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: y Use only recommended fuel and lu-

bricants.
y Use only genuine HITACHI parts.
y Failure to use recommended fuel, lu-
bricants, and genuine Hitachi parts
will result in loss of Hitachi product
warranty.
y Never adjust engine governor or hy-
draulic system relief valve.
y Protect electrical parts from water and
steam.
y 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 (1) open when
the machine is parked on a slope, or while the
wind is blowing hard. The access doors (1)
may close accidentally, possibly resulting in
personal injury.
• When opening or closing the access doors (1),
take extra care not to catch fingers between the
base machine and the access doors (1).

• 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.

5
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 5
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

7 2 6
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

(1). Turn cap (1) 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
5
6

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

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

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 High pressure filters to Blocks (2) 4 5 2
Hoses
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

10

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

11

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

14

13 12

M18M-07-020

14
13

12

13

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

13

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 Ä ÌÌ
Pins Other Front Pins 20 Ä ÌÌ
2. Backhoe Front Joint Bucket and Link Pins 14 Ä ÌÌ
Pins Other Front Pins 18 Ä ÌÌ
3. Swing Bearing 24 Ä
350 L
4. Swing Internal Gear
(92.5 US gal)
5. Center Joint 1 Ä
NOTE: ÌÌ Maintenance required when operating in water or mud.
Ä 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) Ä
Change Premium Ì
120L Ú Ì
Reserve TankÏ
(31.7 US gal)
260L
Engine Oil Pan
(68.7 US gal) Ä
Change Standard Ì
258L Ú Ì
Reserve TankÏ
(68.2 US gal)
4. Replace Engine Oil Filter 4 Ä
NOTE: Ä First time only
Ì When change engine oil, change the oil in engine oil pan and reserve tank at the same time.
Ú 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: Ï 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 Ä
Trans- Engine Change Oil 62 L (16.4 US gal) Ä
mission Oil Replace Filter 2
Gear Clean Breather 1
2. Swing Check Oil Level 4 Ä
Gear
Reduction Change Oil 75 L (19.8 US gal)×4 Ä
Oil
Gear Clean Breather 4
3. Travel Check Oil Level 2
Gear
Reduction
Oil Change Oil 220 L (58.1 US gal)×2 Ä
Gear
NOTE: Ä 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 Ä
2. Drain Hydraulic Oil Tank Sump 1
4000 L
3. Change Hydraulic Oil Ì Ì Ì
(1060 US gal)
4. Replace Full-Flow Filter and Drain Filter 6 Ä
5. Replace Bypass Filter 1 Ä
6. Replace Pilot Oil Filter 1 Ä
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: Ì 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 Ä
5. Clean Radiator, LTA Cooler Interior 1+1 When changing coolant
6. Clean Radiator, LTA Cooler Core 1+1
NOTE: Ä 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 Ä ÌÌ
Pins Other Front Pins 20 Ä ÌÌ
2. Backhoe Front Joint Bucket and Link Pins 14 Ä ÌÌ
Pins Other Front Pins 18 Ä ÌÌ
3. Swing Bearing 24 Ä
350 L
4. Swing Internal Gear
(92.5 US gal)
5. Center Joint 1 Ä
NOTE: ÌÌ Maintenance required when operating in water or mud.
Ä 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
Ñ : Lubrication points

M18M-07-027

M18M-07-028

M18M-07-026

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

Ñ : Lubrication points

M18M-07-032

M18M-07-031

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

M18M-07-034

M18M-07-033

M18M-07-035

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

Ñ : Lubrication points

3 3

M18M-07-029

7-29
 MAINTENANCE
4. Grouped Grease Fittings (4) --- Arm
Ñ : 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) Ä
Change Premium Ì
120L Ú Ì
Reserve TankÏ
(31.7 US gal)
260L
Engine Oil Pan
(68.7 US gal) Ä
Change Standard Ì
258L Ú Ì
Reserve TankÏ
(68.2 US gal)
4. Replace Engine Oil Filter 4 Ä
NOTE: Ä First time only
Ì When change engine oil, change the oil in engine oil pan and reserve tank at the same time.
Ú 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: Ï 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
standard in accordance with the oil you use on dip- Reserve Tank
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 Ä
Trans- Engine Change Oil 62 L (16.4 US gal) Ä
mission Oil Replace Filter 2
Gear Clean Breather 1
2. Swing Check Oil Level 4 Ä
Gear
Reduction Change Oil 75 L (19.8 US gal)×4 Ä
Oil
Gear Clean Breather 4
3. Travel Check Oil Level 2
Gear
Reduction
Oil Change Oil 220 L (58.1 US gal)×2 Ä
Gear
NOTE: Ä 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

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.

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 Nxm (7 kgfxm, 51 lbfxft).
11. Wrap oil supply plug (3) threads with sealing-type
tape. Install oil supply plug (3). Tighten oil supply plug
(3) to 196 Nxm (20 kgfxm, 145 lbfxft).
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 Nxm (7 kgfxm, 51 lbfxft).
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 Nxm (7 kgfxm, 51 lbfxft).
16. Wrap the threads of oil supply plug (3) with
sealing-type tape. Reinstall oil supply plug (3) and
tighten it to 196 Nxm (20 kgfxm, 145 lbfxft).
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 Ä
2. Drain Hydraulic Oil Tank Sump 1
4000 L
3. Change Hydraulic Oil Ì Ì Ì
(1060 US gal)
4. Replace Full-Flow Filter and Drain Filter 6 Ä
5. Replace Bypass Filter 1 Ä
6. Replace Pilot Oil Filter 1 Ä
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: Ì Hydraulic oil changing interval differs according to the kind of hydraulic oil used. See recommended
oil chart.
Ä 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 Nxm (0.45 kgfxm, 3.3 lbfxft)
Jubilee Clamp: 5.9 to 6.9 Nxm
(0.6 to 0.7 kgfxm, 4.3 to 5.1 lbfxft)
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) Φ8 Φ10
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 N⋅m 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

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.
8 9
M146-03-034

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 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 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 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.

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
hot just after operation. Be sure to allow oil and Case Assembly
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 Nxm (27 kgfxm, 195 6 Line Side
lbfxft). 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 nozzle 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 injury.
To avoid this hazard, search for leaks with a
piece of cardboard.
Take care to protect hands and body from
high-pressure fluids.
If an accident occurs, see a doctor familiar with
this type of injury immediately. SA-031
Any fluid injected 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 injury.
To avoid this hazard :
• 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 .

14

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
Nxm 93 137 175 205
Fastening
(kgfxm) (9.5) (14) (18) (21)
torque
(lbfxft) (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

Nxm 29.5 39 93
Fastening torque
(kgfxm) (3) (4) (9.5)
(lbfxft) (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

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)

9

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

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

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 Ä
5. Clean Radiator, After Cooler Interior 1+1 When changing coolant
6. Clean Radiator, After Cooler Core 1+1
NOTE: Ä 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

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)

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
Quantity Sight Glass

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) N⋅m (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) N⋅m (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) N⋅m (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

9

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

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.

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

12

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 Nxm (15 kgfxm, 108
lbfxft).

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 Q’ty Wrench Torque
(mm) Size (mm) Nxm (kgfxm) (lbfxft)
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
Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft)
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 Nxm.
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:

1 m ×120 N = 120 Nxm

To produce the same torque with a wrench of

0.25 m:
0.25 m × N = 120 Nxm

Necessary force will be:

120 Nxm ÷ 0.25 m = 480 N

7-133
 MAINTENANCE
1. Engine cushion rubber mounting bolts.

Tool: 55 mm
Torque: 3140 Nxm (320 kgfxm, 2310 lbfxft)

M18M-07-058
2. Engine bracket mounting bolts.
Engine flywheel side
a
Tool: 50 mm
Torque: 1950 Nxm (200 kgfxm, 1440 lbfxft)

a b
b
Tool: 30 mm
Torque: 540 Nxm (55 kgfxm, 400 lbfxft)

M18M-07-059

Engine fan side

c
Tool: 32 mm
Torque: 740 Nxm (75 kgfxm, 540 lbfxft)

M18M-07-060

7-134
 MAINTENANCE
3. Hydraulic tank mounting bolts.
Tool: 50 mm
Torque: 1910 Nxm (195 kgfxm, 1410 lbfxft)

M146-07-052

4. Fuel tank mounting bolts.

Tool: 50 mm
Torque: 1910 Nxm (195 kgfxm, 1410 lbfxft)

M146-07-053
5. Pump transmission mounting bolt.
Tool: 19 mm
Torque: 110 Nxm (11 kgfxm, 81 lbfxft)

M18M-07-059
6. Pump mounting bolts.
Main pump
Tool: Hex. Wrench 36 mm
Torque: 950 Nxm (97 kgfxm, 700 lbfxft)

Fan pump
Tool: Hex. Wrench 30 mm
Torque: 550 Nxm (56 kgfxm, 410 lbfxft)

M146-07-054

7-135
 MAINTENANCE
7. Gear pump mounting bolt.
Tool: 22 mm
Torque: 140 Nxm (14 kgfxm, 103 lbfxft)

146-07-076

8. Air con. compressor drive pump mounting bolt.

Tool: 22 mm
Torque: 140 Nxm (14 kgfxm, 103 lbfxft)

M146-07-076

9. Control valve mounting bolts.

Tool: 30 mm
Torque: 390 Nxm (40 kgfxm, 290 lbfxft)

M146-07-055

10. Swing device mounting bolts.

Tool: 55 mm
Torque: 3140 Nxm (320 kgfxm, 2315 lbfxft)

Tool: 36 mm
Torque: 950 Nxm (97 kgfxm, 700 lbfxft)

M146-07-028

7-136
 MAINTENANCE
11. Swing motor mounting bolt.
Tool: 30 mm
Torque: 390 Nxm (40 kgfxm, 290 lbfxft)

M146-07-028

12. Battery mounting bolts.

Tool: 10 mm
Torque: 20 Nxm (2 kgfxm, 15 lbfxft)

13. Cab mounting bolt. M146-07-080

Tool: 27 mm
Torque: 300 Nxm (31 kgfxm, 220 lbfxft)

M18M-07-061

14. Cab bed mounting bolt.

Tool: 19 mm
Torque: 110 Nxm (11 kgfxm, 81 lbfxft)

M146-07-057

7-137
 MAINTENANCE
15. Cab cushion rubber mounting bolts.
Tool: 19 mm
Torque: 110 Nxm (11 kgfxm, 81 lbfxft)

(Front Side)
M146-07-063

(Rear Side) M146-07-064

7-138
 MAINTENANCE
16. Swing bearing mounting bolt.

Upperstructure
Tool: 85 mm
Torque: 9810 Nxm (1000 kgfxm, 7230 lbfxft)

Track M144-07-100

Remove cover (A) and check the tightening torque.

Tool: 85 mm
Torque: 9810 Nxm (1000 kgfxm, 7230 lbfxft)

M146-07-023

17. Counterweight mounting bolt.

Tool: 85 mm
Torque: 6860 Nxm (700 kgfxm, 5060 lbfxft)

M146-01-022

M18M-07-069

7-139
 MAINTENANCE
18. Travel motor mounting bolt.
Tool: 30 mm
Torque: 390 Nxm (40 kgfxm, 290 lbfxft)

M145-07-079

19. Upper roller mounting bolt.

Tool: 32 mm
Torque: 740 Nxm (75 kgfxm, 540 lbfxft)

M146-07-077

20. Lower roller mounting bolt.

Tool: 70 mm
Torque: 4710 Nxm (480 kgfxm, 3470 lbfxft)

M117-07-089

7-140
 MAINTENANCE
21. Radiator mounting bolts.
Tool: 41 mm
Torque: 1370 Nxm (140 kgfxm, 1010 lbfxft)

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 N⋅m (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)

(C) Tool: 36 mm
Torque: 932 N⋅m (95 kgf⋅m, 687 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

E
D

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° (tanθ = 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