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EX3600-6 Operator Manual

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592 views

EX3600-6 Operator Manual

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Juanka Pugliese

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INTRODUCTION

Read this manual carefully to learn how to operate This warranty provides you the assurance that Hitachi
and service your machine correctly. Failure to do so will back its products when defects occur within the
could result in personal injury and/or machine dam- warranty period. In some circumstances, Hitachi also
age. provides field improvements, often without charge to
the customer, even if the product is out of warranty.
This manual should be considered a permanent Should the equipment be abused or modified to
part of your machine and should remain with the ma- change its performance beyond the original fac-
chine when you sell it. tory specifications, the warranty will become void
and field improvements may be denied. Setting fuel
This machine is of metric design. Measurements in delivery above specifications or otherwise overpower-
this manual are metric. Use only metric hardware and ing machines will result in such action.
tools as specified. Moreover, when replacement parts are required, be
sure to use genuine Hitachi parts. Failure to do so may
Write product identification numbers in the Ma- result in voiding the warranty and/or denial of field im-
chine Numbers section. Accurately record all the provements.
numbers to help in tracing the machine should it be Only qualified, experienced operators officially li-
stolen. Your dealer also needs these numbers when censed (according to local law) should be allowed
you order parts. If this manual is kept on the machine, to operate the machine.
also file the identification numbers in a secure place Moreover, only officially licensed personnel
off the machine. should be allowed to inspect/service the machine.

Warranty is provided as a part of Hitachi's support The Yellow Pages in this operator s manual con-
program for customers who operate and maintain their tain IMPORTANT SAFETY INFORMATION.
equipment as described in this manual. The warranty Read these pages thoroughly and familiarize your-
is explained on the warranty certificate which you self with the safety standards and recommenda-
should have received from your dealer. tions set forth in these yellow pages of the man-
ual.
Follow all safety instructions prior to and while
operating the excavator.

Prior to operating this machine, in a country other than

a country of its intended use, it may be necessary to
make modifications to it so that it complies with the
local regulatory standards (including safety standards)
and legal requirements of that particular country.
Please do not export or operate this machine outside
of the country of its intended use until such
compliance has been confirmed. Please contact
Hitachi Construction Machinery Co., Ltd. or any of our
authorized distributor or dealer if you have any
questions concerning compliance.

All information, illustrations and specifications in this manual are based on the latest product information available
at the time of publication. The right is reserved to make changes at any time without notice.
COPYRIGHT © 2007
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved.
MACHINE NUMBERS
MACHINE TYPE AND SERIAL NUMBER

MODEL/TYPE:
PRODUCT
IDENTIFICATION
NUMBER:

M18M-00-001
PRODUCT IDENTIFICATION NUMBER

PRODUCT
IDENTIFICATION
NUMBER:

NOTE:
Marks to indicate the
HCM18M00P00001001 start and end of the
PIN
PRODUCT IDENTIFICATION
NUMBER (PIN)

M146-07-018

ENGINE TYPE AND SERIAL NUMBER

TYPE:
MFG. NO.

M18M-00-002
TRAVEL MOTOR TYPE AND SERIAL NUMBER

TYPE:
MFG. NO.(LEFT FRONT) :
MFG. NO.(LEFT REAR) :
MFG. NO.(RIGHT FRONT) :
MFG. NO.(RIGHT REAR) :

M145-07-079
MACHINE NUMBERS
SWING MOTOR TYPE AND SERIAL NUMBER

TYPE:
MFG. NO.(FRONT LEFT) :
MFG. NO.(FRONT RIGHT):
MFG. NO.(REAR LEFT):
MFG. NO.(REAR RIGHT):

M146-07-028
HYDRAULIC PUMP TYPE AND SERIAL
NUMBER

TYPE:
MFG. NO.(1, 2):
MFG. NO.(3, 4):
MFG. NO.(5, 6):
MFG. NO.(7, 8):

FRONT TYPE AND SERIAL NUMBER M146-07-059

(LOADING SHOVEL)

TYPE:
MFG. NO.:

M146-07-060

BUCKET TYPE AND SERIAL NUMBER

(LOADING SHOVEL)

TYPE:
MFG. NO.:

M117-12-003
MACHINE NUMBERS
FRONT TYPE AND SERIAL NUMBER
(BACKHOE BOOM)

TYPE:
MFG. NO.:

M146-07-060

FRONT TYPE AND SERIAL NUMBER

(BACKHOE ARM)

TYPE:
MFG. NO.:

M146-07-061

BUCKET TYPE AND SERIAL NUMBER

(BACKHOE)

TYPE:
MFG. NO.:

M146-01-020
CONTROL VALVE TYPE AND SERIAL Upper Right Upper Left
NUMBER

TYPE:
MFG. NO.(UPPER LEFT):
MFG. NO.(UPPER RIGHT):
MFG. NO.(LOWER LEFT):
MFG. NO.(LOWER RIGHT):
Lower Right Lower Left

M18M-00-003
MACHINE NUMBERS
MEMO
......................................................................................................................................................................................

......................................................................................................................................................................................

......................................................................................................................................................................................
CONTENTS
MACHINE NUMBERS Remove Paint Before Welding or Heating ........ S-26
Beware of Asbestos Dust.................................. S-26
SAFETY Prevent Battery Explosions ............................... S-27
Recognize Safety Information..............................S-1 Service Air Conditioning System Safely............ S-27
Understand Signal Words....................................S-1 Handle Chemical Products Safely..................... S-28
Follow Safety Instructions ....................................S-2 Dispose of Waste Properly ............................... S-28
Prepare for Emergencies.....................................S-2
Wear Protective Clothing.....................................S-3 SAFETY SIGNS .................................. S-29
Protect Against Noise ..........................................S-3
Inspect Machine...................................................S-3 COMPONENTS NAME ......................... 1-1
General Precautions for Cab ...............................S-4
Use Handholds and Steps ...................................S-5 HANDLING STAIRWAY/EMERGENCY ROPE
Adjust the Operator s Seat ..................................S-5 Using Stairway .................................................... 1-2
Fasten Your Seat Belt..........................................S-6 Operating Stairway.............................................. 1-2
Move and Operate Machine Safely .....................S-6 Emergency Escape ............................................. 1-5
Handle Starting Aids Safely .................................S-6 Emergency Exit ................................................... 1-6
Operate Only from Operator s Seat .....................S-7 Evacuating in Case of Fire .................................. 1-6
Jump Starting ......................................................S-7
Keep Riders Off Machine ....................................S-7 OPERATOR S STATION
Investigate Job Site Beforehand..........................S-8 Cab Features .......................................................1-8
Protect Against Falling Stones and Debris ..........S-8 Monitor Display.....................................................1-9
Provide Signals for Jobs Involving Multiple Starting Check Screen .........................................1-9
Numbers of Machines ...................................S-9 Meter Check Screen ..........................................1-10
Confirm Direction of Machine to be Driven..........S-9 Tachometer..................................................1-11
Drive Machine Safely.........................................S-10 Coolant Temperature Gauge .......................1-11
Avoid Injury from Rollaway Accidents................S-11 Hydraulic Oil Temperature Gauge ...............1-11
Avoid Injury from Back-Over Fuel Gauge ..................................................1-11
and Swing Accidents ...................................S-12 Engine Oil Pressure Gauge .........................1-12
Keep Person Clear from Working Area .............S-13 Engine Oil Temperature Gauge ...................1-12
Never Position Bucket Over Anyone .................S-13 Hour Meter ...................................................1-12
Avoid Undercutting ............................................S-13 Warning Indicators .......................................1-12
Avoid Tipping .....................................................S-14 Alternator Indicator.......................................1-12
Never Undercut a High Bank .............................S-14 Pump Transmission Oil Level Indicator .......1-13
Dig with Caution.................................................S-15 Engine Stop Indicator...................................1-13
Operate with Caution .........................................S-15 Engine Oil Pressure Indicator ......................1-13
Avoid Power Lines .............................................S-15 Coolant Overheat Indicator ..........................1-13
Object Handling .................................................S-16 Coolant Level Indicator ................................1-14
Protect Against Flying Debris ............................S-16 Engine Over Run Indicator...........................1-14
Park Machine Safely..........................................S-17 Fuel Temperature Indicator .........................1-14
Handle Fluids Safely Avoid Fires ....................S-17 Hydraulic Oil Level Indicator ........................1-14
Practice Safe Maintenance................................S-18 Stop Valve Indicator .....................................1-15
Warn Others of Service Work ...........................S-19 Auto-Lubrication Indicator ............................1-15
Support Machine Properly .................................S-19 Fast-Filling Indicator.....................................1-16
Stay Clear of Moving Parts ................................S-19 Emergency Engine Stop Indicator ...............1-16
Prevent Parts from Flying ................................S-20 Tension Indicator .........................................1-16
Store Attachments Safely ..................................S-20 Electric Lever Indicator ................................1-16
Prevent Burns ....................................................S-21 Caution Indicators ........................................1-17
Replace Rubber Hoses Periodically ..................S-21 Exhaust Temperature Indicator ...................1-17
Avoid High-Pressure Fluids ...............................S-22 Engine Warning Indicator ............................1-17
Prevent Fires .....................................................S-23 Hydraulic Oil Overheat Indicator ..................1-17
Evacuating in Case of Fire.................................S-24 Pump Contamination Indicator.....................1-17
Beware of Exhaust Fumes ................................S-24 Stairway Position Indicator...........................1-18
Precautions for Welding and Grinding...............S-25 Air Cleaner Restriction Indicator ..................1-18
Avoid Heating Near Pressurized Fluid Lines .....S-25 Electrical Equipment Box Indicator ..............1-18
Avoid Applying Heat to Lines Containing Status Indicators ..........................................1-18
Flammable Fluids ........................................S-25 Auto-Idle Indicator ........................................1-18
CONTENTS
Travel Mode Indicator.................................. 1-19 Emergency Engine Stop Switch .........................3-14
Prelub Indicator ........................................... 1-19 Engine Stop Switches ........................................3-15
Left Console....................................................... 1-20
Warning Lamp ............................................. 1-20 DRIVING THE MACHINE
Caution Lamp .............................................. 1-20 Drive the Machine Carefully .................................4-1
Key Pad ....................................................... 1-20 Steering the Machine Using Pedals .....................4-2
Monitor Contrast Switch .............................. 1-20 Steering the Machine Using Levers .....................4-3
Wiper Switch ............................................... 1-21 Travel Mode Switch..............................................4-4
Washer Switch ............................................ 1-21 Travel Alarm.........................................................4-5
Wiper Delay Selector Switch ....................... 1-21 Traveling ..............................................................4-6
Air Conditioners ................................................. 1-22 Operating on Soft Ground ....................................4-7
Designations and Functions of Controls ............ 1-23 Raise One Track Using Boom and Arm...............4-7
Cooling ........................................................ 1-25 Towing Machine a Short Distance .......................4-8
Heating ........................................................ 1-25 Operating Ground Condition ................................4-9
Dehumidifying and Heating ......................... 1-25 Precautions for Traveling on Slopes ..................4-10
Defrosting .................................................... 1-26 Parking the Machine on Slopes .........................4-11
Blower Operation without Cooling Parking the Machine ..........................................4-11
or Heating .............................................. 1-26
Ventilation the Cab ...................................... 1-26 OPERATING THE MACHINE
AM/FM Radio Operation .................................... 1-27 Control Lever (ISO Pattern Backhoe) ................5-1
Digital Clock Setting Procedure ......................... 1-28 Control Lever (HITACHI Pattern Backhoe) ........5-2
Right Console .................................................... 1-29 Control Lever (ISO Pattern Loading Shovel) ......5-3
Key Switch ................................................... 1-29 Control Lever (HITACHI Pattern
Emergency Engine Stop Switch .................. 1-30 Loading Shovel) ...........................................5-4
Engine Start Switch ..................................... 1-30 Bucket Open-Close Pedals (Loading Shovel)......5-5
Engine Stop Switch ..................................... 1-30 Pilot Control Shut-Off Lever .................................5-6
Engine Speed Control Dial .......................... 1-31 Engine Speed Control ..........................................5-7
Work Light Switch........................................ 1-32 Auto-Idle ...............................................................5-8
Dome Light Switch....................................... 1-33 Warming-Up Operation ........................................5-9
Maintenance Light Switch............................ 1-34 Warming-Up the Cylinders and Motors..............5-10
Entrance Light Switch.................................. 1-35 Precautions for Operations ................................5-11
Travel Mode Switch ..................................... 1-36 Operate the Machine Safely...............................5-12
Auto-Idle Switch........................................... 1-36 Operating Backhoe ............................................5-13
Buzzer Stop Switch...................................... 1-37 Grading Operation..............................................5-13
Fast-Filling System ...................................... 1-38 Avoid Abusive Operation....................................5-14
Rear Console..................................................... 1-39 Operating Tips....................................................5-15
Horn Switch ....................................................... 1-40 Avoid Swinging Bucket to Move Objects............5-15
Adjusting the Seat.............................................. 1-41 Loading Shovel Operation..................................5-16
Seat Belt ............................................................ 1-44 Prohibited Operation ..........................................5-16
Cab Door Release Button.................................. 1-45 Object Handling..................................................5-18
Opening Cab Left Window................................. 1-45 Overnight Storage Instructions...........................5-19

BREAK-IN MAINTENANCE
Observe Machine Closely.................................... 2-1 Correct Maintenance and Inspection Procedures....7-1
Every 10 Hours or Each Shift .............................. 2-1 Check the Hour Meter Regularly..........................7-2
After the First 50 Hours ....................................... 2-2 Use Correct Fuels and Lubricants .......................7-2
Prepare Machine for Maintenance .......................7-3
OPERATING THE ENGINE Open Access Doors for Service ...........................7-5
Inspect Machine Daily Before Starting................. 3-1 Inspection/Maintenance Lights.............................7-6
Before Turning Power ON ................................... 3-2 Use a Chain to Prevent Falling Accidents............7-7
Turning Power ON ............................................... 3-3 Electric Pump (Optional) ......................................7-8
Starting the Engine .............................................. 3-8 Construction Outline...........................................7-10
Starting in Cold Weather ..................................... 3-9 Hydraulic System ...............................................7-11
Check Instruments After Starting ...................... 3-10 Periodic Replacement of Parts ..........................7-14
Using Booster Batteries..................................... 3-11 Periodic Replacement of Rubber Hoses............7-15
Stopping the Engine .......................................... 3-13 Maintenance Interval Guide ...............................7-20
CONTENTS
A. Greasing .................................................... 7-24 Check DCA4 Concentration in Coolant........7-86
Loading Shovel Front Joint Pins.................. 7-25 Replace Coolant Filter .................................7-94
Backhoe Front Joint Pins ............................ 7-28 Change Coolant ...........................................7-95
Swing Bearing ............................................. 7-31 Clean Radiator, After Cooler Interior............7-95
Swing Internal Gear..................................... 7-32 Clean Radiator, After Cooler Core ...............7-97
Center Joint ................................................. 7-33 H. Air Conditioner .............................................7-98
Operating the Lubricator.............................. 7-34 Recirculation Air Filter ..................................7-98
B. Engine ......................................................... 7-36 Ventilation Air Filter ......................................7-99
Engine Oil Level in Engine Oil Pan.............. 7-37 Check Refrigerant Quantity........................7-100
Check LED Monitor Signal Check Compressor Belt Tension ...............7-101
(on Reserve Tank) ................................ 7-38 Clean Condenser Core ..............................7-102
Change Engine Oil in Engine Oil Pan.......... 7-39 Check Tightening Torque ..........................7-103
Replace Engine Oil Filters ........................... 7-39 Seasonal Maintenance ..............................7-104
C. Transmission ............................................. 7-43 I. Electrical System ......................................7-105
Pump Transmission Gear ........................... 7-44 Batteries .....................................................7-105
Pump Transmission Oil Level...................... 7-44 Replace Batteries.......................................7-109
Change Oil................................................... 7-45 Replacing Fuses ........................................7-110
Replace Filter .............................................. 7-46 Power Source Terminal .............................7-113
Clean Breather ............................................ 7-46 High Current Fuse......................................7-114
Swing Reduction Gear................................. 7-47 Check Electrical Cables and
Check Oil Level ........................................... 7-47 Wire Harnesses for Short Circuits .......7-116
Change Gear Oil.......................................... 7-48 Check Emergency Engine Stop Switch .....7-118
Clean Breather ............................................ 7-48 J. Miscellaneous ..........................................7-119
Travel Reduction Gear ................................ 7-49 Check Bucket Teeth ..................................7-120
Check Oil Level ........................................... 7-49 Inspect Emergency Evacuation
Change Gear Oil.......................................... 7-50 Equipment and Hanger ........................7-122
D. Hydraulic System......................................... 7-51 Auto-Lubrication System ............................7-123
Inspection and Maintenance Check and Replace Seat Belt ....................7-127
of Hydraulic Equipment ......................... 7-52 Check Windshield Washer Fluid Lever......7-127
Check Hydraulic Oil Level ........................... 7-54 Clean Air Horn Compressor Filter..............7-128
Drain Hydraulic Oil Tank Sump ................... 7-55 Check and Adjust Track Sag .....................7-129
Change Hydraulic Oil................................... 7-56 Check Accumulator and Track
Replace Full-Flow Filter and Drain Filter ..... 7-59 Adjuster Cylinder Circuit ......................7-131
Replace Bypass Filter.................................. 7-61 Check Side Frame Area ............................7-131
Replace Pilot Oil Filter ................................. 7-63 Check Tightening Torque of Bolts
Suction Filter .............................................. 7-65 and Nuts...............................................7-132
Replace Suction Filter ................................. 7-66
Replace High-Pressure Strainer.................. 7-67 MAINTENANCE UNDER SPECIAL
Clean Oil Cooler Core ................................. 7-68 ENVIRONMENTAL CONDITIONS
Check Hoses and Lines .............................. 7-69 Maintenance Under Special
Service Recommendations for Environmental Conditions ..............................9-1
Hydraulic Fittings ................................... 7-72
E. Fuel System................................................. 7-74 STORAGE
Drain Fuel Tank Sump ................................ 7-76 Storing the Machine ...........................................10-1
Drain Fuel Filter Sediment........................... 7-76 Removing the Machine from Storage ................10-2
Replace Fuel Element ................................. 7-77 Transporting the Machine ..................................10-2
Replace Fuel Filter ...................................... 7-78
Check Fuel Hoses ....................................... 7-79 TROUBLESHOOTING
Clean Fuel Cooler Core............................... 7-81 Cummins Fault Code Lamps and
Clean Fuel Tank Breather ........................... 7-81 Diagnostic Switches .....................................11-1
F. Air Cleaner................................................... 7-82 Engine ................................................................11-2
Clean Air Cleaner Outer Element ................ 7-82 Electrical System................................................11-6
Replace Air Cleaner Outer Mode Selection ..................................................11-9
and Inner Elements ............................... 7-82 Hydraulic System ...............................................11-9
G. Cooling System ........................................... 7-84 Auto-Idle ...........................................................11-12
Check Coolant Level ................................... 7-85
CONTENTS
SPECIFICATIONS
Specifications ................................................... 12-1
Working Range (Loading Shovel)...................... 12-2
Working Range (Backhoe) ................................ 12-3

INDEX ............................................................. 14-1

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 in-
jury.
Follow recommended precautions and safe operating
practices.

SA-688

001-E01A-0001

UNDERSTAND SIGNAL WORDS

On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious in-
jury.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
Some safety signs don t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine. SA-1223

To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates
a situation which, if not avoided, could result in damage
to the machine.

NOTE indicates an additional explanation for an

element of information.

002-E01A-1223

S-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS

Carefully read and follow all safety signs on the machine

and all safety messages in this manual.

Safety signs should be installed, maintained and re-

placed when necessary.

If a safety sign or this manual is damaged or missing,

order a replacement from your authorized dealer in
the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering). SA-003

Learn how to operate the machine and its controls cor-

rectly and safely.

Allow only trained, qualified, authorized personnel to op-

erate the machine.

Keep your machine in proper working condition.

Unauthorized modifications of the machine may impair

its function and/or safety and affect machine life.

The safety messages in this SAFETY chapter are in-

tended to illustrate basic safety procedures of machines.
However it is impossible for these safety messages to
cover every hazardous situation you may encounter. If
you have any questions, you should first consult your
supervisor and/or your authorized dealer before operat-
ing or performing maintenance work on the machine.
003-E01B-0003

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.
To ensure that a fire-extinguisher can be always used
when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
SA-437
Establish emergency procedure guidelines to cope
with fires and accidents.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near
your telephone.

004-E01A-0437

S-2
SAFETY
WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appro-

priate to the job.

You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438

Respirator or filter mask.

Be sure to wear the correct equipment and clothing for
the job. Do not take any chances.

Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating the machine.
005-E01A-0438

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
006-E01A-0434

INSPECT MACHINE

Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal in-
jury.

In the walk-around inspection, be sure to cover all

points described in the PRE-START INSPECTION
chapter in the operator s manual.

007-E01A-0435 SA-435

S-3
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 result-
ing in a personal accident.
Do not leave parts and/or tools lying around the op-
erator s seat. Store them in their specified locations.
Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
Keep all flammable objects and/or explosives away
from the machine.
After using the ashtray, always cover it to extinguish
the match and/or tobacco.
Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may ex-
plode.

524-E01A-0000

S-4
SAFETY
USE HANDHOLDS 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.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, steps,
SA-439
and handrails when leaving the machine.

008-E01A-0439

ADJUST THE OPERATOR S SEAT

A poorly adjusted seat for either the operator or for the

work at hand may quickly fatigue the operator leading to
misoperations.

The seat should be adjusted whenever changing the

operator for the machine.
The operator should be able to fully depress the ped-
als and to correctly operate the control levers with his
back against the seat back.
If not, move the seat forward or backward, and check SA-378

again.

009-E01A-0378

S-5
SAFETY
FASTEN YOUR SEAT BELT

If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.

Prior to operating the machine, thoroughly examine

webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
Be sure to remain seated with the seat belt securely SA-237
fastened at all times when the machine is in operation
to minimize the chance of injury from an accident.
We recommend that the seat belt be replaced every
three years regardless of its apparent condition.
010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over.

Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the ma-
chine starts to move.
Use a signal person when moving, swinging, or oper-
ating the machine in congested areas. Coordinate
hand signals before starting the machine. SA-426

011-E01A-0426

HANDLE STARTING AIDS SAFELY

Starting fluid:

Starting fluid is highly flammable.

Keep all sparks and flame away when using it.

Keep starting fluid well away from batteries and ca-
bles.
Remove container from machine if engine does not
need starting fluid.
To prevent accidental discharge when storing a pres-
surized container, keep the cap on the container, and
store it in a cool, well-protected location.
SA-293
Do not incinerate or puncture a starting fluid container.
036-E01A-0293-3

S-6
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 from the operator s seat.

NEVER start the engine while standing on the track or
on ground.
Do not start engine by shorting across starter termi-
nals.
SA-444
Before starting the engine, confirm that all control lev-
ers are in neutral.

012-E01B-0444

JUMP STARTING

Battery gas can explode, resulting in serious injury.

If the engine must be jump started, be sure to follow

the instructions shown in the OPERATING THE EN-
GINE chapter.
The operator must be in the operator s seat so that
the machine will be under control when the engine
starts. Jump starting is a two-person operation.
Never use a frozen battery.
SA-032

Failure to follow correct jump starting procedures

could result in a battery explosion or a runaway ma-
chine.

S013-E01A-0032

KEEP RIDERS OFF MACHINE

Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the ma-
chine.

Only allow the operator on the machine. Keep riders

off.
Riders also obstruct the operator s view, resulting in
the machine being operated in an unsafe manner.

SA-379

014-E01B-0379

S-7
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.
Make a work plan. Use machines appropriate to the
work and job site.
SA-380
Reinforce ground, edges, and road shoulders as nec-
essary. Keep the machine well back from the edges of
excavations and road shoulders.
When working on an incline or on a road shoulder,
employ a signal person as required.
Confirm that your machine is equipped a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
When the footing is weak, reinforce the ground before
starting work.
When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing becomes loose
and slippery.
Beware the possibility of fire when operating the ma-
chine near flammable objects such as dry grass.
015-E01A-0380

PROTECT AGAINST FALLING STONES AND

DEBRIS

Confirm that your machine is FOPS cab equipped

before working in areas where the possibility of falling
stones or debris exist.

SA-490

015-E01A-0380

S-8
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES

For jobs involving multiple numbers of machines, pro-

vide signals commonly known by all personnel involved.
Also, appoint a signal person to coordinate the job site.
Make sure that all personnel obey the signal person s
directions.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO BE

DRIVEN

Incorrect travel pedal/lever operation may result in seri-

ous injury death.

Before driving the machine, confirm the position of the

undercarriage in relation to the operator s position. If
the travel motors are located in front of the cab, the
machine will move in reverse when travel ped-
als/levers are operated to the front.

SA-491
017-E01A-0491

S-9
SAFETY
DRIVE MACHINE SAFELY

Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the direc-
tion you wish to drive.

Be sure to detour around any obstructions.

Avoid traveling over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Don t allow personnel to stay around the
machine while traveling.
SA-387

Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.

When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 0.5 to 1.0
m (A) above the ground.
If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.

SA-388

SA-441

Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure
sage operation.

SA-589

019-E01C-0492

S-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS

Death or serious injury may result if you attempt to

mount or stop a moving machine.

To avoid rollaways:
Select level ground when possible to park machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle switch and the H/P mode switch off. SA-391

Run the engine at slow idle speed without load for 5

minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK position.
Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must
park on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.
SA-392
020-E02A-0493

S-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS

If any person is present near the machine when backing

or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:

Always look around BEFORE YOU BACK UP AND
SWING THE MACHINE. BE SURE THAT ALL BY-
STANDERS ARE CLEAR.
Keep the travel alarm in working condition (if SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local regula-
tions, when work conditions require a signal person.
No machine motions shall be made unless signals are
clearly understood by both signalman and operator. SA-384

Learn the meanings of all flags, signs, and markings

used on the job and confirm who has the responsibility
for signaling.
Keep windows, mirrors, and lights clean and in good
condition.
Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
Read and understand all operating instructions in the
operator s manual.

021-E01A-0494

S-12
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA

A person may be hit severely by the swinging front at-

tachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

Keep all persons clear from the area of operation and

machine movement.
Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to pre-
vent anyone from entering the work area.

SA-386
022-E01A-0386

NEVER POSITION BUCKET OVER ANYONE

Never lift, move, or swing bucket above anyone or a

truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

SA-487
023-E01A-0487

AVOID UNDERCUTTING

In order to retreat from the edge of an excavation if the

footing should collapse, always position the undercar-
riage perpendicular to the edge of the excavation with
the travel motors at the rear.

If the footing starts to collapse and if retreat is not

possible, do not panic. Often, the machine can be se-
cured by lowering the front attachment, in such cases.

024-E01A-0488
SA-488

S-13
SAFETY
AVOID TIPPING

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE --- SERIOUS OR FATAL CRUSHING INJU-
RIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN
JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating
on a grade, possibly resulting in serious injury or death.

To avoid tipping: SA-012

Be extra careful before operating on a grade.

Prepare machine operating area flat.

Keep the bucket low to the ground and close to the
machine.
Reduce operating speeds to avoid tipping or slipping.
Avoid changing direction when traveling on grades.
NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable.
Reduce swing speed as necessary when swinging
loads. SA-440

Be careful when working on frozen ground.

Temperature increases will cause the ground to be-
come soft and make ground travel unstable.

025-E01B-0495

NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could occur

causing serious injury or death.

SA-489

026-E01A-0489

S-14
SAFETY
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.

Before digging check the location of cables, gas lines,

and water lines.
Keep the minimum distance required, by law, from ca-
bles, gas lines, and water lines.
If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in seri-
SA-382
ous eye injury.
Contact your local diggers hot line if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382

OPERATE WITH CAUTION

If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.

Take care to avoid hitting overhead obstacles with the

boom or arm.

028-E01A-0389 SA-389

AVOID POWER LINES

Serious injury or death can result if the machine or front

attachments are not kept a safe distance from electric
lines.

When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m plus
twice the line insulator length.
Check and comply with any local regulations that may
apply.
Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381

029-E01A-0381

S-15
SAFETY
OBJECT HANDLING

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.

When using the machine for craning operations, be

sure to comply with all local regulations.
Do not use damaged chains or frayed cables, sables,
slings, or ropes.
Before craning, position the upperstructure with the
travel motors at the rear.
SA-014

Move the load slowly and carefully. Never move it

suddenly.
Keep all persons will away from the load.
Never move a load over a person s head.
Do not allow anyone to approach the load until it is
safely and securely situated on supporting blocks or
on the ground.
Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.

030-E01A-0014

PROTECT AGAINST FLYING DEBRIS

If flying debris hit eyes or any other part of the body, se-
rious injury may result.

Guard against injury from flying pieces of metal or de-

bris; wear goggles or safety glasses.
Keep bystanders away from the working area before
striking any object.

SA-432
031-E01A-0432

S-16
SAFETY
PARK MACHINE SAFELY

To avoid accidents:
Park machine on a level surface.
Lower bucket to the ground.
Turn auto-idle switch and H/P mode switch off.
Run engine at slow idle speed without load for 5 min-
utes.
Turn key switch to OFF to stop engine.
Remove the key from the key switch.
Pull the pilot control shut-off lever to the LOCK posi- SA-390

tion.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.

033-E08B-0390

HANDLE FLUIDS SAFELY AVOID FIRES

Handle fuel with care; it is highly flammable. If fuel ig-

nites, an explosion and/or a fire may occur, possibly re-
sulting in serious injury or death.

Do not refuel the machine while smoking or when

near open flame or sparks.
Always stop the engine before refueling the machine.
Fill the fuel tank outdoors.

All fuels, most lubricants, and some coolants are flam- SA-018
mable.

Store flammable fluids well away from fire hazards.

Do not incinerate or puncture pressurized containers.
Do not store oily rags; they can ignite and burn spon-
taneously.
Securely tighten the fuel and oil filler cap.

SA-019

034-E01A-0496

S-17
SAFETY
PRACTICE SAFE MAINTENANCE

To avoid accidents:
Understand service procedures before doing 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.
Keep hands, feet and clothing away from
power-driven parts.

Before servicing the machine:

1. Park the machine on a level surface.
SA-028
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5
minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by mov-
ing the control levers several times.
7. Remove the key from the switch.
8. Attach a Do Not Operate tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK posi-
tion.
10. Allow the engine to cool.
If a maintenance procedure must be performed with
the engine running, do not leave machine unattended.
If the machine must be raised, maintain a 90 to 110
angle between the boom and arm. Securely support
SA-527
any machine elements that must be raised for service
work.
Never work under a machine raised by the boom.
Inspect certain parts periodically and repair or replace
as necessary. Refer to the section discussing that part
in the MAINTENANCE chapter of this manual.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
When cleaning parts, always use nonflammable de-
tergent oil. Never use highly flammable oil such as
fuel oil and gasoline to clean parts or surfaces.
Disconnect battery ground cable ( ) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02B-0497

S-18
SAFETY
Sufficiently illuminate the work site. Use a mainte-
nance 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, anti-
freeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious in-

jury.

Before performing any work on the machine, attach a

Do Not Operate tag on the control lever.
This tag is available from your authorized dealer.

501-E01A-0287
SA-287

SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without securing

the machine first.

Always lower the attachment to the ground before you

work on the machine.
If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a SA-527
jack.

519-E01A-0527

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 be-
come entangled when working around rotating parts.

502-E01A-0026

SA-026

S-19
SAFETY
PREVENT PARTS FROM FLYING

Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in se-
rious injury, blindness, or death.

Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
As pieces may fly off, be sure to keep body and face
away from valve.

SA-344
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.

503-E01B-0344

STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.

Securely store attachments and implements to pre-

vent falling. Keep children and bystanders away from
storage areas.

504-E01A-0034 SA-034

S-20
SAFETY
PREVENT BURNS

Hot spraying fluids:

After operation, engine coolant is hot and under pres-

sure. Hot water or steam is contained in the engine, ra-
diator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.

To avoid possible injury from hot spraying water. DO

NOT remove the radiator cap until the engine is cool.
SA-039
When opening, turn the cap slowly to the stop. Allow
all pressure to be released before removing the cap.
The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.

Hot fluids and surfaces:

Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
SA-225
Wait for the oil and components to cool before starting
any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

Rubber hoses that contain flammable fluids under pres-

sure may break due to aging, fatigue, and abrasion. It is
very difficult to gauge the extent of deterioration due to
aging, fatigue, and abrasion of rubber hoses by inspec-
tion alone.

Periodically replace the rubber hoses. (See the page

of Periodic replacement of parts in the operator s
manual).

SA-019
Failure to periodically replace rubber hoses may cause a
fire, fluid injection into skin, or the front attachment to fall
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.

S506-E01A-0019

S-21
SAFETY
AVOID HIGH-PRESSURE FLUIDS

Fluids such as diesel fuel or hydraulic oil under pressure

can penetrate the skin or eyes causing serious injury,
blindness or death.

Avoid this hazard by relieving pressure before dis-

connecting hydraulic or other lines.
Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard; take care SA-031

to protect hands and body from high-pressure fluids.

Wear a face shield or goggles for eye protection.
If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044
507-E03A-0499

S-22
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.
Tighten, repair or replace any missing, loose or dam-
aged clamps, lines, hoses, oil-cooler and oil-cooler
flange bolts.
Do not bend or strike high-pressure lines. SA-019

Never install bent or damaged lines, pipes or hoses.

Check for Shorts:

Short circuits can cause fires.

Clean and tighten all electrical connections.

Check before each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal
caps.
DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc..

Clean up Flammables:
Spilled fuel, oil, antifreeze fluid and window washer fluid,
and trash, grease, debris, accumulated coal dust, and
other flammables may cause fires.

Prevent fires by inspecting and cleaning the machine

daily, and by removing spilled or accumulated flam-
mables immediately.

Check Key Switch:

If fire breaks out, failure to stop the engine will escalate
fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm
that the engine stops.
If any abnormalities are found, be sure to repair them
before operating the machine.

508-E02B-0019

S-23
SAFETY
Check Emergency Engine Stop Switch:
If a fire breaks out, failure to release pressurized air in-
side the hydraulic tank will escalate fire, hampering fire
fighting.
Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pressur-
ized air inside the hydraulic oil tank is released (a
hissing sound should be heard).
If any abnormalities are found, be sure to repair them
before operating the machine.
Check Heat Shields:
Damaged or missing heat shield may lead to fires.
Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393

EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the follow-

ing way:
Stop the engine by turning the key switch to the OFF
position if there is time.
Use a fire extinguisher if there is time.
Exit the machine.
In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with SA-393
the emergency evacuation hammer to escape from the
cab. Refer the explanation pages on the Emergency
Evacuation Method.
518-E02B-0393

SS-1510

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 ex-
tension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
509-E01A-0016 SA-016

S-24
SAFETY
PRECAUTIONS FOR WELDING AND GRIND-
ING

Welding may generate gas and/or small fires.

Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grind-
ing.
After finishing welding and grinding, recheck that there SA-818

are no abnormalities such as the area surrounding the

welded area still smoldering.

523-E01A-0818

AVOID HEATING NEAR PRESSURIZED FLUID

LINES

Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to your-
self and bystanders.

Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable mate-
rials.
Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install tem-
porary fire-resistant guards to protect hoses or other
materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAIN- SA-030

ING 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.

510-E01B-0030

S-25
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING

Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.

Avoid potentially toxic fumes and dust.

Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.

Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust. SA-029

Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove solvent
or paint stripper containers and other flammable ma-
terial from area. Allow fumes to disperse at least 15
minutes before welding or heating.
511-E01A-0029

BEWARE OF ASBESTOS DUST

Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung
cancer.
Depending on the wok site conditions, the risk of in-
haling asbestos fiber may exist. Spray water to pre-
vent asbestos from becoming airborne. Don t use
compressed air.
When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask rated
to prevent the inhalation of asbestos.
Keep bystanders out of the work site during operation. SA-029

Asbestos might be present in imitation parts. Use only

genuine Hitachi Parts.

S-26
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.
Do not charge a frozen battery; it may explode. Warm
the battery to 16 C (60 F) first.
Do not continue to use or charge the battery when
SA-032
electrolyte level is lower than specified. Explosion of
the battery may result.
Loose terminals may produce sparks. Securely tighten
all terminals.

Battery electrolyte is poisonous. If the battery should ex-

plode battery electrolyte may be splashed into eyes, pos-
sibly resulting in blindness.

Be sure to wear eye protection when checking elec-

trolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM

SAFELY

If spilled onto skin, refrigerant may cause a cold contact

burn.

Refer to the freon container for proper use when ser-

vicing the air conditioning system.
Use a recovery and recycling system to avoid venting
freon into the atmosphere.
Never let the freon stream make contact with the skin.

SA-405

513-E01A-0405

S-27
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause se-

rious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides spe-

cific details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
Check the MSDS before you start any job using a haz-
ardous chemical. That way you will know exactly what SA-309
the risks are and how to do the job safely. Then follow
procedures and use recommended equipment.
See your authorized dealer for MSDS s (available only
in English) on chemical products used with your ma-
chine.

515-E01A-0309

DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the envi-

ronment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or
into any water source.
Air conditioning refrigerants escaping into the air can SA-226

damage the Earth s atmosphere. Government regula-

tions may require a certified air conditioning service
center to recover and recycle used air conditioning re-
frigerants.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling cen-
ter, or from your authorized dealer.

516-E01A-0226

S-28
SAFETY SIGNS
All safety signs and their locations affixed on the ma-
chine are illustrated in this group. Make sure of the
contents described in the safety signs through reading
actual ones affixed on the machine to ensure safe
machine operation. Always keep the safety signs clean.
In case a safety sign is broken or lost, immediately,
obtain a new replacement and affix it again in position
on the machine. Use the part No. indicated under the
right corner of each safety sign illustration when plac-
ing an order of it to the Hitachi dealer.

M146-07-080

SS3091469

S-29
SAFETY SIGNS

1020878

SS-442

M146-01-022

SS-445
SS-688

1 2 1

(Loading Shovel) SS-446

SS-2835
2

SS-742

S-30
SAFETY SIGNS

SS-410
SS-2835

SS3108517

M18K-01-012

S-31
SAFETY SIGNS

SS-413

M146-01-024

M146-01-025

SS4193223

M146-01-025

S-32
SAFETY SIGNS

SS-449

M146-01-027

4331848
SS-2836
SS-710

SS-2837

SS-3091472

S-33
SAFETY SIGNS
MEMO
......................................................................................................................................................................................

......................................................................................................................................................................................

S-34
COMPONENTS NAME
COMPONENTS NAME
Loading Shovel

1- Bucket 1 2 3 4 5 6 7 8 9 10 11 12

2- Bucket Cylinder
3- Arm
4- Level Cylinder
5- Arm Cylinder
6- Boom Cylinder
7- Boom
8- Cab
9- Emergency Rope Hook
10- Emergency Rope Case
13
11- Fuel Tank
12- Radiator
13- Counterweight
16 15 14
14- Stairway
M18M-01-001
5
15- Travel Device
Backhoe
16- Track Shoe
3 6
7

M18M-01-002

1-1
HANDLING STAIRWAY/EMERGENCY ROPE
USING STAIRWAY

Always use stairway (1) when getting on and off the ma-
chine.
Do not attempt to climb onto or off the machine any other
way.
WARNING:
Always mount or dismount the machine only
when the stairway is fully extended.
When you get on and off the machine, always
maintain a three point contact with the steps
and handrails and face the machine.
Never jump on or off the machine. Never mount
or dismount a moving machine. 1 M18M-01-029

Thoroughly remove and clean slippery materi-

als such as mud and/or grease from the steps
and/or hand rails.

OPERATING STAIRWAY

WARNING:
Check that no personnel are present around
the machine before beginning operation.
Never operate the machine when any person-
nel are present near machine.
Lower the stairway only after checking that no
obstructions are present in the spot where the
stairway is lowered.

NOTE: When the key switch is turned ON, the stairway

cannot be operated unless the pilot control
shut-off lever is in the LOCK position.

1-2
HANDLING STAIRWAY/EMERGENCY ROPE
Extending
1. Be sure to pull the lever (2) to disengage the lock (3)
before extending. In case the lock is difficult to dis-
engage, press RETRACT button (4) two to three
times to disengage the lock.
2. Press and hold the EXTEND (5) button until the 2
stairway is fully extended. When the button is re-
leased, the stairway stops extending.

NOTE: The alarm starts to sound when the lock (3) is

disengaged.
The alarm continues to sound until stairway is
fully extended.

Retracting
1. Press and hold the RETRACT button (4) until the
stairway is fully retracted. When the button is re-
leased, the stairway stops retracting.
3
2. Be sure to pull the lever (2) down to engage the lock
(3) after fully retracting.

NOTE: The alarm starts to sound when the stairway

starts to retract. M18M-01-030

The alarm stops to sound when the lock (3) is

engaged after fully retracted.
NOTE: Swing operation is inoperable unless the stair-
way operations are fully retracted and lock (3)
is engaged.

NOTE: The switch (6) is stairway emergency stop

switch.
Use the stairway emergency stop switch (6)
only for emergency stop.
The engine will not stop when the stairway
emergency stop switch (6) is used.
M18M-03-007

6 5
M18M-01-031

1-3
HANDLING STAIRWAY/EMERGENCY ROPE
Emergency Operation

When the stairway cannot work by trouble, retract the

stairway following the procedure shown below.
This procedure can be used only for retracting.

1. Check that the engine is not running.

2. Check that the stairway is fully extended or that the
bottom of the stairway is contacting the ground and
cannot be extend any further.
3. Remove the air breather on the hydraulic tank and
release the pressure.
4. Remove the step (1) and step (2).
5. Disassemble pipe (6), plug (5) and plug the pipe us-
ing plug (5).
Cab
6. Replace plug (7) and hose (8).
Stairway M18M-01-005

7. Loosen nut (4) on stop valve (3) and check if the

valve can be opened or shut.
8. Fully close stop valve (3).
9. Start the engine and keep the engine in low idle.
10. Slowly open stop valve (3) and retract the stairways.
1
(Stairway may retract rapidly and can be dangerous.
Make sure to open stop valve (3) slowly. Retracting
speed can be adjusted by opening or closing stop 2
valve (3)).
11. Position stairway in the retracted position.
12. Lock the manual lock on the stairway.
13. Shut stop valve (3) and tighten nut (4).
Switch
14. Stop the engine. (Stairway)

15. Reassemble plug (5), (7), pipe (5), hose (8) back to
its original state and also reassemble step (1), (2).
16. Contact your authorized dealer. M18M-01-042

after before 4
before
7 8

5 6
after 5
6
VIEW C

8 7
VIEW B M18M-01-045 VIEW A 3

M18M-01-044 M18M-01-043

1-4
HANDLING STAIRWAY/EMERGENCY ROPE
EMERGENCY ESCAPE

How to Use
Emergency escape device is provided in case (1) at the left
1
outside the cab.

1. Unlock latch (2) on case (1) to open the cover.

2
2. Hang hook (3) onto the cab upper-left surface hanger
(4).
3. Drop rope wound reel (5).
4. Fasten life belt (6) around your chest.
5. While holding two ropes, move to the outside fence
and face toward the cab (as long as the two ropes M118-07-102
are held, emergency escape device will not operate.)
6 5
6. As soon as the ropes are released, your body is
slowly lowered. Descend while softly pushing the
machine surface by hand to prevent the body from
turning.
7. After landing, immediately take life belt (6) off and
evacuate to a safe place.

M118-07-104

M118-07-108

M146-07-005 M118-07-109

1-5
HANDLING STAIRWAY/EMERGENCY ROPE
EMERGENCY EXIT

If the operator s cab door should not open in an emergency,

escape in the following methods:
1

1. Open left window (1). Escape through the window.

WARNING: Be sure to wear safety glasses before

breaking the window glass.

2. If left window (1) should be difficult to open, break the

left window glass using emergency evacuation tool
(2). Then, escape through the broken window.

M18M-01-003
NOTE: The emergency exit decal (3) is affixed to the
upper side of the air conditioner circulation air
inlet port (under the emergency exit).

EVACUATING IN CASE OF FIRE M18G-01-010

A fire on the machine can result in serious personal injury 3

or death.
Avoid the risk of injury or death while evacuating from the
machine during a fire by checking the following regularly:

Always check if left window (1) can be opened and

closed smoothly before starting the engine. If it fails to
open or close smoothly, repair the window. Left win-
dow (1) can be used as an emergency exit.
Malfunction of emergency escape device (5) worn
rope or broken hanger may cause falling accident
when evacuating. Before operating the machine, be M18K-01-012

sure to check if emergency escape device (5) or

hanger (4) is not damaged. If any abnormalities are
found, replace with new parts.
Before operating the machine for the first time, all new 4
operators must practice evacuating with this rope at
least once. 5

M118-07-103

1-6
HANDLING STAIRWAY/EMERGENCY ROPE
If a fire breaks out, evacuate the machine in the following
way: 5
NOTE: Beside emergency engine stop switch (6)
provided in the cab, two switches are located in
engine compartment and one in pump
compartment.

1. Stop the engines by turning emergency engine stop

switch (6) to the EMERG STOP position if there is
time.

2. Pull the pilot control shut-off lever to the LOCK posi-

tion. M118-07-109

6
3. Use a fire extinguisher if there is time.

4. Exit the machine in the following manner.

Evacuate from cab (7) through cab door (8) to cab
side platform (9). Then, get off the machine using
emergency device (5).
Emergency device (5) is provided in the case located
on the left outside wall of the cab. (See the EMER-
GENCY ESCAPE section.)
If it is difficult to open cab door (8), evacuate the cab
by opening left window, and stepping to platform (9). M18M-01-004
Then, get off the machine using the emergency rope.
If left window cannot be opened, break the window-
pane using emergency evacuation tool (2) to gain ac-
cess to platform (9).

WARNING: Avoid possible injury to your eyes.

Wear a pair of safety glasses or goggles when
breaking windowpane with emergency evacua-
tion tool (2).
8

9
M18M-01-005

M18G-01-010

1-7
OPERATOR S STATION
CAB FEATURES 2 3 4 5 6 7

1- Left Console
2- Left Control Lever/Horn Switch
1 8
3- Left Travel Pedal
4- Left Travel Lever
5- Right Travel Lever
6- Right Travel Pedal
7- Right Control Lever/Horn Switch
9
8- Right Console
M18M-01-006
9- Operator s Seat
10 11 12
10- Bucket Close Pedal (For Loading Shovel)
11- Bucket Open Pedal (For Loading Shovel)
12- Pilot Control Shut-Off Lever
13- Rear Console
14- Trainer s Seat
15- Hot & Cool Box 13

M18M-01-007

M18G-01-016

1-8
OPERATOR S STATION
MONITOR DISPLAY

Starting check screen and meter check screen will be dis-

played when key switch is turned to the ON position.

M18G-01-018

1 2 3
STARTING CHECK SCREEN

When key switch is turned to the ON position, starting

4
check screen will be displayed at first.

1- Coolant Level Check Indicator

2- Engine Oil Level(Oil Pan) Check Indicator
3- Engine Oil Level(Reserve Tank) Check Indicator
4- Hydraulic Oil Level Check Indicator

Level check indicators will become green when fluid levels

are appropriate.

M18M-01-008

1-9
OPERATOR S STATION
METER CHECK SCREEN

When key switch is turned to the ON position, meter check 1 2 3 4 5 6 7

screen will be displayed next to starting check screen.

1- Model Name 8
2- Hydraulic Oil Temperature Gauge
3- Front Type
4- Coolant Temperature Gauge 9
5- Control Lever Pattern
6- Tachometer
7- Hour Meter 10
8- Engine Oil Pressure Gauge
9- Engine Oil Temperature Gauge
10- Clock
11- Battery Voltage Gauge
12- Fuel Gauge M18M-01-009

13 12 11
13- Ambient Temperature
14- Alternator Indicator
14 15 16 17 18 19 20 21 22 23 24 25 26 27
15- Engine Stop Indicator
16- Coolant Overheat Indicator
17- Exhaust Temperature Indicator
18- Fuel Temperature Indicator
19- Engine Warning Indicator
20- Prelub Indicator 38 37 36 35 34 33 32 31 30 29 28
21- Hydraulic Oil Level Indicator
M18M-01-010
22- Auto-Lubrication Indicator
23- Hydraulic Oil Overheat Indicator
24- Stairway Position Indicator
25- Fast-Filling Indicator
26- Tension Indicator
27- Auto-Idle Indicator
28- Travel Mode Indicator
29- Electric Lever Indicator
30- Emergency Engine Stop Indicator
31- Electlical Equipment Box Indicator
32- Pump Contamination Indicator
33- Stop Valve Indicator
34- Air Cleaner Restriction Indicator
35- Engine Over Run Indicator
36- Coolant Level Indicator
37- Engine Oil Pressure Indicator
38- Pump Transmission Oil Level Indicator

1-10
OPERATOR S STATION
TACHOMETER
-1
Tachometer indicates engine speed in min (R.P.M).

COOLANT TEMPERATURE GAUGE

White zone (A) : Low temperature. Warming up op-

eration is required.
M18M-01-011
Blue zone (B) : Normal operating temperature. C
Red zone (C) : High temperature. Coolant is over-
heating.
B
If needle enters the red zone (C), reduce load immediately
and run the engine at high idle or auto idle until needle
returns to the blue zone (B). Stop the engine after cooling
down and check radiator for restriction and clean fins or
check the coolant leakage. If the problem continues, con-
tact your authorized dealer.

IMPORTANT: Prevent possible engine damage. A M18M-01-012

Do not stop the engine when needle en-

ters red zone, as temperature will rise
further. Instead, reduce load and run the
engine at high idle or auto idle.

HYDRAULIC OIL TEMPERATURE GAUGE

White zone (A) : Low temperature. Warming up op-

eration is required. B

Blue zone (B) : Normal operating temperature.

Red zone (C) : High temperature. Hydraulic oil is
overheating.
If needle enters the red zone (C), reduce load immediately
and run the engine at high idle or auto idle to cool down
until needle returns to the blue zone (B). Stop the engine
A
after cooling down and check oil cooler for restriction and M18M-01-013

clean fins or check the hydraulic oil leakage. If the problem

continues, contact your authorized dealer.

FUEL GAUGE
C
As fuel level goes down, blue lights of fuel level indicator
(A) will go OFF. When the fuel remains come to approxi-
mately 755 liters (200 US gal), fuel level warning indicator
B
(B) will become amber. When the fuel is full, full indicator
(C) will light.

A M18M-01-014

1-11
OPERATOR S STATION
ENGINE OIL PRESSURE GAUGE

Engine oil pressure gauge indicates engine oil pressure.

M18M-01-039

ENGINE OIL TEMPERATURE GAUGE

Engine oil temperature gauge indicates engine oil tem-

perature.

M18M-01-040

HOUR METER

The right hand number indicates tenth (six minutes) of an

hour.
M18M-01-015

WARNING INDICATORS

Warning indicators described below.

ALTERNATOR INDICATOR

When alternator output is low, alternator indicator will come

ON. Check the electrical system.

NOTE: When key switch is turned to the ON position,

this indicator normally stays ON until the engine
starts.

M144-01-023

1-12
OPERATOR S STATION
PUMP TRANSMISSION OIL LEVEL INDICA-
TOR

When pump transmission oil does not circulate, pump

transmission oil level indicator will come ON and buzzer
will sound. Stop the engine immediately. Check the oil
leakage.

NOTE: Cold oil, low oil level, or operating on a steep

slope may cause indicator to come ON.
NOTE: When key switch is turned to the ON position,
this indicator normally stays ON until the engine M144-01-024

starts.

ENGINE STOP INDICATOR

When electrical signals from sensors on the engine are

judged abnormal, engine stop indicator will come ON. You
must stop the engine immediately. Check the fault code on
the monitor and contact your authorized dealer.

NOTE: When key switch is turned to the ON position,

this indicator normally stays ON until the engine
starts.

M144-01-026

ENGINE OIL PRESSURE INDICATOR

When engine oil pressure is low, engine oil pressure

indicator in yellow or red will come on. Engine power will be
reduced automatically. Stop the engine immediately. Check
the fault code on the monitor and contact your authorized
dealer.

NOTE: Cold oil, low oil level, or operating on a steep

slope may cause indicator to come ON.

M481-01-007

COOLANT OVERHEAT INDICATOR

When coolant overheats, coolant overheat indicator in yel-

low or red will come on and engine power will be reduced
automatically. Reduce load immediately and run the engine
at High idle or auto idle to cool down the engine until nee-
dle returns to the green zone (B) of coolant temperature
gauge. Stop the engine after cooling down and check ra-
diator for restriction and clean fins or check the coolant
leakage. If the problem continues, contact your authorized
dealer.
M424-01-012

1-13
OPERATOR S STATION
COOLANT LEVEL INDICATOR

When coolant level is lower than the warning level, coolant

level indicator in yellow or red will come on. Check coolant
level and the coolant leakage

NOTE: Operating on a steep slope may cause indicator

to come ON.

M117-01-035

ENGINE OVER RUN INDICATOR

1
When engine speed over to 2150 min (2150 rpm), engine
over run indicator will come ON and fuel injections of en-
gine disables until speed falls below the over speed limit.
Stop the engine and check on operating condition.

M18G-01-029

FUEL TEMPERATURE INDICATOR

When fuel temperature is high, fuel temperature indicator in

yellow or red will come ON and engine power will be re-
duced automatically. Stop the engine and check fuel cooler
for restriction and clean fins.

M18M-01-016

HYDRAULIC OIL LEVEL INDICATOR

When hydraulic oil level in the hydraulic oil tank is lower

than the warning level, hydraulic oil level indicator will
come ON and buzzer will sound. Stop the engine immedi-
ately. Check the hydraulic oil level and hydraulic oil leak-
age.

NOTE: Operating on a steep slope may cause indicator

to come ON.

M117-01-049

1-14
OPERATOR S STATION
STOP VALVE INDICATOR

When stop valve (4 used: 2 in the return circuits and 2 in

the suction circuits) is closed, stop valve indicator will come
ON. Buzzer will sound and engine will stop automatically.
And the starter motor will not rotate even if engine start
switch is pressed.

M117-01-041

AUTO-LUBRICATION INDICATOR

When auto-lubrication toggle switch on panel near grease

can is in the AUTO-GREASING position, auto-lubrication
indicator (A) in green will come ON. If the grease can is
empty or auto-lubrication system is malfunctioning,
auto-lubrication warning indicator (B) in red will come ON.
When the switch is in the MANUAL GREASING or OFF
position, manual greasing indicator (C) or greasing OFF
indicator (D) in red will come ON, respectively. A M18G-01-065

M117-01-036

C M18G-01-066

D M18G-01-067

1-15
OPERATOR S STATION
FAST-FILLING INDICATOR

When the fast-filling panel is lowered, fast-filling indicator

will come ON and buzzer will sound. The machine will not
be able to swing.

M117-01-091

EMERGENCY ENGINE STOP INDICATOR

When the emergency engine stop switch is turned to the

EMERG STOP position, emergency engine stop indicator
will come ON and engine will stop.
And the starter motor will not rotate even if engine start
switch is pressed.

TENSION INDICATOR
When the cushion cylinder is retracted to the stroke end M117-01-040
due to material packing around the front idler, tension in-
dicator will come ON and travel will stop automatically.
Drive the machine to remove the packed material in the
opposite direction against the direction the machine was
being driven. Check the track sag and the adjuster cylinder
accumulator for any abnormality.

M18G-01-032

ELECTRIC LEVER INDICATOR

When any abnormality occurs in the electric lever system,

electric lever indicator will come ON. Buzzer will sound and
operation will be stopped automatically.
Stop the engine immediately.

M18G-01-028

1-16
OPERATOR S STATION
CAUTION INDICATORS

Caution indicators described below.

EXHAUST TEMPERATURE INDICATOR

When engine exhaust temperature increases abnormally,

exhaust temperature indicator will become red. And when
exhaust temperature of some engine cylinders is abnor-
mally lower or higher than the others, exhaust temperature
indicator will become yellow. And then, the difference of
exhaust temperature increases further, exhaust tempera-
ture indicator will also become red.
Contact your authorized dealer.

M146-01-037

ENGINE WARNING INDICATOR

When electrical signals from some sensors on the engine

except in relation to engine stop indicator, engine warning
indicator will come ON. Stop the engine immediately and
contact your authorized dealer.

NOTE: When key switch is turned to the ON position,

this indicator normally stays ON for approxi-
mately 2 seconds.

M144-01-028

HYDRAULIC OIL OVERHEAT INDICATOR

When hydraulic oil overheats, hydraulic oil overheat
indicator will come ON. Reduce load immediately and run
the engine at high idle or auto idle to cool down until needle
of hydraulic oil temperature gauge returns to the green
zone. Stop the engine after cooling down and check oil
cooler for restriction and clean fins or check the hydraulic
oil leakage. If the problem continues, contact your
M18G-01-031
authorized dealer.

PUMP CONTAMINATION INDICATOR

When contamination of any of the 8 main pumps and 5

swing or travel motors increases, pump contamination
indicator will come ON. Follow the instruction displayed on
the monitor.

M117-01-039

1-17
OPERATOR S STATION
STAIRWAY POSITION INDICATOR

When the stairway is extended, stairway position indicator

will come ON and buzzer will sound. The machine will not
be able to swing. When the stairway retracts fully, stairway
position indicator will go OFF and the machine will be able
to swing.

M18M-01-037

AIR CLEANER RESTRICTION INDICATOR

When the air cleaner elements are clogged, air cleaner

restriction indicator will come ON.
Clean or replace the elements.

M117-01-038

ELECTRICAL EQUIPMENT BOX INDICATOR

When electric equipment box is opened, electrical
equipment box indicator will come on. When electric
equipment box is closed, electrical equipment box indi-
cator will go off.

M18M-01-017

STATUS INDICATORS

Status indicators described below will become green.

AUTO-IDLE INDICATOR

When the auto-idle mode is turned ON with auto-idle switch,

auto-idle indicator will come ON.

M117-01-044

1-18
OPERATOR S STATION
TRAVEL MODE INDICATOR

When the travel speed mode is shifted to slow with travel A

mode switch, slow travel mode indicator (A) will come ON.
And when the travel speed mode is shifted to fast with
travel mode switch, fast travel mode indicator (B) will come
ON.
M117-01-043

M585-01-010

PRELUB INDICATOR

When the engine start switch is pressed, the prelub motor

drives until the engine starts. This indicator stays on during
the prelub motor operation.

M117-01-047

1-19
OPERATOR S STATION
LEFT CONSOLE
7
1- Warning Lamp (red)
2- Caution Lamp (yellow)
3
3- Key Pad
4- Monitor Contrast Switch
5- Wiper Switch/Washer Switch
6- Wiper Delay Selector Switch
7- Air Conditioner Panel
8- FM/AM Radio 2
8 5 6 4 1 M18G-01-017

WARNING LAMP

When the warning indicators on the monitor come ON,

warning lamp will come ON in red.

CAUTION LAMP
When the caution indicators on the monitor come ON, cau-
tion lamp will come ON in yellow.
And when electrical signals from controllers or sensors are
judged abnormal, faults code will be displayed on the
monitor and caution lamp will also come ON in yellow.

KEY PAD

The monitor display can be operated with key pad.

MONITOR CONTRAST SWITCH

The monitor contrast can be adjusted with monitor contrast

switch.

Clockwise Turn: Brighter Illumination

Counterclockwise Turn: Darker Illumination

NOTE: When nothing is displayed on the monitor even

if key switch is turned to the ON position, adjust
the monitor contrast at first.

1-20
OPERATOR S STATION
WIPER SWITCH

The wiper can be operated with wiper switch (1) as follows:

OFF position (2): Deactivated

INT position (3): Wiper operates intermittently.
LOW position (4): Wiper continuously operates in slow
speed.
HIGH position (5): Wiper continuously operates in fast 1
2
speed.
3
4 5

M18G-01-035

WASHER SWITCH

IMPORTANT: Washer motor may be damaged if

washer switch (1) is held for more than
20 seconds, or continually operated with
no fluid in the washer tank.

Windshield washer fluid can be squirted with washer switch

(1). 1
Washer fluid will squirt and the wiper will operate as long as
washer switch (1) is pressed. The wiper will operate four
seconds more after washer switch (1) is released.

M18G-01-035

WIPER DELAY SELECTOR SWITCH

When the wiper switch is turned to the intermittent position,

the interval between wiper operation can be adjusted in
four stages with wiper delay selector switch (1) as follows:

SHORT position (2): Wiper operates at approx. 4 seconds

interval.
position (3): Wiper operates at approx. 8 seconds 1
interval.
position (4): Wiper operates at approx. 15 seconds 2
interval.
5
LONG position (5): Wiper operates at approx. 25 seconds 3 M18G-01-035
4
interval.

1-21
OPERATOR S STATION
AIR CONDITIONERS 1

This machine is equipped with three air conditioners, all

located in room under the cab. Airflow vents for these air
conditioners are located inside the cab at the front, side,
and rear, respectively. Moreover, three air conditioner con-
trol panels are provided in the cab, each designated for one
of the three air conditioners.

Component Designation

1- Front Air Flow Vents

2- Side Air Flow Vents Front Air Flow Vents M18G-01-036

3- Rear Air Flow Vents 2

NOTE: Direction of air flowing out of each vent can be

changed by adjusting the louver.

4- Air Conditioner Front Panel

5- Air Conditioner Side Panel
6- Air Conditioner Rear Panel

Side Air Flow Vents M18M-01-018

Rear Air Flow Vents M18M-01-003

6 5
4

M18G-01-017

1-22
OPERATOR S STATION
DESIGNATIONS AND FUNCTIONS OF CON-
TROLS
11 16 14 15 13 12 9
7. Power Switch
8. Air Conditioner Switch 8

9. Ventilation Shift Switch

10. Temperature Control Switches
11. Blower Control Switches M18G-01-039

10 7
12. Air Conditioner Indicator
13. Ventilation Indicator
14. Temperature Indicator
15. Blower Speed Indicator
16. Liquid Crystal Display (LCD)

Power switch (7)

Press power switch (7) to turn power ON. Press it
again to turn power OFF.
Air Conditioner Switch (8)
Press air conditioner switch (8) to turn ON the air
conditioner. Press it again to turn it OFF.
Air Conditioner Indicator (12)
Air conditioner indicator (12) will light when the air
conditioner is turned ON.
Ventilation Shift Switch (9)
Press ventilation shift switch (9) to shift ventilation to
circulation mode. Press it again to shift it to fresh air
mode.
Ventilation indicator (13)
Circulation
Fresh Air

NOTE: When the fresh air mode is selected, the cab is

slightly pressurized, preventing dust from en-
tering into the cab.

Temperature Control Switches (10)

Press temperature control switch (10) to increase
the temperature.
Press temperature control switch (10) to de-
crease the temperature.
Temperature Indicator (14)
The number of the lit LCD indicates the relative tem-
perature of the air blowing out. The higher the number
of the lit LCD, the higher the temperature of the air
blowing out is.

1-23
OPERATOR S STATION
Blower Control Switches (11)
Press blower control switches (11) to control blower
speed. 11 15
Each time blower control switch (11) is pressed,
the blower fan speed is increased from OFF to low, to
medium, and to high.
Each time blower control switch (11) is pressed,
the blower fan speed is decreased from high to me-
dium, to low, then it will be turned OFF.
M18G-01-039
Blower Speed Indicator (15)
Each part of the indicator indicates blower fan
speed as follows:
High Speed
Medium Speed II
Medium Speed I
Lo

1-24
OPERATOR S STATION
COOLING 14
11 8
Set the temperature to the lowest setting using temperature
control switch (10). (Repeatedly press temperature
control switch (10) until only the leftmost indicator (14) is
on.)
Press blower control switch (11) to turn on the blower
fan. Press air conditioner switch (8). (Air conditioner indi-
cator (12) should turn on.) Cool air will flow from the vents. 12
Use temperature control switch (10) and blower control 10 M18G-01-039

switch (11) to adjust the temperature inside the cab.

HEATING
14
11
Set the temperature to the highest setting using tempera-
ture control switch (10). (Repeatedly press tempera-
ture control switch (10) until all temperature indicators (14)
turn on.)
Press blower control switch (11) to turn on the blower
fan. Warm air will flow from the vents.
Use temperature control switch (10) and blower control
M18G-01-039
switch (11) to adjust the temperature inside the cab.
10

DEHUMIDIFYING AND HEATING

(To prevent the windshield from clouding)

Set the temperature to the highest setting using tempera- 14

11 8
ture control switch (10). (Repeatedly press tempera-
ture control switch (10) until all temperature indicators (14)
turn on.)
Press blower control switch (11) to turn on the blower
fan. Press air conditioner switch (8). (Air conditioner indi-
cator (12) should turn on.) Warm air will flow from the
vents.
Adjust front air flow vents (1) and side air flow vents (2) so 12
10 M18G-01-039

that the air flow is directed toward the windshield.

Use temperature control switch (10) and blower control
switch (11) to adjust the temperature inside the cab.

2
1

M18M-01-018

M18G-01-036

1-25
OPERATOR S STATION
DEFROSTING 14 15
11
Set the temperature to the highest setting using tempera-
ture control switch (10). (Repeatedly press tempera-
ture control switch (10) until all temperature indicators (14)
turn on.)
Repeatedly press blower switch (11) to the high speed
position (until blower indicator (15) comes to high speed).
Adjust front air flow vents (1) and side air flow vents (2) so
that the air flow is directed toward the windshield. 10 M18G-01-039

1
2

M18G-01-036
M18M-01-018

BLOWER OPERATION WITHOUT COOLING

OR HEATING 11 14

Set the temperature to the lowest setting using temperature

control switch (10). (Repeatedly press temperature
control switch (10) until only the leftmost indicator (14) is
on.)
Press blower control switch (11) to turn on the blower
fan. Air will flow from the vents. M18G-01-039

VENTILATION THE CAB

14 13
Turn on the fresh air indicator (13) using ventilation 11 9
switch (9).
Set the temperature to the lowest setting using temperature
control switch (10). (Repeatedly press temperature
control switch (10) until only the leftmost temperature in-
dicator (14) is on.)
Press blower control switch (11) to turn on the blower.
Fresh air will flow from the vents. M18G-01-0391

1-26
OPERATOR S STATION
AM/FM RADIO OPERATION
Radio

Controls on the radio

1- Power Switch/Volume Control Knob
2- Tone Adjustment Ring
3- AM/FM Switch
4- Station Presets
5- Tuning Switches
6- Display Mode Change Switch
7- Digital Display
8- Time Set Switches
M18G-01-017

Tuning Procedure
4 7 5 2
Manual Tuning Procedure
Repeatedly tap one of tuning switches (5) until the
desired station is reached.
Each time the tuning switch is pressed, the frequency
changes at an interval.
Tap the tuning switch [UP] ( ) to increase the fre-
quency.
Tap the tuning switch [DOWN] ( ) to decrease the
3 6 8 1
frequency.
M1G6-01-026
Automatic Search Function
Press and hold one tuning switch (5) for more than
half a second, then release. The frequency display will
move up to the next higher frequency station.
To go up to the next higher frequency station, press
and hold the tuning switch [UP] ( ).
To go down to the next lower frequency station,
press and hold the tuning switch [DOWN] ( ).

In order to deactivate the automatic search function

while it is operating (while searching the next available
frequency station), simply tap tuning switch (5) again.
If the receiving radio waves are weak, i. e. such as
when the machine is located between high rising
buildings, etc., use the manual tuning procedure to
select the desired station.

1-27
OPERATOR S STATION
Station Presetting Procedure
4
1. Select the desired station using tuning switches (5). 7
(Refer to the Tuning Procedure section.)
2. Press and hold one station preset (4) for more than 1
second until an electronic tone is heard. Now, the
selected station is preset for the selected station
preset. The frequency of the preset station will be in-
dicated on digital display (7).

M1G6-01-026
Once the presetting is complete for a station preset (4),
5
the radio will be tuned to the preset station when station
preset (4) is pressed (for less than 1 second).

DIGITAL CLOCK SETTING PROCEDURE 7

NOTE: In order to set the clock, digital display (7) must

be in the time display mode.

1. Press display mode button (6) to indicate the hour

display on digital display (7).
2. Press and hold time set button (RST) (8) for longer
than 1 second. The hour display will start flashing and 6 8 M1G6-01-026

the time set mode will be selected.

3. Press time set button (H or M) (8) to set the clock.
Each time set button (H or M) (8) is pressed, the time
display will increase by one. If time set button (H or
M) (8) is pressed and held, the time display will
change continuously.
When setting the hour, press time set button (H)
(8).
When setting the minute, press time set button (M)
(8).
The time is displayed in 12 hour standard.
If either of the switches (H) or (M) is pressed and held,
the hour or minute display will change continuously
until the switch is released.
4. When the hour display is 12, if time set button (H)
(8) is pressed, the hour display will be reset to 1.
When the minute display is 59, if time set button
(M)(8) is pressed, the minute display will be reset to
00. However, the hour display remains unchanged
in this case.
5. After the clock setting is complete, press and hold
time set button (RST)(8) again for longer than 1 sec-
ond, or turn the radio switch OFF to end the clock
time setting procedure. Digital display (7) stops
flashing and changes to stay ON.

1-28
OPERATOR S STATION
RIGHT CONSOLE

1- Emergency Engine Stop Switch 1

2- Engine Speed Control Dial 2

3- Engine Start Switch
13
3
4- Dome Light Switch
12 4
5- Entrance Light Switch
11 5
6- Auto Idle Switch
7- Fast-Filling Switch 6

8- Key Switch 10 7

9- Buzzer Stop Switch

9
10- Travel Mode Switch
11- Maintenance Light Switch 8

12- Work Light Switch

13- Engine Stop Switch
M18M-01-041

KEY SWITCH
8
1- OFF (Power OFF) (1)
(2)
2- ACC (Horn, Radio, etc)
(3)
3- ON (Power ON)

M18G-01-034

1-29
OPERATOR S STATION
EMERGENCY ENGINE STOP SWITCH
NORMAL EMERG. STOP
1. Turn emergency engine stop switch from the NOR-
MAL position to the EMERG STOP position when
emergency engine stop is required.
2. Engine will stop.
3. Turn emergency engine stop switch to the NORMAL
position before attempting to restart the engine.
NOTE: Do not use this switch when performing any in-
spection/service work.

M18M-01-004

ENGINE START SWITCH

When engine start switch is kept pressed, the engine will

continue to crank until the engine starts.

M18M-01-004
ENGINE STOP SWITCH

When engine stop switch is kept pressed until the engine

stops rotating completely, the engine will stop.

M18M-01-004

1-30
OPERATOR S STATION
ENGINE SPEED CONTROL DIAL

Engine speed can be controlled with engine speed control

dial.

The fully clockwise position (1): Fast Idle

The fully counterclockwise position (2): Slow Idle

M18M-01-004

2 1

M18G-01-040

1-31
OPERATOR S STATION
WORK LIGHT SWITCH

All 9 work lights (1) will be turned ON with work light switch.
In addition, illumination for key pad (2), air conditioner
panels (3) and radio (4) will be turned ON.

On the cab roof toward front (2 pieces)

On the room under the cab toward front (2 pieces)
On the step in front of the right unit toward front (2 pieces)
On the back of the engine unit toward left back (1 piece)
On the back of the engine unit toward right back (1 piece)
On the side of the engine unit toward left side (1 piece) M18M-01-019

3
2

1
1

M18G-01-017
1

1
1
M18M-01-005

1 M18M-01-038

1-32
OPERATOR S STATION

M18M-01-019

DOME LIGHT SWITCH 1

All 2 dome lights (1) located on the front and rear part of the
cab ceiling will be turned ON with dome light switch.

Front M18G-01-043

M18G-01-044
Rear

1-33
OPERATOR S STATION
MAINTENANCE LIGHT SWITCH

All 7 maintenance lights (1) will be turned ON with

maintenance light switch.

In room under the cab (1 piece)

In pump room (1 piece)
In engine room (2 pieces)
In radiator room (1 piece)
In oil cooler room (1 piece)
On engine unit for the control valve (1 piece)
1 M18G-01-033

In Room Under the Cab M18M-01-022

1 M18M-01-005

In Engine Room M18M-01-023

1
On Engine Unit For the Control Valve M18M-01-025

In Oil Cooler Room M18M-01-024

In Pump Room M18M-01-026

1-34
OPERATOR S STATION
ENTRANCE LIGHT SWITCH

All 2 entrance lights (1) will be turned ON with entrance

light switch.

NOTE: Entrance lights (1) will stay ON depending on

the delayed power OFF time after the key
switch is turned OFF with entrance light switch
ON.

M18G-01-033

M18M-01-027

M18M-01-028

M18M-01-005
1

1-35
OPERATOR S STATION
TRAVEL MODE SWITCH

Slow travel speed and fast travel speed can be selected

with travel mode switch.

Slow mode : Slow travel mode indicator is displayed

in the part (1) of monitor.
Fast mode : Fast travel mode indicator is displayed in
the part (1) of monitor.

M18M-01-019

1
M18M-01-010

AUTO-IDLE SWITCH

Auto-idle mode will be turned ON with auto-idle switch.

Auto-idle Indicator (2) will come ON when auto-idle mode is
turned on.

M18M-01-019

M18M-01-010

1-36
OPERATOR S STATION
BUZZER STOP SWITCH

The buzzer will sound in the following cases.

1. Pump transmission oil does not circulate.

(Pump transmission oil level indicator (38) comes
ON .)
2. Hydraulic oil tank oil level is low.
(Hydraulic oil level indicator (21) comes ON also.)
3. Stop valve for suction piping or return piping is closed.
(Stop valve indicator (33) comes ON also.) M18M-01-019

4. Fast-filling panel is lowered. 21

5. Stairway is extended.
6. Electric lever system is abnormal. (Electric lever
indicator (29) comes ON also)

38 33 29
When buzzer stop switch is pressed, the buzzer will stop
M18M-01-010
sounding. However, indicators will stay ON. The buzzer is
kept deactivated even after the switch is released until the
key switch is turned OFF and is turned ON again or after all
abnormalities are eliminated. During deactivation, if a new
abnormal condition occurs, the indicator comes ON but the
buzzer does not sound. When all abnormal conditions
disappear, the buzzer is automatically reset and only
sounds when a new abnormal condition occurs.

1-37
OPERATOR S STATION
FAST-FILLING SYSTEM

This machine is equipped with the fast-filling system for

adding fuel, hydraulic oil, gear oil, engine oil, coolant and
grease on the ground.

Fast-filling panel (1) at the rear of the machine will be

raised or lowered with fast-filling switch as follows.

1. Pull the pilot control shut-off lever back to the LOCK

position.
M18M-01-019
2. Run the engine at slow idle. 2

3. Press fast-filling system switch.

4. Fast-filling indicator (2) will come ON and fast-filling
panel (1) will start to go down.
5. When fast-filling panel (1) is completely lowered, it will
stop going down automatically.
6. Stop the engine.
WARNING: Never operate engine while adding
oil.
NOTE: While fast-filling panel is lowered, the machine
will not be able to swing.
M18M-01-009
7. Add fuel, hydraulic oil, gear oil, engine oil, coolant and
grease via the fast-filling panel.
8. Start the engine and run it at slow idle.
9. Press fast-filling system switch again.
10. Fast-filling panel (1) will start to go up.
11. When fast-filling panel (1) is completely raised, it will
stop going up automatically and fast-filling indicator
(2) will go OFF. 1

M18G-01-052

Coolant Engine Oil In Engine Oil Out

(Radiator Outside) (Reserve Tank) (Reserve Tank)
Engine Oil
(Engine Oil Pan) Hyd. Oil

Fuel
Gear Oil
(Front Right Side
Swing Device)

Spare

Pump
Transmission Oil
Coolant Gear Oil Gear Oil Gear Oil M18M-01-020
(Radiator Engine (Front Left Side (Rear Left Side (Rear Right Side Grease
Side) Swing Device) Swing Device) Swing Device)

1-38
OPERATOR S STATION
REAR CONSOLE

1- Cigar Lighter
2- Fuse Box
3- DLU Download Connector
4- ECM Data Link Connector

M18M-01-007

1 2 3

T18G-01-02-026

1-39
OPERATOR S STATION
HORN SWITCH

The horn (1) will continue to sound while horn switch is

kept pressed.

WARNING: If horn (1) does not sound when

pressed, immediately stop the engine and contact
your authorized dealer. Operating the machine
with a malfunctioning horn may result in personal
injury or death.

M18M-01-006

M18M-01-038

1-40
OPERATOR S STATION
ADJUSTING THE SEAT

1- Seat Inclination Adjustment Lever

2- Seat Fore-Aft Adjustment Lever
3- Seat Height Adjustment Lever
4- Seat/Armrest/Backrest Fore-Aft Adjustment Lever
5- Seat/Backrest Fore-Aft Adjustment Lever
6- Backrest Adjustment Lever
7- Armrest Height Adjustment Lever
8- Absorber Adjusting Lever
1
2 M18G-01-054
6 8 5 4 3
Seat Inclination Adjustment
Pull lever (1) up to adjust the seat cushion angle (8
positions in 2.5 increments). When raising the rear side
angle of the seat cushion, place your bodyweight on the
front side of the cushion seat while pulling lever (1) up.
When lowering the rear side angle of the seat cushion,
place your bodyweight on the rear side of the cushion
seat while pulling lever (1) up.

Seat Fore-Aft Adjustment

Pull lever (2) up to adjust the seat fore-aft position. The
adjusting positions are provided in 4 places in 15 mm
increments. 7

Armrest Height Adjustment

WARNING: When armrest lock lever (7) is raised,
the armrest will suddenly be moved up to the
maximum height by spring force. If armrest lock M18G-01-055

lever (7) is raised with the arm placed on the

armrest arm, arm injury may result. Raise armrest
lock lever (7) only after removing your arm from
the armrest to avoid injury.

Pull armrest lock lever (7) up while pressing the armrest

with your arm. Control your arm force to adjust the
armrest height (4 positions). Release armrest lock lever
(7) to lock the armrest in the desired position. Both right
and left armrest heights can be independently adjusted.

1-41
OPERATOR S STATION
Seat/Backrest Fore-Aft Adjustment
Pull lever (5) up to adjust the seat/backrest fore-aft
position. The adjusting positions are provided in 12
places in 10 mm increments.

Seat Height Adjustment

IMPORTANT: The seat is supported by the air
suspension system. Turn the key switch
ON to supply air from the compressor.

Pull lever (3) once and release it. The seat height should
automatically adjust corresponding to your weight. When
further adjustment is required, pull lever (3) continuously M18G-01-054

to raise the seat height further. When lever (3) is pushed 5 4 3

downward, the seat height is lowered.

Seat/Armrest/Backrest Fore-Aft Adjustment

Pull lever (4) to adjust the fore-aft position of the seat,
armrest, and backrest as a unit. The adjusting positions
are provided in 15 places in 10 mm increments.

Absorber Adjusting
The absorber setting of the seat can be adjusted.
Turn the lever (8) to the desired position and release.

1- Soft
2- Hard

M8R8-01-087

1-42
OPERATOR S STATION
Backrest Adjustment
Pull lever (6) to adjust the tilt angle of the backrest. The
backrest can be tilted forward up to the level position. 6
The backward tilt adjusting positions are provided in 2
increments up to 80 .

WARNING: Adjust the backrest tilt angle while

keeping your back in contact with the backrest. If
the backrest is tilted forward without your back
contacting the backrest, the backrest may be
suddenly tilted, possibly resulting in injury to
your back.

M18G-01-054

Lumbar Support Adjustment

Turn dial (9) to adjust the lumber support position.

Headrest Adjustment
Headrest (10) position can be adjusted in 7 positions in
100 mm increments in the up-down direction and up to
38 in the forward direction. 9

M18G-01-056

M18G-01-057

1-43
OPERATOR S STATION
SEAT BELT

WARNING: Be sure to use the seat belt when

operating the machine.
Before operating the machine, be sure to examine
belt (1), buckle (2), or attaching hardware.
Replace belt (1), buckle (2), or attaching hardware
if they are damaged, or worn. 2
Replace seat belt every three years, regardless of
appearance.

Seat Belt
1
1. Securely insert the end of seat belt (1) into buckle (2).
Confirm that seat belt (1) is not twisted. M18G-01-058

2. Pull out the end of belt (1) and securely insert it into
buckle (2). Confirm that belt (1) is not twisted.
3. Push button (3) on buckle (2) to unfasten belt (1).
4. Seat belt (4) is also provided on the trainer seat. 3

M18G-01-059

M18M-01-003

1-44
OPERATOR S STATION
CAB DOOR RELEASE BUTTON

When opening the cab door, lock it in the fully opened

position.

CAUTION: Open the cab door all the way until it

securely locks in the latch on the side of the cab.
1
Push button (1) to unlock the door.

M18G-01-060

OPENING CAB LEFT WINDOW

The cab left window can be opened.

Pull out lock pin (2) to unlock and open the cab left window. 2
Rotate the knob to open the cab left window.

WARNING:
Do not keep the cab left window open when the
machine is parked on a slope, or while the wind
is blowing hard. The cab left window may close
accidentally, possibly resulting in personal
injury.
When opening or closing the cab left window,
take extra care not to catch fingers between the
base machine and the cab left window

M18M-01-003

1-45
OPERATOR S STATION
MEMO
......................................................................................................................................................................................

......................................................................................................................................................................................

1-46
BREAK-IN
OBSERVE MACHINE CLOSELY

IMPORTANT: Be extra cautious during the first 50

hours, until you become thoroughly
familiar with the sound and feel of
your new machine.
Do not attempt to travel the machine
at full speed before the break-in pe-
riod is over, as the lower rollers and
front idlers may seize. For the first
200 hours of operation, operate the
machine with the travel speed switch
set to the slow speed mode.
When moving the machine to the
jobsite after completion of local re-
assembly, be sure to operate the
machine with the travel speed switch
set to the slow speed mode.
Check lower rollers and front idlers
every 10 minutes for excessively high
temperature.
Perform correct break-in procedures
for the front-attachment pins.

1. Operate the engine horsepower up to about 80 % of

full load.
2. Avoid excessive engine idling.
3. Check indicator lights and gauges frequently during
operation.

EVERY 10 HOURS OR EACH SHIFT

1. Perform 10-hour or each shift service. (See Mainte-

nance interval guide -- 10 hours.)
2. Watch for fluid leaks.
3. Lubricate working tool pivots every 10 hours for the
first 50 hours and when working in mud and water.

2-1
BREAK-IN
AFTER THE FIRST 50 HOURS

1. Check coolant, engine oil, and hydraulic oil level and

for leaks every day. Refill with the recommended oils
and coolant.
2. Check and grease the greasing points at the regular
intervals. Grease the front attachment pins every day.
3. Retighten bolts at the regular intervals.
4. Re-drive in the tooth (point) holding wedges.
5. Check the monitor for any abnormality while operat-
ing the machine.
6. Operate the machine after thoroughly warming up the
engine and hydraulic oil.
7. Check the machine for any abnormal operations while
operating the machine.

2-2
OPERATING THE ENGINE
INSPECT MACHINE DAILY BEFORE STARTING
Backhoe Front Attachment

Arm Cylinder

Arm

Boom
Bucket
Cylinder

Link B
Link A
Loading Shovel Front Attachment
Level Cylinder Bucket
Boom Cylinder
Arm
Boom
Boom Cylinder
Bucket Cab T146-01-03-002
Swing Device
Lubricator
Oil Cooler
Hydraulic Oil Tank
Muffler
Battery
Air Cleaner
Pump
Arm Cylinder
Counterweight
Dump Cylinder
Bucket Cylinder

Emergency Evacuation
Equipment Air Fan
Washer Tank
Engine
Fuel Tank
Front Idler Engine Oil Re-
Track Adjuster serve Tank
Upper Roller
Side Frame Control Valve
Radiator Water Tank
Accumulator
Stairway Travel Device
Lower Roller
M18M-03-007

For other inspection and maintenance procedures, refer to the MAINTENANCE Section.

ELECTRICAL SYSTEM: Check for worn or frayed LUBRICATION: Check lubrication points.
wires and loose or corroded connections.
PROTECTIVE DEVICES: Check guards, shields, and
BOOM, BUCKET, SHEET METAL, TRACKS, covers.
HARDWARE: Check for bent, broken, loose, or miss-
ing parts. FIRE PREVENTION: Clean machine of debris.

FUEL SYSTEM: Drain water and deposits from fuel SAFETY: Walk around machine to clear all persons
tank. from machine area.

HYDRAULIC SYSTEM: Check for leaks, missing or

loose clamps, kinked hoses, and lines or hoses that
rub against each other or other parts.

3-1
OPERATING THE ENGINE
BEFORE TURNING POWER ON

1. Confirm that pilot control shut-off lever (1) is in the

LOCK position.
2. Confirm that all control levers are placed in neutral.
3. Adjust the seat to allow full pedal and control levers
stroke with operator s back against the backrest.
Fasten the seat belt.

M18M-01-018
LOCK Position

3-2
OPERATING THE ENGINE
TURNING POWER ON 1

1. Turn key switch (1) to the ON position.

2. Starting check screen (2) will be displayed on the
monitor.
3. Fluid level check is automatically performed. Level
check indicators for coolant (3), engine oil in oil pan
(4), engine oil in reserve tank (5) and hydraulic oil (6)
will become green when fluid levels are appropriate.
NOTE: When nothing is displayed on the monitor even 2 3 4 5 M18M-01-019
if key switch is turned to the ON position, adjust
the monitor contrast switch (7) at first.

IMPORTANT: The monitor does not guarantee the 6

machine conditions. Do not rely on the
monitor alone. Check each fluid level
visually at the regular intervals.

4. Make sure that all checking items indicate NORMAL.

If one of the level checks indicates ABNORMAL,
check the fluid level concerned and add as needed. In
case other items indicate ABNORMAL, contact your
authorized dealer.
5. The monitor will automatically shift from starting M18M-01-008

check screen (2) to meter check screen (8).

NOTE: When key switch (1) is turned to the ON posi-

tion, electric lever indicator (9) will come ON if
both electric levers are not in the neutral posi-
tion. The electric lever not in the neutral position
cannot be moved further. After turning the key
switch to the OFF position, return both electric
levers to the neutral position. Then, turn the key
switch to the ON position again.
7
M18G-01-035

M18M-01-009

3-3
OPERATING THE ENGINE

NOTE: 1. Level check screen (11) will be displayed

Monitor Display
when press button (10) on key pad.
2. Level check screen (11) shows up only when
the engine is not running.
3. Meter check screen (8) will be displayed
again with button (10) on key pad.

Key Pad

M18G-01-018

Key Pad

M18G-03-005
11

M18M-03-001
8
6. Warning indicators of alternator (12), pump transmis- 12
sion oil level (13) will stay ON.

M18M-01-009

3-4
OPERATING THE ENGINE
7. Make sure not faults exist before starting engine. If
any fault messages (14) exist, fault mark (15) will Key Pad
appear. Press button (16) on key pad and current
fault list (17) will be displayed. Meter check screen (8)
will be displayed again with button (18) on key
pad. After confirming the faults messages on display,
report the error codes (Cummins or HCM or both) to
your authorized dealer.

8 M18G-03-005

M18M-03-002
15

M18M-03-003

3-5
OPERATING THE ENGINE
8. Make sure not alarms exist before starting engine. If
any alarm messages (19) exist, alarm mark (20) will Key Pad
appear. Press button (21) on key pad, current
alarm list (22) will be displayed. Meter check screen
(8) will be displayed again with button (18) on key
pad. After confirming the alarm messages on display,
report the error codes (Cummins or HCM or both) to
your authorized dealer.
21

8 M18G-03-005

M18M-03-004
20

M18M-03-005

3-6
OPERATING THE ENGINE
MONITOR SCREEN FLOW -1
Power ON

Starting Check Screen Level Check Screen

M18M-01-008 M18M-03-001
Automatic If Engine is not running

Meter Check Screen

M18M-01-009

Current Alarms List Current Faults List

M18M-03-005 M18M-03-003

3-7
OPERATING THE ENGINE
STARTING THE ENGINE

1. Turn engine speed control dial (1) to the slow idle 1

position.
2. Turn auto-idle switch (2) OFF.
3. Sound the horn with either one of both horn switches
(3) to alert bystanders.
4. Press and hold engine start switch (4) until the engine
starts. Prelub indicator (5) will light.
NOTE: This machine is equipped with the Prelub
system. This system functions to automati-
cally lubricate engine components before the M18M-01-004

engine starts, immediately after the engine 2

start switch (4) is pressed. The Prelub indi-
cator remains lit while this function is operat-
ing.
Hold the engine start switch (4) until the en-
gine starts after Prelub indicator (5) goes
OFF.

IMPORTANT: Prevent damage to the starter. Never run

the starter continuously for more than 15
seconds. If the engine fails to start, wait
for 2 to 3 minutes and try again. 3
M18M-01-019

5. After the engine has started, immediately release the

engine start switch (4).

IMPORTANT: After a false start, do not press the start

switch (4) until the engine completely
stops rotating, or the starter may be
damaged.

M18M-01-006

M18M-01-009

M18M-01-019

3-8
OPERATING THE ENGINE
STARTING IN COLD WEATHER 1

IMPORTANT: Cold starting system (either) is optional.

The machine shipped from the factory
does not have this system parts. If you
need, contact your authorized dealer.
WARNING: Prevent possible injury from explod-
ing container. Starting fluid is highly flammable.
Keep container away from heat, sparks, and open
flame. Contents are pressurized. Do not puncture
or incinerate container. Remove container from
machine if engine does not need starting fluid.

IMPORTANT: An ether is injected automatically.

M18M-03-006
1. Install an ether container on holder (1) located in the
engine room.
2

2. Turn the engine speed control dial (2) to the slow idle
position.

3. Press and hold engine start switch (3) until the engine
starts. Prelub indicator (4) will light.

4. The starter will rotate to start the engine after Prelub

indicator (4) goes OFF. M18M-01-004

5. A shot of ether will be injected.

6. After the engine has started, release the engine start

switch (3).

7. Be sure to remove the ether container once the en-

gine is started.

M18G-01-040

NOTE: When starting the engine at temperatures below

20 C ( 4 F), contact your authorized dealer. A
coolant heater, jacket water heater or extra bat-
3
tery capacity may be required.
4

M18M-01-019

M18M-01-009

3-9
OPERATING THE ENGINE
CHECK INSTRUMENTS AFTER STARTING

IMPORTANT: Prevent possible damage to engine.

If warning indicators described below do
not go OFF after starting engine, IMME-
DIATELY STOP THE ENGINE and correct
the cause.
1 4 3
Check that
1. Alternator indicator (1) goes OFF.
2. Pump transmission oil level indicator (2) goes OFF.
3. Other warning or caution indicators do not indicate 2
abnormal.
4. Tachometer (3) indicates slow idle.
5. Coolant temperature gauge (4) indicates the blue or
white zone. 5

6. Hydraulic oil temperature gauge (5) indicates the blue

or white zone.
7. Engine noise and exhaust gas are normal. M18M-01-009

NOTE: Handy engine troubleshooting can be done by

checking the exhaust gas color (Check with the
engine running, with no load, after sufficient
warm-up operation.)

Colorless
or faint blue : normal (proper combustion)
Black : abnormal (improper combustion)
White : abnormal (oil ring worn, or
coolant leakage into cylinder)

IMPORTANT: Operate machine at less-than-normal

loads and speeds until engine is at
normal operating temperature.

3-10
OPERATING THE ENGINE
USING BOOSTER BATTERIES

WARNING:
An explosive gas is produced while batteries
are in use or being charged. Keep flames or
sparks away from the battery area. Charge the
batteries in a well ventilated area.
Do not continue to use or charge the battery
when electrolyte level is lower than specified.
Explosion of the battery may result.
Park the machine on a dry, firm or concrete
surface, not on steel plates, if the machine is
parked on steel plates, dangerous sparks may
be unexpectedly created on the machine. SA-032

Never connect a positive terminal to a negative

terminal, as a dangerous short circuit will
occur.
The operator must be in the operator s seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.

IMPORTANT: The machine electrical system is a 24 Connecting the Booster Batteries

volt negative ( ) ground. Use only 24 volt
booster batteries.

When the machine batteries are exhausted, start the 1 Upper

engine using booster batteries as shown below.

Connecting the booster batteries Machine Batteries

1. Stop the engine of the machine on which booster

batteries are mounted.
2. Connect one end of red cable to the positive (+) (Red) Lower
terminal of machine batteries (1), and the other end to
the positive (+) terminal of booster batteries (2).
3. Connect one end of black cable to the negative ( ) 4
terminal of booster batteries (3), and then make (Black)
ground connection to the frame of the machine to be To Upperstructure
started with the other end of black ( ) cable. In the of the Machine
last connection to machine frame (4), be sure to
connect the cable end as far away from the machine
batteries as possible. 2 3
4. Start the engine of the machine on which booster
batteries are mounted. Booster Batteries
5. Start the engine of the troubling machine. M117-03-002

6. After the engine starts, disconnect cables (1) and (2),

following the procedure below.

3-11
OPERATING THE ENGINE
Disconnecting the booster batteries Connecting the Booster Batteries
1. Disconnect black negative ( ) cable from machine
frame (4) first.
2. Disconnect the other end of black negative ( ) cable 1 Upper
from booster batteries (3).
3. Disconnect red positive (+) cable from booster
batteries (2). Machine Batteries

4. Disconnect red positive (+) cable from machine

batteries (1).
(Red) Lower

4
(Black)
To Upperstructure
of the Machine

2 3

Booster Batteries
M117-03-002

3-12
OPERATING THE ENGINE
STOPPING THE ENGINE

Engine stop procedure

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn auto-idle switch (2) OFF and engine speed
control dial (3) to the slow idle position.
4. Run the engine at slow idle without load for 5
minutes.
5. Press and hold engine stop switch (4) until the engine 1
completely stops rotating.
M18M-01-018
LOCK Position
IMPORTANT: Turbocharger may be damaged if the
engine is not properly shut down. 3 4 2 5

6. Turn key switch (5) to the OFF position. Remove the

key from the key switch (5).
7. Pull pilot control shut-off lever (1) to the LOCK
position.

M18M-01-019

OFF ACC

5
M18G-01-034

3-13
OPERATING THE ENGINE
EMERGENCY ENGINE STOP SWITCH
NORMAL EMERG. STOP

IMPORTANT: Normally, use the engine stop switch (1)

to stop the engine. Use the emergency
engine stop switch (2) only for
emergency stops, or if the engine stop 2
switch (1) malfunctions. If the engine is
shut off without cooling down, the 1
turbocharger free-wheels without
receiving lubricant, resulting in serious
damage to the turbocharger.

1. Turn emergency engine stop switch (2) from the

M18G-01-013
NORMAL position to the EMERG STOP position
when emergency engine stop is required in the cab. 3

2. Engine will stop simultaneously and emergency stop

indicator (3) will come ON. In addition, the air
pressure is bled from the hydraulic oil tank.
3. Turn emergency engine stop switch (2) to the
NORMAL position and return the conditions to the
normal engine stop before attempting to restart the
engine.
NOTE: Do not use emergency engine stop switch (2) in
cab when performing any inspection/service
work. Use the engine stop switches at the area
where any inspection/service works are
performed to avoid possible personal injury.
M18M-01-009

3-14
OPERATING THE ENGINE
ENGINE STOP SWITCHES

WARNING: When performing any

inspection/service work, use engine stop switch
(2) at the area where any inspection /service work
are performed to avoid possible personal injury.

Engine stop switches (2) are located as follows to ensure

safe inspection work in the engine compartment.
2 In the engine room
1 In the pump room
1 In the oil cooler room
1 In the radiator room
M18M-01-004

When engine stop switch (2) is turned to the EMERG.

STOP position, the engine will not be started with key
switch. 2
Engine emergency stop indicator (3) will come ON.
NOTE: The air pressure will not be bled from the
hydraulic oil tank.

When engine stop switch (2) is turned to the EMERG.

STOP position, the engine will be stopped.

IMPORTANT: If the engine is shut off without cooling

down, the turbocharger free-wheels Rear Side In the Engine Room M18M-07-002
without receiving lubricant, resulting in
serious damage to the turbocharger.

Turn engine stop switch (2) to the NORMAL position to

restart the engine. 2

M18M-01-005
3

M18M-01-009

3-15
OPERATING THE ENGINE
MEMO
......................................................................................................................................................................................

......................................................................................................................................................................................

3-16
DRIVING THE MACHINE
DRIVE THE MACHINE CAREFULLY

IMPORTANT: During freezing weather, park machine

on a hard surface to prevent tracks from
freezing to the ground. Clean debris
from tracks and track frame.

If tracks are frozen to the ground, raise

tracks using boom, move machine
carefully to prevent damage to drive
train and tracks.

If engine stops under load, remove the

load. Start engine immediately. Run the
engine 30 seconds in slow idle speed
before you add load.

Select a route that is as flat as possible. Steer machine as

straight as possible making small, gradual changes in di-
rection.

When driving over rough terrain, reduce engine speed to

lessen the possibility of undercarriage damage.

4-1
DRIVING THE MACHINE
STEERING THE MACHINE USING PEDALS

WARNING: In the standard travel position, the

idlers are positioned at the front of the machine Front Idler
and the travel motors at the rear. If the travel Cab

motors are positioned at the front of the machine,

the control actions of the travel pedals will be
reversed. Be sure to confirm the position of the
travel motors before traveling.

FORWARD TRAVEL
Push down on front (A) of both pedals. Travel Motor
M104-04-001
REVERSE TRAVEL
Push down on rear (B) of both pedals.
NEUTRAL POSITION (C)
When the travel pedals are placed in neutral, travel
brakes automatically will be applied to hold the ma- A
chine.
A C
RIGHT TURN B
Push down on front of left pedal.
C
LEFT TURN
B
Push down on front of right pedal.
SHORT TURN (Spin turn) Forward and Reverse
Push down the front of one pedal and the rear of the
M18M-04-001
other. M104-04-003

Pivot Turn M18M-04-002

M104-04-005

Spin Turn
M18M-04-003
M104-04-007

4-2
DRIVING THE MACHINE
STEERING THE MACHINE USING LEVERS

WARNING: In the standard travel position, the

idlers are positioned at the front of the machine Front Idler
Cab
and the travel motors at the rear. If the travel
motors are positioned at the front of the machine,
the control actions of the travel levers will be re-
versed. Be sure to confirm the position of the
travel motors before traveling.

FORWARD TRAVEL
Push both levers forward (A).
Travel Motor M104-04-001
REVERSE TRAVEL A
A
Pull both levers rearward (B). C
NEUTRAL POSITION (C)
When the travel levers are placed in neutral, travel C
B
brakes automatically will be applied to hold the ma- B
chine.
RIGHT TURN
Push left lever forward.
LEFT TURN
Push right lever forward.
SHORT TURN (Spin turn)
Push one lever forward and pull the other rearward. Forward and Reverse
M18M-04-001

. M104-04-003

Pivot Turn M18M-04-002

M104-04-005

Spin Turn
M18M-04-003
M104-04-007

4-3
DRIVING THE MACHINE
TRAVEL MODE SWITCH

WARNING: Tipping accidents can cause serious

personal injury. Do not change travel mode while
traveling; especially, changing speed to the fast
mode when descending slopes will create a very
dangerous situation. Always stop the machine
before changing the travel mode speed. Confirm
the travel mode using the indicators after chang-
ing modes.
When descending steep slopes, avoid quick ac- 1 M18M-01-019
celeration and deceleration in the fast travel
mode. Damage to the travel motors may result. 2

Fast speed (rabbit) or slow speed (turtle) can be se-

lected by pushing travel mode switch (1) at any engine
speed.
Indicator lights (2) show mode selection.

To decrease travel speed, for traveling on a slope or in a

tight space, press switch to turtle position.

1- Travel mode Switch

2- Travel mode Indicator

M18M-01-009

4-4
DRIVING THE MACHINE
TRAVEL ALARM

The travel alarm functions to alert bystanders when the

machine is traveling.

WARNING: If the travel alarm does not sound

when the travel levers or pedals are operated,
immediately stop the engine and contact your
authorized dealer for repair. Operating with the
travel alarm malfunctioning may result in a seri-
ous accident.

1- Travel Alarm

M18M-04-004
1

4-5
DRIVING THE MACHINE
TRAVELING

WARNING: Use a signal person when moving,

swinging or operating the machine in congested
areas. Coordinate hand signals before starting
the machine.

Before moving machine, determine which way to

move travel pedals/levers for the direction you want to
go. When the travel motors are in the rear, pushing
down on the front of the travel pedals or pushing the Travel Motor
levers forward moves the machine forward, towards
the idlers. M145-05-003

Select a travel route that is as flat as possible. Steer

the machine as straight as possible, making small
gradual changes in direction.
When traveling on a level surface, position the front
with boom (1) fully raised, and arm (2) fully retracted,
as illustrated, in order to apply the road as evenly as
possible to all of the lower rollers.
Before traveling on them, check the strengths of
bridges and road shoulders, and reinforce if neces-
sary.
Use wood plates in order not to damage the road sur-
face. Be careful of steering when operating on asphalt M145-05-004
roads in summer.
When crossing train tracks, use wood plates in order
not to damage them.
1 2
Do not make contact with electric wires or bridges.
When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the
river when the depth of the river is deeper than the
upper edge of the upper roller.
When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
M145-05-027
Avoid operations that may damage the track and un-
dercarriage components.
1 2
During freezing weather, always clean snow and ice
from track shoes before loading and unloading ma-
chine, to prevent the machine from slipping.

M145-05-022

4-6
DRIVING THE MACHINE
OPERATING ON SOFT GROUND Boom
Arm
Avoid traveling on very soft ground that does not have
sufficient strength to firmly support the machine.
If the machine is operated on very soft ground or be-
comes stuck, it may be necessary to clean the track 90 to
frame area. 110

Swing the upperstructure 90° and lower the bucket to

raise one track off the ground. Make sure to keep the
angle between the boom and arm 90 to 110° and posi- Boom M145-05-007
tion the bucket s round side on the ground.
Arm
Rotate the raised track back and forth to remove mud
and dirt.
After lowering the track to the ground, move the
engine speed control lever to the medium speed 90 to
position and slow travel speed. Carefully move the 110
machine to firm ground.
Utilize the boom and arm functions to pull the machine M145-05-025
toward firm ground.
Tow the machine if it becomes stuck but can still
operate its engine. Be sure to attach a towing wire
correctly. (Refer to the TOWING MACHINE A SHORT
DISTANCE section on the next page.)

RAISE ONE TRACK USING BOOM AND ARM

Boom
WARNING: Keep the angle between boom and Arm
arm 90 to 110° and position the bucket s round
side on the ground.

Swing the upperstructure 90° and lower the bucket to raise 90 to

track off ground. Do not dig bucket teeth into the ground 110
when using the loader bucket.

Place blocks under machine frame to support the machine.

Boom M145-05-007
IMPORTANT: When the machine is equipped with the
loading shovel front attachment, don t Arm
raise the machine off the ground by
bucket tooth force with the bucket cyl-
inder fully retracted. Failure to do so will
cause excessive loads to be applied to 90 to
the bucket pins and cylinders so that 110
damage to the pins may result.
M145-05-025

4-7
DRIVING THE MACHINE
TOWING MACHINE A SHORT DISTANCE

RIGHT
WARNING: Cables, straps, or ropes can break
causing serious injury. Do not tow machine with
damaged chains, frayed cables, slings, straps, or Protector
wire ropes.
Always wear gloves when handling cable, straps
or wire ropes. Shackle

When your machine becomes struck but the engine is still

operational, attach wire rope tow lines as illustrated at right,
and slowly tow your machine to firm ground using another Wire Rope
machine.
Be sure to attach the wire ropes around the track frames of M114-05-100

both machines as illustrated.

To prevent the wire ropes from being damaged, place
some protective material between the track frame and the
wire ropes.

IMPORTANT: Slowly tow, keeping the tow line hori-

zontal and in a straight line with the
tracks.
When the machine is towed, release
parking brakes by operating the travel
levers.

4-8
DRIVING THE MACHINE

OPERATING GROUND CONDITION

Operate the machine on flat footing.

The machine should not be operated in water or mud.
There is a possibility that travel motors, travel reduction
gears, and parts inside of the track frame damage with
machine sinking.
In very soft footing, beware the possibility of the machine
sinking gradually.
Always pay attention around the undercarriage.

If you must travel in water, check that towing will be possi-

ble.
The following conditions apply to travel across water;
The bed of water is flat. 1100 mm
(3' 7")
The flow of water is slow. M18M-04-005

While you cross in water, carefully confirm the depth and

footing condition.
Do not move the machine into an area that has a water
depth that is greater than 1,100 mm (3 ft 7 in) from the
ground.
If the footing is weak and water flow is fast, take special
care not submerge the swing bearing, swing pinion gears
due to the machine sinking and the force of strong water
current.

If submerge the swing bearing, swing pinion gears and

center joint by mistake, do not operate the machine with
such a condition continuously, it cause to wear swing
bearing and swing pinion gears abnormally and may break
swing bearing and gears.
Remove the drain plug to drain mud and water, and re-
place grease in the swing bearing bath or disassemble the
swing bearing area immediately.
Please stop the machine operation and contact authorized
distributor or dealer when submerge the swing bearing,
swing pinion gears and center joint.

4-9
DRIVING THE MACHINE
PRECAUTIONS FOR TRAVELING ON SLOPES

WARNING: Avoid possible injury from traveling

on slopes. Tipping over or skidding down of the
machine may result. Thoroughly read and under-
stand precautions below and be sure to travel at
slow speed on slopes. Never attempt to travel on 0.5 to 1.0 m
slopes with the bucket loaded or any load sus- (1 8 to 3 3 )
pended by the bucket.

Never attempt to ascend or descend 30 degrees or

steeper slopes. M145-05-016

Be sure to fasten the seat belt.

Keep the bucket pointed in the direction of travel, ap-
proximately 0.5 to 1.0 m (1 8 to 3 3 ) above the
ground. If the machine starts to skid or becomes un-
stable, lower the bucket immediately.
Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If 0.5 to 1.0 m
the direction must be changed, move the machine to (1 8 to 3 3 )
level ground, then, change the direction to ensure
safe operation.
M145-05-024
Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to
neutral. Then, restart the engine.
Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not
warmed up sufficiently, sufficient performance may not
be obtained. SA-441

Turn the travel mode switch to the slow mode position WRONG
on level ground before traveling down a slope. Never
operate the travel mode switch while descending a
slope. Failure to do so may possibly result in causing
the machine to slip.
When descending steep slopes, avoid quick accelera-
tion and deceleration in the fast travel mode. Damage
to the travel motors may result.

SA-442

4-10
DRIVING THE MACHINE
PARKING THE MACHINE ON SLOPES

WARNING: Avoid parking machine on slopes.

The machine may tip over, possibly resulting in
personal injury.

If parking the machine on a slope is unavoidable:

Thrust the bucket teeth into the ground.
Return the control levers to neutral and pull the pilot
control shut-off lever to the LOCK position.
Block
Block both tracks. M145-05-006

PARKING THE MACHINE 1 2 3

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if the

engine is not properly shut down.

4. Move engine speed control Dial (1) to the slow idle

position. M18M-01-019
OFF ACC
Run the engine approximately 5 minutes to cool the
engine.
5. Press and hold engine stop switch (2) until the engine ON
completely stops rotating.
6. Turn key switch (3) to OFF. Remove the key from the
key switch.
7. Pull pilot control shut-off lever (4) to the LOCK posi- 3
tion. M18G-01-034

IMPORTANT: Protect cab electrical components from

bad weather. Always close windows,
roof vent and cab door when parking the
machine.

8. Close windows, roof vent, and cab door.

9. Lock all access doors and compartments.

M18M-01-018
LOCK Position

4-11
DRIVING THE MACHINE
MEMO
......................................................................................................................................................................................

......................................................................................................................................................................................

4-12
OPERATING THE MACHINE
CONTROL LEVER (ISO PATTERN BACKHOE)

WARNING: Never place any part of body beyond

window frame. It could be crushed by the boom if
boom control lever is accidentally bumped or
otherwise engaged. If window is missing or bro-
ken, replace immediately.
Prevent possible injury from unexpected machine
movement.
Make sure you know the location and function of
each control before operating.

The machine is equipped with a label showing the control 1 5

T18G-01-02-053

patterns of the levers and pedals.

IMPORTANT: When digging, avoid hitting tracks with

3 4 7 8
boom cylinders.
When digging over the end of the tracks,
travel motors should be at the rear to
maximize machine stability and lift ca- 2 6
pacity.

When a lever is released, it will automatically return to

neutral, and that machine function will stop.

1- Arm Roll-Out
2- Arm Roll-In M18M-01-006

3- Swing Left
1 4
4- Swing Right
5- Boom Lower 3
2
6- Boom Raise
7- Bucket Roll-In.
8- Bucket Roll-Out.

M142-05-002

7
5
8

M142-05-003

5-1
OPERATING THE MACHINE
CONTROL LEVER (HITACHI PATTERN
BACKHOE)

WARNING: Never place any part of body beyond

3 4 7 8
IMPORTANT: When digging, avoid hitting tracks with
boom cylinders.
When digging over the end of the tracks,
travel motors should be at the rear to 2 6
maximize machine stability and lift ca-
pacity.

When a lever is released, it will automatically return to

neutral, and that machine function will stop.

1- Swing Right
M18M-01-006

2- Swing Left
3- Arm Roll-Out 3 1
4- Arm Roll-In 2
5- Boom Lower 4

6- Boom Raise
7- Bucket Roll-In.
8- Bucket Roll-Out.

M142-05-002

7
5
8

M142-05-003

5-2
OPERATING THE MACHINE
CONTROL LEVER (ISO PATTERN LOADING
SHOVEL)

WARNING: Never place any part of body beyond

When a lever is released, it will automatically return to

neutral, and that machine function will stop.

1- Arm Extend
M18M-01-006

2- Arm Retract
3- Swing Left
4- Swing Right 4
5- Boom Lower 3
6- Boom Raise
7- Bucket Tilt-In
1
8- Bucket Tilt-Out 2

M117-05-027

5
8

M117-05-025

5-3
OPERATING THE MACHINE
CONTROL LEVER (HITACHI PATTERN
LOADING SHOVEL)

WARNING: Never place any part of body beyond

When a lever is released, it will automatically return to

neutral, and that machine function will stop.

1- Swing Right
M18M-01-006

2- Swing Left
3- Arm Retract
4- Arm Extend 1
5- Boom Lower 2
6- Boom Raise
7- Bucket Roll-In.
4
8- Bucket Roll-Out. 3

M117-05-027

5
8

M117-05-025

5-4
OPERATING THE MACHINE
BUCKET OPEN-CLOSE PEDALS (LOADING 9 10
SHOVEL)

9- Bucket Closing
10- Bucket Opening

M18M-01-006

M18G-05-004

5-5
OPERATING THE MACHINE
PILOT CONTROL SHUT-OFF LEVER

Pilot control shut-off lever (1) functions to prevent

misoperation of the machine from occurring if the control
levers are accidentally moved when leaving the operator's
seat or when entering the cab.

WARNING:
Always pull pilot control shut-off lever (1) into
the full LOCK position. The pilot control
shut-off function will not be activated
otherwise.
When leaving the machine:
Stop the engine.
Then, pull the pilot control shut-off lever up to
the LOCK position.
Always check to be sure that the pilot control
lever is pulled up to the LOCK position before:
Transporting the machine.
Leaving the machine at the end of the shift.

Pilot Control Shut-Off Lever Operation

Before Leaving the Machine:
1. Park the machine on a firm, level surface. Lower the
bucket to the ground. Return all control levers to neu-
tral. Properly shut down the engine.
2. Pull pilot control shut-off lever (1) up into the full
LOCK position.

Before Starting Operation:

1. Confirm that pilot control shut-off lever (1) is pulled up
to the LOCK position.
1
After starting the engine:
1. Confirm that all control levers and pedals are in LOCK Position M18M-01-018

neutral and that no part of the machine is in motion.

2. Lower pilot control shut-off lever (1) to the UNLOCK
position.
If any part of the machine (any actuator) moves when the
pilot control shut-off lever is lowered to the UNLOCK
position despite the fact that all controls are placed in
neutral, the machine is malfunctioning. Immediately pull
the pilot control shut-off lever back to the LOCK position,
and stop the engine. Then, see your authorized dealer.
1

UNLOCK Position M18M-05-001

5-6
OPERATING THE MACHINE
ENGINE SPEED CONTROL

The engine speed is controlled with engine speed control

dial.

The fully clockwise position (1) : Fast Idle

The fully counterclockwise position (2) : Slow idle

Before stopping the engine, always turn engine speed

control dial to the slow idle position and run the engine
five minutes at slow idle.

M18M-01-004

2 1

M18G-01-040

5-7
OPERATING THE MACHINE
AUTO-IDLE

When auto-idle switch (1) is turned ON, approximately 4

seconds later after the control levers are returned to neutral,
engine speed will be decreased to the auto-idle speed
automatically to save the fuel consumption at no operation.
If the control levers are operated, engine speed will return
to the speed depending on the engine speed control dial
(2) position immediately. 1

WARNING:
M18M-01-019
Always check if auto-idle indicator (3) is turned
on or off before starting operation. If the indi-
cator is on, the auto-idle function will be acti-
vated.
2
Always be aware of the engine speed control
dial (2) position when auto-idle switch (1) is
turned on. If the engine speed control dial (2) is
in the fast idle position, and if the operator is
not aware of that, the engine speed will unex-
pectedly increase when any control lever is
operated, causing unexpected machine
movement, thus possibly resulting in serious
personal injury.
Prevent the machine from unexpected move-
ment. Be sure to turn auto-idle switch (1) off
M18M-01-004
when unexpected machine movement is unde-
sirable. 3

Note that auto-idle function can be turned on or off only

when the key switch is in ON position. Always check if the
auto-idle function is turned on or off with auto-idle indicator
(3).

Auto-Idle Function ON : Auto-Idle Indicator (3) ON

Auto-Idle Function OFF : Auto-Idle Indicator (3) OFF

In order to deactivate the auto-idle function, simply

press auto-idle switch (1) when auto-idle indicator (3)
is turned on. Auto-idle indicator (3) will go off.
M18M-01-009

NOTE: When the engine speed set by the engine

speed control dial (2) is lower than that of the
auto-idle level, auto-idle circuit will not work
even if auto-idle indicator (3) is turned ON.

5-8
OPERATING THE MACHINE
WARMING-UP OPERATION

IMPORTANT: The proper engine operating coolant

temperature and machine operating hy- A
1
draulic oil temperature are correspond-
ing to the blue zone (A) of the coolant
temperature gauge (1) and hydraulic oil
temperature gauge (2), respectively. If
the machine is operated excessively B
when the coolant and hydraulic oil tem-
perature are lower than the middle of the
white zone (B), damage to the engine
M18M-01-012
and hydraulic component may result.

Start the engine and warm up the machine until the needles A 2
of the each gauges enter the middle of the white zone (B)
in the following procedures before starting to work.

1. Run the engine at slow idle for 5 minutes.

2. Increase the engine speed to middle speed by oper- B
ating the engine speed control dial (3). Run the en-
gine for 5 minutes with the bucket held in the
rolled-out (tilted-out) position.
M18M-01-013
(Do not operate other functions than the bucket at this
time.)
3. Increase the engine speed to the maximum speed.
Run the engine for 5 to 10 minutes with the bucket 3
rolled-in (tilted-in) or arm rolled-in (cylinder extend).
(Do not operate other functions than the bucket or
arm at this time.)
4. Operate the bucket and arm respectively until the
needles of the each gauges enter the middle of the
white zone (B).

M18M-01-004

M18G-01-040

5-9
OPERATING THE MACHINE
WARMING-UP THE CYLINDERS AND MO-
TORS 1

IMPORTANT: In cold weather, be sure to thoroughly

warm-up the cylinders and motors.
If the hydraulic circuit is continuously
relieved for a certain amount of time,
the temperature in the control valve
would rise excessively. Never operate
to stroke end more than 15 seconds.
After relieving any function, up to 15
seconds, be sure to have a 5 10 sec-
ond intermission.

1. Run the engine for at least 5 minutes on slow idle.

M18M-01-006

2. Run the engine for at least 5 minutes at medium

speed.
3. Extend the bucket cylinder to the far stroke end.
Do not operate bucket control lever (1) for over 30
seconds at this time.
4. Retract the bucket cylinder to the near stroke end. Do
not operate bucket control lever (1) for over 30
seconds at this time.
5. Repeat procedures 3 and 4 until the bucket working
speed becomes normal. When atmospheric
temperature is extremely low, extend the medium
speed operating time.
6. Operate the other cylinders and the motors in the
same way until the each of working speed becomes
normal.

5-10
OPERATING THE MACHINE
PRECAUTIONS FOR OPERATIONS

WARNING: Investigate the work site before start-

ing operations.
Be sure to install an overhead cab guard when
operating in a work site which has a possibility
of falling objects.
If operation on soft ground is required, suffi-
ciently reinforce the ground beforehand.

Be sure to wear close fitting clothing and safety

equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
Clear all persons and obstacles from area of operation
and machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obsta-
cles, take care not to hit the upperstructure against
obstacles.
When loading onto trucks, bring the bucket over the M117-05-006
truck beds from the rear side. Take care not to swing
the bucket over the cab or over any person.

NOTE: The standard specification machine is equipped

with the head guard integrated cab.

5-11
OPERATING THE MACHINE
OPERATE THE MACHINE SAFELY

WARNING: Prevent the machine from tipping

over and from being involved in a ground col-
lapse. Take the necessary precautions as follows:
Make sure the worksite has sufficient strength
to firmly support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks
positioned perpendicular to the cliff face with
travel motors at the rear, so that the machine
can more easily evacuate if the cliff face col-
lapses.
If working on the bottom of a cliff or a high
bank is required, be sure to investigate the area
first and confirm that no danger of the cliff or
bank collapsing exists. If any possibility of cliff M117-05-007
or bank collapsing exists, do not work on the
area.
Soft ground may collapse when operating the
machine on it, possibly causing the machine to
tip over. When working on a soft ground is re-
quired, be sure to reinforce the ground first
using large pieces of steel plates strong and
firm enough to easily support the machine.
Note that there is always a possibility of ma-
chine tipping over when working on rough ter-
rain or on slopes. Prevent machine tipping over
from occurring. When operating on rough ter-
rain or on slopes:
Reduce the engine speed.
Select slow travel speed mode.
Operate the machine slowly and be cau-
tious with machine movements.

5-12
OPERATING THE MACHINE
OPERATING BACKHOE 100 mm (4 )

1. Place the bucket teeth on the ground with the bottom 100 mm (4 )
of the bucket at a 45 degree angle to the ground.
2. Pull the bucket toward the machine using the arm as
the main digging force.
3. When soil sticks to the bucket, remove it by moving
the arm and/or bucket rapidly back and forth.
4. When lowering the boom, avoid sudden stops that
M145-05-008
may cause shock load damage to the machine.
5. When operating the arm, avoid bottoming the cylinder
to prevent cylinder damage.
6. When digging at an angle, avoid striking the tracks
with the bucket teeth.
7. When digging a deep excavation, avoid striking the
boom or bucket cylinder hoses against the ground.
8. When trenching a straight line, position the tracks
parallel to the trench. After digging to the desired
depth, move the machine as required to continue the
trench.
M145-05-009

NOTE: When crowding the arm, it is normal for the arm

to pause briefly at the lowest point of its curve,
as shown. This is due to the fact that the force
of gravity pulls the arm down quickly, and it
takes a moment for the hydraulic force in the
cylinder to catch up. This does not indicate
machine trouble.

GRADING OPERATION

WARNING: Do not pull or push dirt with the

bucket when traveling.

Position the arm slightly forward of the vertical position with

bucket rolled back, as shown.

Operate arm roll-in function while slowly raising the boom.

Once the arm moves past, the vertical position slowly lower
the boom to allow the bucket to maintain a smooth surface.

Grading operation can be more precisely done by operat-

ing the boom, arm and bucket simultaneously. M145-05-010

5-13
OPERATING THE MACHINE
AVOID ABUSIVE OPERATION

WARNING: Do not use travel as an additional WRONG

digging force. Severe machine damage may re-
sult.

Do not raise rear of machine to use the machine s

weight as additional digging force. Severe ma-
chine damage may result.

M145-05-011

WRONG

M145-05-012

5-14
OPERATING THE MACHINE
OPERATING TIPS
WRONG
Do not hit the track with the bucket when digging.
Whenever possible, position your machine on a level sur-
face.
Do not use the bucket as a hammer or pile driver. Do not
attempt to shift rocks and break walls using swing motion.

WARNING: To avoid damaging cylinders, do not

strike the ground with the bucket nor use the
bucket for tamping with the bucket cylinder fully
extended (the bucket completely curled under).

Adjust the length and depth of each cut to produce a full

bucket with every pass.
Full loads on every pass are more productive than a faster
cycle with a partially filled bucket. M145-05-013

Full load should be the first objective, followed by speed, to

increase productivity.

WARNING: Do not attempt to break ledge rock by

extending the arm to maximum reach and drop-
ping the front of the bucket on the bucket teeth
for penetration. Serious damage to the machine
can result.

Once the trench is open, ledge rock can be broken by pull-

ing the bucket up under the layers. The top layers are
pulled out first, with one or two layers being lifted at a time.

AVOID SWINGING BUCKET TO MOVE OB-

JECTS

WARNING: Do not use the bucket for shifting

rocks, breaking walls, and etc. using the swing
motion.
These uses will damage the front attachment.

5-15
OPERATING THE MACHINE
LOADING SHOVEL OPERATION

1. To dig, position the bucket bottom parallel to and

touching the ground and extend the arm while crowd-
ing the bucket.
2. Digging force increases as the arm is retracted. Try to
dig with the arm retracted where strong digging forces
are required.
M18G-04-003

PROHIBITED OPERATION

1. Never dig with the bucket retracted too closely to the

undercarriage, as the machine components will be
subjected to excessive force. If closely retracted dig-
ging is unavoidable, keep a distance of at least 3 m
between the rear end of the bucket and the front end
of the undercarriage. More than 3 m M18G-04-004

2. Never dig with the bucket fully retracted and the WRONG
bucket teeth stuck in the ground as the front attach-
ment will be subjected to excessive force.

3. Do not use the rear of the bucket for grading opera- M18G-04-005

tion, as this will damage it.

WRONG

M18G-04-006

WRONG
4. Do not push rocks or other heavy materials with the
side of the bucket (using the swing movement of the
upperstructure), as this may damage the front at-
tachment. If such pushing is unavoidable, be sure to
do it slowly and carefully.

M117-05-020

5-16
OPERATING THE MACHINE

WARNING: When excavating with boom extended WRONG

to high levels, do not tilt bucket back, as materi-
als will spill on operator s cab. Dump bucket
slightly to prevent spilling.

M18G-04-007

IMPORTANT: When digging with the upperstructure WRONG

at an angle to the undercarriage, avoid
striking the tracks with the bucket.
Avoid further extension of the bucket
cylinder after the bucket comes into
contact with the stopper, as the arm
cylinder will be extended, moving the
bucket forward.

M18G-04-008

5. Do not use the weight of the base machine to pry

earth as illustrated. WRONG
Doing so will damage the base machine and may
cause personal injury.

M117-05-009
6. Machine stability is greater when the load is posi-
tioned parallel with the tracks.
Machine stability is reduced when the load is swung
to the side and when operating the front attachment
perpendicular to the tracks.
Sudden stop of boom lowering movement is espe-
cially likely to cause tipping over.
When working on weak/soft surfaces or when loading
high-density materials, operate the machine at re-
duced bucket loads. M117-05-010

WRONG

M117-05-011

5-17
OPERATING THE MACHINE
OBJECT HANDLING --- IF EQUIPPED

WARNING: When you use machine for object

handling, be sure to comply with all local regula-
tions.
Cables, straps, or ropes can break, causing se-
rious injury. Do not use damaged chains, frayed
cables, slings, straps, or ropes to crane.

Never move the load quickly. Never move load

over a person s head. Do not allow any persons
near load.

Keep all persons away from wire-rope-attached

load, lifted or sitting on the ground unless it is
securely sitting on blocks or on the ground.

Position upperstructure so that the travel motors

are at the rear.

Do not attach sling/chain to the bucket teeth. SA-014

Secure sling/chain tightly to the load to be lifted. Wear

gloves when securing sling/chain.
Fasten sling/chain to bucket loop, with the bucket
curled and arm retracted.
Coordinate hand signals with your signal man before
starting.
Be aware of the location of all persons in the working
area.
Attach a hand line to load and make sure person
holding it is well away from load.
Before lifting, test your load.
1. Park your machine close to load.
2. Attach load to the machine.
3. Raise load 50 mm above the ground.
4. Swing the load all the way to one side.
5. While keeping load close to the ground, move it
away from machine.
6. If there is any indication of reduced stability of your
machine, lower load to the ground.
Lift load only as high as necessary.

5-18
OPERATING THE MACHINE
OVERNIGHT STORAGE INSTRUCTIONS

1. After finishing the day s operation, drive the machine

to a firm, level ground where no possibility of falling
stones, ground collapse, or floods.
Park the machine referring to the
PARKING THE MACHINE in the DRIVING THE
MACHINE section.
2. Fill the fuel tank with fuel.
3. Clean the machine.
4. If anti-freeze or long life coolant is not used in cold
weather, be sure to drain coolant from the radiator
and the engine jacket. Also, be sure to put a No
Water in Radiator tag in a visible place if the coolant
has been drained.

M117-05-023

5-19
OPERATING THE MACHINE
MEMO
......................................................................................................................................................................................

......................................................................................................................................................................................

5-20
MAINTENANCE
CORRECT MAINTENANCE AND INSPECTION
PROCEDURES

Learn how to service your machine correctly. Follow the

correct maintenance and inspection procedures shown in
this manual.

Inspect machine daily before starting.

Check controls and instruments.
Check coolant, fuel and oil levels.
Check for leaks, kinked, frayed or damaged hoses
and lines. SA-005

Walk around machine checking general appearance,

noise, heat, etc.
Check for loose or missing parts.

If there is any problem with your machine, repair it before

operating or contact your authorized dealer.

IMPORTANT: Use only recommended fuel and lu-

bricants.
Use only genuine HITACHI parts.
Failure to use recommended fuel, lu-
bricants, and genuine Hitachi parts
will result in loss of Hitachi product
warranty.
Never adjust engine governor or hy-
draulic system relief valve.
Protect electrical parts from water and
steam.
Never disassemble electrical compo-
nents such as main controller, sen-
sors, etc.

7-1
MAINTENANCE
CHECK THE HOUR METER REGULARLY 1

Check hour meter (1) to determine when your ma-

chine needs periodic maintenance.
Intervals on the periodic maintenance chart are for
operating in normal conditions. If you operate your
machine in more adverse conditions, you should ser-
vice it at SHORTER INTERVALS.
Lubricate, make service checks and adjustments at
intervals shown on periodic maintenance chart (2) lo-
cated on the inside of the cab rear right.

M18M-01-009

M18M-07-001

USE CORRECT FUELS AND LUBRICANTS

IMPORTANT: Always use recommended fuels and lu-

bricants.
Failure to do so will result in machine
damage and loss of Hitachi product war-
ranty.

7-2
MAINTENANCE
PREPARE MACHINE FOR MAINTENANCE

Before performing the maintenance procedures given in

the following chapters, park the machine as described be-
low, unless otherwise specified.
1
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the M18M-01-018

engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Stop the engine. Remove the key from the key switch.
(If maintenance must be performed with engine run-
ning, do not leave machine unattended.)
6. Pull the pilot control shut-off lever (1) to the LOCK
position.
7. Before performing any work on the machine, attach a
M146-01-021
Do Not Operate tag on the right control lever.
8. Ground Disconnector
This machine is equipped with a battery ground dis-
connector located outside of engine unit compart- 2
ment on the right side. The battery ground circuit can
be disconnected by pulling disconnector lever (2)
down before replacing the battery, checking the elec-
trical system, or performing welding work on the ma-
chine.

IMPORTANT: Do not pull the ground disconnector M146-07-062

down while operating the machine.

9. When using a vacuum pump to create negative pres-

3 Open
sure in the hydraulic oil tank while working on the hy-
draulic lines, close stop valve cock (3) on the hydrau-
lic oil tank air bleed valve. Be sure to open cock (3)
Close
after completing the repair work.

M146-01-033

Close Open
M18M-07-068

7-3
MAINTENANCE
10. Before starting to check and/or service the inside of
the engine compartment, turn engine stop switch (4)
located at the engine compartment entrance to the
EMERG. STOP position to assure safety.
4

M18M-07-002

7-4
MAINTENANCE
OPEN ACCESS DOORS FOR SERVICE 1 2

WARNING:
Do not keep the access doors open when
the machine is parked on a slope, or while the
wind is blowing hard. The access doors
may close accidentally, possibly resulting in
personal injury.
When opening or closing the access doors ,
take extra care not to catch fingers between the
base machine and the access doors .

To keep the access door open, lower rod (2) into a

gap on the platform or into locking hole (3), as illus- M146-07-015
trated.

3 2 M18M-07-003

M18M-01-005

7-5
MAINTENANCE
INSPECTION MAINTENANCE LIGHTS

All 7 maintenance lights (1) will be turned ON with mainte-

nance light switch.

Use switch (5), located on the switch panel in the cab, to

turn on/off these lights.

M18M-01-019

1
1

1 M18M-01-005

7-6
MAINTENANCE
USE A CHAIN TO PREVENT FALLING ACCI- 1
DENTS

When inspection or maintenance is required on cab front

step (2), tighten chain (1) as described below to prevent
falling from cab front step (2).

WARNING: Before starting inspection or mainte-

nance on the cab front step, be sure to attach the
chain to the step handrail. Before attaching the
chain, check to be sure that the chain has no
damage. If any damage such as wear or breaks 2
are found, replace with new one. M146-01-029

3 4
1. Remove chain (1) from hook (3) located on the
left-upper front cab and from handrail (5).
2. Install the free end of chain (1) to right hook (7) to at-
tach the chain.
3. Check that chain (1) is securely installed to both
hooks (6) and (7).
4. Before re-starting machine operation, remove chain
(1) from right hook (7). After hanging the chain on 1
hook (4), let it wrap around handrail (5). Then,
re-install the end of chain (1) to left upper hook (3). M18M-07-015 M18M-07-011

2
M18M-07-012

7-7
MAINTENANCE
ELECTRIC PUMP Optional
2
This machine is equipped with an electric pump to draw
hydraulic oil from the suction and return pipe lines to the 1
hydraulic oil tank. The pump is driven by battery power.
Continuously operate it while servicing the machine.

How to Operate Electric Pump A

WARNING: Hydraulic oil may be hot just after

operation. Be sure to wait for oil to cool before
starting work.
M18M-07-004
1. Stop the engines. 4
NOTE: Refer to page 7-3 for stopping the engines
properly.

2. Release pressure of the hydraulic oil tank.

WARNING: Keep body and face away from cap

. Turn cap slowly and remove the cap only
after releasing the internal pressure completely.
3
(1) Insert the wrench as shown and turn the wrench
View A M18M-07-005
clockwise and hold the wrench.
Cap (1)
(2) Turn cap (1) counter-clockwise about 30 , at which
point stop cap (1) to release the air.
(3) Turn cap (1) further and remove cap (1). Allow (b)

(4) Align the projected part of cap (1) with the Projection
projected part of the case and install cap (1).
Case Assembly

3. Connect suction hose (3) of electric pump (2) to quick Projection

coupler (4). Side Hole
Quick Couplers are located in;
Wrench 4 mm
Suction Line: Suction Manifold under Pump Unit M110-07-022
Return Line: Return Line beside Control Valve

4. Before drawing oil, open stop valve (5).

M18M-07-006

Suction Line
4

M18M-07-007

7-8
MAINTENANCE
5. Turn the key switch ON.
6. Remove plugs (6) and (7) on the pipe line to allow the
electric pump to draw oil easily.
Plugs are located at
Suction Line: Suction pipe of main pump
Return Line: Top of oil cooler

7. Close 2 stop valves (8) on the suction pipes under

Return Line
the hydraulic oil tank. B M18M-07-008

8. Turn electric pump (2) switch ON. The pump starts to

draw oil.
9. After drawing oil, turn electric pump (2) switch OFF.
10. Install plugs (6) and (7). Close stop valve (5).
Disconnect suction hose (3) of electric pump (2). 4

Section B M18M-07-009

M18M-07-010
Main Pump Plugs

M18M-07-063

M18M-07-064

7-9
MAINTENANCE
CONSTRUCTION OUTLINE
Backhoe

Arm Cylinder
Arm

Boom
Bucket
Cylinder

Link B

Link A
Bucket

Boom Cylinder T146-01-03-002

Loading Shovel
Level Cylinder Bucket
Boom Cylinder
Arm
Boom
Bucket Cab
Swing Device
Lubricator
Oil Cooler
Hydraulic Oil Tank
Muffler
Battery
Air Cleaner
Pump
Arm Cylinder
Counterweight
Dump Cylinder
Bucket Cylinder

7-10
MAINTENANCE
HYDRAULIC SYSTEM

IMPORTANT: Hydraulic equipment such as hydraulic

pumps, control valves, and relief valves
have been adjusted at the factory. Do not
attempt to disassemble or turn the
adjusting screws, as they are very
difficult to readjust.
Consult your authorized dealer if any
trouble should occur.

1. Oil from the main pumps flows through the control

valves to the cylinders and motors. Most return oil
from the control valves flows back to the hydraulic oil
tank via the full-flow filters; a small amount returns via
oil coolers directly. High pressure strainers are
provided in the pump delivery lines between the
pumps and control valves.

2. The solenoid valves actuated by the electric control

levers/pedals send pilot oil from the pilot pumps to the
control valves, moving their spools. This spool
movement routes the pump delivery oil to the
cylinders and motors.

3. Relief valves of sufficient capacity are provided in the

control valves, full-flow filters and the pilot and oil
cooler circuits in order to protect each circuit from
abnormally high pressure.

4. The excavator is equipped with an accumulator in the

pilot oil line which makes it possible to operate the
front attachment for a few seconds after the engine
has stopped. The accumulator is charged with high
pressure gas; do not attempt to remove or
disassemble it, and do not expose the accumulator to
flame.

5. The excavator is equipped with an independent oil

cooler and circulation pump for the pump
transmission, which functions to cool pump
transmission oil.

7-11
MAINTENANCE
Loading Shovel

1. BUCKET CYLINDER
2. DUMP CYLINDER
3. ARM CYLINDER
4. BOOM CYLINDER
5. LEVEL CYLINDER
6. ELECTRIC CONTROL LEVER (Travel)
7. ELECTRIC CONTROL LEVER (Bucket Open
and Close)
8. ELECTRIC CONTROL LEVER (Front/Swing)
9. ELECTRIC CONTROL LEVER (Front)
10. ELECTRIC LEVER CONTROLLER
11. AIR CON. COMPRESSOR MOTOR
12. SWING MOTOR
13. CENTER JOINT
14. GREASE PUMP
15. OIL COOLER FAN MOTOR
16. OIL COOLER
17. PILOT FILTER
18. CONTROL VALVE (Bucket)
19. CONTROL VALVE (Bucket Rollin/Arm Rollin)
20. CONTROL VALVE (Boom)
21. CONTROL VALVE (Swing)
22L. CONTROL VALVE (Left Travel)
22R. CONTROL VALVE (Right Travel)
23. CONTROL VALVE (Bucket Open/Close)
24. CONTROL VALVE (Arm)
25. HYDRAULIC OIL TANK
26. FULL-FLOW FILTER
27. LOW PRESSURE RELIEF VALVE
28. BYPASS FILTER
29. DRAIN FILTER
30. SUCTION FILTER
31. SUCTION MANIHOLD
32. ENGINE
33. PUMP TRANSMISSION
34. MAIN PUMP (No.1)
35. MAIN PUMP (No. 2)
36. MAIN PUMP (No. 3)
37. MAIN PUMP (No. 4)
38. MAIN PUMP (No. 5)
39. MAIN PUMP (No. 6)
40. MAIN PUMP (No. 7)
41. MAIN PUMP (No. 8)
42. RADIATOR FAN DRIVE PUMP
43. OIL COOLER FAN DRIVE PUMP Supply Line from Pumps
44. PILOT PUMP Return Line
45. AIR-CON. COMP. DRIVE PUMP Suction Line
46. PUMP TRANSMISSION OIL COOLER PUMP Actuator Line
47. PUMP TRANSMISSION OIL FILTER Drain and Pilot Line
48. PUMP TRANSMISSION OIL COOLER Electric Line
49. LTA COOLER
50. RADIATOR
51. RADIATOR FAN MOTOR M18M-07-013
52. HIGH PRESSURE FILTER, CHECK VALVE
53. BRAKE VALVE
54. TRAVEL MOTOR
55 SOLENOID VALVE
56. AIR FAN MOTOR FOR ENGINE ROOM
57. AIR FAN DRIVE PUMP FOR ENGINE ROOM

7-12
MAINTENANCE
Backhoe

1. BUCKET CYLINDER
2. ARM CYLINDER
3. BOOM CYLINDER
4.
5.
6. ELECTRIC CONTROL LEVER (Travel)
7.
8. ELECTRIC CONTROL LEVER (Front/Swing)
9. ELECTRIC CONTROL LEVER (Front)
10. ELECTRIC LEVER CONTROLLER
11. AIR CON. COMPRESSOR MOTOR
12. SWING MOTOR
13. CENTER JOINT
14. GREASE PUMP
15. OIL COOLER FAN MOTOR
16. OIL COOLER
17. PILOT FILTER
18. CONTROL VALVE (Bucket)
19. CONTROL VALVE (Bucket Rollin/Arm Rollin)
20. CONTROL VALVE (Boom)
21. CONTROL VALVE (Swing)
22L. CONTROL VALVE (Left Travel)
22R. CONTROL VALVE (Right Travel)
23. CONTROL VALVE (Bucket Open/Close)
24. CONTROL VALVE (Arm)
25. HYDRAULIC OIL TANK
26. FULL-FLOW FILTER
27. LOW PRESSURE RELIEF VALVE
28. BYPASS FILTER
29. DRAIN FILTER
30. SUCTION FILTER
31. SUCTION MANIHOLD
32. ENGINE
33. PUMP TRANSMISSION
34. MAIN PUMP (No.1)
35. MAIN PUMP (No. 2)
36. MAIN PUMP (No. 3)
37. MAIN PUMP (No. 4)
38. MAIN PUMP (No. 5)
39. MAIN PUMP (No. 6)
40. MAIN PUMP (No. 7)
41. MAIN PUMP (No. 8)
42. RADIATOR FAN DRIVE PUMP
43. OIL COOLER FAN DRIVE PUMP
44. PILOT PUMP Supply Line from Pumps
45. AIR-CON. COMP. DRIVE PUMP Return Line
46. PUMP TRANSMISSION OIL COOLER PUMP Suction Line
47. PUMP TRANSMISSION OIL FILTER Actuator Line
48. PUMP TRANSMISSION OIL COOLER Drain and Pilot Line
49. LTA COOLER Electric Line
50. RADIATOR
51. RADIATOR FAN MOTOR M18M-07-014
52. HIGH PRESSURE FILTER, CHECK VALVE
53. BRAKE VALVE
54. TRAVEL MOTOR
55. SOLENOID VALVE
56. AIR FAN MOTOR FOR ENGINE ROOM
57. AIR FAN DRIVE PUMP FOR ENGINE
ROOM

7-13
MAINTENANCE
PERIODIC REPLACEMENT OF PARTS

To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire hazards. It
is very difficult to gauge the extent of deterioration, fatigue,
or weakening of the parts listed below simply by visual
inspection alone. For this reason, replace these parts at the
intervals shown in the table below. However, if any of these
parts are found to be defective, replace before starting
operation, regardless of the interval. Use genuine Hitachi
parts.
Also, when replacing hoses, check the clamps for
deformation, cracks, or other deterioration, and replace as
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective parts
found, as necessary.
Consult your authorized dealer for correct replacement.

Periodic Replacement Parts Q'ty in Use Replacement Intervals

No.
Pump Delivery Hoses
1 Main Pumps to High Pressure Filters 8
2 High Pressure Filters to Blocks 4
3 Blocks to High Pressure Pipes 4
4 High Pressure Pipes to Control Valves 4
Fan Pumps to Oil Cooler Fan Motor
5
and Radiator Fan Motor 4
6 Tail Hoses 6
Front Hoses
7 Control Valves to Front 2
Loading Shovel Front Hoses Every 2 years or 8,000 hours of operation, whichever
comes first
8 Mainframe to Boom 16
Backhoe Front Hoses
9 Mainframe to Boom 16
Travel Hoses and Swing Hoses
10 Control Valves to Center Joint 4
11 Control Valves to Swing Motors 8
Fuel Hoses
12 Fuel Tank to Engine 3
13 Engine to Fuel Cooler 5
14 Fuel Cooler to Fuel Tank 5

NOTE: Be sure to replace seals, such as O-rings and

gaskets, when replacing hoses.

7-14
MAINTENANCE
PERIODIC REPLACEMENT OF RUBBER 5
HOSES

WARNING: Rubber hoses, such as hydraulic

hoses, lubrication hoses, fuel hoses, and heater
hoses, may break due to aging, fatigue, and
abrasion, possibly resulting in serious injury or
death.
1

In order to avoid serious personal injury, be sure 1

to replace the hoses listed in the following table
every two years, or 8000 hours of operation,
whichever comes first. Use genuine Hitachi parts.

It is very difficult to gauge the extent of

deterioration due to aging, fatigue, and abrasion
of rubber hoses by inspection alone. Thus, if
rubber hoses are not replaced periodically,
serious personal injury may result due to falls of M146-07-095

the front, penetration of high pressure oil into the

skin, or fire. Block 2
2
Regardless of regular replacement intervals, if
hoses are found to be defective by periodic
inspection (refer to pages 7-70 and 7-80), be sure
to repair or replace them before operating the
machine. Be sure to replace seals, such as
O-rings and hose clamps along with replacing
hoses. 3
Consult your authorized dealer for correct hose
replacement.

Hydraulic Hoses

Hoses Q'ty 3 M146-07-066

Pump Main pumps to High pressure filters (1) 8

Delivery 4
High pressure filters to Blocks (2) 5
Hoses 2
Blocks to High pressure pipes (3) 4
High pressure pipes to Control valves (4) 4
1
Fan pumps to oil cooler fan motor and
4
radiator fan motor (5)
Tail hoses (6) 6 2
Front 6
Control Valves to Front (7) 2
Hoses 6
1

5
6

3 M146-07-113
3

7-15
MAINTENANCE
Hydraulic Hoses

Hoses Q'ty 7
Pump Main pumps to High pressure filters (1) 8
Delivery High pressure filters to Blocks (2) 4
Hoses
Blocks to High pressure pipes (3) 4
High pressure pipes to Control valves (4) 4
Fan pumps to oil cooler fan motor and
4
radiator fan motor (5)
Tail hoses (6) 6
3
Front
Control Valves to Front (7) 2
Hoses

M146-07-096

7-16
MAINTENANCE

Hoses Q ty in Use
Loading Shovel Main Frame to 8
16
Front Hoses Boom (8)

M146-07-097

Hoses Q ty in Use
Backhoe Front Main Frame to
16
Hoses Boom (9) 9

M146-07-017

7-17
MAINTENANCE

Hoses Q'ty
Travel
Hoses Control Valves to Center Joint (10) 4

Swing
Hoses Control Valves to Swing Motors (11) 8

Center Joint
M18M-07-016
Swing Motors

M18M-07-017

11 11

11 M18M-07-025

M18M-07-018

Swing Motors

7-18
MAINTENANCE
Fuel Hoses

Hoses Q ty in Use 14

Fuel Tank to Engine (12) 3 12

Engine to Fuel Cooler (13) 5
Fuel Cooler to Fuel Tank (14) 5

M18M-07-019

13 12

M18M-07-020

14
13

M18M-07-023 M18M-07-021
Fuel Cooler

14
13 14

M18M-07-024 M18M-07-022

7-19
MAINTENANCE
MAINTENANCE INTERVAL GUIDE
A. GREASING (See Page 7-24)
Interval (hours)
Parts Quantity
5 10 250 500 1000 1500 2000
1. Loader Front Joint Bucket Pins 10
Pins Other Front Pins 20
2. Backhoe Front Joint Bucket and Link Pins 14
Pins Other Front Pins 18
3. Swing Bearing 24
350 L
4. Swing Internal Gear
(92.5 US gal)
5. Center Joint 1
NOTE: Maintenance required when operating in water or mud.
Auto-lubrication is available.
B. ENGINE (See Page 7-36)
Classification Interval (hours)
Parts Quantity
of Oil 10 50 250 500 1000 1500 2000
1. Engine Oil Check Engine Oil Pan 1
Oil LevelReserve Tank 1
2. Check LED Monitor Signal (on Reserve Tank) 1
3. Engine Oil 260L
Engine Oil Pan
(68.7 US gal)
Change Premium
120L
Reserve Tank
(31.7 US gal)
260L
Engine Oil Pan
(68.7 US gal)
Change Standard
258L
Reserve Tank
(68.2 US gal)
4. Replace Engine Oil Filter 4
NOTE: First time only
When change engine oil, change the oil in engine oil pan and reserve tank at the same time.
Total quantity of oil (Engine Oil Pan and Reserve Tank) achieves 500 hours replacement interval.
It differs according to the kind of engine oil used.
The capacity of reserve tank is 280L (74 US gal).
NOTE: The machine has a reserve system.
Reserve system is the system that oil is circulated between engine oil pan and reserve tank by the
pump on reserve tank.
C. TRANSMISSION (See Page 7-43)
Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Pump Check Oil Level 1
Trans- Engine Change Oil 62 L (16.4 US gal)
mission Oil Replace Filter 2
Gear Clean Breather 1
2. Swing Check Oil Level 4
Gear
Reduction Change Oil 75 L (19.8 US gal) 4
Oil
Gear Clean Breather 4
3. Travel Check Oil Level 2
Gear
Reduction
Oil Change Oil 220 L (58.1 US gal) 2
Gear
NOTE: First time only.

7-20
MAINTENANCE
D. HYDRAULIC SYSTEM (See Page 7-51)
Interval (hours)
Parts Quantity
10 50 250 500 2000 2500 4000 12000
1. Check Hydraulic Oil Level 1
2. Drain Hydraulic Oil Tank Sump 1
4000 L
3. Change Hydraulic Oil
(1060 US gal)
4. Replace Full-Flow Filter and Drain Filter 6
5. Replace Bypass Filter 1
6. Replace Pilot Oil Filter 1
Clean Filter 6 When changing hydraulic oil
7. Suction Filter
Replace Filter 6
8. Replace High-Pressure Strainer 8
9. Clean Oil Cooler Core 4
10. Check Hoses and Lines (for leak, loose)
Check Hoses and Lines (for crack, bend, etc.)

NOTE: Hydraulic oil changing interval differs according to the kind of hydraulic oil used. See recommended oil
chart.
* First time only.

E. FUEL SYSTEM (See Page 7-74) Tank capacity 7450 liter (1970 US gal)
Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Drain Fuel Tank Sump 1
2. Drain Fuel Filter Sediment Stage 1 filter 3 Weekly or as required
3. Replace Fuel Element Stage 1 filter 3
4. Replace Fuel Filter Stage 2 filter 3
Check Fuel Hoses (for leak, loose)
5.
Check Fuel Hoses (for crack, bend, etc.)
6. Clean Fuel Cooler Core 1
7. Clean Tank Breather 2
NOTE: The machine has 2 stage filtration system on suction fuel line.
Stage 1 filter is equipped in front of fuel tank.
Stage 2 filter is equipped on engine.

F. AIR CLEANER (See Page 7-82)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
Cleaning 2 2 As required
1. Air Cleaner Outer Element
Replacement 2 2 Replace per 6 cleaning
2. Air Cleaner Inner Element Replacement 2 2 when outer element is replaced

7-21
MAINTENANCE
G. COOLING SYSTEM (See Page 7-84)
Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Check Coolant Level 1
2. Check DCA4 Concentration in Coolant -
3. Replace Coolant Filter 2
4. Change Coolant 614 L (162 US gal) Twice a year, in spring and autumn
5. Clean Radiator, LTA Cooler Interior 1+1 When changing coolant
6. Clean Radiator, LTA Cooler Core 1+1
NOTE: Before leaving the Hitachi factory, the cooling system is filled with a mixture of water and Genuine
Hitachi Long-Life Coolant. As long as Genuine Hitachi Long-Life Coolant is used, the service
intervals between changing the coolant is once every two years, or every 4000 hours, whichever
comes first.

H. AIR CONDITIONER (See Page 7-98)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
Cleaning 3 As required
1. Recirculation Air Filter
Replacement 3 Replace per 4 cleaning
Cleaning 3 As required
2. Ventilation Air Filter
Replacement 3 Replace per 4 cleaning
3. Check Refrigerant Quantity 3
4. Check Compressor Belt Tension 3
5. Clean Condenser Core 3
6. Check Tightening Torque
7. Seasonal Maintenance Preseason (once a year), Off-season (once a week)

7-22
MAINTENANCE
I. ELECTRICAL SYSTEM (See Page 7-105)

J. MISCELLANEOUS (See Page 7-119)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 3000
1. Check Bucket Teeth for Wear and Looseness 6
2. Inspect Emergency Rope and Rope Mounting
1
Hardware
3. Check Auto-Lubrication System 1
Check 2
4. Seat Belt
Replacement 2 At least once every 3 years
5. Check Washer Tank 2 As required
6. Air Horn Compressor Filter Cleaning 1 As required
7. Check and Adjust Track Sag 2
8. Check Accumulator and Track Adjuster
2 Every year
Cylinder Circuit
9. Clean Side Frame Area 2
10. Check Tightening Torque of Bolts and Nuts
NOTE: First time only.

7-23
MAINTENANCE
A. GREASING

Interval (hours)
Parts Quantity
5 10 250 500 1000 1500 2000
1. Loader Front Joint Bucket Pins 10
Pins Other Front Pins 20
2. Backhoe Front Joint Bucket and Link Pins 14
Pins Other Front Pins 18
3. Swing Bearing 24
350 L
4. Swing Internal Gear
(92.5 US gal)
5. Center Joint 1
NOTE: Maintenance required when operating in water or mud.
Auto-lubrication is available.
1 1 1

T146-01-03-002

3 4 5
M18M-03-007

Brand Names of Recommended Grease

Where to be Front Joint Pins,
Swing Internal Gear
applied Swing Bearing

Manufacturer 20 to 50 °C ( 4 to 122 °F)

British Petroleum BP Energrease LS-EP2 BP Energrease LS-EP1
Caltex Oil Multifax EP2 Multifax EP1
Esso Beacon EP2 Beacon EP1
Idemitsu Kosan Daphne Coronex Daphne Coronex
Grease EP2 Grease EP1
Mobil Oil Mobilux EP2 Mobilux EP1
Nippon Oil Epinoc Grease AP2 Epinoc Grease AP1
Shell Oil Shell Alvania EP Shell Alvania EP
Grease 2 Grease 1

NOTE: The machine is shipped from the factory is filled with

lubricants marked with .

7-24
MAINTENANCE
Loading Shovel Front Joint Pins --- daily 1
Add grease to all fittings shown below every 10 hours or
each shift before starting. Most of the fittings are grouped,
as shown, for quick and safe lubrication.
NOTE: Auto-lubrication can be used for the fittings on
the loading shovel front.

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Pull the pilot control shut-off lever to the LOCK
position.
4. Apply grease to fittings until grease can be seen
escaping from greasing places.
5. Take care not to supply excessive grease.

Manually greasing places are as illustrated below.

1. Grouped Grease Fittings (1) --- Bucket
: Lubrication points

M18M-07-027

M18M-07-028

M18M-07-026

7-25
MAINTENANCE
2. Grouped Grease Fittings (2) --- Boom
: Lubrication Points

M146-07-084
3. Grouped Grease Fittings (3) --- Boom Foot

3 3

M18M-07-029

7-26
MAINTENANCE
4. Grouped Grease Fittings (4) --- Arm
: Lubrication Points

M146-07-085

7-27
MAINTENANCE

Backhoe Front Joint Pins --- daily

1
Add grease to all fittings shown below every 10 hours or
each shift before starting. Most of the fittings are grouped,
as shown, for quick and safe lubrication.

NOTE: Auto-lubrication can be used for the fittings on

the backhoe front except for the bucket and link.
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Pull the pilot control shut-off lever to the LOCK
M18M-07-030
position.
4. Apply grease to fittings until grease can be seen
escaping from greasing places.
1
5. Take care not to supply excessive grease.

Manually greasing places are as illustrated below.

1. Grouped Grease Fittings (1) --- Bucket

: Lubrication points

M18M-07-032

M18M-07-031

7-28
MAINTENANCE
2. Grouped Grease Fittings (2) --- Boom
: Lubrication points

M18M-07-034

M18M-07-033

M18M-07-035

3. Grouped Grease Fittings (3) --- Boom Foot

: Lubrication points

3 3

M18M-07-029

7-29
MAINTENANCE
4. Grouped Grease Fittings (4) --- Arm
: Lubrication points

M18M-07-036

7-30
MAINTENANCE

Swing Bearing --- every 250 hours

(Grouped Grease Fittings --- Main Frame)
NOTE: Auto-lubrication can be used for the fittings on
the swing bearing.
WARNING: Lubricating both the swing bearing
and gear and rotating the upperstructure must be
done by one person. Before you lubricate the
swing bearing, clear the area of all persons.

Each time you leave the cab

Lower the bucket to the ground.
Pull the pilot control shut-off lever to the LOCK
position.
Use handrails.
M18M-07-029
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Pull the pilot control shut-off lever to the LOCK
position.
4. With the upperstructure stationary, apply grease to
the twenty-four grease fittings.
5. Raise the bucket several inches off the ground and
rotate the upperstructure 45 (1/8 turn).
6. Lower the bucket to the ground.
7. Repeat the procedure three times, beginning with
step 3.
8. Apply grease to the swing bearing until grease can
be seen escaping from the swing bearing seals.
9. Total amount of grease to be applied is
approximately 10 to 12 strokes by grease lubricator.
10. Take care not to supply excessive grease.

7-31
MAINTENANCE

Swing Internal Gear --- every 2000 hours

WARNING: Adding or changing swing internal
gear grease and rotating the upperstructure must
be done by one person. Before you start, clear the
area of all persons.

Each time you leave the cab

Lower the bucket to the ground.
Stop the engine.
Pull the pilot control shut-off lever to the LOCK
position.
Use handrails.
1
1. Park the machine on a level surface. M146-07-022

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off. 2

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engine at slow idle speed without load for five
minutes.
5. Press and hold the engine stop switch until stopping
the engine completely. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK
position. M146-07-023

7. Open cover (1) on the right side of the

upper-structure.

8. Remove cover (1) on the underside of the swing gear

housing and thoroughly remove old grease from the
swing gear.

9. Remove cover (2) on the left side of the

upperstructure. In order to add new grease evenly to
the swing gear, swing the upperstructure twelve 30
intervals (one full turn) and add grease at each
interval using a putty knife.
Total amount of grease applied should be
approximately 350 liter (92.5 US gal).

7-32
MAINTENANCE

Center Joint --- every 500 hours

(Grouped Grease Fittings --- Main Frame)
NOTE: Auto-lubrication can be used for the fittings on
the center joint.
WARNING:
Each time you leave the cab
Lower the bucket to the ground.
Pull the pilot control shut-off lever to the LOCK
position.
Use handrails.

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Pull the pilot control shut-off lever to the LOCK
position. M18M-07-029

4. With the upperstructure stationary, apply grease to

the one grease fitting.
5. Total amount of grease to be applied is
approximately 5 to 6 strokes by grease lubricator.

7-33
MAINTENANCE
OPERATING THE LUBRICATOR

The machine is equipped with hose reel (5) and the

lubricator, including the grease pump. This device is
used for adding grease to the grouped fittings on the
main frame and front attachment.

Greasing
IMPORTANT: Run the engine at medium or higher
speed whenever the lubricator is used.

1. Connect hose (1) to coupler (2).

2
2. Move auto-lubrication toggle switch (3) located in oil
cooler room to the MANUAL position.
1
3. Hold the high-pressure grease gun (4) attached to the
hose end and pull out the hose from reel (5).
4. Stop pulling hose at any desired position; reel (5) M18M-07-037

clicks and automatically locks the hose.

5. Insert the end of the grease gun in the desired fitting
and pull gun lever; automatically adds grease to the
fitting. 3

Storing Grease Hose After Finishing Greasing

1. Slightly pull out the hose; reel (5) unlocks,
automatically winds, and stores the hose.

2. Move auto-lubrication toggle switch (3) located in oil

cooler room to the AUTO LUB position.
IMPORTANT: When the auto-lubrication system is M18M-07-038
provided, always be sure to turn
auto-lubrication switch (3) to the
AUTOMATIC GREASING position after
completing manual greasing.

5
3. Disconnect hose (1) at coupler (2).

4. Pull gun lever to release residual pressure; a small

amount of residual grease will escape from grease
gun (4).

M146-07-105

7-34
MAINTENANCE
Replacing Grease
When the grease can is empty, replace it following the
procedure shown below. 6

1. Remove wing nuts (7) to remove cover assembly (6)

from the grease can. Remove cover assembly (6). 7

2. Remove follower plate (8) from the grease can.

Replace the grease can with a new one.

3. Install follower plate (8) into the grease can. 8

4. Install cover assembly (6) on the lubricator housing

while aligning grease tube with the hole on the
follower plate, in order not to push down the plate into
grease when installing the cover. Tighten wing nuts
(7).

NOTE: Greasing can be made from the ground through M146-07-107

the fast-filling panel installed at the rear section

of the machine. Refer to page 1-38 for
fast-filling panel operation.

M113-07-025

Grease M113-07-026

7-35
MAINTENANCE
B. ENGINE

Classification Interval (hours)

Parts Quantity
of Oil 10 50 250 500 1000 1500 2000
1. Engine Oil Check Engine Oil Pan 1
Oil Level
Reserve Tank 1
2. Check LED Monitor Signal (on Reserve Tank) 1
3. Engine Oil 260L
Engine Oil Pan
(68.7 US gal)
Change Premium
120L
Reserve Tank
(31.7 US gal)
260L
Engine Oil Pan
(68.7 US gal)
Change Standard
258L
Reserve Tank
(68.2 US gal)
4. Replace Engine Oil Filter 4
NOTE: First time only
When change engine oil, change the oil in engine oil pan and reserve tank at the same time.
Total quantity of oil (Engine Oil Pan and Reserve Tank) achieves 500 hours replacement interval.
It differs according to the kind of engine oil used.
The capacity of reserve tank is 280L (74 US gal).
NOTE: The machine has a reserve system.
Reserve system is the system that oil is circulated between engine oil pan and reserve tank by the
pump on reserve tank.

Engine Oil Viscosity Requirements

Classification API Service
Type Viscosity Grade (SAE) Temperature Ranges
of Oil Class
CF-4 All Season Multigrade 15W-40 -18° to 50°C (0° to 122°F)
Standard
CG-4 All Season Multigrade 15W-40 -18° to 50°C (0° to 122°F)
CH-4 All Season Multigrade 15W-40 -18° to 50°C (0° to 122°F)
Premium
CI-4 All Season Multigrade 15W-40 -18° to 50°C (0° to 122°F)
NOTE: Oils with nominal ash content must be 1.0 to 1.5 percent mass. Oils with higher ash content, up to
1.85 percent ash, can be used in areas where the sulfur content of the fuel is normally 1 to 1.5
percent mass. Limiting ash content is critical to the prevention of valve and piston deposit formation.
The machine is shipped from the factory is filled with lubricants, Hitachi Super Wide DH-1 15W-40
(Class CF-4 (API Service Classification)).
Refer to the manual for Cummins Engine.
For further details, refer to Cummins B/No. 3810470-01 Maintenance and Operation Practices for
Maximum Engine Life .

7-36
MAINTENANCE

Engine Oil Level in Engine Oil Pan

--- check daily
IMPORTANT: For most accurate readings, check the 1
oil level every day before starting the
machine. Be sure the machine is on a
level surface.
1. Stop the engine.
2. Remove dipstick (1). Wipe oil off with a clean cloth.
Reinsert dipstick (1).
3. Remove dipstick (1) again. Read oil level. Oil level must
be the center of the marks static H and L on dipstick (1).
The dipstick has STATIC and RUNNING reading on
each side. Read the oil level on STATIC side. M18M-07-075

IMPORTANT: Oil level in engine oil pan is constantly

2
controlled to the center of static H and L Suction Line
by withdrawal pipe (2) for reserve Oil Level
system. If oil level is the center of static Return Line
H and L, oil level does not need to be
static H to add oil.
NOTE: Checking the oil level immediately after shut
down will result in inaccurate readings. Be sure
to allow the oil to settle for at least 10 minutes
before checking.
4. If the oil level is lower than static L, add oil to the
center of the marks static H and L. Be sure to use
only the oil to meet requirement and check the oil
level in the reserve tank.
M18M-07-076
Engine Oil Level in Reserve Tank Engine Oil Pan
--- check daily
3
IMPORTANT: For most accurate readings, check the
oil level every day before starting the
machine. Be sure the machine is on a
level surface.
1. Stop the engine.
2. Remove dipstick (3). Wipe oil off with a clean cloth.
Reinsert dipstick (3).
3. Remove dipstick (3) again. Read oil level. Oil level
must be above the line of premium or standard in
accordance with the oil you use on dipstick (3).
NOTE: It is not necessary to add the oil until the oil
M18M-07-077
level becomes lower than the line of premium or Reserve Tank
standard, once fill the oil up to the reserve tank.
Judge by premium line when use premium oil,
and judge by STD line when use standard oil.
4. If necessary, remove dipstick (3) and add oil. Be sure
to use only the oil to meet the requirement.
NOTE: Checking the oil level immediately after shut
M18M-07-078
down will result in inaccurate readings. Be sure 3
to allow the oil to settle for at least 10 minutes
before checking.

7-37
MAINTENANCE

Check LED Monitor Signal (on Reserve Tank)

--- check daily
Pump #2 1
1. Start the engine.
2. Check LED monitor (1) to confirm if the pump
normally works or not. LED monitor (1) signals the To Engine
following states in response to operation of pump. Oil Pan

a. Steady: This signal indicates that the Pump #1 From

only is running and is transferred oil Reserve
from the engine oil pan to the reserve Tank
tank. To Reserve From
b. Flashing: This signal indicates that the Pump #1 Tank Engine Oil
and #2 are running and oil is being Pan
transferred from the reserve tank to the
engine oil pan by pump 2.

IMPORTANT: The signal should alternate between Pump #1

M18M-07-079

periods of Steady and Flashing so that

required engine oil level is being
maintained on during operation.
NOTE: If the LED monitor does not work, contact your
authorized dealer.

7-38
MAINTENANCE

Change Engine Oil in Engine Oil Pan

--- every 500 hours
(first time after 50 hours)

Replace Engine Oil Filters --- every 500 hours

(first time after 50 hours)
1. Run the engine to warm oil. DO NOT run the engine
until oil is hot.
M18M-07-080
2. Park the machine on a level surface. 1

3. Lower the bucket to the ground.

4. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

5. Run the engine at slow idle speed without load for 5

minutes.
6. Stop the engine. Remove the key from the key switch.
3
7. Pull the pilot control shut-off lever to the LOCK
position.
2
WARNING: Engine oil may be hot just after M18M-07-081

operation. Use care to be sure you are not burned

from hot oil.
Oil Pan

8. Prepare a container of 260 liter (68.7 US gal) or more

capacity for the drain oil. Clean Cloth

9. Remove drain plug (1) near the engine oil pan. Container

10. Open drain cock (2) to drain the engine oil.

11. Check if foreign material like metal particles are M104-07-010
included in the drain oil by filtering it with a clean
cloth.
12. Tighten drain plug (1) and close drain cock (2)
securely.
13. Unscrew main filter cartridges (3), then discard them.
14. Fill the filters with lubricating oil to prevent crankshaft
or bearing damage. Apply a light even coat of
lubricating oil to the gasket sealing surface prior to
installing the filters.
15. Position the filters to the filter head. Tighten by hand
until the seal touches the filter head.
16. Tighten cartridges (3) one-half to three-fourths turn
more using filter wrench.

7-39
MAINTENANCE
17. Remove oil filler cap (4) and fill with 260 liter (68.7 US 4
gal) oil.
18. Confirm oil level and adjust the oil level to be the
center of the marks static H and L on dipstick (5).
Start the engine and run at slow idle speed for 5
minutes. Stop the engine after confirming that engine 5
oil pressure is rising. Ten to twenty minutes later,
check oil level again and add oil if necessary.
IMPORTANT: After one shift, the oil level check must
be done if oil level is the center of the
marks static H and L.

NOTE: Checking the oil level immediately after shut

down will result in inaccurate readings. Be sure
to allow the oil to settle for at least 10 minutes
before checking. M18M-07-075

NOTE: Oil can be refilled from the ground using the

Fast-Filling panel located in the rear of the base
machine. Refer to page 1-38 for the Fast-Filling
panel operation.

Change Engine Oil in Reserve Tank

--- every 500 hours
(first time after 50 hours)
1. Run the engine to warm oil. DO NOT run the engine
until oil is hot.
2. Park the machine on a level surface.
3. Lower the bucket to the ground.
4. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

5. Run the engine at slow idle speed without load for 5

minutes.
6. Stop the engine. Remove the key from the key switch.
7. Pull the pilot control shut-off lever to the LOCK
position.
WARNING: Engine oil may be hot just after
operation. Use care to be sure you are not burned
from hot oil.

7-40
MAINTENANCE
8. Prepare a container of 280 liter (74 US gal) or more
9
capacity for the drain oil.
9. Remove drain plug (6).
10. Open drain cock (7) and (8) to drain the engine oil.
11. Check if foreign material like metal particles are in-
cluded in the drain oil by filtering it with a clean cloth.
12. Tighten drain plug (6) and close drain cock (7) and
(8) securely.
13. Remove dipstick (9) and put the quantity of oil you
need.
7
14. Confirm that oil level is above the line of premium or M18M-07-077
Reserve Tank
standard in accordance with the oil you use on dip-
stick (9). Reserve Tank

NOTE: Checking the oil level immediately after shut

down will result in inaccurate readings. Be sure
to allow the oil to settle for at least 10 minutes
before checking.
NOTE: Oil can be refilled from the ground using the
Fast-Filling panel located in the rear of the base
machine. Refer to page 1-38 for Fast-Filling
panel operation. If refilling the reserve tank up
with oil, automatic fill system is available. See
How to operate automatic fill system next
page.

8 6
M18M-07-082

Oil Pan

Clean Cloth
Container

M104-07-010

7-41
MAINTENANCE
How to operate automatic fill system
1. Turn power switch (4) to ON position. 7 6 4 5
2. Turn start switch (5) to ON position.
3. The shut-off valve on the reserve tank opens. The
shut-off valve open indicator (6) lights up.
4. Oil can begin filling the reserve tank through the
shut-off valve.
5. When the oil in the reserve tank reaches the proper
full level, the shut-off valve closes and full indicator
(7) lights up.
6. Turn power switch (4) to the OFF position to turn the
power off. M18M-01-020

7-42
MAINTENANCE
C. TRANSMISSION

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Pump Check Oil Level 1
Trans- Engine Change Oil 62 L (16.4 US gal)
mission Oil Replace Filter 2
Gear Clean Breather 1
2. Swing Check Oil Level 4
Gear
Reduction Change Oil 75 L (19.8 US gal) 4
Oil
Gear Clean Breather 4
3. Travel Check Oil Level 2
Gear
Reduction
Oil Change Oil 220 L (58.1 US gal) 2
Gear
NOTE: First time only.

3
M18M-03-007

Brand Names of Recommended Gear Oil Recommended brands of Class CD oils (API Service Classi-
Kinds of Lubricants Gear oil fication) are shown in the chart below.
Where to be Swing and Travel Reduction Gear If any oil other than these recommended oils is used, the oil
applied must be Class CD or CF (API Service Classification) and
20 to 50°C ( 4 to 122°F)
Manufacturer
meet the MILL2104C specifications (US military specifica-
British Petroleum BP Gear oil SAE90EP tions).

Caltex Oil Universal Thuban SAE90

Esso Gear Oil GP80W-90 or Recommended Brands of Engine Oil (Reference)

Esso
GP85W-90 Manufacturer Brands
Idemitsu Kosan Apolloil Gear HE90 Nippon Oil Co., Ltd. Diamond HDS-3 Engine Oil
Hi-Diesel S-3
Mobil Oil Mobilube GX90 Idemitsu Kosan Apolloil Diesel Motive S-330
Japan Energy JOMO Delstar DX
Nippon Oil Gear Lube SP90
Cosmo Oil Cosmo Diesel CD
Shell Oil Shell Spirax EP90 Showa Shell Sekiyu White Pallot Super S-3 Oil
Mobil Sekiyu Mobil Delvac 1300
Remarks API GL 4 Class Esso Sekiyu Exxon D-3
NOTE: The machine is filled with oil marked by General Sekiyu General Gemico Super S-3
when shipped from the factory.
NOTE: The machine shipped from the factory is filled
with Apolloil Diesel Motive S-330.

7-43
MAINTENANCE
PUMP TRANSMISSION GEAR

Recommended Brands of Engine Oil

CAUTION: Avoid mixing oils of different brands.

In most cases, different brands are not compati-
ble with each other and, when mixed, can seize
parts, or abnormally wear moving parts. It is best
to stick with one and the same brand of oil at
successive service intervals.

Recommended Oil Viscosities

Recommended Oil Viscosities
Air temperature °C [-22] [-13] [-4] [5] [14] [23] [32] [41] [50] [59] [68] [77] [86] [95] [104] [113] [122]

[°F] -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

Oil viscosities ( ) SAE15W-40 SAE15W-40

SAE30

SAE40

NOTE: At air temperature of 10°C or less ( ), SAE15W-40 with heating device is available. Contact your au-
thorized dealer about heating device.

Pump Transmission Oil Level

--- Check every 50 hours
(first time after 10 hours)

IMPORTANT: For most accurate readings, be sure the

machine is on a level surface.

1. Stop the engines.

NOTE: Refer to page 3-13 for stopping the engines

properly.
1
2. Remove dipstick (1). Wipe oil off with a clean cloth.
Reinsert dipstick (1).
M18M-07-039
3. Remove dipstick (1) again. Read level. Oil level must
be between the circle marks on dipstick (1). 1

4. If necessary, remove cap (2) and add oil.

Be sure to use only recommended oil (see Recom-
mended Engine Oil Chart). M18M-07-040

5. Recheck oil level. 2

NOTE: Always allow oil to settle before checking the

level. This may require 15 minutes.
NOTE: Oil can be refilled from the ground using the
Fast-Filling panel located in the rear of the base
machine. Refer to page 1-38 for the Fast-Filling
panel operation.

M18M-07-065

7-44
MAINTENANCE

Change Oil --- every 500 hours

(first time after 50 hours)

1. Run the engines until oil is warm to drain completely.

DO NOT run the engines until oil is hot.
2. Park the machine on a level surface.
3. Lower the bucket to the ground.
4. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.
4
5. Run the engine at slow idle speed without load for
five minutes.
6. Stop the engine. Remove the key from the key 3
M18M-07-041
switch.
7. Pull the pilot control shut-off lever to the LOCK
position

WARNING: Oil may be hot just after operation. Be

sure to wait for oil to cool before starting work.

8. Prepare a container of 55 liter (14.5 US gal) or more Clean Cloth

capacity for the drain oil.
Container
9. Remove drain plug (3) on the pump transmission
housing, and loosen cock (4) to drain the oil.
10. Check if foreign material like metal particles are M107-07-095
included in the drain oil by filtering it with a clean
cloth.
11. Tighten drain plug (3) and cock (4) securely. Fill the
pump transmission housing with 62 liter (16.4 US gal)
oil.
12. Confirm that the oil level is between the circle marks
on dipstick (1).Refer to the previous page.

NOTE: Oil can be refilled from the ground using the

Fast-Filling panel located in the rear of the base
machine. Refer to page 1-38 for the Fast-Filling
panel operation.

7-45
MAINTENANCE

Replace Filter --- every 500 hours

5
1. Unscrew cartridge filter (5) from the filter head, dis-
card the cartridge filter.

2. Fill the filter with oil. Apply a light even coat of lubri-
cating oil to the gasket sealing surface prior to in-
stalling the cartridge filter.

3. Position cartridge filter (5) to the filter head. Tighten

by hand until the seal touches the filter head, tighten
an additional three-fourths turn.
Be careful not to over tighten.
M146-07-068

6
Clean Breather --- every 500 hours
Remove breather cap (6) and clean the element.

M18M-07-042

7-46
MAINTENANCE
SWING REDUCTION GEAR 1

Rear-Left Rear-Right Front-Right Front-Left

Check Oil Level --- every 50 hours Swing Device Swing Device Swing Device Swing Device
(first time after 10 hours)
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Stop the engine. Remove the key from the key
5
switch. M146-07-027

6. Pull the pilot control shut-off lever to the LOCK 1

position.

WARNING: Gear oil may be hot just after

operation. Be sure to wait for gear oil to cool
before starting work.

7. Open cocks (5).

M114-07-181
8. Remove dipstick (1). Wipe oil off with a clean cloth.
Reinsert dipstick (1).
9. Remove dipstick (1) again. Read level. Oil level must
be between the top and notch on dipstick (1).
10. If necessary, remove oil supply plugs and add oil. Be
sure to use only reccomended oil. (See reccomended
Gear Oil Chart) Refer to next page to know how to
add oil.
11. Recheck oil level.
12. Install dipsticks (1).
13. Close cocks (5) after checking.

NOTE: Always allow oil to settle before checking the

7-47
MAINTENANCE
2
Change Gear Oil --- every 1000 hours
(first time after 50 hours)
1. Swing the machine until oil is warm to drain com-
pletely. DO NOT swing the machine until oil is hot.
2. Park the machine on a level surface.
3. Lower the bucket to the ground.
3
4. Turn the auto-idle switch off.

3
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down. M146-07-029

5. Run the engine at slow idle speed without load for

five minutes.
6. Stop the engine. Remove the key from the key switch.
7. Pull the pilot control shut-off lever to the LOCK
position.

WARNING: Gear oil may be hot just after

operation. Be sure to wait for gear oil to cool
before starting work.

8. Prepare a container of 75 L (20 US gal) or more ca- 4

pacity for the drain oil. Front Side
M146-07-030

9. Remove drain plug (3) and loosen drain cock (2) to

drain oil.
10. Check if foreign material like metal particles are in-
cluded in the drain oil by filtering it with a clean cloth
4
11. Tighten drain cock (2) and drain plug (3).
12. Remove oil supply plug (4) and fill with 75 L (20 US
gal) oil. Be sure to use only recommended oil (see
Recommended Gear Oil Chart).
13. Confirm that the oil level is between the top and notch
on dipstick (1). Start the engine and swing the ma- 4
Control Valve
chine at slow speed for about 5 minutes. Stop the
engine. Rear Side
M18M-07-043
Ten to twenty minutes later, check oil level again and
add oil if necessary.

5
Clean Breather --- every 1000 hours
1. Remove breather cap (5) and clean the element.

NOTE: Oil can be refilled from the ground using the

Fast-Filling panel located in the rear of the base
machine. Refer to page 1-38 for the Fast-Filling
panel operation.
M146-07-028

7-48
MAINTENANCE
TRAVEL REDUCTION GEAR

Check Oil Level --- every 250 hours

1
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engine at slow idle speed without load for M145-07-048

five minutes.
5. Stop the engine. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK 3
position.

3
WARNING: Keep body and face away from oil
level check plug (air release plug) (1). Gear oil
may be hot just after operation. Be sure to wait
for gear oil to cool and then gradually loosen oil
level check plug (air release plug) (1) to release
M145-07-079
pressure. 2

7. After gear oil has cooled, slowly loosen oil level check
plug (air release plug) (1) to release pressure.
8. Remove oil level check plug (1). Oil must be up to the
bottom of hole.
9. If necessary, after oil supply plugs (3) have been
removed, add oil until oil flows out of the oil level
check plug hole. Be sure to use only reccomeded oil.
(See Reccomed Gear Oil Chart)
10. Wrap oil level check plug (1) threads with
sealing-type tape. Install oil level check plug (1).
Tighten the plug to 69 N m (7 kgf m, 51 lbf ft).
11. Wrap oil supply plug (3) threads with sealing-type
tape. Install oil supply plug (3). Tighten oil supply plug
(3) to 196 N m (20 kgf m, 145 lbf ft).
12. Check the gear oil level in the other travel reduction
gear.

7-49
MAINTENANCE

Change Gear Oil

--- every 2000 hours (first time after 500 hours)
1. Drive the machine until oil is warm to drain completely.
1
DO NOT drive the machine until oil is hot.
2. Park the machine on a level surface.
3. Lower the bucket to the ground.
4. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.
5. Run the engine at slow idle speed without load for
five minutes. M145-07-048

6. Stop the engine. Remove the key from the key switch.
7. Pull the pilot control shut-off lever to the LOCK
position.
3
WARNING: Keep body and face away from oil
level check plug (air release plug) (1). Gear oil
may be hot just after operation. Be sure to wait 3
for gear oil to cool and then gradually loosen oil
level check plug (air release plug) (1) to release
pressure.

8. After gear oil has cooled, slowly loosen oil level check
plug (air release plug) (1) to release pressure. 2 M145-07-079

9. Prepare a container of 220 L (58 US gal) or more

capacity for the drain oil.
10. Remove drain plugs (2) to drain oil.
11. Check if foreign materials like metal particles are in-
cluded in the drain oil by filtering it with a clean cloth.
12. Wrap the threads of drain plug (2) with sealing- type
tape. Install drain plug (2).
Tighten the plug to 69 N m (7 kgf m, 51 lbf ft).
13. Remove oil level check plug (1). Clean Cloth
14. After oil supply plug (3) has removed, add oil until oil
Container
flows out of the oil level check plug hole. Be sure to
use only recommended oil. (See Recommended
Gear Oil Chart.)
15. Wrap the threads of oil level check plug (1) with M107-07-095

sealing-type tape. Reinstall oil level check plug (1)

and tighten it to 69 N m (7 kgf m, 51 lbf ft).
16. Wrap the threads of oil supply plug (3) with
sealing-type tape. Reinstall oil supply plug (3) and
tighten it to 196 N m (20 kgf m, 145 lbf ft).
17. Repeat steps 7 to 13 for the other travel reduction gear.
18. Start the engine and drive the machine at slow speed
for about 5 minutes. Stop the engine.
Ten to twenty minutes later, check oil level again and
add oil if necessary.
NOTE: Always allow oil to settle before checking the
level. This may require 15 minutes.

7-50
MAINTENANCE
D. HYDRAULIC SYSTEM
Interval (hours)
Parts Quantity
10 50 250 500 2000 2500 4000 12000
1. Check Hydraulic Oil Level 1
2. Drain Hydraulic Oil Tank Sump 1
4000 L
3. Change Hydraulic Oil
(1060 US gal)
4. Replace Full-Flow Filter and Drain Filter 6
5. Replace Bypass Filter 1
6. Replace Pilot Oil Filter 1
Clean Filter 6 When changing hydraulic oil
7. Suction Filter
Replace Filter 6
8. Replace High-Pressure Strainer 8
9. Clean Oil Cooler Core 4
10. Check Hoses and Lines (for leak, loose)
Check Hoses and Lines (for crack, bend, etc.)

NOTE: Hydraulic oil changing interval differs according to the kind of hydraulic oil used. See recommended
oil chart.
First time only. 9 1 2 3 4

6 7 10

5 8

M18M-03-007
Brand Names of Recommended Hydraulic Oil
Kind of Lubricant Hydraulic Oil
Where to be applied Hydraulic System
Change Interval 4000 hours 2500 hours 2000 hours
Environmental
20 to 50°C 10 to 50°C 20 to 50°C 10 to 50°C 20 to 50°C 10 to 50°C
Temp.
4 to 122°F) (14 to 122°F) 4 to 122°F) (14 to 122°F) 4 to 122°F) (14 to 122°F)
Manufacturer
Hitachi Super EX 46HN
Idemitsu Kosan Super Hydro 46 WRHU
British Petroleum Bartran HV46
Rando Oil
Caltex Oil
HD46
Rando Oil
Texaco INC.
HD46
Chevron U.S.A INC. Chevron AW46
Esso NUTO H46
Mobil Oil DTE 25
Remarks Anti-wear type hydraulic oil

NOTE: Use proper hydraulic oil in accordance with the atmospheric temperature.
The machine shipped from the factory is filled with oil marked .

7-51
MAINTENANCE
INSPECTION AND MAINTENANCE OF
HYDRAULIC EQUIPMENT

WARNING: During operation the parts of the

hydraulic system become very hot.
Allow the machine to cool down before begining
inspection or maintenance.

1. Be sure that the machine is parked on a level, firm

surface before servicing hydraulic equipment.
2. Lower the bucket to the ground and stop the engine.
3. Begin servicing hydraulic components only after
components, hydraulic oil and lubricants are com-
pletely cooled, and after releasing residual pressure.
3.1 Bleed air from the hydraulic oil tank to release in-
ternal pressure.
3.2 Allow the machine to cool down.
Note that servicing heated and pressurized hydrau-
lic components may cause hot parts and/or oil to fly
off or escape suddenly, possibly resulting in per-
sonal injury.
3.3 Keep body parts and face away from plugs or
screws when removing them.
Hydraulic components may be pressurized even
when cooled.
3.4 Never attempt to service or inspect the travel and
swing motor circuits on slopes. They are highly
pressurized due to self-weight.

7-52
MAINTENANCE
4. When connecting hydraulic hoses and pipes, take
special care to keep seal surfaces free from dirt and A couple of threads left unwrapped
to avoid damaging them. Keep these precautions in
mind:
4.1 Wash hoses, pipes, and the tank interior with a
washing liquid and thoroughly wipe it out before re-
connecting them.
4.2 Only use O-rings that are free of damage or defects.
Be careful not to damage them during reassembly. Direction of
Tape Winding
4.3 Do not allow high pressure hoses to twist when
connecting them. The life of twisted hoses will be M114-07-041
shortened considerably.
4.4 Carefully tighten low pressure hose clamps to fol-
lowing torque specifications. Do not overtighten.
T Bolt Clamp: 4.4 N m (0.45 kgf m, 3.3 lbf ft)
Jubilee Clamp: 5.9 to 6.9 N m
(0.6 to 0.7 kgf m, 4.3 to 5.1 lbf ft)
4.5 When connecting screw type joints, apply seal tape
to the threads of male screw. Be sure to leave a
couple of threads at the male screw top unwrapped,
as shown. Do not overwrap. Apply seal tape around T Bolt Clamp Jubilee Clamp
threads as shown, so that the tape does not loosen
when the female screw is tightened.
M114-07-042 M114-07-043

4.6 Carefully tighten nut for bandy pipe to following

torque specifications on the right side. Do not over- Bandy Pipe
tighten.
Pipe Dia. (A) 8 10
5. When adding hydraulic oil, always use the same Width Across Flat (B) (mm) 17 19
brand of oil; do not mix brands of oil. As the machine Fastening Torque Nm 34 49
is filled with Super EX 46HN when it is shipped from (kgf m) (3.5) (5)
the factory, use it as a general rule. When selecting (lbf ft) (25.5) (36)
to use another brand of oil listed in the table Brand
names of recommended hydraulic oil , be sure to
completely replace the oil in the system.
6. Do not use hydraulic oils other than those listed in the
table Brand names of recommended hydraulic oil .
7. Only 50 to 60% of the total hydraulic circuit oil on a
large size excavator can be replaced at a time. Ac-
cordingly, conduct minimum flushing twice.
8. In case the machine is used for dredging operations, M117-07-149

replace the hydraulic oil at a 2000 hour interval re-

gardless of the oil brand used.
9. If any other hydraulic oil (having a different replace-
ment interval) is unavoidably used, replace the oil in
accordance with the individual replacement interval
standard.
10. Never run the engine without oil in the hydraulic oil
tank.

7-53
MAINTENANCE

Check Hydraulic Oil Level --- daily

IMPORTANT: Never run the engine without oil in hy-

draulic oil tank.

1. Park the machine on a level surface.

2. Position the machine with the front attachment posi-
tioned as illustrated on the right. M142-07-093

3. Lower the bucket to the ground.

4. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

5. Run the engine at slow idle speed without load for

five minutes. M117-07-127

6. Stop the engine. Remove the key from the key

switch.
7. Pull the pilot control shut-off lever to the LOCK posi-
tion.
8. Check oil level gauge (1) on hydraulic oil tank. Oil 1
must be between marks on the gauge (1). If neces-
sary, add oil.

WARNING: Keep body and face away from cap

(3). Turn cap (3) slowly and remove the cap only
after releasing the internal pressure completely.

To add oil:

9. Insert the wrench as shown and turn the wrench

clockwise and hold the wrench.
10. Turn cap (2) counterclockwise about 30 , at which
point stop cap (2) to release the air.
11. Turn cap (2) further and remove cap (2). M146-07-034

12. Align the projected part of cap (2) with the projected 2
part of the case and install cap (2).
13. Add oil. Recheck oil level gauge (1).
14. Install cap (2).
Arrow
NOTE: Always allow oil to settle before checking the Projection
level. This may require 15 minutes.
Case Assembly
NOTE: Oil can be refilled from the ground using the
Fast-Filling panel located in the rear of the base
machine. Refer to page 1-38 for the Fast-Filling Projection
panel operation.
Side Hole
Wrench 4 mm
M110-07-022

7-54
MAINTENANCE

1
Drain Hydraulic Oil Tank Sump
--- every 250 hours

IMPORTANT: Never run the engine without oil in hy-

draulic oil tank.

1. Park the machine on a level surface with the upper-

structure rotated 90 for easier access.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.
M146-07-031
4. Run the engine at slow idle speed without load for Cap (1)
five minutes.
5. Stop the engine. Remove the key from the key
switch.
Arrow
6. Pull the pilot control shut-off lever to the LOCK posi-
Projection
tion.
Case Assembly
WARNING: Keep body and face away from cap
(1). Turn cap (1) slowly and remove the cap only
Projection
after releasing the internal pressure completely.

7. Insert the wrench as shown and turn the wrench Side Hole
clockwise and hold the wrench. Wrench 4 mm
M110-07-022
8. Turn cap (1) counterclockwise about 30 , at which
point stop cap (1) to release the air. 2
9. Turn cap (1) further and remove cap (1).
10. Align the projected part of cap (1) with the projected
part of the case and install cap (1).

WARNING: Do not loosen the drain cock until oil

is cool. Hydraulic oil may be hot just after opera-
tion, potentially causing serious injury.

11. After oil is cool, remove drain plug (3) and open drain
cock (2) to drain water and sediment.
12. After draining water and sediment, tighten drain cock
(2) securely and install drain plug (3). 3 M146-07-032

7-55
MAINTENANCE

Change Hydraulic Oil

--- every 4000 hours, 2500 hours or 2000 hours

IMPORTANT: Hydraulic oil changing intervals differ

according to kind of hydraulic oils used.
(See Recommended Oil Chart in this
group)

WARNING: Hydraulic oil may be hot just after

M142-07-092
operation. Be sure to wait for oil to cool before
starting work.

1. Park the machine on a level surface with the upper-

structure rotated 90 for easier access.
2. Position the machine with the arm cylinder fully re-
tracted and the bucket cylinder fully extended.
3. Lower the bucket to the ground as illustrated.
4. Turn the auto-idle switch off.
M117-07-126

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

5. Run the engine at slow idle speed without load for

five minutes.
6. Stop the engine. Remove the key from the key
switch.
7. Pull the pilot control shut-off lever to the LOCK posi-
tion.
8. Clean the top of the hydraulic oil tank to keep dirt out
of the hydraulic system.

WARNING: Keep body and face away from cap

(1). Turn cap (1) slowly and remove the cap only 4 1
M146-07-031
after releasing the internal pressure completely.
1
9. Insert the wrench as shown and turn the wrench
clockwise and hold the wrench.
10. Turn cap (1) counterclockwise about 30 , at which
point stop cap (1) to release the air. Arrow
Projection
11. Turn cap (1) further and remove cap (1).
12. Align the projected part of cap (1) with the projected Case Assembly
part of the case and install cap (1).
13. Remove cover (4). Projection

14. Drain oil using a suction pump.

The hydraulic oil tank capacity, up to specified oil Side Hole
level, is approximately 2950 liter (780 US gal).
Wrench 4 mm
M110-07-022

7-56
MAINTENANCE
15. Remove drain plug (2) on the suction manifold and 3
loosen drain valve (3).
Allow oil to drain.
16. Remove drain plug (9) under oil tank and loosen
drain cock (8) to drain water and sediment com-
pletely.
17. Install drain cock (8).
18. Tighten drain valve (3).
19. Clean, install and tighten drain plug (2).
20. Add oil via cover (4) hole until it is between the marks 2
on sight gauge (5) of hydraulic oil tank. Be sure to M146-03-033
use only recommended oil (see Recommended Hy-
draulic Oil Chart).
21. Reinstall cover (4) with bolts (4 used). At this time, be
sure to replace the O-ring with new one and check
that it is correctly installed.
22. Bleed any air remaining in the hydraulic system

NOTE: Refer to page 7-58 for bleeding air properly.

23. Confirm that the oil level is at the mark on gauge (5).
Start the engine and operate all cylinders and motors 4 M146-07-031
at slow speed for about 15 minutes. Stop the engine
after bleeding air from the hydraulic circuit sufficiently.
Ten to twenty minutes later, check oil level again and
add oil if necessary.

NOTE: Always allow oil to settle before checking the

M146-07-034

7-57
MAINTENANCE
Bleeding Air from Hydraulic Pump
Main Pump
IMPORTANT: If the hydraulic pump is not filled with oil, 8 locations
it will be damaged when the engine is
started.
Fan Drive Pump
1. Loosen hose connectors (1) of the 8 main pumps to 2 locations
release trapped air. Retighten hose connectors (1)
when air stops and oil flows from hose connectors
(1).
2. Loosen hose connectors (2) on the drain line of the 2
fan drive pumps to release trapped air. Retighten pipe
connectors (2) when air stops and oil flows from pipe M18G-07-115

connectors (2). 1 1
3. Start the engine and run at slow idle.
4. Purge air from the hydraulic system by running the
engine at slow idle and operating the control levers
slowly and smoothly for 15 minutes.
5. Position the machine as illustrated in the oil level
checking procedure.
6. Stop the engine. Remove the key from the key
switch.
7. Pull the pilot control shut-off lever to the LOCK
position.
M18M-07-044

8. Check the hydraulic oil tank gauge. Add oil if 2

necessary.

2 M18M-07-045

M142-07-092

M117-07-126

7-58
MAINTENANCE

Replace Full-Flow Filter and Drain Filter

--- every 500 hours (first time after 50 hours)

1. Park the machine on a level surface.

2. Lower the bucket to the ground as illustrated.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if the M142-07-093

engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Stop the engine. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK posi- M117-07-127
tion.
1

WARNING: Hydraulic oil and components may be

hot just after operation. Be sure to allow oil and
components to cool before starting work.

WARNING: Keep body and face away from cap

(1). Turn cap (1) slowly and remove the cap only
after releasing the internal pressure completely.

7. Insert the wrench as shown and turn the wrench

clockwise and hold the wrench.
8. Turn cap (1) counterclockwise about 30 , at which
point stop cap (1) to release the air.
Full-Flow Filter
9. Turn cap (1) further and remove cap (1). Drain Filter M146-07-031

10. Align the projected part of cap (1) with the projected 1
part of the case and install cap (1).

Arrow
Projection

Case Assembly

Projection

Side Hole

Wrench 4 mm
M110-07-022

7-59
MAINTENANCE

NOTE: There is spring tension under the cover. Hold

down the cover when removing last two bolts.
2
3
11. Hold down filter cover (2) against light spring load
when removing the last two bolts. Remove filter cover
(2). 4

12. Remove spring (5), valve (6), and element (7). 5

NOTE: Remove the element and inspect for metal par-

ticles and debris in the bottom of the filter case. 6
Excessive amounts of brass and steel particles
can indicate a failed hydraulic pump, motor, 7
valve or an impending failure. A rubber type of
material can indicate cylinder packing failure.

13. Discard element (7) and O-ring (4).

14. Install a new element (7), valve (6) and spring (5).
15. Install filter cover (2) with a new O-ring (4).
16. Install and tighten bolts (3) to 49 N m (5 kgf m, 36
lbf ft).
M111-07-040
17. Repeat steps 11 to 16 for the other filter.

7-60
MAINTENANCE

Replace Bypass Filter

--- every 500 hours (first time after 50 hours)
1. Park the machine on a level surface.
2. Lower the bucket to the ground as illustrated.
3. Turn the auto-idle switch off.

M142-07-093
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Stop the engine. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK M117-07-127

position.

WARNING: Hydraulic oil and components may be

hot ust after operation. Be sure to allow oil and
components to cool before starting work.
WARNING: Keep body and face away from cap
(1). Turn cap (1) slowly and remove the cap only
after releasing the internal pressure completely.

7. Insert the wrench as shown and turn the wrench 3

clockwise and hold the wrench.
8. Turn cap (1) counterclockwise about 30 , at which
1
point stop cap (1) to release the air.
M146-07-031
9. Turn cap (1) further and remove cap (1).
10. Align the projected part of cap (1) with the projected 1
part of the case and install cap (1).

Arrow
Projection

Case Assembly

Projection

Side Hole

Wrench 4 mm
M110-07-022

7-61
MAINTENANCE
11. Loosen bolts (2) and remove cover (3).
2 3

12. Remove filter element (5) and O-ring (4) from the fil-
ter housing.

NOTE: Remove the element and inspect for metal par-

ticles and debris in the bottom of the filter case.
Excessive amounts of brass and steel particles
can indicate a failed hydraulic pump, motor,
4
valve or an impending failure. A rubber type of
material can indicate cylinder packing failure.

13. Inspect filter element (5) and the filter housing for
metal particles and debris.

5
14. Discard O-ring (4) and element (5).

15. Install new element (5) into the filter housing.

16. Install filter cover (3) with new O-ring (4).

17. Install and tighten bolts (2) to 88 N m (9 kgf m, 65 M114-07-051

lbf ft).

7-62
MAINTENANCE

Replace Pilot Oil Filter

--- every 500 hours (first time after 50 hours)
1. Park the machine on a level surface.
2. Lower the bucket to the ground as illustrated.
3. Turn the auto-idle switch off.

M142-07-093
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Stop the engine.
6. Operate the right and left control levers to release
pressure from the pilot accumulator. M117-07-127

7. Remove the key from the key switch.

8. Pull the pilot control shut-off lever to the LOCK posi-
tion.

WARNING: Hydraulic oil and components may be

hot ust after operation. Be sure to allow oil and
components to cool before starting work.

WARNING: Keep body and face away from cap

(1). Turn cap (1) slowly and remove the cap only
after releasing the internal pressure completely.

9. Insert the wrench as shown and turn the wrench 1

clockwise and hold the wrench. M146-07-031

10. Turn cap (1) counterclockwise about 30 , at which

point stop cap (1) to release the air. 1
11. Turn cap (1) further and remove cap (1).
12. Align the projected part of cap (1) with the projected
part of the case and install cap (1).
Arrow
Projection

Case Assembly

Projection

Side Hole

Wrench 4 mm
M110-07-022

7-63
MAINTENANCE
13. Remove bolts (2). Hold down filter cover (4) when
removing last two bolts.

NOTE: There is spring tension under filter cover (4).

Hold down filter cover (4) when removing last
two bolts (2).

14. Remove spring (5), valve (6), O-ring (7) and filter
element (8) from filter housing (9).

NOTE: Remove element and inspect for materials on

element and in bottom of filter housing. Exces-
sive amounts of foreign materials can indicate
abnormalities in the system.

15. Inspect filter element (8) and filter housing (9) for for-
M146-07-035
eign materials.
16. Install new filter element (8), valve (6), and spring (5)
into filter housing (9). 2

17. Install washer (3), cover (4) and new O-ring (7). 3
18. Tighten bolts (2) to 88 N m (9 kgf m, 65 lbf ft). 4
5
6

M114-07-053

7-64
MAINTENANCE

Suction Filter 1
Cleaning Suction Filter
--- when replacing hydraulic oil

6 unit suction filters are provided in the hydraulic oil tank.

Clean them when replacing hydraulic oil.

WARNING: Sufficiently ventilate before entering

the hydraulic oil tank after draining hydraulic oil.

1. After draining oil, remove cover (1) to remove rod

assembly (2).
2. Clean the inside of the hydraulic oil tank and the suc- M146-07-070

tion filters.
3. Before installing, check dimensions of rod assembly
(2) by referring the figure below. Securely re-install
the rod assembly into pipe (3).
2
4. Replace the O-ring with new one and check that it is
correctly installed before re-installing cover (1). Se-
cure cover (1) with bolts.
5. Bleed any air remaining in the hydraulic system (refer
to [Air Bleeding Procedures] on page 7-58). 3

M146-07-012

340 mm (13.4 in)

25 mm

Rod Assembly M146-07-013

7-65
MAINTENANCE
Replace Suction Filter
1
--- every 12000 hours
6 unit suction filters are provided in the hydraulic oil tank.
Clean them when replacing hydraulic oil. Replace all suc-
tion filters.

WARNING: Sufficiently ventilate before entering

the hydraulic oil tank after draining hydraulic oil.

1. After draining oil, remove cover (1) to remove rod

assembly (2).
2. Clean the inside of the hydraulic oil tank.
M146-07-070

3. Replace the element of rod assembly (2).

4. Before installing, check dimensions of rod assembly
(2) by referring the figure below. Securely re-install
the rod assembly into pipe (3).
5. Replace the O-ring with new one and check that it is 2
correctly installed before re-installing cover (1). Se-
cure cover (1) with bolts.
6. Bleed any air remaining in the hydraulic system (refer
to [Air Bleeding Procedures] on page 7-58). 3

M146-07-012

340 mm (13.4 in)

25 mm

Rod Assembly M146-07-013

7-66
MAINTENANCE

Replace High-Pressure Strainer

--- every 12000 hours
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes. 1
M146-07-031
5. Stop the engine. Remove the key from the key
switch. 1
6. Pull the pilot control shut-off lever to the LOCK posi-
tion. Arrow (b)
Projection
WARNING: Hydraulic oil and components may be
Case Assembly
hot ust after operation. Be sure to allow oil and
components to cool before starting work.
Projection
WARNING: Keep body and face away from cap
Side Hole
(1). Turn cap (1) slowly and remove the cap (1)
Wrench 4 mm
only after releasing the internal pressure com- M110-07-022

pletely.

7. Insert the wrench as shown and turn the wrench

clockwise and hold the wrench.
8. Turn cap (1) counter-clockwise about 30 , at which
point stop cap to release the air.
9. Turn cap (1) further and remove cap (1).
10. Align the projected part of cap with the projected part
of the case and install cap (1)
11. Remove bolts (2), cover (3) and strainer assembly
(6) from housing (7).
12. Discard O-rings ((4) and (5)) and strainer assembly M146-07-036

(6). 2

13. Install new strainer assembly (6) into housing (7) with 3
the rubber seal down and the welding bead line on
4
strainer assembly (6) away from the housing inlet.
5
14. Install cover (3) with new O-rings ((4) and (5)).
Welding Bead
15. Install and tighten bolts (2) to 265 N m (27 kgf m, 195 6 Line Side
lbf ft). Rubber Seal
16. Repeat steps 11 to 15 for the other strainer.
7

Inlet
M114-07-062

7-67
MAINTENANCE

Clean Oil Cooler Core

--- every 500 hours

WARNING: Wear safety glasses or goggles when

using compressed air to clean oil cooler core.

IMPORTANT: High pressure air or water can damage

the cooler core fins. Use air pressure
2
0.2 MPa (2 kgf/cm ) or less and keep
the no le more than 500 mm away from
the core surface.

Clean the oil cooler core using compressed air 0.2 MPa (2
2
kgf/cm ) or less or tap water. Upper and lower covers (2
and 3) can be removed from oil cooler frame (1). Remove
the covers to clean the cooler core thoroughly. Four oil
coolers (4) units are arranged in both series and parallel.
Clean all the cooler units.
M146-07-037

IMPORTANT: If upper cover (2) and lower cover (3) are 4

incorrectly installed, the cooler per-
formance will be deteriorated. Be sure to
reinstall them in their original positions.

M146-07-089

7-68
MAINTENANCE

Check Hoses and Lines

--- daily
--- every 250 hours

WARNING: Escaping fluid under pressure can

penetrate the skin causing serious in ury.
To avoid this ha ard, search for leaks with a
piece of cardboard.
Take care to protect hands and body from
high-pressure fluids.
If an accident occurs, see a doctor familiar with
this type of in ury immediately. SA-031
Any fluid in ected into the skin must be surgically
removed within a few hours or gangrene may re-
sult.

WARNING: Hydraulic oil and lubricant leaks can

lead to fire that may result in serious in ury.
To avoid this ha ard :
Park the machine on a firm, level surface.
Lower the bucket to the ground.
Stop the engine. Remove key from the key
switch. Pull the pilot control shut-off lever to
the LOCK position.
Check for missing or loose clamps, kinked SA-292

hoses, lines or hoses that rub against each

other, damaged oil cooler, and loose oil cooler
flange bolts, for leaks.
Check hoses, lines and oil cooler at the check
points indicated below for leaks and other
damage that may result in future leaks.
If any abnormalities are found, replace or re-
tighten them, as shown in Tables 1-3.
Tighten, repair or replace any missing, loose or SA-044
damaged clamps, hoses, lines, oil cooler, and
loose oil cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged hoses or lines.

7-69
MAINTENANCE

Table 1. Hoses
Interval(hours) Check Points Abnormalities Remedies 3 2
1
Daily Hose covers Leak (1) Replace
Hose ends Leak (2) Replace 2
Fittings Leak (3) Retighten or replace 3
Every 250 Hose covers Crack (4) Replace
hours Hose ends Crack (5) Replace
M115-07-145

4
Hose covers Exposed reinforcement (6) Replace
Hose covers Blister (7) Replace 5

M115-07-146

7
Hose Bend (8) Replace
6

M115-07-147

Hose Collapse (9) Replace 8

(Use proper bend
radius)

Hose ends and Deformation or Replace M115-07-148

fittings Corrosion (10) 9

NOTE: Refer to the illustrations in Fig.1 for each check point location or for a descrip-
tion of the abnormality. Use genuine Hitachi parts.

10
M115-07-149

Fig.1

7-70
MAINTENANCE
Table 2. Lines
Interval(hours) Check Points Abnormalities Remedies
Daily Contact surfaces of Leak (11) Replace 11
flange joints O-ring 13 12
and/or
retighten bolts
Welded surfaces on Leak (12) Replace
joints
Clamps Loose Retighten M115-07-150
Every 250 hours Welded surfaces Crack (13) Replace Fig. 2
on joints
Clamps Missing Replace
Deformation Replace
NOTE: Refer to the illustrations in Fig.2 for each check point location or for a descrip-
tion of the abnormality. Use genuine Hitachi parts.

Table 3. Oil cooler

Interval(hours) Check Points Abnormalities Remedies
Every 250 hours Contact surfaces of Leak (14) Replace 14 15
flange joints O-ring
and/or
retighten bolts

Oil cooler Leak (15) Replace

NOTE: Refer to the illustrations in Fig.3 for each check point location .

M115-07-151
Fig. 3

7-71
MAINTENANCE
SERVICE RECOMMENDATIONS FOR HY-
DRAULIC FITTINGS
2 6 1 4 5
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
6
leakage.
3
M104-07-033
1. Inspect fitting sealing surfaces (6). They must be
free of dirt or defects.
2. Replace O-ring (1) with a new one when assembling
fittings.
3. Lubricate O-ring (1) and install it into groove (3) us-
ing petroleum jelly to hold it in place.
4. Tighten fitting (2) by hand, pressing the fitting joint
together to ensure O-ring (1) remains in place and is
not damaged.
5. Tighten fitting (2) or nut (4) to the torque values
shown. Do not allow hose (5) to twist when tightening
fittings.
6. Check for leaks. If oil leaks from a loose connection,
do not tighten fitting (2). Open the connection, re-
place O-ring (1) and check for correct O-ring position
before tightening the connection.
Torque specifications ±10%
Width across flats (mm) 27 32 36 41,46
Nm 93 137 175 205
Fastening
(kgf m) (9.5) (14) (18) (21)
torque
(lbf ft) (69) (101) (130) (152)

7-72
MAINTENANCE
Metal Face Seal Fittings
7 9 8 10 5
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.

IMPORTANT: Defects in the tube flare cannot be re-

paired. Overtightening a defective flare M202-07-051
fitting will not stop a leak.

2. Tighten fitting (7) by hand.

3. Tighten fitting (7) or nut (8) to the torque values
shown. Do not allow hose (5) to twist when tightening
fittings.

Width across flats (mm) 19 22 27

Nm 29.5 39 93
Fastening torque
(kgf m) (3) (4) (9.5)
(lbf ft) (21.5) (29) (69)

7-73
MAINTENANCE
E. FUEL SYSTEM

Tank capacity 7450 liter (1970 US gal)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Drain Fuel Tank Sump 1
2. Drain Fuel Filter Sediment Stage 1 filter 3 Weekly or as required
3. Replace Fuel Element Stage 1 filter 3
4. Replace Fuel Filter Stage 2 filter 3
Check Fuel Hoses (for leak, loose)
5.
Check Fuel Hoses (for crack, bend, etc.)
6. Clean Fuel Cooler Core 1
7. Clean Tank Breather 2
NOTE: The machine has 2 stage filtration system on suction fuel line.
Stage 1 filter is equipped in front of fuel tank.
Stage 2 filter is equipped on engine.

WARNING: Use only recommended DIESEL FUEL

OIL (JIS K-2204 or ASTM2-D). Never use gasoline.
If gasoline is used accidentally, fire will break out,
resulting in serious personal injury or death.

Recommended Fuel
Use only high-quality DIESEL FUEL OIL in accordance
with JIS K-2204, ASTM2-D, or equivalent. For further
details, refer to the manual for Commins Engine.

Refueling
1. Park the machine on a firm, level surface.
2. Lower the bucket to the ground.
M18M-01-009

3. Turn the auto-idle switch off. 1

4. Check fuel gauge (1) on the monitor. Add fuel if
necessary, as follows.
Fuel Tank Capacity: 7450 liter (1970 US gal)

NOTE: Avoid condensation. Fill the tank at the end of

each day s operation.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

5. Run the engine at slow idle for 5 minutes.

6. Stop the engine. Remove the key from the key
switch.
7. Pull the pilot control shut-off lever to the LOCK
position.

7-74
MAINTENANCE

WARNING:
Shut down the engine when fueling. Do not
smoke while fueling or when handling fuel
containers.
Fuel leaked or spilled onto hot surface or elec-
trical components can cause a fire.
After fueling, secure filler cap.

IMPORTANT: Keep all dirt, dust, water and other

foreign materials out of the fuel system. 2

NOTE: Take care not to spill fuel on the machine or M146-07-038

ground. Do not fill the tank more than specified.

8. Remove filler cap (2). Add fuel via the filler tube. Do
not fill the tank more than specified.
Be sure to select a charging pump of appropriate
capacity when fueling to avoid overflowing.

9. A filter is provided in the filler port. Clean the filter in

light oil at the regular interval.
Fuel Tank Indicator

10. Reinstall filler cap (2).

NOTE: Fuel can be supplied from the ground using the

fast-filling panel located in the rear of the base
machine. Refer to page 1-38 for the fast-filling
panel operation.

NOTE: Full of the tank can be confirmed by the fuel

tank indicator on the fast-filling panel.
As filling the tank, flash interval of the indicator
changes short. When the tank is full, the indi-
cator flashes continuously. M18M-01-020
Stop refueling within 30 seconds after the indi-
cator flashes continuously.

7-75
MAINTENANCE

Drain Fuel Tank Sump --- daily

1. Park the machine on a level surface with the upper-

structure rotated 90° for easier access.
2. Lower the bucket to the ground.
3. Turn the auto-idle off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
M18M-07-069

5. Stop the engine. Remove the key from the key

switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
7. Open drain cock (1) for several seconds to drain wa-
ter and sediment. Close drain cock (1).

Drain Fuel Filter Sediment

--- Weekly or as required
(Water visible in clear bowl)

1. Stop the engine.

WARNING: Fuel may be hot just after operation.

Be sure to wait for fuel to cool before starting
work.

2. Loosen fuel vent cap (2) to open.

3. Loosen drain valve (3) to drain water.
M18M-07-070

4. Collect water into a cup. 2

5. When fuel flows out of the drain, close drain valve
(3).
6. Close fuel vent cap (2).
7. Start the engine. Increase engine speed for one min-
ute to purge the air from the fuel system.

3 M18M-07-071

7-76
MAINTENANCE

Replace Fuel Element

--- every 250 hours

IMPORTANT: When fuel level reaches top of filter ele-

ment in clear cover before 250 hours,
replace fuel element before change in-
terval. 1

Be sure to prepare a container large

enough to collect fuel when replacing
fuel filter to avoid ground contamination
and for safety.

1. Stop the engine. M18M-07-071

2
WARNING: Fuel may be hot just after operation.
Be sure to wait for fuel to cool before starting
work.

2. Close cock (1) on the inlet line. 6

3. Loosen fuel vent cap (2) to break the air lock in the 7
filter.
4. Open drain valve (3) and drain the fuel level below 4
collar (4) level, then close drain valve (3).
5. Using Collar/Vent Cap Wrench (5), remove clear
cover (6) by removing collar (4). Discard the o-ring
M18M-07-072
from clear cover (6). (A new o-ring is supplied with
the new filter.)
3
6. Remove filter element (7). Be sure the sealing
grommet is removed from the center stud.
7. Install new filter element (7) (supplied with a sealing
grommet inserted into the element.) on the center
5
stud by pushing down.
8. After checking the new o-ring (supplied with the new M18M-07-074
filter) at clear cover (6) is in place, install clear cover
(6) and collar (4). Hand tighten collar (4) until seated.
Do not use Collar/Vent Cap Wrench (5) to tighten.
9. Remove fuel vent cap (2) from the top of clear cover
(6). Fill clear cover (6) with enough clean fuel to cover
the bottom half of the filter element.
10. Reinstall fuel vent cap (2) and tighten by hand only.
11. Open cock (1) on the inlet line.
12. Start the engine. When the lubrication system
reaches its normal operating pressure, increase en-
gine speed for one minute.

Refer to the manual for Cummins Engine.

7-77
MAINTENANCE

Replace Fuel Filter

--- every 250 hours

IMPORTANT: Be sure to prepare a container large

enough to collect fuel when replacing
fuel filter to avoid ground contamination
and for safety.

1. Stop the engine.

WARNING: Fuel may be hot just after operation.

Be sure to wait for fuel to cool before starting
work.

2. Close cock (1) on the inlet line.

3. Unscrew spin-on filters (2) from the filter head, dis- 1 2 M18M-07-075

card filters.

4. Fill the filter with clean fuel. Apply a light even coat of
lubricating oil to the gasket sealing surface prior to
installing the filter.

5. Position filter (2) to the filter head. Tighten by hand

until the seal touches the filter head, tighten an addi-
tional one-half to three-fourths turn.

6. Open cock (1) on the inlet line.

NOTE: Be sure to tighten the filter by hand. If any tools

are used for tightening, breakage or deforma-
tion of the filter head may arise.

Refer to the manual for Cummins Engine.

7-78
MAINTENANCE

Check Fuel Hoses

--- daily
--- every 250 hours

WARNING: Fuel leaks can lead to fires that may

result in serious injury.
To avoid this hazard :

1. Park the machine on a firm, level surface. Lower the

bucket to the ground. Stop the engine. Remove key
from the key switch. Pull the pilot control shut-off
lever to the LOCK position.
2. Check for kinked hoses, and hoses that rub against
each other parts for leaks.
Check hoses at the check points indicated below for
leaks and other damage that may result in future
leaks. If any abnormalities are found, replace or re-
tighten them, as shown in Table 4.
3. Repair or replace any loose or damaged hoses.
Never install bent or damaged hoses.

7-79
MAINTENANCE

Table 4. Hoses 3 2
Interval (hours) Check Points Abnormalities Remedies
Daily Hose covers Leak (1) Replace 1
Hose ends Leak (2) Replace
Fittings Leak (3) Retighten or replace 2
3
M115-07-145

Every 250 Hose covers Crack (4) Replace

hours 4
Hose ends Crack (5) Replace
5

M115-07-146

Hose covers Exposed rein- Replace 7

forcement (6)
Hose covers Blister (7) Replace 6

M115-07-147

8
Hose Bend (8) Replace

Hose Collapse (9) Replace M115-07-148

(Use proper bend radius)

Hose ends and fit- Deformation Replace

tings or corrosion
10
(10)
M115-07-149

NOTE: Refer to the illustrations in Fig. 4 for each check point location or for Fig. 4
a description of the abnormality. Use genuine Hitachi parts.

7-80
MAINTENANCE

Clean Fuel Cooler Core

--- every 500 hours

WARNING: Always wear safety glasses or gog-

gles when using compressed air (Less than 0.2
2
MPa, 2 kgf/cm , 28 psi) to clean oil cooler core.

IMPORTANT: High-pressure air or water can damage

fins. When cleaning the oil cooler and
pump transmission oil cooler core with
high-pressure air or water, keep the noz-
zle 200 mm (8 in) or more away from the
core face in order not to cause any dam-
age.
M18M-07-083

Clean oil fuel core with compressed air (Less than 0.2 MPa,
2
2 kgf/cm , 28 psi) or water.

Clean Fuel Tank Breather

--- every 500 hours

1. Stop the engine.

1
M18K-07-017

WARNING: Fuel tank may be hot just after opera-

tion. Be sure to wait for fuel tank to cool before
starting work.

2. Remove fuel breather cap (1) and clean element (2).

NOTE: Element (2) cannot remove from breather cap

(1).

2 M18K-07-018

7-81
MAINTENANCE
F. AIR CLEANER

Clean Air Cleaner Outer Element

--- as required
1
Replace Air Cleaner Outer and Inner
Elements
--- per 6 cleaning or when outer element is
replaced 2

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
M117-07-015

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.
4. Run the engine at slow idle speed without load for
five minutes. 3

5. Stop the engine. Remove the key from the key

switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
7. Remove wing nut (1).
Remove outer element (2).
M117-07-016

WARNING: Use reduced compressed air pres-

2
sure (Less than 0.2 MPa, 2 kgf/cm , 28 psi). Clear
area of bystanders, guard against flying chips,
and wear personal protection equipment includ-
ing goggles or safety glasses.
8. Clean outer element (2) using compressed air (Less
2
than 0.2 MPa, 2 kgf/cm , 28 psi). Direct the air to the
inside of the filter element, blowing out. Inspect outer
element (2) for any damage. If outer element is dam-
aged, replace with a new one.
9. Clean body (3) interior before installing outer element
(2). Install outer element (2).

NOTE: Check air cleaner restriction indicator on the

monitor panel. If air cleaner restriction indicator
comes ON. Stop the engine and replace outer
element.

7-82
MAINTENANCE
Replacement
1
1. When replacing air cleaner filter element, replace
both, outer (2) and inner (4) elements together.
2. Remove wing nut (1) and outer element (2).
3. Clean the filter housing (3) interior before removing
inner element (4). 2
4. Remove nut (5) and inner element (4).
5. First install inner element (4) and nut (5) and then in-
stall outer element (2) and wing nut (1).
M117-07-015

M117-07-016

7-83
MAINTENANCE
G. COOLING SYSTEM

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Check Coolant Level 1
2. Check DCA4 Concentration in Coolant
3. Replace Coolant Filter 2
4. Change Coolant 614 L (162 US gal) Twice a year, in spring and autumn
5. Clean Radiator, After Cooler Interior 1+1 When changing coolant
6. Clean Radiator, After Cooler Core 1+1
NOTE: Before leaving the Hitachi factory, the cooling system is filled with a mixture of water and Genuine
Hitachi Long-Life Coolant. As long as Genuine Hitachi Long-Life Coolant is used, the service inter-
vals between changing the coolant is once every two years, or every 4000 hours, whichever comes
first.

Coolant
Use a proper coolant mix of water, antifreeze and anti-
corrosive agent DCA4.

NOTE: DCA4 is a brand name of Dry Chemical Addi-

tive manufactured by the America Fleetguard
Co.

1. Water
Use soft water with fewer impurities or tap water as a
coolant.
If hard water with many impurities is used, the anti-
corrosive agent DCA4 will be neutralized and loose
its effect as an anticorrosive agent.

2. Long-Life Coolant
Long-Life coolant protects the cooling system from
rusting and freezing.
Long-life coolant can be used throughout the year
without changing.
As long as Genuine Hitachi Long-Life Coolant is used,
the service interval between changing the coolant is
once every two years, or every 4000 hours, which-
ever comes first.

IMPORTANT: Long-Life Coolant concentration is usu-

ally 50%. However Long-Life Coolant
concentration should be changed for the
cold weather range. Refer to the manual
for Cummins Engine.

7-84
MAINTENANCE

Check Coolant Level --- daily 1

2
WARNINGN: Do not remove water tank cap (1)
until the coolant is cool; otherwise
high-temperature steam may escape, potentially
causing scalding. Slowly loosen cap (1) to re-
lease pressure after the system has cooled and
then remove.

Check that the coolant level is between the HIGH and

LOW marks on water tank level gauge (2).
If the coolant level is below the LOW mark, remove cap (1)
on the water tank and add coolant via the opening.
M18M-07-046
2

High Level

Low Level

M18M-07-047

7-85
MAINTENANCE

Check DCA4 Concentration in Coolant

--- every 500 hours

Anticorrosive Agent DCA4

Be sure to use the anticorrosive agent DCA4 in your
Cummins Cooling System. DCA4 protects the cooling
system from rusting, makes an anticorrosive film on the
cylinder liner to prevent the liner from corroding, and re-
duces sediments in the engine coolant passages. Main-
tain the acceptable concentration range of 1.2 to 3 units
per 3.78 L (1 US gal) of coolant.
DCA4 concentration is adjusted by replacing the
DCA4-containing filter and/or adding DCA4 liquid.

Coolant Filter
The following solid DCA4 containing coolant filter is
available.

Fleetguard Cummins Hitachi Part Number of

Application
Part No. Part No. No. DCA Units

Check and
WF-2075 3100308 4228689 15
Maintenance

DCA4 Liquid
The following DCA4 liquid units are available for refill.

Application Fleetguard Cummins Hitachi Number of

Part No. Part No. Part No. DCA Units

DCA60L 4275270 5
Refill 3305373
DCA65L 4280278 20

7-86
MAINTENANCE
Precautions for using DCA4

WARNING: DCA4 includes alkali. Avoid splashing

DCA4 in your eyes or swallowing it. If DCA4 is
splashed into your eyes or swallowed, follow the
instructions shown below. Keep out of reach of
children.

1. Exposure tolerances
Slight skin exposure to DCA4 will cause no
serious problems. However, longer or re-
peated exposure times, inhaling, swallowing
or splashing DCA4 in your eyes will cause se-
rious problems. Take the emergency meas-
ures shown below.

Cause Symptoms Emergency Measure

The nose
Inhaling Breathe fresh air.
smarts.

Wash with fresh water.

Long or
The skin Take off clothes contaminated
repeated
smarts. with DCA4 and clean them thor-
exposure
oughly.

Wash immediately with fresh wa-

Splashing The eyes
ter for 15 minutes and see a phy-
in eyes smart.
sician.

Drink a lot of carbonated bever-

Swallowing
ages and see a physician.

2. Disposal
Be careful not to spill DCA4 on machine or
ground. If DCA4 is spilt, wipe it up and clean
contaminated surface thoroughly.
Use a container to collect spilt DCA4 and con-
sign it to professional disposers. Disposal of
surplus DCA4 when changing coolant should
also be assigned to professional disposers.

7-87
MAINTENANCE
Checking and Adjusting DCA4 Concentration

Initial Charge (when replacing coolant totally)

Replace the coolant filter and add the DCA4 liquid for re-
fill. Use coolant filter (WF-2075). One DCA65L unit is
equivalent to four DCA60L units. The sample combina-
tions of DCA65L and DCA60L are shown in the following
table. Appropriately combine both DCA65L and DCA60L
so that the required concentration can be obtained.

Antifreeze or DCA Units per Coolant Required Filter Nos. of Quantity DCA4 Nos. of Quantity Total Units
LLC Concen- 1 gal of Water Volume Concent- Units Liquid for Units
tration Plus ration Refill
Anti-freeze or
(%) LLC (L) (Unit) (P/No.) (Unit) (P/No.) (Unit) (Unit)

325 WF-2075 15 2 330 DCA Unit

Over 50% 2 614 DCA65L 20 15
(614/3.78 2 = 325 DCA Unit) (15 2+20 15)

Replacing Coolant Filter --- every 500 hours

DCA4 deteriorates its function after being used for a
long time. Normally replace it every 500 hours. However,
when the DCA4 concentration is measured:
When the antifreeze or LLC concentration is 50%: If
over 3 units concentration is measured, no replace-
ment is required, allowing the replacement hour to
extend up to max. 1000 hours.

Checking Coolant Concentration

1. If a large quantity of coolant was added when repair-
ing the engine or radiator, check the coolant concen-
tration in accordance with Item 5 Inspection Proce-
dure in this manual and maintain the proper coolant
concentration. (If the total coolant was replaced, con-
duct the initial charge in accordance with Item above
on this page.)
2. The coolant concentration may be outside the speci-
fication according to operation conditions or due to an
unexpected failure. Then, it is recommendable to
check the concentration every 500 hours.

7-88
MAINTENANCE
Inspection Procedures of Coolant Concentration

Check the concentration of DCA4 in coolant using

the inspection kit shown below.

Cummins Hitachi
Name of Kit
Parts No. Parts No.
Inspection Kit CC2602 4404083

Contents of the Kit:

Color
Specimen

Plastic Coolant Receiver Pipette Plastic Test Paper Box.

(I) (II) (III)
M162-07-077
Outline

1. Both A and B reagents are coated on CC2602 test

paper, allowing to measure the color changes on both
A and B reagents.
2. At the same time, one more reagent is coated to eas-
ily determine the antifreeze concentration through
color change. (The antifreeze concentration checked
by this method should be just a guide line. When the
exact antifreeze concentration is required, measure it
using a specified equipment.)

1 2 3 CC2602 Test Paper

A SODIUM NITRITE
Concentration

B SODIUM MOLYBDATE
Concentration

Antifreeze Concentration
M162-07-076

3. Do not use diluted coolant for measurement. Collect

coolant into the attachment beaker. Directly dip the
test paper into the collected coolant. Compare the
reagent color change on the test paper with the color
specimen coated on the test paper box 45 seconds
after desiccating.

7-89
MAINTENANCE
Precautions for Using CC2602 Test Kit
The effective life time of the reagent is printed on
Maintain coolant temperature to 10 to 54 C while check- the upper section of the CC2602 container.
ing. Otherwise, incorrect color change may result. Do not use any reagents after the effective life
time expires.
Compare the reagent color with the color specimen to
measure the concentration in daylight. If the reagent color has changed to light brown or
In case it is difficult to specify the color concentration pink, avoid using such reagent.
through the comparison of the reagent color with the
If the color specimen was spoiled, wipe stain with
color specimen, adopt the lighter side concentration as a
a cloth. Do not use any soap or solvent.
safer value.
The reagent color continues to change from soon
The reagents provided in the test kit are sensitive to light,
after being dipped into coolant and stops after it is
heat, and excessive moisture so that they should be
dried up. Therefore, measure the coolant concen-
stored in a plastic container. Unless the test papers are
tration within the specified time range.
used, be sure to close the container cover correctly.
Avoid to expose the test kit to the direct ray of the sun
while storing and maintain the ambient temperature of
the storing place to 32 C or lower.

Concentration Check Table

% GLYCOL/FREEZEPOINT ( F)
25% 33% 40% 50% 60%

+10 +5 0 5 10 20 30 45 60

DCA Unit/3.78L (1 US gal)

(SCA UNITS PER GALLON)

ROW 6 0.0 1.7 2.8 3.1 3.7 4.1 4.9 5.7

ROW 5 0.0 1.7 2.3 2.7 3.1 3.5 4.3 5.1

ROW 4 0.0 1.4 1.8 2.0 2.4 2.8 3.6 4.4

ROW 3 0.0 1.2 1.5 1.7 2.1 2.5 3.3 4.1

(SODIUM
MOLYBDATE ROW 2 0.0 1.0 1.2 1.4 1.8 2.2 3.0 3.8
LEVEL)
ROW 1 0.0 0.6 0.9 1.1 1.5 1.9 2.7 3.5

ROW 0 0.0 0.3 0.6 0.8 1.2 1.6 2.4 3.2

A B C D E F G H

(SODIUM NITRITE LEVEL)

7-90
MAINTENANCE
How to Use Test Kit

IMPORTANT: Measure time precisely to obtain the

correct test results. Use a stop watch or
watch with a second hand. If the reagent
color change is checked too early or too
late, correct measurement results won t
be obtained. If coolant is maintained
based on incorrect check data, damage
to the engine may result.

1. Use coolant collected from the radiator or the engine

drain cock for checking. Don t collect coolant from the
reservoir. Wait to cool the collected coolant tempera-
ture to 10 to 54 C before checking.

2. As soon as one test paper is taken out of the plastic

container, close the cover correctly. Do not touch the
area coated with the reagent. If the area has already
changed to light brown use another test paper.

3. Dip the test paper into the collected coolant for one
second. After taking up the test paper, desiccate the
extra coolant.

4. Wait 45 seconds. Then, compare the changed re-

agent color on the test paper with the color specimen
and determine the coolant concentration by following
procedures.

(1) Take a record of the anti freeze concentration by

comparing the color on reagent section (1) with
the anti freeze color specimen printed on the test
paper plastic box (III).
(2) Take a record of concentration by comparing the
color on reagent section (2) with the SODIUM
MOLYBDATE color specimen printed on the test
paper plastic box (III).
(3) Take a record of concentration by comparing the
color on reagent section (3) with the SODIUM NI-
TRITE color specimen printed on the test paper
plastic box (III).

5. Complete all color comparison check within 75 sec-

onds after dipping the test paper into the coolant.

7-91
MAINTENANCE
6. In case the reagent color corresponds to that be-
tween the color specimens, take the intermediate
value. If it is difficult to determine which value should
be taken, adopt the lighter color side concentration as
a safer value.
7. Using the concentration check table, find the inter-
section between the recorded SODIUM MOLYBDATE
concentration and the SODIUM NITRITE concentra-
tion. This intersection shows the coolant additive
agent concentration per 1 US gal of the coolant.
8. The colored concentration values in the concentration
check table printed on the test paper box represents
the values to be applied when the LLC concentration
is 50%. When the LLC concentration is 40% or less,
do not determine by color. Determine by figure val-
ues.
9. Record the measured coolant additive agent concen-
tration value on the maintenance record sheet as ref-
erence data when performing next maintenance ser-
vices.

Concentration Check Table

% GLYCOL/FREEZEPOINT ( F)
25% 33% 40% 50% 60%

+10 +5 0 5 10 20 30 45 60

DCA Unit/3.78L (1 US gal)

(SCA UNITS PER GALLON)

ROW 6 0.0 1.7 2.8 3.1 3.7 4.1 4.9 5.7

ROW 5 0.0 1.7 2.3 2.7 3.1 3.5 4.3 5.1

ROW 4 0.0 1.4 1.8 2.0 2.4 2.8 3.6 4.4

ROW 3 0.0 1.2 1.5 1.7 2.1 2.5 3.3 4.1

(SODIUM
MOLYBDATE ROW 2 0.0 1.0 1.2 1.4 1.8 2.2 3.0 3.8
LEVEL)
ROW 1 0.0 0.6 0.9 1.1 1.5 1.9 2.7 3.5

ROW 0 0.0 0.3 0.6 0.8 1.2 1.6 2.4 3.2

A B C D E F G H

(SODIUM NITRITE LEVEL)

7-92
MAINTENANCE
Checking and Controlling Coolant
Obtain the concentration value from the concentration
check table. Concentration and its control are as follows.

Coolant Additive Agent DCA4 Control Standard

Concentration of Concentration per 1 US gal

Antifreeze or of Coolant Additive Agent Control Method
LLC DCA4

1.2 or less Replace the coolant filter. Add one bottle of DCA60L (con-
taining 5 DCA units) per 15 L of coolant.

1.2 to 3.0 Perform the normal maintenance service. Replace the coolant
filter every 500 hours.

3.0 or more Keep using the coolant until concentration is reduced to 3

units without replacing the filter.
50% Use the filter up to the next 500 hour replacement time
(maximum useable time limit: 1000 hours). In case concentra-
tion is over 4.0 units, replace the total coolant and conduct the
initial charge in accordance with Item in this manual.

Necessary DCA4 Volume to Add 1.75 DCA units per 1 US gal (3.785 L) of coolant.
be Added When Replacing
Total Coolant.

IMPORTANT: Water with a lot of impurity or insuffi-

cient quantity of DCA4 will lead to corro-
sion of cylinder liners, which will result
in engine damage.

7-93
MAINTENANCE

Replace Coolant Filter

--- every 500 hours
Check the DCA4 concentration every 500 hours. (Refer
to page 7-86 for the checking procedure.) If the concen-
tration is lower than the acceptable range, and if the
coolant filter has to be replaced as a result (Refer to
Concentration Check Table section on page 7-88.), re-
place the WF-2075 coolant filter, following the procedure
below:

WARNING: Do not attempt to loosen coolant filter

(1) until the engine is cool.

IMPORTANT: Be sure to prepare a container large

enough to collect coolant when re-
placing water filter to avoid ground
contamination and for safety.
Be sure to tighten the filter by hand. 1
If any tools are used for tightening,
breakage or deformation of the filter
head may arise. For details other
than filter replacement intervals, re-
fer to the manual for Cummins En-
gine.
M18M-07-048
1. Move shut-off valves knob (2) to the OFF position.
2. Remove filters (1) and discard it.
3. Apply a thin film of lubricating oil to the gasket sealing
2
surface prior to installing new filters (1).
4. Position new filters (1) to the filter head.
Tighten until the seal touches the filter head; tighten
an additional one-half to three-fourths turn.
5. Move shut-off valves knob (2) back to the ON posi-
tion.
1
M117-07-018

7-94
MAINTENANCE

Change Coolant
--- twice a year (in spring and autumn)

Clean Radiator, After Cooler Interior

--- when changing coolant
1
NOTE: Before leaving the Hitachi Factory, the cooling
system is filled with a mixture of water and
Genuine Hitachi Long-Life Coolant.
As long as Genuine Hitachi Long-Life Coolant is
used, the service intervals between changing 6
the coolant is once every two years, or every
4000 hours, whichever comes first.

WARNING: Do not loosen the radiator cap until

the engine is cool. Loosen the radiator cap
slowly to the stop. Release all pressure before
removing the radiator cap.

1. Park the machine on a solid and level surface. Lower

the bucket to the ground. Stop the engine. M18M-07-046

5
2. Remove water tank cap (1). Remove the hoses (2), 4 3
(3) and open drain cocks (4) and (5) on the drain
pipes to allow the coolant to drain completely. Re-
move impurity such as water scale at the same time.

3. Close drain cocks (4) and (5) and reinstall the hoses
(2) and (3). Fill the radiator with soft water containing
less impurity or tap water and a radiator cleaner
agent via the water tank cap (1). And fill the water
tank in same way between the HIGH and LOW
marks on water tank level gauge (6). Reinstall water
tank cap (1).

4. Start the engine and run it at a speed slightly higher

2
than slow idle; when the needle of the coolant tem- M18M-07-049

perature gauge reaches the blue zone, run the en-

gine for about ten more minutes.

5. Stop the engine and drain water in same way. Flush

out the cooling system with soft water or tap water,
until draining water is clear. This helps remove rust
and sediment.

6. Close drain cocks (4), (5) and reinstall the hoses (2)
and (3). Fill the radiator and water tank with soft wa-
ter or tap water in same way. At that time, mix the
LLC. The concentration of LLC is 50%. Slowly add
coolant to avoid mixing air bubbles in the system.

7-95
MAINTENANCE
IMPORTANT: Long-Life Coolant concentration is usu-
ally 50%. However Long-Life Coolant
concentration should be changed for the
cold weather range. Refer to the manual
for Cummins Engine.

7. Add 1.2 to 3.0 DCA units per 1 US gal (3.78 L) of

coolant.

8. Confirm that the coolant level is between the marks H

and L on gauge (6). Start the engine and run at slow
idle speed for about 5 minutes. Stop the engine after 6
bleeding air from the cooling system sufficiently.
Check coolant level again and add coolant if neces-
sary.

NOTE: Coolant can be refilled from the ground using

the Fast-Filling panel located in the rear of the
base machine. Refer to page 1-38 for the
Fast-Filling panel operation.

M18M-07-046

7-96
MAINTENANCE

Clean Radiator, After Cooler Core

--- every 500 hours

WARNING: Always wear safety glasses or gog-

gles when using compressed air (Less than 0.2
2
MPa, 2 kgf/cm , 28 psi) to clean radiator core.

IMPORTANT: High-pressure air or water can damage

fins. When cleaning the radiator core
with high-pressure air or water, keep the
nozzle 200 mm (8 in) or more away from
the core face in order not to cause any
damage.

1. Remove cover in front of the radiator. Clean radiator

core with compressed air (Less than 0.2 MPa, 2
2 M18M-07-050
kgf/cm , 28 psi) or water.

2. Remove the covers (1) beside radiators and remove

the covers (2) between radiator core (3) and after-
cooler core (4). 1

3. Clean radiator core (3) and aftercooler core (4) from

space between cores in same way.

4. Same as opposite side.

5. After cleaning, install the covers (2) and (1).

M18M-07-084

4 3

M18M-07-052

7-97
MAINTENANCE
H. AIR CONDITIONER

Recirculation Air Filter

WARNING: Always wear safety glasses or gog-

gles when using compressed air (Less than 0.2
2
MPa, 2 kgf/cm ) to clean filters.

IMPORTANT: Plugged inner or outer air filter will re-

duce cooling capacity of the air condi- 1
tioner. Be sure to clean them periodi-
cally.

Cleaning --- As required

M18M-03-007
1. Recirculation air filters (2) (three pieces) are located
in room (1) under the cab. Open cover (3). Remove
recirculation air filters (2).
2. Clean recirculation air filters with compressed air
2
(Less than 0.2 MPa, 2 kgf/cm ) or a soft brush.

Replacing --- Replace per 4 cleaning

If the cooling capacity decreases even after cleaning re-
circulation air filters due to filter clogging, replace them.

NOTE: Same filter elements are used for the air condi-
tioner recirculation and ventilation air filters.
3 M18G-07-083

7-98
MAINTENANCE

Ventilation Air Filter

Clean Air Filter --- As required

WARNING: Always wear safety glasses or gog-

gles when using compressed air (Less than 0.2
2
MPa, 2 kgf/cm ) to clean filters.

IMPORTANT: Plugged inner or outer air filter will re-

duce cooling capacity of the air condi- 1
tioner. Be sure to clean them periodi-
cally.

1. Ventilation air filters (2) (three pieces) are located in

room (1) under the cab. M18M-03-007

Remove ventilation air filters (2).

2. Clean ventilation air filters (2) with compressed air
2
(Less than 0.2 MPa, 2 kgf/cm ) or a soft brush.

2
Replace Air Filter --- Replace per 4 cleaning
Changing interval of ventilation air filters (2) differs de-
pending on environmental conditions.

If the cooling capacity decreases after cleaning ventila-

tion air filters (2), caused by filter plugging, replace it ear-
lier than the standard interval.

NOTE: Same filter elements are used for the air condi-
tioner recirculation and ventilation air filters.

M18G-07-132

7-99
MAINTENANCE

Check Refrigerant Quantity

--- every 250 hours

WARNING: DO NOT allow liquid refrigerant to

contact eye or skin. Liquid refrigerant will freeze
eye or skin on contact. Be careful not to loosen
connections in the air conditioner circuit.

IMPORTANT: Do not operate the compressor 1

without refrigerant in the air condi-
tioning circuit, as doing so may
damage them.
Do not overcharge the system with
refrigerant to avoid dangerous high M18M-03-007
pressure and low cooling effect.

Air conditioner liquid tanks (2) (three pieces) are located

in room (1) under the cab. Insufficient refrigerant quan-
tity lowers cooling effect of the air conditioner. Check the
refrigerant quantity through sight glass on liquid tanks (2)
2
(three pieces).

1. Start the engine and run at fast idle speed.

2. Turn the air conditioner and blower fan speed to the
high speed.
3. Press temperature control switch repeatedly until the
air temperature is maximum cool.
4. Check the refrigerant quantity through sight glass.
M18G-07-084

Refrigerant
Sight Glass
Quantity

Almost clear. Gas bubbles may be seen but will dis-appear by

Appropriate
changing engine speed.
M114-07-090

A steady stream of gas bubbles is seen in the liquid flowing from

Insufficient
the receiver-dryer.

M114-07-091

Scarce No bubbles but misty.

M114-07-092

5. If the refrigerant level is low, consult your authorized

dealer.

7-100
MAINTENANCE

Check Compressor Belt Tension

--- every 250 hours
Remove box-type cover (2), located on bed (1) under the
step, to gain access to the compressor belt.
Visually check belt for wear. Replace if necessary. Start
the engine and run for 10 minutes. Check belt tension by
depressing the midpoint between the hydraulic motor
and compressor pulleys with the thumb. Deflection must
be 13 to 14 mm (0.5 to 0.6 in) at a depressing force of 1
approximately 98 N (10 kgf, 22 lbf).
If tension is not within specifications, loosen the
compressor mounting bolts to adjust belt tension.

M18M-07-053

M146-07-071

M146-07-001

7-101
MAINTENANCE

Clean Condenser Core

--- every 500 hours

WARNING: Always wear safety glasses or 1

goggles when using compressed air (Less than
2
0.2 MPa, 2 kgf/cm , 28 psi) to clean condenser
core.

Remove condenser cover (2) (three pieces), located in

room (1) under the cab.
2
Use compressed air (Less than 0.2 MPa, 2 kgf/cm , 28
psi) to clean the condenser core (three pieces).

M18M-07-053

M18G-07-086

7-102
MAINTENANCE

Check Tightening Torque

--- every 250 hours
Check the tightness of mounting bolts, hose connections
and fittings every 250 hours. Tighten to torque
specifications if any are loose.

Torque Specifications for Hose Connections:

Wrench Fastening Torque
Size
(mm) Nm (kgf m) (lbf ft)
19 11.5 to 14.5 (1.2 to 1.5) (8.7 to 10.5)
24 19.5 to 24.5 (2 to 2.5) (14.5 to 18)
M146-07-001
27 29.5 to 34 (3 to 3.5) (21.5 to 25.5)

Torque Specifications for Compressor Mounting Bolts:

Wrench Fastening Torque
Size
(mm) Nm (kgf m) (lbf ft)
10 19.5 to 29.5 (2 to 3) (14.5 to 21.5)

Torque Specifications for Liquid Tank:

Wrench Fastening Torque
Size
(mm) Nm (kgf m) (lbf ft)
10 7.8 to 11.5 (0.8 to 1.2) (5.8 to 8.7)

7-103
MAINTENANCE

Seasonal Maintenance
--- preseason
--- off-season
WARNING: Do not attempt to loosen connections
in air conditioning circuit when the air
conditioner malfunctions. Doing so may cause
high pressure gas to spout, resulting in serious
injury. Consult your authorized dealer
immediately.

1. Preseason maintenance

Prior to the season, consult your authorized dealer for

maintenance of the air conditioner in order to operate
it in good condition during the season.

This maintenance includes replenishment of

refrigerant, inspection and replacing (if necessary) of
inner and outer air filters, line connections, pressure
switches and inspection and cleaning of evaporator.

2. Off-season maintenance

(1) Operate the compressor once a week at low speed

for several minutes in order to maintain its parts in
well lubricated condition. Be sure to run the engine
at slow idle and air temperature to MEDIUM COOL.
This operation also prevents refrigerant leakage
caused by a dried up shaft seal.
(2) Check for refrigerant leakage. If the refrigerant
level is low during off-season, rust will form inside
the circuit.

NOTE: Do not remove compressor belt from the

compressor during off-season.

7-104
MAINTENANCE
I. ELECTRICAL SYSTEM

WARNING: Improper radio communication

equipment and associated parts, and/or improper
installation of radio communication equipment
effects the machine's electronic parts, causing
involuntary movement of the machine.
Also, improper installation of electrical
equipment s may cause machine failure and/or a
fire on the machine.
Be sure to consult your authorized dealer when
installing radio communication equipment or
additional electrical parts, or when replacing
electrical parts.

Never attempt to disassemble or modify the

electrical/electronic components. If replacement
or modification of such components is required,
contact your authorized dealer.
SA-036

WARNING: Never allow to wash the electric parts

in the machine by water. Example: harness,
control box, and relay box etc.

Batteries

WARNING: Battery gas can explode. Keep sparks

and flames away from batteries. Use a flashlight
to check the battery electrolyte level.

Do not continue to use or charge the battery

when electrolyte level is lower than specified.
Explosion of the battery may result.
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into the
eyes.

Avoid hazard by:

1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper booster battery starting
procedures.
If you spill acid on yourself:
1. Flush your skin with water.

7-105
MAINTENANCE
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:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.

IMPORTANT: Add water to batteries in freezing

weather before you begin operating your
machine for the day, or else charge the
batteries.

IMPORTANT: If the battery is used with the electrolyte

level lower than the specified lower level,
the battery may deteriorate quickly.

M409-07-072
IMPORTANT: Don t refill electrolyte more than the
specified upper level. Electrolyte may
spill, damaging the painted surfaces
and/or corroding other machine parts.

NOTE: In case electrolyte is refilled more than the

specified upper level line or beyond the bottom
end of the sleeve, remove the excess
electrolyte until the electrolyte level is down to
the bottom end of the sleeve using a pipette.
After neutralizing the removed electrolyte with
sodium bicarbonate, flush it with plenty of water,
otherwise, consult the battery manufacturer.

7-106
MAINTENANCE
Electrolyte Level Check
1. Check the electrolyte level at least once a month.
2. Park the machine on level ground and stop the
engine.
3. Check the electrolyte level.
3.1 When checking the level from the battery side:
Clean around the level check lines with a wet towel.
Don t use a dry towel. Static electricity may be
developed, causing the battery gas to explode. U.L (Upper Level)
Check if the electrolyte level is between U.L (Upper
L.L (Lower Level)
Level) and L.L (Lower Level). In case the electrolyte
M146-07-109
level is lower than the middle level between the U.L
and L.L, immediately refill distilled water or
commercial battery fluid. Be sure to refill with Filler Port
distilled water before recharging (operating the
machine). After refilling, securely tighten the filler
plug.
Sleeve
3.2 When impossible to check the level from the battery Upper Level
side or no level check mark is indicated on the side: Lower Level
After removing the filler plug from the top of the Separator Top
battery. Check the electrolyte level by viewing Proper M146-07-110

through the filler port. It is difficult to judge the Since the electrolyte surface touches the bottom end of
accurate electrolyte level in this case. Therefore, the sleeve, the electrolyte surface is raised due to surface
when the electrolyte level is flush with the U.L, the tension so that the electrode ends are seen curved.
level is judged to be proper. Then, referring to the M146-07-111
right illustrations, check the level. When the Lower
electrolyte level is lower than the bottom end of the When the electrolyte surface is lower than the bottom end
of the sleeve, the electrode ends are seen straight.
sleeve, refill with distilled water or commercial
battery fluid up to the bottom end of the sleeve. Be
M146-07-112
sure to refill with distilled water before recharging
(operating the machine). After refilling, securely
tighten the filler plug.
3.3 When an indicator is available to check the level,
follow its check result.
4. Always keep around the battery terminals clean to
prevent battery discharge. Check terminals for loose
and/or rust. Coat terminals with grease or petroleum
jelly to prevent corrosion build up.

M409-07-072

7-107
MAINTENANCE
Check electrolyte specific gravity
IMPORTANT: Check the specific gravity of the
electrolyte after it is cooled, not
immediately after operation.

Check the electrolyte specific gravity in each battery cell.

The lowest limit of the specific gravity for the electrolyte
varies depending on electrolyte temperature. The
specific gravity should be kept within the range shown
below. Charge the battery if the specific gravity is below
the limit.

Recommended range of specific gravity by electrolyte temperature

104 °F 40 °C

68 °F 20 °C
Working range
Fluid temp. 32 °F 0 °C

4 °F 20 °C

40 °F 40 °C
1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32

Specific gravity of battery fluid

7-108
MAINTENANCE
REPLACE BATTERIES

Your machine has four 12-volts batteries with negative ( )

ground.
If one of four batteries in a 24-volt system has failed but the
others are still good, replace all the batteries together with
new ones of the same type. For example, replace a failed
maintenance-free battery with a new maintenance-free
battery. Different types of batteries may have different rates
of charge. This difference could overload one of the
batteries and cause it to fail.

IMPORTANT: Do not pull the disconnector lever (1)

down during operation and the delayed
power OFF time after the key switch is
turned off.
All controllers are shut down after the
delayed power OFF time.

NOTE: Ground Disconnector M146-01-021

This machine is equipped with a battery ground
disconnector located outside of engine unit
compartment on the right side. The battery
ground circuit can be disconnected by pulling
disconnector lever (1) down before replacing
1
the battery, checking the electrical system, or
performing welding work on the machine.

CAUTION: Do not replace the battery in human

strength. Use the crane to replace safely.

M146-07-062

7-109
MAINTENANCE

Replacing Fuses --- as required

If any electrical component fails, first check the fuses in
the fuse box, located in room (A) under the cab. Remove
fuse box cover and confirm that the fuses shown below
are provided.
A
IMPORTANT: Install fuse with correct amperage rating
to prevent electrical system damage
from overload.

M18M-07-053

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20
T18G-05-07-001

21 22 23 24 25 26 27 28 29 30

M18M-07-054
31 32 33 34 35 36 37 38 39 40
T18G-05-07-001

1- MC MAIN POWER 5A 11- OPT. C/U MAIN POWER 10A 21- WASHER MOTOR RELAY 5A 31- A/C MAIN POWER (FRONT)
2- DELAYED POWER OFF RELAY 12- OPT. C/U MAIN POWER 10A 22- TRAVEL SPEED SELECT RELAY 15A
5A 13- OPT. C/U KEY ON SIG. 5A 5A 32- A/C MAIN POWER (SIDE) 15A
3- ----- 14- OPT. C/U KEY ON SIG. 5A 23- A/C MAIN RELAY (FRONT) 5A 33- A/C MAIN POWER (REAR) 15A
4- MMS BACKUP 5A 15- MC KEY ON SIG. 5A 24- A/C MAIN RELAY (SIDE) 5A 34- A/C C. FAN (FRONT) 20A
5- HMU MAIN POWER 5A 16- ELU PWM POWER RELAY 5A 25- A/C MAIN RELAY (REAR) 5A 35- A/C C. FAN (SIDE) 20A
6- AIR HORN COMPRESSOR (L) 17- DLU OPT. KEY SW ON SIG. 5A 26- BATTERY RELAY 5A 36- A/C C. FAN (REAR) 20A
30A 18- ------ 27- A/C CONTROL AMP (FRONT) 5A 37- DLU SERVICE TOOL 5A
7- AIR HORN COMPRESSOR (R) 19- ECM LAMP POWER 5A 28- A/C CONTROL AMP (SIDE) 5A 38- ORBCOMM MAIN PAWER 5A
30A 20- HMU KEY ON SIG. 5A 29- A/C CONTROL AMP (REAR) 5A 39- MMS MAIN PAWER 5A
8- FOLDING STAIRWAY SOL(A) 10A 30- MOTION ALARM 5A 40- CHARGE SIG. 5A
9- BOX LIGHT 5A
10-CAB. BATTERY POWER 30A

7-110
MAINTENANCE

41 42 43 44 45 46 47 48 49 50

51 52 53 54 55 56 57 58 59 60
T18G-05-07-001

61 62 63 64 65 66 67 68 69 70

T18G-05-05-001
71 72 73 74 75 76 77 78 79 80
T18G-05-07-001

11- SEAT SUSPENTION 21- MC SOL. POWER 10A 31- WORK LIGHT (1) 10A 41- --------
AIR COMPRESSOR 15A 22- MC PWM POWER 10A 32- WORK LIGHT (2) 10A 42- --------
12- ------ 23- ELU SOL. POWER 15A 33- WORK LIGHT (3) 10A 43- ENTRANCE LIGHT (1) 10A
13- ------ 24- ------ 34- WORK LIGHT (4) 10A 44- --------
14- TRAVEL SPEED SELECTOR 25- ECM DATA LINK 15A 35- WORK LIGHT (5) 10A 45- WIPER MOTOR (LOW) 30A
SOL. 5A 26- ------ 36- WORK LIGHT (6) 10A 46- WIPER MOTOR (HIGH) 30A
15- FOLDING STAIRWAY SOL (B) 27- ------ 37- MAINTENANCE LIGHT (1) 10A 47- WASHER MOTOR 10A
5A 28- ------ 38- MAINTENANCE LIGHT (2) 10A 48- FAST FILLING SYSTEM SOL.
16- DOME LED LIGHT 5A 29- ENG.OIL RESERVE TANK 39- MAINTENANCE LIGHT (3) 10A 5A
17- AIR BREATHER SOL. 5A PUMPING UNIT 15A 40- MAINTENANCE LIGHT (4) 10A 49- CSU MAIN POWER 5A
18- TERMINAL (24V) 15A 30- OIL PUMP 20A 50- --------
19- DC/DC CONVERTER (1) 15A
20- DC/DC CONVERTER (2) 15A

7-111
MAINTENANCE
Remove cover (A) on the rear console in the cab. Also,
check the fuses.

1- MAIN POWER KEY SW 20A

2- ELU MAIN POWER 5A

3- IDU MAIN POWER 5A

4- DLU MAIN POWER 5A

5- ORBCOMM BATTERY POWER 5A

6- RADIO BACKUP 5A

7- ELU KEY ON SIG. 5A

8- IDU KEY ON SIG. 5A

9- DLU KEY ON SIG. 5A A

10- BUZZER 5A

11- KEY ON SIG. (CONTROL BOX) 5A M18M-01-007

12- ECM KEY ON SIG. 5A 20 19 18 17 16 15 14 13 12 11

13- RADIO (ACC) 5A

14- AIR HORN COMP. ACC SIG. 5A

15- LIGHTER 10A

16- TERMINAL (ACC) 10A

17- TERMINAL (12V) 15A

18- --------
10 9 8 7 6 5 4 3 2 1
19- MONITOR CONTROL UNIT 5A
T18G-01-02-030
20- PILOT CONTROL SHUT-OFF LEVER SW 5A

7-112
MAINTENANCE

Power Source Terminal

12 Volts and 24 Volts Terminal
Remove cover (1) on the rear console in the cab. 12
volts and 24 volts terminal are located in the rear console.
Use this terminal to power electrical devices of 12 volts
and 24 volts rating. Fuses for this terminal are provided
with 5 ampere and 10 ampere fuses.

1
M18M-01-007

T18G-01-02-026

24V 5A

24V 10A

12V 10A

M18M-07-062

7-113
MAINTENANCE

High Current Fuse

High current fuses are located in engine unit (A). A
High current fuses protect electric main circuit against
excessive current.
If high current fuses is melted and disconnected by short
circuit, see your authorized dealer.

High Current Fuse Connection Table (1)

M18M-07-055

No.

1 75A FUSE BOX; FUSE No.1, 2, 4 to 12, 55

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

Fuse 1
6
2
No.
7
11 10A ENG. OIL FILL. SYS. VALVE 3
12 5A IDU (PRELUB SIG.) 8

13 30A ZENER DIODE 4

5 10

M18M-07-056

7-114
MAINTENANCE
High Current Fuse Connection Table (2)

No. Amp
1 400A PRELUB RELAY
2 250A FOLDING STAIRWAY MOTOR 1
3 250A FOLDING STAIRWAY MOTOR 2
2

M18M-07-056

7-115
MAINTENANCE

Check Electrical Cables and Wire Harnesses

for Short Circuits

WARNING: Short circuits can cause fires that

may result in serious injury.
To avoid this hazard:

1. Park the machine on a solid, level surface. Lower the

bucket to the ground. Stop the engine. Remove key
from the key switch. Pull the pilot control shut-off lever
to the LOCK position.

2. Clean and tighten all electrical connections.

3. Check before each shift or after ten (10) hours of

operation for loose, kinked, hardened or frayed
electrical cables and wires.
Check before each shift or after ten (10) hours of
missing or damaged terminal caps.
DO NOT OPERATE MACHINE if cable or wire are
loose, kinked, etc.

Check cables and harnesses at the check points

indicated below for damage that may result in future
short circuits. If any abnormalities are found, replace,
retighten or reconnect them, as shown in Table 1.

4. Tighten, repair or replace any loose or damaged

electrical cables, wires, and terminal caps before
operating the machine.

7-116
MAINTENANCE
Table 1. Electrical Cables and Wire Harnesses

Interval
Check Points Abnormalities Remedies
(hours)

Daily Wire harnesses and Degree of hardening Replace

1
cables (1) Cracks Replace
Worn tape Replace
Contact with part edge Replace
Missing cap (harness terminal) Replace
M115-07-152
Loose screw terminal Retighten
Damaged at the contacting part with Replace
clamps

Lead wires of sensor Degree of hardening Replace

and solenoid valve Cracks Replace 2
(2)
Worn tape Replace
Contact with part edge Replace

Connector (3) Degree of Hardening Replace M115-07-153

Loose locking Lock

3
Contact with part edge Replace
Damaged and crushed parts Replace
Loose or worn part Replace

Terminal and Degree of hardening of cover Replace

terminal cover (4) Cracks Replace M115-07-154

Worn cover Replace 4

Missing cover Replace
Loose locking Reconnect

Clamps of the Missing Replace

harnesses or Clamping positions Correcting M115-07-155

connectors (5)
Damage Replace
5
NOTE: Refer to the illustrations in Fig. 1 for each check point location.
Replace the damaged parts with genuine Hitachi parts.

M115-07-156

Fig. 1

7-117
MAINTENANCE

Check Emergency Engine Stop Switch NORMAL EMERG.STOP

--- Every 250 Hours
Check the emergency engine stop switch function every 1
250 hours, following the procedures below.

1. Start the engine and run at slow idle.

2. Turn emergency engine stop switch (1) to the
EMERG STOP position.
3. Confirm that the engine stops.

If any abnormalities are found, be sure to repair them

before operating the machine.

M18M-01-004

7-118
MAINTENANCE
J. MISCELLANEOUS

2 5
M146-07-051

9 8 M18M-03-007

1 T146-01-03-002

7-119
MAINTENANCE

Check Bucket Teeth --- every 10 hours

RIGHT WRONG
1. Check bucket teeth for wear and looseness

Replace teeth if tooth wear exceeds the designated

service limit shown below.

Dimension A in mm (ft, in.) 1 2 M117-07-153

New Limit of Use
520 290
Loading Shovel Bucket
(1' 8 ) (11 )
470 260
Backhoe Bucket
(1' 7 ) (10 )

If point (1) is worn excessively, making a hole, new

point (1) cannot be installed on worn nose (2).

NOTE: Check the bucket teeth periodically so that wear

does not exceed the designed service limit.
M115-07-094

Alternate buckets may use different tooth

assemblies.

2. Replacing procedure Wedge 4

WARNING: Guard against injury from flying

pieces of metal. Wear goggles or safety glasses.

1. Install point (1) and locking pin (3).

The side of the locking pin marked up must be
installed upward as shown in the figure.
2. Use a 7 to 10 kg (15 to 22 lb) hammer and drive out Point 1 3 Locking Pin
M115-07-136
wedge (4).
3. Drive the wedge so that the difference between the
top of wedge and the surface of the point is less than
50 mm (2 in).
Less than 50 mm (2 in) Top of Wedge
4. Cut the lower end the wedge longer than the surface
of the point by gas.

Gas cutting part

Lower-end of Wedge

M115-07-097

7-120
MAINTENANCE
3. Maintenance
1. Drive wedge (4) using a hammer again after op- 5
erating 2 to 4 hours.
2. Drive wedge (4) every morning for the first week
of operation.
3. Drive wedge (4) once a month from the second
week.
4. Cut the projected part using gas when the lower
1
end of wedge (4) projects from the bottom sur-
face of point (1).
5. Replace the wedge (4) with oversize wedge
3
110W 2 (4202527) when its top is flush with the M145-07-037
upper surface of point (1). 4

6. When wedge (4) tends to come out of point (1),

apply spot welding to wedge (4) and spool (3)
after driving the wedge in point (1).

NOTE: When installing new point and shroud (5), re-

move the hooks attached to them using gas.

7-121
MAINTENANCE

Inspect Emergency Evacuation Equipment

2
and Hanger --- daily
Inspect emergency evacuation equipment (1) and
hanger (2) before operating the machine. If any item is
worn and/or damaged, replace the equipment and/or
hanger with genuine Hitachi parts. 1

M146-07-002

7-122
MAINTENANCE

Auto-Lubrication System --- daily

The machine is equipped with auto-lubrication system

for the front attachment joint pins, swing bearing and 1
center joint.

Checking Indicator Pins

IMPORTANT: The auto-lubrication system is equipped

with injectors (3) for greasing. Check in-
dicator pins (2) of injectors (3) every day
to confirm that greasing is done cor-
rectly. Also, check grease piping for
leakage. M18M-07-038

1. Move auto-lubrication toggle switch (1) located in

front of oil cooler to the MANUAL position. Check that
the grease pump begins operating and indicator pins
(2) retract.
2

2. Move auto-lubrication toggle switch (1) to the AUTO

LUB. position. Indicator pin positions are as follows:
3
Indicator pins (2) are retracted while the grease pump
is operating.

Indicator pins (2) are extended while the grease

pump is stopped. M145-07-029

2
NOTE: The stroke of pin movement differs depending
on the greasing volume of injectors (3).

M117-07-173

7-123
MAINTENANCE
Check Grease Level --- daily
Remove two wing nuts (4). Open grease-can top cover
assembly (5) to check quantity of grease inside. Add
grease if necessary.
5
4
Automatic Greasing
Move auto-lubrication toggle switch (1) to the AUTO LUB.
position. Disconnect hose (7) at coupler (6). The grease
pump intermittently delivers grease for approximately
one minute with an interval of 10 minutes according to
the greasing schedule preset at the factory. The greas-
ing schedule, interval and volume, can be adjusted as
shown next page.

IMPORTANT: Do not adjust greasing interval to be too

long or the greasing volume to be too
small.

M146-07-107

M18M-07-037

7-124
MAINTENANCE
1. Adjusting Greasing Interval

Turn adjusting switch (9) located in room (8) under

the cab to the desired position out of four possible
positions: 3, 5, 10, and 15 minutes.
8
Greasing Interval
(minutes)
3
5
10
15

M18M-07-053

M18M-07-057

2. Adjusting Greasing Volume

10
Loosen locknut (11) on injector (2). Turn adjusting nut
(10) clockwise until it stops. This is the minimum de-
3 3
livery position of 0.168 cm (0.010 in ). Turn adjusting 11
nut (10) counterclockwise approximately 10 turns.
3
This is the maximum delivery position of 1.165 cm
3
(0.071 in ). Select appropriate greasing volume be-
2
tween the maximum and minimum volumes. Tighten
locknut (11).

NOTE: Injectors (2) have been adjusted as shown be-

low at the time of shipment:

Front attachment joint pins: Maximum

Swing bearing: Minimum
Center joint: Minimum

Model SL-I SL-II

Min. Volume 0.168 40% 1.165 15% M117-07-173
Max. Volume 1.165 40% 8.163 5%

7-125
MAINTENANCE
Manual Greasing

Connect hose (7) to coupler (6).

Move auto-lubrication toggle switch (1) to the MANUAL
position.

Apply grease using a grease gun. Refer to pages 7-24 to

7-35 of this manual.
After finishing greasing, disconnect hose (7) from cou-
pler (6), release grease pressure in hose reel (12) via
the grease gun.

NOTE: When manual greasing is selected, the

auto-lubrication indicator on the monitor display 6
will come on. This is not abnormal.

M18M-07-037

M18M-07-038

M146-07-105

7-126
MAINTENANCE

Check and Replace Seat Belt

Check --- daily
Replace --- every 3 years 2

Always maintain the seat belt in a functional condition

and replace when necessary to ensure proper perform-
ance.

Prior to operating the machine, thoroughly examine belt

(1), buckle (2) and attaching hardware. If any item is
damaged or materially worn, replace the seat belt or
component before operating the machine.
1
M18G-01-058
We recommend that the seat belt be replaced every
three years regardless of its apparent condition.

Check Windshield Washer Fluid Lever

--- as required
Windshield washer tank (2) is located in room (1) under
the cab.
Check fluid in windshield washer tank (2).
If the fluid level is low, remove cap of windshield washer
tank (2) and add fluid via the opening.
During winter season, use all season windshield washer 1
which will not freeze.

M18M-07-053

M18G-07-084

7-127
MAINTENANCE

Clean Air Horn Compressor Filter

--- as required

Air horn compressor (2) is located in room (1) under the

cab. Remove the cap (3) and clean the filter.

M18M-07-053

M18M-07-066

3 M18K-07-024

7-128
MAINTENANCE

Check and Adjust Track Sag

--- every 50 hours

WARNING: Be sure to place blocks under the

machine frame to support the machine when one
track is raised off ground.
90 to
Swing the upperstructure 90° and lower the bucket to raise 110
the track off the ground as shown.

Keep the angle between the boom and arm 90 to 110 and M117-05-030

position the bucket s round side on the ground. Place

blocks under the machine frame to support the machine.
Rotate track one full rotation. Thoroughly clean track area
to remove soil.

Measure distance (A) at the middle of the track frame from

the bottom of the track frame to the back face of the track Track frame
shoe. bottom

Track sag specifications --- 580 to 620 mm

A
(22.8 in to 24.4 in)
Track shoe back face
NOTE: When operating the machine on sand, gravel, M115-07-170

snow or mud, providing longer track sag is rec-

ommended in the above-mentioned value
range.

Precautions for Adjusting Track Sag

1. When measuring track sag after adjusting, be sure to
rotate the raised track one full rotation.
2. When adjusting track sag, lower the bucket to the
ground to raise one track off the ground.
Repeat this procedure to raise the other track.
Each time, be sure to place blocks under the ma-
chine frame to support the machine.
3. When operating the machine after it has been stored
for a long time or its track adjuster cylinder hose or
piping has been replaced, first push the right travel
lever forward to extend adjuster cylinder, and then
add grease to the fitting to tighten the tracks.

7-129
MAINTENANCE
Loosen the Track

WARNING: Do not loosen valve (1) quickly or

loosen it too much as high-pressure grease in
1
the adjusting cylinder may spout out. Loosen
carefully, keeping body parts and face away from
valve (1).
Never loosen grease fitting (2). 2

IMPORTANT: When gravel or mud is packed between

sprockets and track links, remove it be-
fore loosening.
M117-07-074

1. To loosen the track, slowly turn valve (1) counter-

clockwise using long socket 24; grease will escape
from the grease outlet.
2. Between 1 to 1.5 turns of valve (1) is sufficient to
loosen the track. Grease
Outlet 1
3. If grease does not drain smoothly, slowly rotate the
raised track.
2
4. When proper track sag is obtained, turn valve (1)
clockwise and tighten to 147 N m (15 kgf m, 108
lbf ft).

M117-07-105

Tighten the Track

WARNING: It is abnormal if the track remains

tight after turning valve (1) counterclockwise or if
the track is still loose after charging grease to fit-
ting (2). In such cases, NEVER ATTEMPT TO DIS-
ASSEMBLE the track shoes or track adjuster,
because of dangerous high-pressure grease in-
side the track adjuster. See your authorized
dealer immediately.

To tighten the track, connect grease lubricator or a grease

gun to grease fitting (2) and add grease until the sag is
within specifications.

7-130
MAINTENANCE

Check Accumulator and Track Adjuster Cyl-

inder Circuit --- every year

WARNING: Accumulator (1) in the track adjuster

cylinder circuit is charged with high-pressure ni-
trogen. Be sure to release pressure before ser-
vicing the hose between accumulator and track
adjuster cylinder circuit, following the procedure
shown below.
1. Loosen lock nut (4) of valve (2) located under
accumulator (1).
2. Confirm that handle (5) is sufficiently tight-
ened by turning it clockwise. Remove plug (3). M146-01-025

3. Slowly turn handle (5) counterclockwise to 1

1
open valve; pressurized oil escapes gradually.

IMPORTANT: Low pressure in the track adjuster cyl-

inder circuit will cause damage to the
track adjuster and travel device. Be sure
to check the accumulator and adjuster
cylinder circuit regularly to maintain
correct circuit pressure. Consult your
authorized dealer when checking accu-
mulator.

M146-07-081

Check Side Frame Area --- daily

Soil or rocks stuck in the side frame area will disturb
smooth rotation of the undercarriage components such
as the lower rollers, upper rollers, sprockets or front
idlers.

Remove soil and rocks from the area every day. In addi-
tion, clean the area at least once a week.

Be sure to thoroughly clean the area in cold seasons to

M117-07-075
prevent excessive wear of upper rollers due to freezing.

7-131
MAINTENANCE

Check Tightening Torque of Bolts and Nuts

--- every 250 hours (first time after 50 hours)
Check tightness after the first 50 hours then every 250
hours. Tighten to torque shown if any are loose. Bolts and
nuts should be replaced with those of the same or higher
grade.

IMPORTANT: Check and tighten bolts and nuts using

a torque wrench.

Torque Specifications
No. Descriptions Bolt Dia ty Wrench Torque
(mm) Size (mm) Nm (kgf m ) (lbf ft)
1 Engine cushion rubber mounting bolt 36 10 55 3140 (320) (2310)
Engine bracket mounting bolt a 33 16 50 1950 (200) (1440)
2 b 20 32 30 540 (55) (400)
c 22 6 32 740 (75) (540)
3 Hydraulic oil tank mounting bolt 33 12 50 1910 (195) (1410)
4 Fuel tank mounting bolt 33 18 50 1910 (195) (1410)
5 Pump transmission mounting bolt 12 16 19 110 (11) (81)
Pump mounting bolt (Main pump) 24 16 36 950 (97) (700)
6
Pump mounting bolt (Fan pump) 20 4 30 550 (56) (410)
7 Gear pump mounting bolt 14 6 22 140 (14) (103)
Air con. Compressor drive pump mounting
8 14 2 22 140 (14) (103)
bolt
9 Control valve mounting bolt 20 16 30 390 (40) (290)
36 48 55 3140 (320) (2315)
10 Swing device mounting bolt
24 96 36 950 (97) (700)
11 Swing motor mounting bolt 20 16 30 390 (40) (290)
12 Battery mounting bolt 6 16 10 20 (2) (15)
13 Cab mounting bolt 18 10 27 300 (31) (220)
14 Cab bed mounting bolt 12 49 19 110 (11) (81)
15 Cab cushion rubber mounting bolt 12 40 19 110 (11) (81)
Swing bearing mounting bolt (Upperstructure) 56 60 85 9810 (1000) (7230)
16
Swing bearing mounting bolt (Track) 56 60 85 9810 (1000) (7230)
17 Counterweight mounting bolt 56 11 85 6860 (700) (5060)
18 Travel motor mounting bolt 20 16 30 390 (40) (290)
19 Upper roller mounting bolt 22 24 32 740 (75) (540)
20 Lower roller mounting bolt 45 64 70 4710 (480) (3470)
21 Radiator mounting bolt 27 8 41 1370 (140) (1010)
Travel device mounting bolt (A) 30 24 46 1910 (195) (1410)
22 Travel device mounting bolt (B) 39 56 60 4410 (450) (3250)
Travel device mounting bolt (C) 20 36 30 390 (40) (290)
23 Side frame mounting bolt 56 68 85 9810 (1000) (7230)
24 Track pin-retaining bolt 30 152 46 1910 (195) (1410)
Front pin-retaining bolt (Loader) (A) 12 40 19 88 (9) (65)
Front pin-retaining bolt (Loader) (B) 16 12 24 205 (21) (152)
25 Front pin-retaining bolt (Loader) (C) 24 12 36 932 (95) (690)
Front pin-retaining bolt (Loader) (D) 20 24 30 540 (55) (400)
Front pin-retaining bolt (Loader) (E) 27 10 (19) 1029 (105) (760)
Front pin-retaining bolt (Backhoe) (A) 20 24 30 390 (40) (290)
26 Front pin-retaining bolt (Backhoe) (B) 16 12 24 205 (21) (152)
Front pin-retaining bolt (Backhoe) (C) 24 12 36 932 (95) (687)

7-132
MAINTENANCE
Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft)
M8 13 6 30 (3.0) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.5) (48) 50 (5.0) (37) 20 (2.0) (15.0)
M12 19 10 110 (11) (81) 90 (9) (66) 35 (3.5) (26.0)
M14 22 12 180 (18) (135) 140 (14) (103) 55 (5.5) (41)
M16 24 14 270 (27) (200) 210 (21) (155) 80 (8.0) (59)
M18 27 14 400 (40) (295) 300 (30) (220) 120 (12) (89)
M20 30 17 550 (55) (410) 400 (40) (295) 170 (17) (125)
M22 32 17 750 (75) (550) 550 (55) (410) 220 (22) (162)
M24 36 19 950 (95) (700) 700 (70) (520) 280 (28) (205)
M27 41 19 1400 (140) (1030) 1050 (105) (770) 400 (40) (295)
M30 46 22 1950 (195) (1440) 1450 (145) (1070) 550 (55) (410)
M33 50 24 2600 (260) (1920) 1950 (195) (1440) 750 (75) (550)
M36 55 27 3200 (320) (2360) 2450 (245) (1810) 950 (95) (700)

CAUTION: If fixing bolts for counterweight are

loosened, consult your nearest authorized dealer.

IMPORTANT: Make sure bolt and nut threads are clean

before installing.
Apply lubricant (e. g. white zinc B solved
into spindle oil) to bolts and nuts to sta-
bilize their friction coefficient.
NOTE: Tightening torque required is shown in N m.
For example, when tightening a bolt or nut with
a wrench of 1 m length, turning the end of it
with a force of 120 N, the torque produced will
be:

1m 120 N = 120 N m

To produce the same torque with a wrench of

0.25 m:
0.25 m N = 120 N m

Necessary force will be:

120 N m 0.25 m = 480 N

7-133
MAINTENANCE
1. Engine cushion rubber mounting bolts.

Tool: 55 mm
Torque: 3140 N m (320 kgf m, 2310 lbf ft)

M18M-07-058
2. Engine bracket mounting bolts.
Engine flywheel side
a
Tool: 50 mm
Torque: 1950 N m (200 kgf m, 1440 lbf ft)

a b
b
Tool: 30 mm
Torque: 540 N m (55 kgf m, 400 lbf ft)

M18M-07-059

Engine fan side

c
Tool: 32 mm
Torque: 740 N m (75 kgf m, 540 lbf ft)

M18M-07-060

7-134
MAINTENANCE
3. Hydraulic tank mounting bolts.
Tool: 50 mm
Torque: 1910 N m (195 kgf m, 1410 lbf ft)

M146-07-052

4. Fuel tank mounting bolts.

Tool: 50 mm
Torque: 1910 N m (195 kgf m, 1410 lbf ft)

M146-07-053
5. Pump transmission mounting bolt.
Tool: 19 mm
Torque: 110 N m (11 kgf m, 81 lbf ft)

M18M-07-059
6. Pump mounting bolts.
Main pump
Tool: Hex. Wrench 36 mm
Torque: 950 N m (97 kgf m, 700 lbf ft)

Fan pump
Tool: Hex. Wrench 30 mm
Torque: 550 N m (56 kgf m, 410 lbf ft)

M146-07-054

7-135
MAINTENANCE
7. Gear pump mounting bolt.
Tool: 22 mm
Torque: 140 N m (14 kgf m, 103 lbf ft)

146-07-076

8. Air con. compressor drive pump mounting bolt.

Tool: 22 mm
Torque: 140 N m (14 kgf m, 103 lbf ft)

M146-07-076

9. Control valve mounting bolts.

Tool: 30 mm
Torque: 390 N m (40 kgf m, 290 lbf ft)

M146-07-055

10. Swing device mounting bolts.

Tool: 55 mm
Torque: 3140 N m (320 kgf m, 2315 lbf ft)

Tool: 36 mm
Torque: 950 N m (97 kgf m, 700 lbf ft)

M146-07-028

7-136
MAINTENANCE
11. Swing motor mounting bolt.
Tool: 30 mm
Torque: 390 N m (40 kgf m, 290 lbf ft)

M146-07-028

12. Battery mounting bolts.

Tool: 10 mm
Torque: 20 N m (2 kgf m, 15 lbf ft)

13. Cab mounting bolt. M146-07-080

Tool: 27 mm
Torque: 300 N m (31 kgf m, 220 lbf ft)

M18M-07-061

14. Cab bed mounting bolt.

Tool: 19 mm
Torque: 110 N m (11 kgf m, 81 lbf ft)

M146-07-057

7-137
MAINTENANCE
15. Cab cushion rubber mounting bolts.
Tool: 19 mm
Torque: 110 N m (11 kgf m, 81 lbf ft)

(Front Side)
M146-07-063

(Rear Side) M146-07-064

7-138
MAINTENANCE
16. Swing bearing mounting bolt.

Upperstructure
Tool: 85 mm
Torque: 9810 N m (1000 kgf m, 7230 lbf ft)

Track M144-07-100

Remove cover (A) and check the tightening torque.

Tool: 85 mm
Torque: 9810 N m (1000 kgf m, 7230 lbf ft)

M146-07-023

17. Counterweight mounting bolt.

Tool: 85 mm
Torque: 6860 N m (700 kgf m, 5060 lbf ft)

M146-01-022

M18M-07-069

7-139
MAINTENANCE
18. Travel motor mounting bolt.
Tool: 30 mm
Torque: 390 N m (40 kgf m, 290 lbf ft)

M145-07-079

19. Upper roller mounting bolt.

Tool: 32 mm
Torque: 740 N m (75 kgf m, 540 lbf ft)

M146-07-077

20. Lower roller mounting bolt.

Tool: 70 mm
Torque: 4710 N m (480 kgf m, 3470 lbf ft)

M117-07-089

7-140
MAINTENANCE
21. Radiator mounting bolts.
Tool: 41 mm
Torque: 1370 N m (140 kgf m, 1010 lbf ft)

22. Travel device mounting bolts. M146-07-058

A. Tool: 46 mm
Torque: 1910 N m (195 kgf m, 1410 lbf ft)

B. Tool: 60 mm M145-07-048

Torque: 4410 N m (450 kgf m, 3250 lbf ft)

C. Tool: 30 mm
Torque: 390 N m (40 kgf m, 290 lbf ft)

M145-07-079

7-141
MAINTENANCE
23. Side frame mounting bolt.
Tool: 85 mm
Torque: 9810 N m (1000 kgf m, 7230 lbf ft)

M145-07-095

24. Track pin-retaining bolt.

Tool: 46 mm
Torque: 1910 N m (195 kgf m, 1410 lbf ft)

M117-07-089

7-142
MAINTENANCE
25. Front pin-retaining bolts.
(Loader)
Tool Torque
mm Nm (kgf m) (lbf ft) C
A 19 88 (9) (65)
B 24 205 (21) (152)
C 36 932 (95) (690)
D 30 540 (55) (400)
19
E 1029 (105) (760)
(Hex. Wrench)

B
M146-07-018

D B

B
M118-07-053
C

M118-07-114

M118-07-115

7-143
MAINTENANCE
26. Front pin-retaining bolt.
(Backhoe)
(A) Tool: 30 mm
Torque: 390 N m (40 kgf m, 290 lbf ft) C

(B) Tool: 24 mm
Torque: 205 N m (21 kgf m, 152 lbf ft)

M146-07-018

A
A C
C

C
B

A T146-01-03-002

M146-07-078

7-144
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

Operating Conditions Precautions for Maintenance

Muddy Soil, Rainy or Before Operation: Check the tightness of plugs and all drain cocks.
Snowy Weather After Operation: Clean the machine and check for cracks, damaged,
loose or missing bolts and nuts. Lubricate all necessary
parts without delay.
Near the Ocean Before Operation: Check the tightness of plugs and all drain cocks.
After Operation: Thoroughly clean the machine with fresh water to wash
off salt. Service electrical equipment often to prevent
corrosion.
Dusty Atmosphere Air Cleaner: Clean the element regularly at shorter service intervals.
Radiator: Clean the oil cooler screen to prevent clogging of the ra-
diator core.
Fuel System: Clean the filter element and strainer regularly at shorter
service intervals.
Electrical Equipment: Clean them regularly, in particular, the terminals of the
alternator and starter.
Rocky Ground Tracks: Carefully operate while checking for cracks, damage and
loose bolts and nuts. Loosen the tracks a little more than
usual.
Front Attachment: Standard attachment may be damaged when digging
rocky ground. Reinforce the bucket before using it, or
use a heavy duty bucket.
Freezing Weather Fuel: Use high quality fuel suitable for low temperature.
Lubricant: Use high quality low viscosity hydraulic oil and engine oil.
Engine Coolant: Be sure to use antifreeze.
Battery: Fully charge the batteries regularly at shorter service in-
tervals. If not fully charged, electrolyte may freeze.
Tracks: Keep the tracks clean. Park the machine on a hard sur-
face to prevent the tracks from freezing to the ground.
Falling Stones Cab: When operating in the area of possible falling rocks or
other debris, be sure to work carefully, paying close at-
tention to falling rocks, though the machine is equipped
with the reinforced cab meeting SAE FOPS.

9-1
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
MEMO
......................................................................................................................................................................................

......................................................................................................................................................................................

9-2
STORAGE
STORING THE MACHINE

1. Inspect the machine. Repair worn or damaged

parts. Install new parts if necessary.
2. Clean the outer air cleaner element.
3. Retract all hydraulic cylinders, if possible. If not,
coat exposed cylinder rods with grease.
4. Lubricate all grease points.
5. Park the tracks on long stable blocks.
6. Wash the machine.
7. Disconnect the battery ground circuit with the
ground disconnector.
8. Add an antirust agent to the coolant. In cold
weather, add an antifreeze, or drain the coolant
completely. Be sure to attach a No Water in Ra-
diator tag on a clearly visible location if the sys-
tem is drained.
9. Loosen the alternator belt.
10. Paint necessary areas to prevent rust.
11. Store the machine in a dry, protected place. If
stored outside, cover with a waterproof cover.
12. If the machine is stored for a long time, operate
hydraulic functions for travel, swing and digging
two to three times for lubrication, at least once a
month.
Be sure to check the level of coolant and all lu-
bricants and lubrication conditions before oper-
ating.

10-1
STORAGE
REMOVING THE MACHINE FROM STOR-
AGE

WARNING: Start the engine ONLY in a

well-ventilated place.

1. Remove grease from the cylinder rods if coated.

2. Adjust alternator belt tension.
3. Fill the fuel tank. Bleed air from the fuel system.
Check all fluid levels.
4. Start the engine.
Run the engine at half speed for several minutes
before full load operation.
5. Cycle all hydraulic functions several times.
6. Carefully check all systems before operating the
machine at full load.

NOTE: When the machine has been stored for a

long time, be sure to perform the following
steps as well:
(a) Check condition of all hoses and con-
nections.
(b) Warm up the engine.
(c) Stop the engine.
(d) Install new fuel filters. Replace the en-
gine oil filter and fill the engine with oil.

IMPORTANT: If the machine has not been used for

a long time, oil films on sliding sur-
faces may have broken down. Cy-
cling hydraulic functions for travel,
swing and digging two to three
times is necessary to lubricate the
sliding surfaces.

TRANSPORTING THE MACHINE

IMPORTANT: In case of transporting the machine

with disassembling, contact your
authorized dealer.

IMPORTANT: In case of transporting the machine

through public road, obey the traffic
law in that region.

IMPORTANT: In case of transporting the machine

by carrier, fix the machine tightly
with wire rope not to fall from the
carrier.

10-2
TROUBLESHOOTING
CUMMINS FAULT CODE LAMPS AND
DIAGNOSTIC SWITCHES

Cummins fault code lamp (1) and diagnostic switch (6) are
located inside electric equipment box (2) in the room (A)
under the cab. A

3- Maintenance lamp
4- Warning lamp
5- Stop lamp
6- Diagnostic switch
7- Increment and decrement switch
M18M-07-053

Active Cummins fault code can be read using the warning

lamp (4) and stop lamp (5).

NOTE: Active Cummins fault code can be also viewed

on monitor display.

1 2
How to read a fault code
Turn the key switch to the ON position.
Hold the diagnostic switch (6) to the ON position

In case one Cummins fault code is recorded, the

Cummins fault code will flash in the following sequence.
First, the warning lamp (4) will flash. Then there will be a
short, one-second pause when the warning lamp (4) and
the stop lamp (5) is off. The numbers of the recorded
Cummins fault code will then flash on stop lamp (5).
There will be a one-second pause between each number.
When the number is done flashing, warning lamp (4) will M18M-07-054

flash again. The number will repeat in the same 3 4 5 6 7

sequence.

In case more than one Cummins fault codes are

recorded, the first Cummins fault code will flash in above
sequence. The Cummins fault code will flash twice per
one fault code. Then, the next Cummins fault code will
flash sequentially in the same manner. To go to the
second Cummins fault code before the first Cummins
fault code flashes twice, move the increment and
decrement switch (7) to the INC position, then release.
To go back to the previous Cummins fault code, move
the increment and decrement switch (7) to the DEC M18M-11-001
position and then release.

11-1
TROUBLESHOOTING

ENGINE
Problem Cause Solution
Engine Cranks But Will Emergency engine stop switch Turn switch off (to NORMAL)
Not Start or Hard to Start
No fuel Add fuel.
Bleed air.
Wrong fuel Drain tank. Use correct fuel.
Contaminated fuel Drain tank and add clean fuel.
Low battery power Charge or install new battery.
Poor electrical connection Clean and tighten battery and starter
motor connections.
Starter motor failure Replace starter.
Wrong engine oil Drain oil. Use correct oil.
Air filter plugged Replace elements.
Fuel filter plugged Remove air from fuel system.
Clean fuel tank strainer.
Engine compression low See your authorized dealer.
Leaks in fuel system Check fuel system connections.
Air in fuel system Bleed air.
Engine Knocks, Runs Ir- Engine oil level low Add oil.
regularly or Stops
Plugged air intake system Clean filter and system.
Low coolant temperature Thermostat not working correctly or too
cool .
Water, dirt or air in fuel system Bleed air from fuel system.
Clean fuel tank outlet screen.
Fuel shut-off solenoid valve failure See your authorized dealer.

11-2
TROUBLESHOOTING

ENGINE
Problem Cause Solution
Engine Not Developing Full Air filters plugged Replace filter elements.
Power Fuel line restricted Repair or replace fuel line.
Contaminated fuel Drain fuel tank and clean outlet screen.
Refill.
Fuel filters plugged Change filters.
Plugged fuel tank breather Clean or install new breather.
Wrong fuel Use correct fuel.
Wrong oil Use correct oil.
Turbocharger failure See your authorized dealer.
Exhaust restriction Remove muffler and run engine.
Engine is too hot or cold See below.
Engine failure See your authorized dealer.
Valve clearance Check and adjust valves.
Intake or exhaust system leakage See your authorized dealer.
Engine Overheats Low coolant level Add coolant.
Thermostat See your authorized dealer.
Engine overloaded Check hydraulic relief valves.
Radiator cap faulty Install new cap.
Radiator core or or fuel cooler core Clean radiator and fuel cooler
plugged
Fan damaged Replace fan.
Air cleaner plugged Clean air cleaner.
Alternator belt loose Tighten or install new belt.
Cooling system passages dirty Flush cooling system.
Temperature gauge or sending unit See your authorized dealer.

11-3
TROUBLESHOOTING

ENGINE
Problem Cause Solution
Coolant Temperature Too Low Thermostat See your authorized dealer.
Temperature gauge or sending unit See your authorized dealer.
Low Engine Oil Pressure Engine oil pump or pump drive See your authorized dealer.
Low oil level Add oil.
Engine oil pressure regulation valve See your authorized dealer.
Plugged oil pump intake screen See your authorized dealer.
Plugged oil filter Install a new oil filter.
Oil leaks Check for leaks.
Oil diluted with fuel or coolant See your authorized dealer.
Engine temperature too high Check cooling system.
Wrong oil Drain oil. Use correct oil.
Engine Uses Too Much Oil Wrong oil Drain oil.Use correct oil.
Oil leaks Check engine oil drain plug.
Engine temperature too high Check cooling system.
Plugged air cleaner Clean element or install new element.
Internal engine component wear See your authorized dealer.
Engine Uses Too Much Fuel Plugged or dirty air intake system Clean air intake system.
Wrong fuel Use correct fuel.
Basic engine failures See your authorized dealer.
Excessive Black or Gray Wrong fuel Drain tank. Use correct fuel.
Exhaust Smoke
Plugged or dirty air intake or exhaust Clean air intake and exhaust system.
system
Basic engine failures See your authorized dealer.

11-4
TROUBLESHOOTING

ENGINE
Problem Cause Solution
Exhaust Gas is White Wrong fuel Drain tank. Use correct fuel.
Cold engine Run engine until warm.
Thermostat faulty or too cool See your authorized dealer.
Coolant leakage into engine cylinder See your authorized dealer.
Turbocharger Excessively Bearings not lubricated Insufficient oil pressure.
Noisy or Vibrates Check for restricted turbocharger oil
line.
Worn bearings See your authorized dealer.
Air leak in engine, intake or exhaust Inspect, repair.
manifold
Improper clearance between turbine See your authorized dealer.
wheel and turbine housing
Broken blades on turbine Remove exhaust elbow and air inlet
hose and inspect.
Oil Dripping from Damaged or worn bearings and/or See your authorized dealer.
Turbocharger Adapter worn seals Inspect and clean air cleaner.
Check for proper engine service
intervals or dirt enter into engine.
Excessive crankcase pressure Check vent tube to ensure tube is not
plugged.
Clean.
Turbocharger oil return line carbon Remove line.
build up where line passes exhaust Inspect, clean.
manifold
Excessive Drag in Carbon build-up behind turbine wheel Inspect, clean.
Turbo-charger Rotating caused by combustion deposits
Members
Dirt build-up behind compressor Inspect, clean.
wheel caused by air intake leaks
Bearing seizure or dirty or worn See your authorized dealer.
bearings, caused by excessive
temperature, unbalanced wheel, dirty
oil, oil starvation, or insufficient
lubrication

11-5
TROUBLESHOOTING

ELECTRICAL SYSTEM
Problem Cause Solution
Nothing Works Battery Recharge or replace.
Nothing Works Battery relay Replace relay.
(Except clock)
Batteries Undercharged Loose or corroded connections Clean and tighten or replace batteries.
Alternator belt loose Tighten or install new belt.
Alternator not charging See your authorized dealer.
Fuse Replace fuse.
Key switch failure Replace key switch.
Starting Motor Will Not Turn Battery undercharged or dead Recharge or replace battery.
Battery cables making poor Clean connections.
connections
High current fuse Replace high current fuse.
Key switch See your authorized dealer.
Start relay See your authorized dealer.
Starter solenoid See your authorized dealer.
Starter Repair or replace start motor.
Starter pinion jammed in flywheel Repair or replace starter.
gear
Major engine failure See your authorized dealer.
Starter Solenoid Chatters Poor connections at batteries or Clean connections.
starter
Low battery charge Recharge or replace batteries.
Starter solenoid hold-in windings See your authorized dealer.
open
Starter Motor Turns but Will Starter pinion gear not engaging See your authorized dealer.
Not Crank Engine flywheel ring gear
Pinion shift mechanism jammed or See your authorized dealer.
malfunctioning
Pinion gear teeth broken See your authorized dealer.
Flywheel gear teeth broken See your authorized dealer.
Engine Cranks Slowly Battery cables damaged or broken Inspect and replace cables.
internally
Battery or starter cable Clean and tighten connections.
connections loose or corroded

11-6
TROUBLESHOOTING

ELECTRICAL SYSTEM
Problem Cause Solution
Engine Cranks Slowly Battery discharged or will not hold a Replace battery.
charge
Starter dragging See your authorized dealer.
Low battery voltage Recharge or replace battery.
Starter Motor Continues to Start relay stuck See your authorized dealer.
Run After Engine Starts Starter solenoid stuck See your authorized dealer.
Starter not disengaging See your authorized dealer.
Key switch See your authorized dealer.
Charging Indicator Light Loose or glazed alternator belt Check belt.
On-Engine Running Replace if glazed, tighten if loose.
Engine speed low Adjust rpm to specification.
Excessive electrical load from added Remove accessories or install higher
accessories output alternator.
Loose or corroded electrical Inspect, clean, or tighten electrical
connections on battery, ground strap, connections.
starter, or alternator
Battery voltage low Change or replace battery.
Alternator or regulator See your authorized dealer.
Indicator circuit See your authorized dealer.
Noisy Alternator Worn drive belt Replace belt.
Worn pulleys Replace pulleys and belt.
Pulley misaligned Adjust alternator mount.
Alternator bearing Loosen alternator belts.
Turn pulley by hand.
If any roughness is felt, repair
alternator.
No Monitor Panel Indicators Fuse Replace fuse.
Work Wiring harness See your authorized dealer.
Individual Light in Monitor Bulb Replace bulb.
Panel is Not Working Fuse Replace fuse.
Wiring harness See your authorized dealer.

11-7
TROUBLESHOOTING

ELECTRICAL SYSTEM
Problem Cause Solution
No Indicators in Gauge Panel Circuit board See your authorized dealer.
Operate Wiring harness See your authorized dealer.
Fuse Replace fuse.
Indicator Light in Gauge Panel Bulb Replace bulb.
is Inoperative Fuse Replace fuse.
Sender Do sender check.
Wiring harness failure See your authorized dealer.
Coolant Temperature Gauge Fuse Replace fuse.
Does Not Work Gauge See your authorized dealer.
Gauge sender Do coolant temperature gauge sender
check.
Wiring harness See your authorized dealer.
Fuel Gauge Does Not Work Fuse Replace fuse.
Gauge See your authorized dealer.
Wiring harness See your authorized dealer.

11-8
TROUBLESHOOTING

MODE SELECTION
Problem Cause Solution
Fast/Slow Travel Speed Travel mode switches See your authorized dealer.
Does Not Function Pilot pressure switch (Travel) See your authorized dealer.
Pump delivery pressure sensor wire See your authorized dealer.
harness
Main controller See your authorized dealer.
Solenoid valve unit See your authorized dealer.
Damaged travel motor See your authorized dealer.
Auto-Idle Does Not Work Fuse Replace fuse.
Switch panel See your authorized dealer.
Electrical connector See your authorized dealer.
Wire harness See your authorized dealer.
EC motor See your authorized dealer.
Pressure switches (Travel, Front) See your authorized dealer.
Main controller See your authorized dealer.

HYDRAULIC SYSTEM
Problem Cause Solution
Hydraulic Functions are Slow Low oil level Fill reservoir to full mark.
Cold oil Warm up hydraulic oil to normal cycle
times.
Wrong oil Drain tank. Use correct oil.
Engine speed too low Increase speed or see your authorized
dealer.
Pilot circuit See your authorized dealer.
Worn pump See your authorized dealer.
Restricted pump suction line See your authorized dealer.
Hydraulic Oil Overheats Wrong oil Use correct oil.
Air leak in pump suction line See your authorized dealer.
Oil lines restricted See your authorized dealer.
Low oil level Fill reservoir to full mark.
Plugged filters Install new filters.
Worn pump See your authorized dealer.
Oil cooler bypass See your authorized dealer.
Relief valve See your authorized dealer.
Contaminated oil Drain oil and refill.
Improperly adjusted hydraulic See your authorized dealer.
components

11-9
TROUBLESHOOTING

HYDRAULIC SYSTEM
Problem Cause Solution
Hydraulic Oil Overheats Oilcooler core plugged Clean and straighten fins.
Fan damaged Replace fan.
Worn fan motor or pump See your authorized dealer.
Oil Foams Air leak in line from reservoir to pump Repair leak or see your authorized
dealer.
Kinks or dents in oil lines Check lines.
Wrong oil Use correct oil.
Water in oil Change oil.
High or low oil level Correct level.
Low or No Oil Pressure Wrong oil Use correct oil.
Improperly adjusted hydraulic See your authorized dealer.
components
No oil in system Fill with correct oil.
Worn cylinder packings See your authorized dealer.
Relief valve See your authorized dealer.
No Hydraulic Functions Hydraulic pump See your authorized dealer.
(Noise from pumps) Lack of hydraulic oil Add oil.
Damaged suction line or hose See your authorized dealer.
Clogged suction filter Clean.
Hydraulic Cylinders Operate Hydraulic pump worn See your authorized dealer.
but Cannot Lift Load Main relief valve pressure low See your authorized dealer.
Hydraulic oil level low Add oil.
Suction screen plugged Clean strainer and system.
Pump suction line leaking Inspect suction line.

11-10
TROUBLESHOOTING

HYDRAULIC SYSTEM
Problem Cause Solution
One Control Lever Does Not Relief valve pressure low See your authorized dealer.
Work Tube or hose damaged Repair or replace.
Hydraulic fittings loose Tighten.
Damaged O-rings in fittings Install new O-ring.
Hydraulic Pump See your authorized dealer.
Electric lever See your authorized dealer.
Pilot lines Repair or replace.
One Cylinder Does Not Work Control valve spool damaged or See your authorized dealer.
contaminated with dirt
Hydraulic lines damaged Repair or replace.
Fittings loose Tighten.
O-ring in fitting damaged Install new O-ring.
Electric lever See your authorized dealer.
Pilot lines Repair or replace.
One Cylinder Does Not Work Piston seals leaking See your authorized dealer.
or Has Little Power Cylinder rod damaged See your authorized dealer.
Pilot lines Repair or replace.
Electric lever See your authorized dealer.
Both Side Travel Motors Do Center joint failure See your authorized dealer.
Not Work Electric lever See your authorized dealer.
Pilot lines See your authorized dealer.

One Travel Motor Does Not Travel motor See your authorized dealer.
Work
Parking brake not releasing See your authorized dealer.
Electric lever See your authorized dealer.
Pilot lines Repair or replace.
Travel is Not Smooth Track adjustment Adjust tension.
Front idler or rollers damaged See your authorized dealer.
Track frame bent See your authorized dealer.
Rocks or mud jammed in track frame Remove and repair.
Travel brake not releasing See your authorized dealer.

11-11
TROUBLESHOOTING

HYDRAULIC SYSTEM
Problem Cause Solution
Swing Does Not Work Swing motor See your authorized dealer.
Electric lever See your authorized dealer.
Pillot lines See your authorized dealer.
Swing is Not Smooth Swing gear See your authorized dealer.
Swing bearing See your authorized dealer.
Lack of grease Apply grease.

AUTO-IDLE
Problem Cause Solution
Auto-Idle Does Not Work Fuse Replace
Auto-Idle switch Replace
Pilot pressure switch Replace
Failure of connector contact Repair or replace
Wiring harness Repair or replace
Engine speed control lever sensor Replace
Controller See your authorized dealer
Controller on the engine See your authorized dealer
Engine Speed Control Lever Failure of connector contact Repair or replace
Does Not Function Wiring harness Repair or replace
Engine speed control lever sensor Replace
Controller on the engine See your authorized dealer

11-12
SPECIFICATIONS
SPECIFICATIONS

A C

J I

H G
M18M-12-001

Model EX3600-6 Hydraulic Excavator

Type of Front-End Attachment Loader Front Backhoe Front
3 3 3 3
Bucket Capacity (Heaped) PCSA 21.0 m (27.5 yd ) PCSA 22.0 m (28.8 yd )
Operating Weight 361000 kg (795900 lb) 359000 kg (791500 lb)
Cummins QSK60-C
Engine -1
1450 kW/1800 min (1971PS/1800 rpm)
A: Overall Width 9420 mm (30 ft 11 in)
B: Cab Height *7830 mm (25 ft 8 in)
C: Rear End Swing Radius 6780 mm (22 ft 3 in)
D: Minimum Ground Clearance *905 mm (2 ft 12 in)
E: Counterweight Clearance *2440 mm (8 ft 0 in)
F: Overall Width of Upperstructure 8670 mm (28 ft 5 in)
G: Undercarriage Length 8700 mm (28 ft 7 in)
H: Undercarriage Width 6770 mm (22 ft 3 in)
I: Sprocket Center to Idler Center 6660 mm (21 ft 10 in)
J: Track Shoe Width 1270 mm (4 ft 2 in) (Grouser shoe)
2 2
Ground Pressure 189 kPa (1.93 kgf/cm , 27.4 psi) 188 kPa (1.92 kgf/cm , 27.3 psi)
1
Swing Speed 3.2 min (rpm)
Travel Speed (Fast/Slow) 2.2/1.7 km/h (4.9/3.8 mph)
Gradeability 31° (tan = 0.60)
NOTE: * The dimensions do not include the height of the shoe lug.

12-1
SPECIFICATIONS
WORKING RANGE

Loading Shovel

C B

M18M-12-002

Category
Loading Shovel
Item
A: Minimum Digging Distance 5850 mm (19 ft 2 in)

B: Minimum Level Crowding Distance 8870 mm (29 ft 1 in)

C: Level Crowding Distance 5050 mm (16 ft 7 in)

D: Maximum Digging Reach 15220 mm (49 ft 11 in)

E: Maximum Cutting Height 16300 mm (53 ft 6 in)

F: Maximum Dumping Height 10990 mm (36 ft 1 in)

G: Maximum Digging Depth 3910 mm (12 ft 10 in)

NOTE: *The dimensions do not include the height of the shoe lug.

12-2
SPECIFICATIONS
WORKING RANGE

Backhoe

B
A

M18M-12-003

Category
Backhoe
Item
A: Maximum Digging Reach 18190 mm (59 ft 8 in)

B: Maximum Digging Reach (on grond) 17610 mm (57 ft 9 in)

C: Maximum Digging Depth 8580 mm (28 ft 2 in)

D: Maximum Cutting Height 17690 mm (58 ft 1 in)

E: Maximum Dumping Height 11590 mm (38 ft 0 in)

NOTE: *The dimensions do not include the height of the shoe lug.

12-3
SPECIFICATIONS
MEMO
......................................................................................................................................................................................

......................................................................................................................................................................................

12-4
INDEX
A Cooling System ..................................................7-84
AM/FM Radio Operation .................................... 1-27 Correct Maintenance and Inspection Procedures....7-1
Adjust the Operator s Seat ..................................S-5 Cummins Fault Code Lamps and
Adjusting the Seat.............................................. 1-41 Diagnostic Switches .....................................11-1
After the First 50 Hours ....................................... 2-2
Air Cleaner......................................................... 7-82 D
Air Cleaner Restriction Indicator ........................ 1-18 DRIVING THE MACHINE ....................................4-1
Air Conditioner ................................................... 7-98 Defrosting...........................................................1-26
Air Conditioners ................................................. 1-22 Dehumidifying and Heating ................................1-25
Alternator Indicator ............................................ 1-12 Designations and Functions of Controls ............1-23
Auto-Idle .......................................................... 11-12 Dig with Caution ................................................ S-15
Auto-Idle .............................................................. 5-8 Digital Clock Setting Procedure .........................1-28
Auto-Idle Indicator.............................................. 1-18 Dispose of Waste Properly ............................... S-28
Auto-Idle Switch................................................. 1-36 Dome Light Switch .............................................1-33
Auto-Lubrication Indicator.................................. 1-15 Drive Machine Safely ........................................ S-10
Avoid Abusive Operation ................................... 5-14 Drive the Machine Carefully .................................4-1
Avoid Applying Heat to Lines Containing
Flammable Fluids ........................................S-25 E
Avoid Heating Near Pressurized Fluid Lines .....S-25 Electric Lever Indicator.......................................1-16
Avoid High-Pressure Fluids ...............................S-22 Electric Pump (Optional) ......................................7-8
Avoid Injury from Back-Over Electrical Equipment Box Indicator ....................1-18
and Swing Accidents ...................................S-12 Electrical System.................................... 7-105, 11-6
Avoid Injury from Rollaway Accidents................S-11 Emergency Engine Stop Indicator......................1-16
Avoid Power Lines .............................................S-15 Emergency Engine Stop Switch ............... 1-30, 3-14
Avoid Swinging Bucket to Move Objects ........... 5-15 Emergency Escape ..............................................1-5
Avoid Tipping .....................................................S-14 Emergency Exit ....................................................1-6
Avoid Undercutting ............................................S-13 Engine ...................................................... 7-36, 11-2
Engine Oil Pressure Gauge ...............................1-12
B Engine Oil Pressure Indicator ............................1-13
BREAK-IN............................................................ 2-1 Engine Oil Temperature Gauge .........................1-12
Before Turning Power ON ................................... 3-2 Engine Over Run Indicator .................................1-14
Beware of Asbestos Dust ..................................S-26 Engine Speed Control ..........................................5-7
Beware of Exhaust Fumes ................................S-24 Engine Speed Control Dial.................................1-31
Blower Operation without Cooling or Heating .... 1-26 Engine Start Switch ............................................1-30
Bucket Open-Close Pedals (Loading Shovel) ..... 5-5 Engine Stop Indicator .........................................1-13
Buzzer Stop Switch............................................ 1-37 Engine Stop Switch ............................................1-30
Engine Stop Switches ........................................3-15
C Engine Warning Indicator...................................1-17
COMPONENTS NAME ....................................... 1-1 Entrance Light Switch ........................................1-35
Cab Door Release Button.................................. 1-45 Evacuating in Case of Fire ......................... S-24, 1-6
Cab Features ....................................................... 1-8 Every 10 Hours or Each Shift ...............................2-1
Caution Indicators.............................................. 1-17 Exhaust Temperature Indicator..........................1-17
Caution Lamp .................................................... 1-20
Check Instruments After Starting ...................... 3-10 F
Check the Hour Meter Regularly ......................... 7-2 Fast-Filling Indicator...........................................1-16
Confirm Direction of Machine to be Driven..........S-9 Fast-Filling System.............................................1-38
Construction Outline .......................................... 7-10 Fasten Your Seat Belt ......................................... S-6
Control Lever (HITACHI Pattern Follow Safety Instructions ................................... S-2
Loading Shovel) ........................................... 5-4 Fuel Gauge ........................................................1-11
Control Lever (HITACHI Pattern Backhoe) ........ 5-2 Fuel System .......................................................7-74
Control Lever (ISO Pattern Backhoe) ................ 5-1 Fuel Temperature Indicator................................1-14
Control Lever (ISO Pattern Loading Shovel) ..... 5-3
Coolant Level Indicator ...................................... 1-14 G
Coolant Overheat Indicator................................ 1-13 General Precautions for Cab............................... S-4
Coolant Temperature Gauge............................. 1-11 Grading Operation..............................................5-13
Cooling............................................................... 1-25 Greasing ...........................................................7-24

14-1
INDEX
H Object Handling........................................ S-16, 5-18
HANDLING STAIRWAY/EMERGENCY ROPE.........1-2 Observe Machine Closely ....................................2-1
Handle Chemical Products Safely .....................S-28 Open Access Doors for Service ...........................7-5
Handle Fluids Safely Avoid Fires ....................S-17 Opening Cab Left Window .................................1-45
Handle Starting Aids Safely .................................S-6 Operate Only from Operator s Seat .................... S-7
Heating .............................................................. 1-25 Operate the Machine Safely...............................5-12
Horn Switch ....................................................... 1-40 Operate with Caution ........................................ S-15
Hour Meter......................................................... 1-12 Operating Backhoe ............................................5-13
Hydraulic Oil Level Indicator .............................. 1-14 Operating Ground Condition ................................4-9
Hydraulic Oil Overheat Indicator........................ 1-17 Operating Stairway...............................................1-2
Hydraulic Oil Temperature Gauge ..................... 1-11 Operating Tips....................................................5-15
Hydraulic System ................................7-11, 51, 11-9 Operating on Soft Ground ....................................4-7
Overnight Storage Instructions...........................5-19
I
INDEX................................................................ 14-1 P
Inspect Machine...................................................S-3 Park Machine Safely ......................................... S-17
Inspect Machine Daily Before Starting................. 3-1 Parking the Machine ..........................................4-11
Inspection/Maintenance Lights ............................ 7-6 Parking the Machine on Slopes .........................4-11
Investigate Job Site Beforehand..........................S-8 Periodic Replacement of Parts ..........................7-14
Periodic Replacement of Rubber Hoses............7-15
J Pilot Control Shut-Off Lever .................................5-6
Jump Starting ......................................................S-7 Practice Safe Maintenance ............................... S-18
Precautions for Operations ................................5-11
K Precautions for Traveling on Slopes ..................4-10
Keep Person Clear from Working Area .............S-13 Precautions for Welding and Grinding .............. S-25
Keep Riders Off Machine ....................................S-7 Prelub Indicator ..................................................1-19
Key Pad ............................................................. 1-20 Prepare Machine for Maintenance .......................7-3
Key Switch ......................................................... 1-29 Prepare for Emergencies .................................... S-2
Prevent Battery Explosions ............................... S-27
L Prevent Burns ................................................... S-21
Left Console....................................................... 1-20 Prevent Fires ..................................................... S-23
Loading Shovel Operation ................................. 5-16 Prevent Parts from Flying ................................ S-20
Prohibited Operation ..........................................5-16
M Protect Against Falling Stones and Debris.......... S-8
MAINTENANCE................................................... 7-1 Protect Against Flying Debris ............................ S-16
MAINTENANCE UNDER SPECIAL Protect Against Noise.......................................... S-3
ENVIRONMENTAL CONDITIONS................ 9-1 Provide Signals for Jobs Involving Multiple
Maintenance Interval Guide............................... 7-20 Numbers of Machines ................................... S-9
Maintenance Light Switch .................................. 1-34 Pump Contamination Indicator...........................1-17
Maintenance Under Special Pump Transmission Oil Level Indicator .............1-13
Environmental Conditions.............................. 9-1
Meter Check Screen.......................................... 1-10 R
Miscellaneous ................................................ 7-119 Raise One Track Using Boom and Arm...............4-7
Mode Selection .................................................. 11-9 Rear Console .....................................................1-39
Monitor Contrast Switch..................................... 1-20 Recognize Safety Information ............................. S-1
Monitor Display .................................................... 1-9 Remove Paint Before Welding or Heating ........ S-26
Move and Operate Machine Safely .....................S-6 Removing the Machine from Storage ................10-2
Replace Rubber Hoses Periodically.................. S-21
N Right Console.....................................................1-29
Never Position Bucket Over Anyone .................S-13
Never Undercut a High Bank .............................S-14 S
SAFETY .............................................................. S-1
O SAFETY SIGNS ................................................ S-29
OPERATING THE ENGINE ................................ 3-1 SPECIFICATIONS .............................................12-1
OPERATING THE MACHINE.............................. 5-1 STORAGE..........................................................10-1
OPERATOR S STATION Seat Belt.............................................................1-44

14-2
INDEX
Service Air Conditioning System Safely.............S-27
Specifications ................................................... 12-1
Stairway Position Indicator................................. 1-18
Starting Check Screen......................................... 1-9
Starting in Cold Weather ..................................... 3-9
Starting the Engine .............................................. 3-8
Status Indicators ................................................ 1-18
Stay Clear of Moving Parts ................................S-19
Steering the Machine Using Levers..................... 4-3
Steering the Machine Using Pedals..................... 4-2
Stop Valve Indicator........................................... 1-15
Stopping the Engine .......................................... 3-13
Store Attachments Safely ..................................S-20
Storing the Machine........................................... 10-1
Support Machine Properly .................................S-19

T
TROUBLESHOOTING ...................................... 11-1
Tachometer ....................................................... 1-11
Tension Indicator ............................................... 1-16
Towing Machine a Short Distance ....................... 4-8
Transmission ................................................... 7-43
Transporting the Machine .................................. 10-2
Travel Alarm ........................................................ 4-5
Travel Mode Indicator ........................................ 1-19
Travel Mode Switch ....................................1-36, 4-4
Traveling .............................................................. 4-6
Turning Power ON ............................................... 3-3

U
Understand Signal Words....................................S-1
Use Correct Fuels and Lubricants ....................... 7-2
Use Handholds and Steps ...................................S-5
Use a Chain to Prevent Falling Accidents ........... 7-7
Using Booster Batteries..................................... 3-11
Using Stairway..................................................... 1-2

V
Ventilation the Cab ............................................ 1-26

W
Warming-Up Operation ....................................... 5-9
Warming-Up the Cylinders and Motors ............. 5-10
Warn Others of Service Work ...........................S-19
Warning Indicators............................................. 1-12
Warning Lamp ................................................... 1-20
Washer Switch................................................... 1-21
Wear Protective Clothing.....................................S-3
Wiper Delay Selector Switch ............................. 1-21
Wiper Switch...................................................... 1-21
Work Light Switch.............................................. 1-32
Working Range (Backhoe) ................................ 12-3
Working Range (Loading Shovel)...................... 12-2

14-3

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