Resistant Devices (continue from previous page) Battery box cover (5), side covers (6), and air conditioner fresh air filter (7) can be locked with the starter key. 90Z7B-1-140-1 90Z7B-1-140-2 MNEC-01-055 1-143…
• Page 206
  OPERATOR’S STATION Seat Belt WARNING:  Be sure to use seat belt (1) when operating the machine.  Before operating the machine, be sure to examine seat belt (1) and attaching hardware for any failure. If any damage and/or wear are found, replace the part concerned.
• Page 207
  BREAK-IN Break-in Period for New Machine Machine life and performance will be greatly affected by the treatment during operation and maintenance of the machine, but especially so during the initial operation. IMPORTANT: Always correctly warm the machine up to operating temperatures before running the machine ! This is always a requirement for good machine life.
• Page 208
  BREAK-IN MEMO …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..
• Page 209
  OPERATING THE ENGINE Inspect Machine Daily Before Starting Perform the required daily check before starting the engine.  Refer to «Maintenance» section for detailed information. Check Points Check Contents Brake System The brake pedal stroke is appropriate, brake performance is sufficient, and the brakes apply evenly.
• Page 210
  OPERATING THE ENGINE Check Points Check Contents Chassis Oil leaks of the transmission and the axle Level, leaks and contamination of the fuel tank. Drain water from fuel tank. Level and leaks of the hydraulic oil tank Operation, play and operating force of control levers and steering wheel Operation of hydraulic equipment.
• Page 211
  OPERATING THE ENGINE Check Before Starting CAUTION: If your machine is equipped with forward/ reverse selector switch (7), be sure to turn the switch in the OFF position before starting the engine to ensure safety. 1. If your machine is equipped with the battery disconnect switch, check that the switch is in the ON position.
• Page 212
  OPERATING THE ENGINE 5. Check that control lever lock switch (7) is in the locked ( ) position. MNEC-07-001 6. Adjust the position of outside rear view mirror (8) and inside rear view mirror (9) so that the best rear visibility can be obtained.
• Page 213
  OPERATING THE ENGINE Starting Engine Follow the following steps to start the engine. Do not depress accelerator pedal (3). 1. Check that both forward/reverse lever (8) and forward/ reverse switch (9) are in the neutral (N) position and neutral lever lock (10) is in the LOCK position. NOTE: If the machine is equipped with joystick steering (option), put the Forward/Reverse switch on the left console in the neutral (N) position.
• Page 214
  OPERATING THE ENGINE IMPORTANT: Never operate the starter for more than 10 seconds at a time. If the engine fails to start, return the key switch to the OFF position. Wait for more than 2 minutes, then try again. Failure to do so may cause damage to the starter and/ or discharge the batteries.
• Page 215
  OPERATING THE ENGINE Starting in Cold Weather Preheating 1. Turn the key switch (1) ON. The ambient temperature sensor is activated so that the engine is automatically preheated. 2. Preheat indicator (2) should turn ON. As long as the preheat indicator stays ON, the engine is being heated.
• Page 216
  OPERATING THE ENGINE Check After Starting IMPORTANT: If any abnormality is found in the monitor functions, immediately stop the engine and investigate the cause of the trouble. Check the monitor operation: 1. Check that service indicator (1) is OFF. 2. Check that discharge warning indicator (2) is OFF. In case the discharge warning indicator stays ON, immediately stop the engine.
• Page 217
  OPERATING THE ENGINE Using Booster Batteries IMPORTANT: The machine electrical system is a 24 volt negative (-) ground. Use only 24 volt booster batteries with sufficient capacity. WARNING:  An explosive gas is produced while batteries are in use or being charged. Keep open flames and sparks away from the battery area.
• Page 218
  OPERATING THE ENGINE 1. Connecting the booster batteries 1.1 Stop the engine on the booster battery mounted machine. 1.2 Connect one end of red booster cable (1) to the positive (+) terminal of the machine battery, and the other end to the positive (+) terminal of the booster battery.
• Page 219
  OPERATING THE ENGINE Warm Up CAUTION: Operating the machine without warm up causes damage to 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. If the machine is operated with the hydraulic oil temperature below 20 °C (68 °F), damage to the hydraulic components may result.
• Page 220
  OPERATING THE ENGINE Cold Weather Warm Up CAUTION: In case the hydraulic oil temperature is low, perform cold weather warm up. Operate the machine only after loading linkage speed is normal. Operating the machine without warming up first causes damage to the engine and hydraulic components.
• Page 221
  OPERATING THE ENGINE 2. Keep the engine running at low to medium speed for about five minutes more. NOTE: At this time, do not operate the engine in slow or fast speed. Use medium engine speeds for safe and quick warm up.
• Page 222
  OPERATING THE ENGINE Stopping Engine Stop the engine in the following manner. IMPORTANT: Never stop the engine while moving the machine. If the engine stops, the steering system may become inoperable, or it may cause other malfunctions or seizure of parking brake. 1.
• Page 223
  MOVING THE MACHINE Driving the Machine Correct operation will result in extending the service life of each part and component as well as saving fuel and oil. Always be sure to safely and efficiently operate the machine while paying attention to the following points. Precautions for starting to move 1.
• Page 224
  MOVING THE MACHINE Starting to Move WARNING: Start to move the machine only after checking that no personnel and/or obstacles are present around the machine. Never turn ride control switch (4) (option) to ON position when traveling the machine or raising the bucket.
• Page 225
  MOVING THE MACHINE 4. Step on brake pedal (6) or (7) and press parking brake switch (8) to the OFF position to release the parking brake. MNEC-01-036 Check that at this time parking brake indicator (1) goes OFF. MNEK-01-500 NOTE: When starting to ascend a slope, turn declutch switch (9) ( ) OFF (clutch engaged), and depress brake pedal (6).
• Page 226
  MOVING THE MACHINE 5. Manual Shift (M) 11, 12 After moving forward/reverse lever (11) to either forward (F) or reverse (R) position, move the shift switch (12) to the desired position. The transmission gear position can be shifted in 4 ranges in the forward and 4 ranges in the reverse mode.
• Page 227
  MOVING THE MACHINE Shift Range of Auto Transmission Mode Shift Position Shift Range 1st range 1st range only 2nd range*  2nd range  2nd L-UP  2nd L-UP  3rd range*  2nd range 3rd range  AUTO 1: range L-UP …
• Page 228
  MOVING THE MACHINE Power Mode Selector Pressing power mode selector switch (14) alternately activates (ON) and deactivates (OFF) the power mode. When the power mode is activated (ON), the indicator “ ” appears on the monitor display. The power mode is suited for heavy digging work prioritizing work effectiveness.
• Page 229
  MOVING THE MACHINE Parking Brake Switch WARNING:  To prevent accidents due to running away of the machine, after parking the machine or before leaving the machine, be sure to apply the parking brake.  Never apply the parking brake switch (1) while moving the machine except in an emergency.
• Page 230
  MOVING THE MACHINE Drive Speed Change The transmission gear range of 1st, 2nd, 3rd and 4th can be selected by turning shift switch (1). Refer to item 6 on page 4-4 for the auto-shifting mode. 1st and 2nd ranges : To be used for excavation and loading work 3rd and 4th ranges : To be used for traveling over long distances.
• Page 231
  MOVING THE MACHINE Steering Wheel Steering Wheel WARNING:  Avoid sudden steering while moving the machine at high speeds, while moving on a steep slope, or while raising the lift arms. Failure to do so may cause the machine to turn over. …
• Page 232
  MOVING THE MACHINE Secondary Steering (Option) If the oil pressure in the steering system lowers, the secondary steering system is activated so that steering operation can be achieved. If the secondary steering system is activated, the secondary steering indicator lights and the buzzer sounds.
• Page 233
  MOVING THE MACHINE Emergency Stop and Restart of Operation Follow the tips described below when required to stop or restart operation when an emergency has occurred. 1. Slowly release the accelerator pedal. Depress the service brake pedal to stop the machine. 2.
• Page 234
  MOVING THE MACHINE Precautions for traveling When operating, observe the previously noted operating precautions along with the others shown below to ensure safe and correct operation. WARNING:  In case a tire is punctured while driving, securely hold the steering wheel and slowly reduce the drive speed.
• Page 235
  MOVING THE MACHINE Operating in Water or on Soft Ground IMPORTANT: If the axles, transmission, etc. should become submerged under water to the point that water enters into them, they must be reconditioned immediately, otherwise the inner gears may wear excessively, or the machine may become damaged.
• Page 236
  MOVING THE MACHINE Precautions for Driving on Slopes WARNING:  Never allow the machine to descend a slope with the forward/reverse lever in neutral (N). This will not only cause the excessive engine revolutions to malfunction but also cause other engine and machine troubles.
• Page 237
  MOVING THE MACHINE Precautions to be Taken if Machine Failure Occurs  Keep alert. While paying attention to the vehicles following you, slowly reduce the travel speed and park the machine on the road shoulder away from flow of traffic. …
• Page 238
  MOVING THE MACHINE Stop 1. Avoid sudden deceleration. Smoothly reduce operating speed. Release accelerator pedal (1) and step on brake pedal (2) to stop the machine. MNEC-01-036 2. Return forward/reverse lever (3) to neutral (N). Place neutral lever lock (4) to the lock ( ) position. 3.
• Page 239
  MOVING THE MACHINE 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.
• Page 240
  MOVING THE MACHINE Parking IMPORTANT: When parking the machine with cab door and windows open, cab electrical components may be damaged by bad weather. Always close windows, roof vent and cab doors when parking the machine. 1. Stop and park the machine on level surface. Lower the bucket to the ground.
• Page 241
  MOVING THE MACHINE Emergency Stopping When the engine has stalled during operation: Pressurized oil in the accumulator acts on the brake when the brake pedal is depressed. Immediately park and stop the machine in a safe location. At this time, do not repeatedly apply the brake pedal.
• Page 242
  MOVING THE MACHINE MEMO …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..
• Page 243
  OPERATING THE MACHINE Loading Control Levers Fingertip Control Type The fingertip control lever is used to operate the lift arm and/or bucket. Lift Arm Control Lever (1) Lever Lift Arm Operation Position Float (Detent): The lift arm free falls and can be moved as loads are applied.
• Page 244
  OPERATING THE MACHINE NOTE: When applying lift arm control lever (1) in the «Raise» position (A), the lever is moved (F) until the lift arm reaches the position preset by the lift arm kickout. When the lift arm moves the preset position, lift arm control lever (1) automatically moves to the Neutral (N) position.
• Page 245
  OPERATING THE MACHINE Loading Multi-Function Joystick Lever (Option) The multi-function joystick lever is used to operate the lift arm and/or bucket. Lever Lift Arm/Bucket Operation Position Float (Detent): The lift arm free falls and can be moved as loads are applied. The lever will stay in this position.
• Page 246
  OPERATING THE MACHINE Control Lever Lock WARNING:  Be sure to press lock ( ) side of control lever lock switch (1).  Before leaving the operator’s seat, be sure to stop the engine. Then, set control lever lock switch (1) to the lock ( ) position.
• Page 247
  OPERATING THE MACHINE Declutch Position Switch To perform digging (scooping) or loading operation, declutch position switch (1) can be set to any position Turn the declutch position switch ON to let the engine speed and power be applied to loading circuits. …
• Page 248
  OPERATING THE MACHINE Adjustment of Bucket Auto Leveler WARNING: CRUSH HAZARD  Be careful to avoid injury and/or death when adjusting the bucket auto leveler.  Stop the engine. Lower the loader arm and bucket to the ground to release oil pressure. …
• Page 249
  OPERATING THE MACHINE Adjustment Procedures IMPORTANT: Do not operate the machine with the bucket dumped more than 10°. 1. After moving the bucket to the desired digging angle, stop the engine. 2. Loosen bolt (2). Slide the end edge of rod (3) up to the center of proximity switch (4) (orange color).
• Page 250
  OPERATING THE MACHINE Adjustment of Bucket Angle Switch WARNING: CRUSH HAZARD  Be careful to avoid injury and/or death when adjusting the bucket angle switch.  Stop the engine. Lower the loader arm and bucket to the ground to release oil pressure. …
• Page 251
  OPERATING THE MACHINE Adjustment Procedures IMPORTANT: Do not operate the machine with the bucket dumped more than 10°. 1. After moving the bucket to the desired operating angle, stop the engine. 2. Loosen bolt (2). Slide the end edge of rod (3) up to the center of proximity switch (4) (orange color).
• Page 252
  OPERATING THE MACHINE Adjustment of Dual Lift Arm Auto Leveler WARNING:  Take extra care to prevent injury and/or death when adjusting the lift arm auto leveler (kickout).  Apply the parking brake to prevent the machine from moving unexpectedly. Chock the wheels with blocks.
• Page 253
  OPERATING THE MACHINE Auto Idling Stop WARNING: This function automatically stops the engine. Carefully operate within the work environment when using this function. When the auto idling stop function is ON (enabled), the engine automatically stops after the preset time from the state in which the specified conditions are met (see the operating condition on the next page).
• Page 254
  OPERATING THE MACHINE Auto Idling Stop Operating condition  The engine is running.  The parking brake switch is ON.  The forward/reverse lever (switch) is in neutral (N).  The accelerator pedal is not depressed.  The brake pedal is not depressed. …
• Page 255
  OPERATING THE MACHINE Aftertreatment Device Manual Regeneration When the manual regeneration is needed, symbol (1) and service indicator (2) as shown to the right will be displayed. Perform manual regeneration in the following procedure. IMPORTANT: Park the machine in a safe area where exhaust Basic Screen temperatures will not damage property or other MNEK-01-280EN…
• Page 256
  OPERATING THE MACHINE 4. When aftertreatment device switch has been pressed, screen (5) appears as shown to the right and manual regeneration starts. The bar graph on the screen (6) indicates regeneration progress. NOTE: The manual regeneration cannot start unless the following items are as indicated.
• Page 257
  OPERATING THE MACHINE 5. Manual Regeneration Completed (Successful) When manual regeneration is completed, «Regeneration Has Completed.» message will be displayed and the regeneration symbol disappears. 6. Manual Regeneration Failed (Unsuccessful) If the message «Regeneration Has Failed.» appears on MNEK-01-284EN the monitor panel, start the regeneration process over again.
• Page 258
  OPERATING THE MACHINE Before Operation Avoid Overloading WARNING: WARNING:  Be sure to install only authorized buckets and  Do not penetrate the bucket into piles of soil other work tools. and/or gravel at fast travel speed.  Never modify or increase the capacity of …

• Page 259: Excavation

  OPERATING THE MACHINE Excavation Loading Accumulated Soil IMPORTANT:  Do not dig or scoop with machine frame articulated.  Avoid operating the machine with the front wheels raised off the ground. Machine traction force is M4GB-05-003 reduced and excessive loads are applied to the undercarriage.
• Page 260
  OPERATING THE MACHINE Digging and Loading Level Ground IMPORTANT: While operating the bucket or fork, never apply excessive force to the tooth tips with the bucket or fork tilted more than 10°. This may result in cracks or damage to the front attachment. Slightly position the bucket edge downward (0 to 10 M4GB-05-007 degrees) and dig the ground while moving the machine…

• Page 261: Grading

  OPERATING THE MACHINE Grading WARNING: When operating a machine equipped with ride control and the lift arm control lever in the float position, when performing works as soil scooping, land grading, or snow removal, be sure to turn the ride control switch OFF. Failure to do so may allow the ride control system to operate so that the M4GB-05-011 front attachment may automatically move up and…

• Page 262: Loading

  OPERATING THE MACHINE Loading IMPORTANT:  Always maintain a clean surface for machine operation. Cleaning of materials such as soil and stones spilled on the work surface will reduce wear and/or damage on tires.  When carrying loads in the bucket, pay attention to the road surface conditions.

• Page 263: Loader And Dump Truck Combination Method

  OPERATING THE MACHINE Loader and Dump Truck Combination Method WARNING:  Always maintain a flat and clean work site surface. Avoid rapid turns and/or sudden braking while raising the lift arm with the bucket loaded to prevent the machine from tipping over. …

• Page 264: Dumping Into Truck Or Hopper

  OPERATING THE MACHINE Dumping into Truck or Hopper WARNING:  When boom is raised, machine stability is reduced and could cause machine to tip over causing serious injury or death.  Do not make quick turns or abrupt braking when boom is raised.

• Page 265: Dozing

  OPERATING THE MACHINE Dozing IMPORTANT:  Dozing or pushing with dumped bucket or attachment may cause severe damage to linkages. It may also cause engine over-heating and torque converter over-heating.  Never attempt to forcibly push piled material higher than the bucket capacity. Premature wear of the tires due to slipping and/or waste of fuel may result.

• Page 266: Removing Snow

  OPERATING THE MACHINE Removing Snow WARNING: When operating a machine equipped with ride control and the lift arm control lever in the float position, when performing work as soil scooping, land grading, or snow removal, be sure to turn the ride control switch OFF.

• Page 267: Precautions For After Operation

  OPERATING THE MACHINE Precautions for After Operation 1. After finishing operation, move the machine to firm, level ground where no possibility of falling stones, ground collapse, or floods are present. (Park the machine referring to the «Parking» in the «MOVING THE MACHINE» chapter.) 2.

• Page 268
  OPERATING THE MACHINE 4. Maintenance for long term machine storage after engaging in snow removal. (Refer to STORAGE section.) Anti-freeze agents such as salt (sodium chloride or calcium chloride) usually are scattered on snow covered roads. When the machine is stored for a long time after Red cap engaging in snow removal work, perform the following maintenance to protect the machine from being…

• Page 269: Transporting

  TRANSPORTING Transporting by Road When transporting the machine on public roads, be sure to first understand and follow all local regulations. 1. For transporting using a trailer, check the width, height, length and weight of the trailer when the machine is loaded. 2.

• Page 270: Loading / Unloading On Trailer

  TRANSPORTING Loading / Unloading on Trailer WARNING: Be sure to use a loading dock or a ramp for loading/unloading. Always load and unload the machine on a firm, level surface. Ramp/Loading Dock: 1. Before loading, thoroughly clean the ramps, loading dock and flatbed.

• Page 271: Loading / Unloading On Trailer

  TRANSPORTING Loading / Unloading on Trailer WARNING:  Keep machine straight while moving up or down a ramp since turning on a ramp may cause the machine to turn over. Never attempt to steer the machine on a ramp. If the travel direction must be changed on a slope, move the machine back to the flat surface on flatbed.

• Page 272: Fastening Machine For Transporting

  TRANSPORTING Fastening Machine for Transporting WARNING: Fasten the machine chassis to the trailer securely with chains and cables. While traveling, loads may shake around, move forward or backward or to the sides. 1. Apply the parking brake. Slowly rest the bucket on the trailer deck or load-carrying platform.

• Page 273: Transporting Wheel Loader (Urgent Situation)

  TRANSPORTING Transporting Wheel Loader (Urgent Situation) The following procedures shall only be applied to cases when urgently moving the wheel loader a short distance is required. When required to transport the wheel loader long distance, use a trailer. Precautions for Driving On Roads Avoid driving the wheel loader long distances at high- speed as much as possible as it may overheat the tires, possibly resulting in premature tire damage and/or wear.

• Page 274: Precautions For Towing

  TRANSPORTING Precautions for Towing WARNING: Never attempt to tow the machine if the brake system is in need of repair. Ask your nearest authorized dealer to repair the machine. Operate the machine only after repairs is completed. Avoid towing the machine as much as possible. If the machine must be towed, be careful about the following points.

• Page 275: Releasing Parking Brake

  TRANSPORTING Releasing Parking Brake WARNING:  Once the parking brake is released, the machine becomes impossible to stop with the parking brake system, possibly resulting in personal injury or death.  Before releasing the parking brake be sure to chock tires with wheel stoppers. CAUTION: …

• Page 276
  TRANSPORTING Procedures WARNING:  Once the parking brake is released, the machine becomes impossible to stop with the parking brake system.  Chock all tires to prevent the machine from moving.  Before restarting to operate the machine, consult your nearest authorized dealer to have the parking brake adjusted.

• Page 277: Towing Method

  TRANSPORTING Towing Method Attach wire ropes to the machine when the machine must be towed, in such cases when the machine cannot be moved from soft ground under its own power. CAUTION:  Use wire cable having the strength more than approx.

• Page 278: Lifting Machine

  TRANSPORTING Lifting Machine WARNING:  The lifting tools are optional. Install specified lifting tools at your nearest authorized dealer.  Use lifting cables and other lifting tools that are free from any damage and/or aging, and properly rated for the load. …

• Page 279: Correct Maintenance And Inspection Procedures

  IMPORTANT:  Use only recommended coolant, fuel, DEF/AdBlue® and lubricants.  Be sure to use only genuine Hitachi parts. Failure to do so may result in serious injury or death and/or machine breakdown.  Failure to use recommended coolant, fuel, DEF/ AdBlue®, lubricants, and genuine Hitachi parts will…

• Page 280
  MAINTENANCE  Machine Information Controller This machine provides a machine information controller that stores machine operation information for preventive maintenance. When maintaining the machine, our authorized service man may down load the stored information via satellite. Consult with your nearest authorized dealer for detailed function of this device. …

• Page 281: Check The Hour Meter Regularly

  MAINTENANCE Check the Hour Meter Regularly Refer to the List of Check and Maintenance for information about lubricants, check and adjustment intervals. The lubrication chart is affixed on the left side of the front chassis. Refer to 7-6 page. This manual recommends grouping the intervals into three categories as follows: Daily Check : To be conducted daily before operation (every 10 hours)

• Page 282: Layout

  MAINTENANCE Layout 90Z7B-7-4-1 1- Bolt on Cutting Edge 17- Transmission 2- Bucket 18- Second (Front and Center) Propeller Shaft 3- Bucket Cylinder Rod Pin 19- Steering Cylinder 4- Bucket Cylinder 20- Front Axle 5- Head Light 21- Lift Arm (Boom) Cylinder 6- Hydraulic Oil Tank 22- Lift Arm Cylinder Rod Pin 7- Air Cleaner…

• Page 283: Lubrication Guide

  MAINTENANCE 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.
• Page 284
  MAINTENANCE  Lubrication Chart 90Z7B-44794-24480  Symbols The following symbols are used in the lubrication chart. Symbols  Grease point Multipurpose grease Hydraulic oil  Check and add if necessary Gear oil Engine oil  Oil replacement Engine oil…

• Page 285: Preparations For Inspection And Maintenance

  MAINTENANCE Preparations for Inspection and Maintenance WARNING: If ride control switch (3) (option) is in the AUTO position, the lift arm may unexpectedly rise. To avoid an accident due to unexpected movement of the lift arm and bucket, always turn ride control switch (3) OFF before beginning the inspection and/or maintenance of the machine.

• Page 286
  MAINTENANCE WARNING: 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.

• Page 287: Articulation Lock

  MAINTENANCE Articulation Lock CAUTION: Before beginning to work near the chassis center hinge (4), install articulation stopper (lock bar) (2) to securely lock and prohibit movement between the front and rear chassis. Avoid accidents from unexpected movement of the machine. 1.

• Page 288: Inspection/ Maintenance Side Access Cover

  MAINTENANCE Inspection/ Maintenance Side Access Cover CAUTION:  Always close side covers (1) during operation.  Do not keep side covers (1) open on a slope or when a strong wind is blowing. Failure to do so may be dangerous because side cover (1) may unexpectedly close.

• Page 289: Rear Grille

  MAINTENANCE Rear Grille WARNING: Open or close rear grille (2) only after stopping the engine. It is very dangerous if you are entangled in the cooling fan. Before operating the machine, always check that the rear grille is well 1, 2 latched.

• Page 290: Inspection And Maintenance Table

  MAINTENANCE Inspection and Maintenance Table Check and/or carry out the maintenance at intervals of IMPORTANT the specified operating hours below or the calender date, Severe applications require more frequent whichever comes first. maintenance. Severe conditions include heavy dust, extremely abrasive material, caustic chemicals, extremely wet conditions or abnormally hot or cold ambient temperatures.

• Page 291
  MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Check Transmission Oil Level 7-33  Replace Transmission Oil Filter Cartridge 7-34  Transmission Replace Transmission Oil 7-34 &…
• Page 292
  MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Check Hydraulic Oil Level 7-44  Check Bucket Teeth and Cutting Edge 7-110  Check Hoses and Lines for Leaks 7-54 …
• Page 293
  MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Clean/Replace Air Conditioner 7-99   Circulation/Fresh Air Filters Check Air Conditioner Compressor Belt 7-102  Check Refrigerant Level 7-103 …

• Page 294: Kind Of Oils

  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…

• Page 295: Axle Oil

  Kind of Oil Gear Oil Axle & Wet Disc Brake Application Air Temperature -25 to 45 °C (-13 to 113 °F) High Gear Oil Hitachi Recommended Product TKTT15150-4th TO-4 SAE50 Fluid, TO-4M Fluid, Alternative Product with 6% friction modifier NOTE:  When using TO-4 SAE50 or TM-4M Fluid other than the listed recommended products, add…

• Page 296: List Of Consumable Parts

  MAINTENANCE List of Consumable Parts 1. Filter Elements Part No. Engine Oil Filter YL00009256 Fuel Main Filter YL00008001 Fuel Pre-Filter Element YL00008002 Air Cleaner Element (outer) K5261250 Air Cleaner Element (inner) K5261252 Hydraulic Oil Tank Suction Filter 4033560150 Hydraulic Oil Tank Filter YA00026486 Pilot Oil Filter (Brake Circuit) 4033060610…

• Page 297
  MAINTENANCE 3. Combination Light and Other Light Part No. Head Light Assembly 4436232 Head Light 3848070850 Bulb (24 V, 70/75 W) Front Combination Light Assembly 2640242432 Front 4570171030 Front Combination Light Lens Rear 4570171040 Bulb 3848070930 Front Work Light Assembly 4336570 Bulb 3848071100…

• Page 298: Greasing

  MAINTENANCE A. Greasing CAUTION: Apply the parking brake and the articulation stopper (lock bar) (Refer to page 7-9). NOTE:  Until break-in is performed for more than 50 hours, lubricate the machine every day to get initial lubrication.  In case excavation is made in mud, water or snow, lubricate the machine after operation is complete.

• Page 299
  MAINTENANCE 6. One point each to right and left lift arm pivot pins (8). — every 500 hours (250 hours at first time only) One point each to right and left lift cylinder pins (9). — every 500 hours (250 hours at first time only) 90Z7-7-21-1 7.
• Page 300
  MAINTENANCE 9. One point each to upper and lower center hinge pins (14 and 15). — every 250 hours Upper (14) Lower (15) 90Z7-7-22-2 10. One point each to front and rear axle support pins (16 and 17). — every 10 hours Front (17) Rear (16) 90Z7B-7-23-1…
• Page 301
  MAINTENANCE 12. One point to propeller shaft pillow unit (19). — every 250 hours 90Z7-7-24-1 13. One point to second (center) propeller shaft universal front side (20). — every 12000 hours One point to second (center) propeller shaft universal rear side (22). — every 12000 hours 14.
• Page 302
  MAINTENANCE 15. Two points to third (rear) propeller shaft universal (23). — every 12000 hours 16. One point to third (rear) propeller shaft splines (24). — every 2000 hours 90Z7-7-24-4 17. Two points to first (main) propeller shaft universal (25). — every 12000 hours NOTE: When the machine is continuously operated under severe conditions for a long time, shorten the…

• Page 303: Engine

  MAINTENANCE B. Engine Check Engine Oil Level — every 10 hours (machine parked on a level surface before starting the engine) IMPORTANT: Incorrect engine oil level may cause engine trouble (The oil level should be between the upper and lower marks on oil level gauge (1)). If engine oil level is too high, lower the oil level to the proper place before starting the engine.

• Page 304: Check Crankcase Breather Tube

  MAINTENANCE Check Crankcase Breather Tube — every 10 hours (daily) WARNING: Immediately after the machine has been operated, all engine parts are hot. Wait for the engine to cool down before starting any maintenance work. Failure to do so may cause severe burns.

• Page 305: Change Engine Oil

  MAINTENANCE Change Engine Oil — every 500 hours WARNING: Immediately after the machine has been operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns. NOTE: Improper disposal of waste oil can threaten the earth’s environment and ecology.

• Page 306: Replace Engine Oil Filter

  MAINTENANCE Replace Engine Oil Filter — every 500 hours (each time when engine oil is changed) WARNING: Immediately after the machine has been operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns. 1.

• Page 307
  MAINTENANCE IMPORTANT: Do not overtighten the filter. 7. Install the filter in reverse order and tighten the filter until the gasket contacts filter head surface. Then tighten it by hand an additional three-fourths to one turn. NOTE: Refer to the instructions supplied with the filter. NOTE: Install the element with care so that the O-ring is not damaged from twisting.

• Page 308: Replace Crankcase Air Breather Element

  MAINTENANCE Replace Crankcase Air Breather Element — Every 2000 hours WARNING: Be sure to wear safety glasses when using compressed air (0.2 MPa (2 kgf/cm , 30 PSI)). 1. Park the machine following the same procedure as described on page 7-7 for preparation of inspection/ maintenance work.

• Page 309
  MAINTENANCE 8. Lubricate the breather element O-ring seal with clean lubricating oil. 90Z7B-7-29-4 9. Install new breather element (3) onto breather base (4). 10. Install crankcase breather cover (1). 11. Install crankcase breather cover capscrews (2) (11 used). Tightening torque: 10 N-m (7.4 lbf-ft) 90Z7B-7-29-2 NOTE: Tighten the capscrews in the sequence shown.

• Page 310: Check Vibration Damper

  MAINTENANCE Check Vibration Damper — Every 2000 hours 1. Park the machine following the same procedure as described on page 7-7 for preparation of inspection/ maintenance work. CAUTION: The silicone fluid in the vibration damper will become solid after extended service and will make the damper inoperative.

• Page 311: Power Train

  MAINTENANCE C. Power Train Check Transmission Oil Level — every 10 hours (daily) WARNING:  Move forward/reverse lever to neutral and turn parking brake switch ON.  After leveling the bucket on the ground, move the control lever lock switch to the lock ( ) position. …

• Page 312: Change Transmission Oil

  MAINTENANCE Change Transmission Oil — every 1000 hours Change Transmission Oil Filter — every 1000 hours Clean Suction Strainer — every 1000 hours NOTE: Be sure to replace the transmission oil filters and clean the transmission oil suction strainer when changing the transmission oil.

• Page 313
  MAINTENANCE IMPORTANT: The machine is equipped with a turbocharged engine. Cool down before stopping the engine. Failure to do so may cause the lubricant on the turbocharger bearing and seal surfaces to be dissipated due to the intense heat present inside the turbocharger, possibly damaging the turbocharger.
• Page 314
  MAINTENANCE 11. Using a filter wrench, turn cartridge filter (6) counterclockwise to remove it. Properly dispose of the oil and filter. 12. Clean the filter-seating surface. After coating the new cartridge filter gasket surface with new oil, lightly turn the cartridge filter clockwise by hand until the cartridge filter sealing surface comes in contact with the filter-seating surface.

• Page 315: Clean Torque Converter Air Breather

  MAINTENANCE Clean Torque Converter Air Breather — every 1000 hours 1. Open the machine left side cover. The air breather is located near the accumulator. 2. Clean the vicinity around air breather (1). 3. Put a cover on the air breather port to prevent foreign matter from entering.

• Page 316: Check Axle Oil Level

  MAINTENANCE Check Axle Oil Level — every 250 hours WARNING: When working under the raised lift arm, be sure to avoid accidental injury or death by placing a safety column or stand under the lift arm to support it. 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work.

• Page 317: Change Axle Oil

  MAINTENANCE Change Axle Oil — every 2000 hours WARNING: Be cautious about the following items.  Starting repair work immediately after operation may cause burns. Wait for oil temperature to lower.  Lock the front and rear chassis with the articulation stopper (lock bar).

• Page 318: Check Surroundings Around Axle And Covers For Oil Leaks

  MAINTENANCE Check Surroundings Around Axle and Covers for Oil Leaks — every 1000 hours Check the areas around the axle and covers for oil leaks. If any oil leaks are found, check the bolts in the oil leaking area for looseness. Retighten as needed. M4GB-07-159 7-40…

• Page 319: Clean Axle Housing Air Breather

  MAINTENANCE Clean Axle Housing Air Breather — every 500 hours Front Axle Breather (1) Rear Axle Breather (2) WARNING: When working under the raised lift arm, be sure to avoid accidental injury or death by placing a safety column or stand under the lift arm to support it.

• Page 320: Hydraulic System

  MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment CAUTION: During operation, the parts of the hydraulic system become very hot. Allow the machine to cool down before beginning inspection or maintenance. 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work.

• Page 321
   When adding hydraulic oil, always use compatible oils; do not mix brands of oil. The machine is filled with Hitachi Super EX 46HN when it is shipped from the factory. When selecting to use another brand of oil listed in the table “Hydraulic Oil”, be sure to completely replace the oil in the system.

• Page 322: Check Hydraulic Oil Level

  MAINTENANCE Check Hydraulic Oil Level — every 10 hours (daily) IMPORTANT: If the oil level is not viewed in the level gauge, immediately refill hydraulic oil up to the correct level. Failure to do so may result in a serious failure in the hydraulic system.

• Page 323: Change Hydraulic Oil

  MAINTENANCE Change Hydraulic Oil — every 4000 hours WARNING: Hydraulic oil becomes hot during operation. Severe burns may result if skin comes in contact with hot hydraulic oil. Wait for the oil to cool before starting any maintenance work. Release trapped hydraulic circuit pressure by using the loader control levers.

• Page 324: Bleed Air From The Hydraulic System

  MAINTENANCE 6. Supply hydraulic oil through filling port (3) while checking the oil level at level gauge (6). Refer to «Hydraulic Oil» on page 7-17. * Capacity of Total oil capacity in hydraulic oil tank the hydraulic system 137 liters 200 liters (36 gallons) (53 gallons)

• Page 325: Clean Suction Filter

  MAINTENANCE Clean Suction Filter — each time the hydraulic oil is changed. IMPORTANT: This upper tank area must be very clean prior to beginning this procedure. Failure to clean the top of tank may lead to hydraulic system problems due to system contamination. A suction filter is located on the bottom of the hydraulic oil tank.

• Page 326: Clean Pilot Oil Filter

  MAINTENANCE Clean Pilot Oil Filter — every 2000 hours WARNING: Hydraulic oil becomes hot during operation. Severe burns may result if skin comes in contact with hot hydraulic oil. Wait for the oil to cool before starting any maintenance work. IMPORTANT: Remove trapped hydraulic circuit pressure by using the loader control levers.

• Page 327
  MAINTENANCE [ Line Filter in Steering Circuit (Reducing Valve Unit) ] 8. Remove plug (4) with O-ring (5). 9. Take out filter element (3) inside, and clean it by applying air or cleaning solution from the oil flow outlet side. 10.

• Page 328: Replace Hydraulic Oil Return Filter

  MAINTENANCE Replace Hydraulic Oil Return Filter — every 1000 hours WARNING: Hydraulic oil becomes hot during operation. Severe burns may result if skin comes in contact with hot hydraulic oil. Wait for the oil to cool before starting any maintenance work. Especially when removing the filter, be careful that the remaining oil in the filter does not spill.

• Page 329: Replace Air Breather Element

  MAINTENANCE Replace Air Breather Element — every 2000 hours WARNING: Hydraulic oil becomes hot during operation. Severe burns may result if skin comes in contact with hot hydraulic oil. Wait for the oil to cool before starting any maintenance work. Replacement Procedures 1.

• Page 330: Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, And Damage

  MAINTENANCE Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage — every 2000 hours NOTE: The loading pilot pressure is supplied from the accumulators in the brake circuit. WARNING: Allow only qualified personnel to handle the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator.

• Page 331: Check Ride Control Accumulator Function, Gas Leakage, Looseness, And Damage (Option)

  MAINTENANCE Check Ride Control Accumulator Function, Gas Leakage, Looseness, and Damage (Option) — every 500 hours WARNING: Allow only qualified personnel to handle the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator. (N is inert.)  Never strike the accumulator. Keep the accumulator away from heat sources.

• Page 332: Check Hoses And Lines

  MAINTENANCE Check Hoses and Lines — every 10 hours (daily) — every 250 hours WARNING: High pressure fluid can penetrate the skin causing serious injury. To avoid this hazard, search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, immediately see a doctor familiar with this type of injury.

• Page 333
  Replace (Use proper bend radius) Hose ends and Deformation or Replace fittings Corrosion (10) M115-07-149 Fig. 1 NOTE: Refer to the illustrations in Fig. 1 for each check point location or for a description of the abnormality. Use genuine Hitachi parts. 7-55…
• Page 334
  Welded surfaces on Crack (12) Replace joints Clamps Missing Replace Deformation Replace M4GB-07-060 Fig. 2 Loose Retighten NOTE: Refer to the illustrations in Fig. 2 for each check point location or for a description of the abnormality. Use genuine Hitachi parts. 7-56…

• Page 335: Service Recommendations For Hydraulic Fittings

  MAINTENANCE Service Recommendations for Hydraulic Fittings Two hydraulic fitting designs are used on this machine. Flat Face O-ring Seal Fitting (ORS Fitting) An O-ring is used on the sealing surfaces to prevent oil leakage. 1. Inspect fitting sealing surfaces (6). They must be free M104-07-033 of dirt or defects.

• Page 336: Metal Face Seal Fittings

  MAINTENANCE Metal Face Seal Fittings Fittings are used on smaller hoses and consist of a metal flare and a metal flare seat. 1. Inspect flare (10) and flare seat (9). They must be free of dirt or obvious defects. 2. Tighten fitting (7) by hand. 3.

• Page 337: Fuel System

  MAINTENANCE E. Fuel System Check Fuel Level — every 10 hours (daily) WARNING: Fuel is flammable. Keep fuel away from fire hazards. IMPORTANT: Always fill the fuel tank with the specified diesel fuel. Failure to do so may cause engine trouble and also making it difficult for the engine to start.

• Page 338: Refueling

  MAINTENANCE Refueling 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down. WARNING: Handle fuel carefully. Shut the engine off before fueling.

• Page 339: Drain Water And Sediment From Fuel Tank

  MAINTENANCE Drain Water and Sediment from Fuel Tank — every 1000 hours Before starting to operate the machine, loosen drain plug (1) on the fuel tank bottom and drain water and/or sediment from the fuel tank. Tighten plug when no more water is draining, and only fuel drainage is seen.

• Page 340: Drain Fuel Filter

  MAINTENANCE Drain Fuel Filter — every 10 hours (daily) IMPORTANT: Drain fuel pre-filter daily before starting operation. The engine may be damaged if failed. Drained water should contain fuel. Follow the local regulations when disposing it. Fuel pre-filter (1) has water separator function, which drains accumulated water.

• Page 341: Bleed Air From The Fuel System

  MAINTENANCE Bleed Air from the Fuel System If Air Mixed After Common Rail Air in the fuel system may make the engine hard to WARNING: INJECTION HAZARD start or make it run rough or not run at all. Fuel under high pressure After draining water and sediment from the fuel High pressure common rail, high pressure lines filter, replacing the fuel filter, cleaning the fuel pump…

• Page 342: Replace Fuel Main Filter Element

  IMPORTANT:  Be sure to use only genuine Hitachi elements for the fuel main filter element and the pre-filter element. Failure to do so may lower engine performance and/or shorten the engine service life.

• Page 343
  MAINTENANCE WARNING: When servicing the engine, do not rotate engine with a high pressure fuel system joint open. Rotating the engine can create highly pressurized fuel in the fuel system. High-pressure fuel spray can penetrate the skin, resulting in serious personal injury or death. 7.

• Page 344: Clean Fuel Pump Strainer

  MAINTENANCE Clean Fuel Pump Strainer — 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.

• Page 345: Check Fuel Hoses

  MAINTENANCE Check Fuel Hoses — every 10 hours (daily) CAUTION: Fuel leaks can lead to fires that may result in serious injury.  Escaping combustible fluid can cause fires. Check for kinked hoses, hoses that chafe against each other, and signs of fuel leaks. …

• Page 346: Air Cleaner

  MAINTENANCE F. Air Cleaner Replace Air Cleaner Element — when the monitor indicator is lit. Air cleaner (1) is comprised of double elements, the outer element and inner element. IMPORTANT: Do not reuse outer element (4). Replace it when the indicator is lit. Replace inner element (5) every after replacing outer element (4) twice.

• Page 347: Clean Dust Ejection Valve

  MAINTENANCE Clean Dust Ejection Valve — daily Dust ejection valve (1) is located on the bottom of air cleaner (2). Hold down the valve from both sides by using your fingers until the end of dust ejection valve (1) opens. If dust is difficult to be removed, loosen the clip at the root of dust ejection valve (1) to remove dust ejection valve (1).

• Page 348: Check Air Inlet System

  MAINTENANCE Check Air Inlet System — every 10 hours (daily) Check pipes and hoses of the air inlet system for wear, damage or loose connections and clamps. Replace damaged pipes and hoses. Retighten loose clamps. Tightening torque: Clamp A: 9 N·m (0.9 kg·m) Clamp B: 17 to 20 N·m (1.7 to 2.0 kg·m) Clamp C: 10 N·m (1.0 kg·m) MNEC-07-121…

• Page 349: Cooling System

  Do not use strong acid or alkaline water. Use of the filter using the specified filter WF2072 every 500 hours. genuine Hitachi Long-Life Coolant (LLC) mixed by 33 to Refer to the following table for the filters and coolant 50 % is recommended.

• Page 350: Check Coolant Level

  MAINTENANCE Check Coolant Level — every 10 hours (daily) CAUTION: If the engine is kept running with insufficient coolant, the EGR cooler maybe damaged due to overheat. IMPORTANT:  When refilling a long life coolant (LLC), use the same brand product and the same mixture ratio as already used in the machine.

• Page 351: Check Drive Belt

  MAINTENANCE Check Drive Belt — every 10 hours (daily) Check drive belt (1) for any trouble. Replace the belt with a new one, if necessary. 90Z7B-7-77-1 OM0099 7-73…

• Page 352: Replace Dca4 Coolant Filter Cartridge

  MAINTENANCE Replace DCA4 Coolant Filter Cartridge — every 500 hours WARNING:  Pressurized radiator tank is used for this machine. Spray of hot coolant may cause burns. Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure.

• Page 353: Inspection Procedures Of Coolant Concentration

  Inspection Procedures of Coolant Concentration Contents of Kit: Check the concentration of DCA4 in coolant using the inspection kit shown below. Color Specimen Cummins Hitachi Part Name of Kit Part No. Inspection Kit CC2602 4404083  Outline Plastic Coolant Receiver…

• Page 354
  MAINTENANCE  Precautions for Using CC2602 Test Kit Maintain coolant temperature to 10 to 54 °C (50 to The effective life time of the reagent is printed on the 129.2 °F) while checking. Otherwise, incorrect color upper section of the CC2602 container. change may result.
• Page 355
  MAINTENANCE  How to Use Test Kit IMPORTANT: Measure time precisely to obtain the 6. In case the reagent color corresponds to that correct test results. Use a stop watch or watch between the color specimens, take the intermediate with a second hand. If the reagent color change is value.

• Page 356: Clean Radiator/Oil Cooler Cores And Other Cooling System

  MAINTENANCE Clean Radiator/Oil Cooler Cores and Other Cooling System — every 500 hours or when the core is clogged. WARNING: When using compressed air pressure [less than 0.2 MPa (2 kgf/cm , 30 PSI)], wear safety glasses or goggles. IMPORTANT: If compressed air with the pressure of more than 0.2 MPa (2 kgf/cm , 30 PSI) or tap water with high delivery pressure is used for cleaning, damage to the…

• Page 357: Check Drive Belt Tensioner

  MAINTENANCE Check Drive Belt Tensioner — every 1000 hours or one year 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. Remove the key and tag «Do Not Operate».

• Page 358: Change Coolant

  (1). NOTE: Refer to page 7-71 for coolant specification. When other than Hitachi LLC is used, contact your nearest authorized dealer for the replacement interval. 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work.

• Page 359
  MAINTENANCE 7. Start the engine and wait for one minute, then run at slightly higher than the low idle speed for about 30 minutes until the water temperature reaches above 85ºC (185ºF). Take care of the water level especially for the first 5 minutes, and add water via sub tank cap (4) as needed.

• Page 360: Electrical System

  MAINTENANCE H. Electrical System IMPORTANT: Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment may effect the machine’s electronic parts, causing involuntary movement of the machine. Also, improper installation of electrical equipment may cause machine failure and/or a fire on the machine.

• Page 361
  MAINTENANCE 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.

• Page 362: Electrolyte Level Check

  MAINTENANCE Electrolyte Level Check — every 100 hours (Do this when machine is cold.) 1. Check the electrolyte solution level at least once a month. 2. Park the machine on level ground and stop the engine. 3. Check the electrolyte solution level. U.L (Upper Level) 3.1 When checking the level from the battery side: L.L (Lower Level)

• Page 363: Check Electrolyte Specific Gravity

  MAINTENANCE Check Electrolyte Specific Gravity — every 250 hours If you spill acid on yourself, call 911, then: 1. Flush your skin with water. CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight 2. Apply baking soda or lime to help neutralize the and a mirror to check the battery electrolyte acid.

• Page 364: Replace Batteries

  MAINTENANCE Replace Batteries IMPORTANT: Before adjusting electrical system or welding on the machine, disconnect the negative side of the battery, or turn the battery disconnect switch to OFF position. Your machine has two 12-volt batteries with negative (-) ground. If one battery in a 24-volt system has failed but the other is still good, replace the failed battery with an operable battery of the same type.

• Page 365: Check Horn And Backup Alarm

  MAINTENANCE Check Horn and Backup Alarm — every 10 hours (daily) WARNING: Before checking the horn and/or the backup alarm, always apply the parking brake and clear the machine area of other personnel. Horn (1) is located on the front chassis. Horn switch button (2) is located at the steering wheel center and on the right console.

• Page 366: Check Electrical Harnesses And Fuses

  MAINTENANCE Check Electrical Harnesses and Fuses — every 50 hours Fuse box A Check the electrical harness and terminals of the batteries, Fuse box B starter motor, and alternator for loose connection and/ or short circuit (broken shield). If any burned mark or a burning odor is noticed at a harness, consult your nearest authorized dealer.

• Page 367: Fuse Box A

  MAINTENANCE Fuse Box A 10- Parking solenoid 20- Option 4 10 A (Joystick steering) 5 A 9- Air conditioner 1 19- Option 3 (ACC2) 10 A (15 A) 8- Stop lamp, Turn signal 18- DEF line heater 15 A 7- Back lamp, Back buzzer 17- DEF supply module 15 A 6- Head lamp (left)

• Page 368: Brake System

  MAINTENANCE I. Brake System Check Right and Left Brake Interlocking Performance — every 10 hours (daily) WARNING: Put up a do not enter sign for the range of 100 m (110 yd) ahead in the forward machine travel direction. Arrange a safety monitor person. WARNING: Do not allow dust and/or soil to accumulate in vicinity (3) of the brake pedal.

• Page 369: Check Parking Brake Force

  MAINTENANCE Check Parking Brake Force — every 10 hours (daily) WARNING: Check the machine in a place where no one is present or ahead in the drive traveling direction. Keep bystanders away from the machine. After confirming the service brakes work normally, test the parking brake.

• Page 370: Check Accumulator Function, Gas Leakage, Looseness, And Damage

  MAINTENANCE Check Accumulator Function, Gas Leakage, Looseness, and Damage — every 500 hours WARNING: Allow only qualified personnel to service the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator. (N is inert, and will not burn.)  Never strike the accumulator. Keep the accumulator away from heat sources.

• Page 371: Check Gas Pressure In Accumulator

  MAINTENANCE 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.

• Page 372: Tire

  MAINTENANCE J. Tire Check and Replace Tire (Tire Pressure) Check appearance — 10 hours (daily) NOTE: Check tire pressure when appearance is questionable or each week (50 hours) Replace — as necessary WARNING:  Secure the front and rear chassis with the articulation stopper (lock bar and pins).

• Page 373: Check Tire For Damage

  MAINTENANCE Check Tire for Damage — every 10 hours (daily) CAUTION: If tire has external damaged such as deep cuts, an accident due to puncture or burst of the tire may occur, possibly resulting in injury or death. Check the external appearance of tires for damage. Check Wheel Bolt Torque — every 500 hours (50 hours at fist time only)

• Page 374: Tire Sizes To Be Used

  MAINTENANCE Bias ply tire Air pressure kPa (psi) Size Pattern Front Rear 26.5-25- 422~441 324~343 20PR (61~64) (47~50) Radial tire Air pressure kPa (psi) Size Front Rear 471~490 373~392 26.5 R25 (68~71) (54~57) Adjust air pressure according to the job site conditions. Adjust tire pressure in conformity with the work mode the machine is engaged in.

• Page 375: Tire Rotation

  MAINTENANCE Tire Rotation Rotate tires when uneven or abnormal wear is recognized on either front or rear, or right and left tire. (Right) (Wrong) Tire rotation is recommended to achieve uniformity of wear on tires for good tire service life. WARNING: This must have no external damage, such as heavy cuts, large bubbled protrusions or other damage that can lead to tire failure.

• Page 376: Removal And Installation Of Tire

  MAINTENANCE Removal and Installation of Tire WARNING: A wheel and tire assembly is a very heavy part so that removal and installation of a tire is hazardous and difficult work. In addition, a crane to lift a tire is required when removing or installing the tire to the wheel.

• Page 377: Air Conditioner

  MAINTENANCE K. Air Conditioner Clean/Replace Air Conditioner Circulation/Fresh Air Filters Clean filters — every 100 hours (or once a week whichever come first) Replace filter — after cleaning filters 10 times (or when the filters are severely clogged) Clean Fresh Air Filter 1.

• Page 378: Clean Circulation Air Filter

  MAINTENANCE Clean Circulation Air Filter 1. Remove screw (6) under cup holder (5) and tilt the cup holder forward. M4GB-07-108 2. Hold handle (7) and pull handle (7) toward you to remove circulation air filter (8). IMPORTANT: Do not use compressed air or water to clean filter (8) as damage to the filter fins may result.

• Page 379: Check Air Conditioner

  MAINTENANCE Check Air Conditioner — every 6 months Check the air conditioner switch panel, air conditioner unit, and condenser mounting areas for any troubles, and check hoses for any damage. NOTE: When the season to use the air conditioner comes close, check the air conditioner to get it ready to use at all times.

• Page 380: Check Air Conditioner Condenser

  MAINTENANCE Check Air Conditioner Condenser — every 6 months If condenser (1) is covered with dirt and/or insects, air conditioner cooling performance will be reduced. Remove dirt or stain foreign material from fins of condenser (1) using tap water. In case the condenser has been severely contaminated, use a soft brush or a plastic fin comb tool.

• Page 381: Check Refrigerant

  MAINTENANCE Check Refrigerant — every 6 months 1. Start the engine and run at approximately 1500 min (rpm). 2. Turn the air conditioner switch to ON. Set the blower switch to HI and set the temperature control switch to the coolest position (18 °C (65 °F) on the monitor screen).

• Page 382: Aftertreatment Device

  MAINTENANCE L. Aftertreatment Device Check and Clean Aftertreatment Device — as required IMPORTANT:  Check and clean flammable objects on the area around the aftertreatment device daily.  Do not disassemble the machine support parts and sensors. NOTE: When the machine is operated in dusty areas, refer to «9-1 Maintenance Under Special Environmental Conditions».

• Page 383: Urea Scr System

  MAINTENANCE M. Urea SCR System IMPORTANT: WARNING:  Use dedicated container recommended by the  Fill specified DEF/AdBlue® into the DEF/AdBlue® business entity who is handling DEF/AdBlue® tank. to store DEF/AdBlue®. Do not use general  If improper DEF/AdBlue® is refilled, fire or system container, a container used for other purpose and failure may result.

• Page 384: Check Def/Adblue® Level

  MAINTENANCE Check DEF/AdBlue® Level —daily Park the machine on a level surface. Lower the bucket to the ground. Check the DEF/AdBlue® level with DEF/ AdBlue® gauge (1). Add DEF/AdBlue® if necessary. Refill DEF/AdBlue® CAUTION: MNEK-01-103EN  Refill DEF/AdBlue® which meets Japanese Industrial Standards (JIS K2247), International Organization for Standardization (ISO 22241) or Deutsche Industrie Normen (DIN 70070) in DEF/…

• Page 385
  MAINTENANCE 5 . Install cap (4) after refilling DEF/AdBlue®. Turn stopper plate (3) to the original position, close the tank cover and lock it with the key. IMPORTANT:  Do not get on top of DEF/AdBlue® tank (2) or sensors and piping on the tank. Failure to do so may damage the machine.

• Page 386: Replace Def/Adblue

  MAINTENANCE Replace DEF/AdBlue® — As required CAUTION: Use rubber glove for protection during operation. Wash DEF/AdBlue® with clean water when it contacts on the skin. IMPORTANT: When contaminated or deteriorated DEF/AdBlue® is used, malfunction may result. Change DEF/AdBlue® periodically to keep cleanliness in the tank.

• Page 387: Replace Def/Adblue® Supply Module Main Filter

  MAINTENANCE Replace DEF/AdBlue® Supply Module Main Filter — every 4500 hours A filter (4) is mounted in the DEF/AdBlue® pump. Periodically replace filter (4). CAUTION: Use rubber glove and goggles or safety glasses for protection during operation. Wash DEF/ AdBlue® with clean water when it contacts on the skin.

• Page 388: Miscellaneous

  MAINTENANCE N. Miscellaneous Check Bucket Teeth and Cutting Edge — every 10 hours (daily) Check bucket teeth for wear and looseness. Replace WARNING: Guard against injury from flying pieces of metal. Wear goggles or safety glasses, hard hat and face shield. 1.

• Page 389: Check And Replace Seat Belt And Lower Tether

  MAINTENANCE Check and Replace Seat Belt and Lower Tether Check — every 10 hours (daily) Replace — every 3 years Examine buckle (1), attaching hardware (2) and seat belt web. Replace the seat belt web, buckle, or attaching hardware if they are damaged, or worn. Replace seat belt and lower tether every 3 years, regardless of appearance.

• Page 390: Check Play Amount In Steering Wheel Movement

  MAINTENANCE Check Play Amount in Steering Wheel Movement — every 10 hours (daily) WARNING: Pinch point. When the steering wheel is turned, the clearance between the front and rear chassis closes, creating a hazardous situation. Keep personnel away from the chassis articulation point during inspection.

• Page 391: Check Accelerator Pedal Operation, And Exhaust

  MAINTENANCE Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise — every 10 hours (daily) WARNING: Move the forward/reverse lever to neutral. Apply the parking brake. After resting the bucket level to the ground, block the wheels. While slowly stepping on accelerator pedal (1), check that the engine speed smoothly increases.

• Page 392: Check Rearview Mirror And Inside Rearview Mirror

  MAINTENANCE Check Rearview Mirror and Inside Rearview Mirror — every 10 hours Check that inside rearview mirror (1) and rearview mirror (2) are adjusted correctly. Check inside rearview mirror (1) and rearview mirror (2) for contamination or damage to the mirror glass.

• Page 393: Clean Engine Compartment And Hood

  MAINTENANCE Clean Engine Compartment and Hood — every 10 hours (daily) CAUTION: Dust or debris accumulated in the engine compartment or around the hood may come in contact with high temperature sections near the aftertreatment device, muffler, engine or hood, possibly causing fires.

• Page 394: Check Tightening Torque Of Nuts And Bolts

  MAINTENANCE Check Tightening Torque of Nuts and Bolts — every 2000 hours (50 hours at first time only) Check tightness after the first 50 hours then every 2000 NOTE: Check nuts and bolts for looseness and missing hours. daily before and after operation. If any loose or missing Tighten or retighten nuts and bolts to the torque specified nuts and/or bolts are found, retighten or supply on the following pages.

• Page 395
  MAINTENANCE 1. Front axle mounting bolt Bolt diameter 30 mm (1.2 in) Quantity Wrench size 46 mm Tightening torque 1420 N·m (145 kgf·m, 1045 lbf·ft) NOTE: Do not lubricate these bolts. 90Z7-7-105-1 2. Rear axle support mounting bolt Bolt diameter 30 mm (1.2 in) Quantity Wrench size…
• Page 396
  MAINTENANCE 3. Wheel rim mounting bolt Bolt diameter 24 mm (0.9 in) Quantity Wrench size 36 mm Tightening torque 890 N·m (91 kgf·m, 658 lbf·ft) M4GB-07-127 4. Propeller shaft mounting bolt Bolt diameter 12 mm (0.5 in) Quantity Wrench size 19 mm Tightening torque 142 N·m (14.5 kgf·m, 105 lbf·ft)
• Page 397
  MAINTENANCE 5. Propeller shaft support bearing mounting bolt Bolt diameter 20 mm (0.8 in) Quantity Wrench size 30 mm Tightening torque 400 N·m (40 kgf·m, 295 lbf·ft) NOTE: Apply LOCTITE#262 or equivalent. 90Z7-7-106-2 6. Transmission mounting bolt Bolt A: Bracket Bolt diameter 16 mm (0.6 in) Quantity…
• Page 398
  MAINTENANCE 8. Engine mounting bolt Bolt A Bolt diameter 16 mm (0.63 in) Quantity Wrench size 24 mm Tightening torque 210 N·m (21 kgf·m, 155 lbf·ft) Bolt B: Cushion rubber Bolt diameter 20 mm (0.8 in) Quantity Wrench size 30 mm 90Z7B-7-116-2 Tightening torque 400 N·m (40 kgf·m, 295 lbf·ft)
• Page 399
  MAINTENANCE 9. Aftertreatment device mounting bolt/nut Bolt A Bolt diameter 12 mm (0.5 in) Quantity Wrench size 19 mm Tightening torque 90 N·m (9.2 kgf·m, 66 lbf·ft) Nut B Nut diameter 10 mm (0.4 in) Quantity Wrench size 17 mm 90Z7B-7-117-1 Tightening torque 20 N·m (2 kgf·m, 15 lbf·ft)
• Page 400
  MAINTENANCE 13. Bottom center pin lock Bolt diameter 20 mm (0.8 in) Quantity Wrench size 30 mm Tightening torque 400 N·m (40 kgf·m, 295 lbf·ft) 90Z7-7-109-1 14. Loader front pin lock Bolt diameter 20 mm (0.8 in) Quantity Wrench size 30 mm Tightening torque 400 N·m (40 kgf·m, 295 lbf·ft)
• Page 401
  MAINTENANCE 16. Radiator mounting bolt Bolt A Bolt diameter 16 mm (0.63 in) Quantity Wrench size 24 mm Tightening torque 210 N·m (21 kgf·m, 155 lbf·ft) Bolt B 90Z7B-7-119-1 Bolt diameter 10 mm (0.39 in) Quantity Wrench size 17 mm Tightening torque 37 N·m (3.8 kgf·m, 27.5 lbf·ft) Bolt C…
• Page 402
  MAINTENANCE 17. Oil cooler mounting bolt Bolt A Bolt diameter 10 mm (0.39 in) Quantity Wrench size 17 mm Tightening torque 50 N·m (5 kgf·m, 37 lbf·ft) Bolt B Bolt diameter 12 mm (0.5 in) Quantity Wrench size 19 mm 90Z7B-7-120-1 Tightening torque 90 N·m (9 kgf·m, 66 lbf·ft)
• Page 403
  MAINTENANCE 19. Air conditioner compressor mounting bolt Bolt A Bolt diameter 8 mm (0.3 in) Quantity Wrench size 13 mm Tightening torque 20 N·m (2 kgf·m, 15 lbf·ft) Bolt B Bolt diameter 8 mm (0.3 in) Quantity Wrench size 17 mm 90Z7B-7-121-1 Tightening torque 50 N·m (5 kgf·m, 37 lbf·ft)
• Page 404
  MAINTENANCE 22. Cutting edge mounting bolt Bolt diameter 1-8UNC in Quantity Wrench size 41 mm Tightening torque 1314 N·m (134 kgf·m, 969 lbf·ft) 90Z7-7-113-1 23. Wear plate mounting bolt Bolt diameter 7/8-9UNC in Quantity Wrench size 36 mm Tightening torque 834 N·m (85 kgf·m, 615 lbf·ft) 90Z7-7-113-2 7-126…

• Page 405: Maintenance Under Special Environmental Conditions

  MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions WARNING: Before operating the machine in a WARNING: Avoid driving the machine into a river, check the riverbed conditions in advance. river where the riverbed is steep and deep or the stream is rapid.

• Page 406: Maintenance Under Special Environmental Conditions

  MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Precautions for Maintenance During Cold Weather Season Before the atmospheric temperature below -0 °C (32 °F), note the following points.  Water and oil in the machine will freeze. Never use water without antifreeze. Use correct windshield washing solution so that windshield washer tanks and pumps will not freeze.

• Page 407
  MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS DANGER: Ventilate the area with fresh air when carrying out warm-up operation indoor. Failure to do so may cause asphyxiation from exhaust gas, resulting in death or severe injury. 6. After preheating, start and warm up the engine. 7.
• Page 408
  MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..

• Page 409: Storage

  STORAGE Storing the Machine WARNING: When servicing indoors for long term storage, open windows and doors to maintain good air ventilation to prevent asphyxiation. Check all lubricants before operating the machine after bring stored. Apply the parking brake while storing. If the machine is to be stored for more than one month, observe the following precautions so that its function will not be impaired during storage.

• Page 410: Removing The Machine From Storage

  STORAGE Removing the Machine from Storage WARNING: When servicing indoors for long term storage, open windows and doors to maintain good air ventilation to prevent asphyxiation. Check all lubricants before operating the machine after bring stored. Apply the parking brake while storing. IMPORTANT:  Lubricants will deteriorate during storage of the machine.

• Page 411
  STORAGE 1. Remove covers. 2. Remove grease from the cylinder rods if coated. 3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels. 4. Adjust alternator and drive belt tension. 5. Check the oil level. Add oil as needed. 6.
• Page 412
  STORAGE MEMO …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..10-4…

• Page 413: Troubleshooting

  TROUBLESHOOTING Troubleshooting If any machine trouble has occurred, immediately repair it. Make certain the cause of the trouble and take necessary measures to prevent the reoccurrence of the same trouble. In case troubleshooting is difficult, or measures marked with * must be taken, consult the nearest authorized dealer.

• Page 414
  TROUBLESHOOTING 3. Engine does not Start. Symptom Cause Solution The starter does not turn. Reduced battery voltage Charge the batteries. Replace. High resistance in the starter circuit * Clean and/or retighten the battery terminals and starter terminals Faulty key switch * Replace Damaged wire harness * Repair or replace…
• Page 415
  TROUBLESHOOTING 4. Control Lever Symptom Cause Solution Hard to move Rusted joint * Lubricate or repair Worn pusher * Replace Does not move smoothly Worn pusher * Repair or replace Faulty pilot valve * Replace Does not return to neutral Faulty pilot valve * Replace The lever is tilted in the…
• Page 416
  TROUBLESHOOTING 6. Drive Function Problem Cause Solution Steering wheel is heavy to Faulty steering pump * Repair, Replace operate. Faulty steering device * Repair, Replace Malfunction of steering cylinder * Repair, Replace Relief valve set pressure reduction * Adjust Faulty steering column Low tire air pressure * Inflate Steering wheel turns in…

• Page 417: Specifications

  SPECIFICATIONS Specifications Intended Use This product is designed for loading, excavation,grading, dozing and/or scooping. Refer to «OPERATING THE MACHINE» for further information. 90Z7B-FK-GSC Bucket Capacity: heaped 4.2 (5.5) 4.7 (6.1) Operating Weight kg (lbs) 24180 (53310) 24670 (54390) Tipping Load (Full Turn) kg (lbs) 16410 (36180) 15550 (34285)

• Page 418
  SPECIFICATIONS MEMO …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..12-2…

• Page 419: Other Attachments

  OTHER ATTACHMENTS Joystick Steering Joystick Steering (Optional) Layout 1- Switch Box 2- Left Console Pipe 3- Left Armrest 4- DSS (Down Shift Switch) 5- Forward/Reverse Switch (Left) 6- Wiper Switch 7- Joystick Steering Selector Switch 8- Joystick Steering Lever 85MNEK-13-01 9- Left Console Lock Release Lever 10- Switch Box Fore/Aft Adjustment Bolt 11- Left Console Height Adjustment Bolt…

• Page 420: Joystick Steering Lever

  OTHER ATTACHMENTS Joystick Steering Joystick Steering Lever This lever controls turning operations. Pressing lever (8) down to the left turns the machine to the left. Pressing lever (8) down to the right turns the machine to the right. How far lever (8) is depressed, controls how fast the machine turns.

• Page 421: Joystick Steering Selector

  OTHER ATTACHMENTS Joystick Steering Joystick Steering Selector Disabled Position IMPORTANT: To use joystick steering selector (7), lower left console (16) to the operating position. If left console (16) is not in the operating position, both the joystick steering selector switch (7) and the Forward/ Operating Position Reverse switch (left) (right) cannot be operated.

• Page 422: Forward/Reverse Switch

  OTHER ATTACHMENTS Joystick Steering Forward/Reverse Switch It is possible to choose between Forward/Reverse switch (left) (5) and Forward/Reverse switch (right) (19). When Forward/ Reverse selector switch indicator (21) is displayed on the monitor, Forward/Reverse switch (left) (5) is selected. When Forward/Reverse selector switch indicator (22) is displayed on the monitor, Forward/Reverse switch (right) (19) is selected.

• Page 423: Left Console Lock Release Lever

  OTHER ATTACHMENTS Joystick Steering Left Console Lock Release Lever WARNING: When leaving the operator’s station, lift up left console (16)  to the disabled position. Once left console (16) is lifted up to the disabled position, it is locked. IMPORTANT:  When raising or lowering left console (16), hold it by left console pipe (2).

• Page 424: Adjusting The Switch Box Fore/Aft Position

  OTHER ATTACHMENTS Joystick Steering Adjusting the Switch Box Fore/Aft Position If switch box fore/aft adjustment bolts (10) are loosened, the 11 A 11 B fore/aft position of switch box (1) can be adjusted through a range of 20 mm. To loosen bolts (10), remove their caps. After adjusting the position, tighten bolts (10) again.

• Page 425: Operating Procedures

  OTHER ATTACHMENTS Joystick Steering Operating Procedures Disabled Position WARNING:  When traveling on public roads, use steering wheel (18). The use of joystick steering lever (8) is Operating Position prohibited.  When traveling at high speeds or driving in narrow areas, use steering wheel (18).
• Page 426
  OTHER ATTACHMENTS Joystick Steering Operations IMPORTANT: In cold weather, or if the hydraulic oil temperature is low, the turning speed may be slow Left when using the joystick steering. Perform a full warm- up by operating joystick steering lever (8) before operating the machine.
• Page 427
  OTHER ATTACHMENTS Joystick Steering Canceling Operation 1. Stop the machine. 2. Put the Forward/Reverse switch (left) (5) in the neutral (N) position. 3. Turn joystick steering selector (7) OFF. Joystick steering indicator (14) and Forward/Reverse selector switch indicator (15) turn OFF on the monitor. 4.

• Page 428: Descriptions Of Warnings

  OTHER ATTACHMENTS Joystick Steering Descriptions of Warnings Joystick Steering Indicator If a problem occurs in the joystick steering system, a warning mark is displayed in the joystick steering indicator (14) on the monitor. Description Display MNEK-01-100 There is a problem in the joystick steering system.

• Page 429
  OTHER ATTACHMENTS Joystick Steering Forward/Reverse Selector Switch Indicator If a problem occurs in the Forward/Reverse switch (right or left) system, a warning mark is displayed in the Forward/ Reverse selector switch indicator (15) on the monitor. Description Display There is a problem in Forward/Reverse switch (left)(5) system.

• Page 430: Axle Oil Cooler

  Application Axle, Parking Brake Manufacturer High Gear Oil Hitachi TKTT 15150-4th NOTE:  When using TO-4 SAE50 or TM-4M Fluid other than the listed recommended products, add 6% additive to prevent or eliminate service brake application noise. Recommended additive package: HCM 9990A or equivalent.

• Page 431
  OTHER ATTACHMENTS Axle Oil Cooler Check Axle Oil Level — every 250 hours WARNING: When working under the raised lift arm, be sure to avoid accidental injury or death by placing a safety column or stand under the lift arm to support it.
• Page 432
  OTHER ATTACHMENTS Axle Oil Cooler Change Axle Oil — every 2000 hours WARNING: Be cautious about the following items.  Starting repair work immediately after operation may cause burns. Wait for oil temperature to lower.  Lock the front and rear chassis with the articulation stopper (lock bar).

• Page 433: Replace Axle Oil Cooler Line Filter (Option)

  OTHER ATTACHMENTS Axle Oil Cooler Replace Axle Oil Cooler Line Filter (Option) — every 500 hours or every 3 months whichever comes first WARNING: Be cautious about the following items.  Starting repair work immediately after operation may cause burns. Wait for oil temperature to lower. …

• Page 434: Clean Axle Oil Cooler Fins (Option)

  OTHER ATTACHMENTS Axle Oil Cooler Clean Axle Oil Cooler Fins (Option) — as required 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work. Stop the engine. IMPORTANT: High pressure air or water may damage oil cooler fins.

• Page 435: Index

  INDEX Before Operation …………….5-16 Beware of Asbestos and Silicon Dust and Other About Biodiesel Fuel …………..7-59 Contamination …………….. S-33 Accelerator Pedal …………….1-90 Beware of Exhaust Fumes…………S-31 Acting Time Setting …………..1-53 Bleed Air from the Fuel System ……….7-63 Adjust Operator’s Seat …………..S-6 Bleed Air from the Hydraulic Circuit ……..

• Page 436
  INDEX Check Gas Pressure in Accumulator ……..7-93 Control Lever Lock …………….5-4 Check Gas Pressure in Ride Control Accumulator Control lever lock indicator (Red) ……….. 1-18 (Option) ………………7-53 Controller Part Name and Function ……..1-116 Check Gas Pressure in Steering Accumulator ….7-53 Cool Head/Warm Feet Operation ………1-120 Check Horn and Backup Alarm ……….
• Page 437
  INDEX Equipment of Head Guard, ROPS, FOPS ……. S-11 Inspection and Maintenance of Hydraulic Equipment … 7-42 Evacuating in Case of Fire …………S-30 Inspection and Maintenance Table ……..7-12 Excavation ………………5-17 Inspection Procedures of Coolant Concentration …. 7-75 Inspection/ Maintenance Side Access Cover……
• Page 438
  INDEX Maintenance Under Special Environmental Conditions …9-1 Precautions for Maintenance During Cold Weather Manual Operation …………..1-106 Season ………………..9-2 Manual Regeneration …………..1-35 Precautions for Operation ……….S-19, 5-16 Manual Regeneration Procedure ……….5-13 Precautions for starting to move ……….4-1 Metal Face Seal Fittings ………….. 7-58 Precautions for Towing …………..6-6 Miscellaneous …………….7-110 Precautions for traveling …………
• Page 439
  INDEX Retighten Front Axle and Rear Axle Support Mounting Time adjustment …………….1-46 Bolts ……………….7-115 Time Remains and Maintenance Interval ……1-75 Ride Control Drive Speed Setting (Option) ……1-37 Tips for Optimal Air Conditioner Usage ……1-121 Ride Control Switch (Option) ……….1-108 Tire …………………
• Page 440
  INDEX MEMO …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..14-6…

ИНСТРУКЦИИ ПО РЕМОНТУ

На нашем сайте пока представлены не все у нас имеющиеся модели, если не нашли что искали или по поводу электро и гидро схем пишите нам на почту ak.zxzxzx@ro.ru

ЭКСКАВАТОРЫ ZX 1 СЕРИИ

ZX-450 450LC 450LCH

ZX-330 370MTH

ZX-210W

ZX 180W

ZX-160W

ZX-130W

ЭКСКАВАТОРЫ ZX 3 СЕРИИ

ZX 850-3 870 LCH-3

ZX 650 LC 670L CH-3

ZX-450-<br /> 520LCH-3

ZX 330-3

ZX 210W-3 ZX 220W-3

ZX 200-3 270-3

ZX 170W-3 190W-3

ZX 160 LC-3 180 LCN-3

ZX140W<br /> -3

ZX110-3 135US-3

ZX 85 USBLC-3

ZX 70-3 85US-3

ЭКСКАВАТОРЫ ZX 5 СЕРИИ

ZX-470- 470LCR-5G

ZX-330- 350LCK-5G

ZX-180 LCN-5G

ЭКСКАВАТОРЫ EX 1 СЕРИИ

EX-700

EX-400

EX-300

EX-270

EX-230

EX-200

EX-120

EX-100

ПОГРУЗЧИКИ LX

LX450-7

LX300-7

LX-130-LX230-7

LX-110-7

ПОГРУЗЧИКИ ZW

ZW310

ZW180

ZW140-150

ZW30-40-50

ZW20