ZW 1806

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, DEF/AdBlue® and oil levels.
 Check for leaks, kinked, frayed or damaged hoses and
lines.
 Walk around machine checking general appearance,
noise, heat, etc.
 Check for loose or missing parts. SA-005
If there is any problem with your machine, repair it before

operating or contact your authorized dealer for repairs.
IMPORTANT:
 Use only recommended coolant, fuel, DEF/AdBlue®
and lubricants.
 Be sure to use only genuine Hitachi parts. Failure to
do so may result in serious injury or death and/or
machine breakdown.
 Failure to use recommended coolant, fuel, DEF/
AdBlue®, lubricants, and genuine Hitachi parts will
result in loss of Hitachi product warranty.
 Never adjust engine governor.
Never adjust hydraulic system relief valve.
 Protect electrical parts from water and steam.
 Never spray high pressure water or steam to
the transmission oil filler port, transmission air
breather, and vicinity of the axle air breather.
 Never disassemble electrical components such as
main controller, sensors, etc.
 Never adjust parts of engine fuel system.
Never adjust hydraulic equipment.
 Using bad quality fuel, drainage agent, fuel
additives, gasoline, kerosene or alcohol refueled
or mixed with specified fuel may deteriorate
performance of fuel filters and cause surface
problems between moving parts at lubricated
contacts in the injector. It also affects the engine
and aftertreatment device parts, leading to
malfunction.
 Use Hitachi genuine high performance filter.
7-1
MAINTENANCE
 Machine Information Controller
This machine provides a machine information controller that stores machine operation information for preventive
maintenance.
When maintaining the machine, our authorized service man may down load the stored information via satellite.
Consult with your nearest authorized dealer for detailed function of this device.
 Communication Terminal Operation (Option)
It is not necessary to check or operate the communication terminal however if any abnormality is found, consult your
nearest authorized dealer.
Before installing any covering attachment such as a head guard, consult your nearest authorized dealer.
Never spray water on the communication terminal and wiring.
 Inquire on the proper way to recycle or dispose of oil, fuel, coolant, DEF/AdBlue®, filters, batteries and other waste
from your local environmental or recycling center, or from your authorized dealer.
7-2
MAINTENANCE
Check the Hour Meter Regularly

Refer to the List of Check and Maintenance for information
about lubricants, check and adjustment intervals. The
lubrication chart is affixed on the left side of the front chassis.
Refer to 7-6 page.
This manual recommends grouping the intervals into three

categories as follows:
Daily Check : To be conducted daily before operation (every 10 hours)
Monthly Check : To be regularly conducted once per month (every 250 hours)
Annual Check : To be regularly conducted once per year (every 2000 hours)
Check and maintenance intervals shown in this manual

are those for the machines to be operated under normal
conditions. In case the machine is operated under more
severe conditions, shorten the intervals.
7-3
MAINTENANCE
Layout
2 3 4 5 6 7 8 9 10 11
12
13
26 25 24 23 22 21 20 19 18 17 16 15 14 27
MNEK-07-001
1. Bolt on Cutting Edge 18. Transmission

2. Bucket 19. Second (Center) Propeller Shaft
3. Bucket Cylinder Pin 20. Steering Cylinder
4. Bucket Cylinder 21. Lift Arm Cylinder
5. Front Combination Lamp 22. Front Axle
6. Batteries 23. Lift Arm Cylinder Pin
7. Hydraulic Oil Tank 24. Bell Crank (Lever) Pin
8. Aftertreatment Device 25. Bucket Link Pin
9. Expansion Tank 26. Bucket Pin
10. Air Cleaner 27. DEF/AdBlue® Tank
11. Radiator, Oil Cooler, and Other Cooling System
12. Work Light
13. Rear Combination Lamp
14. Fuel Tank
15. Engine
16. Rear Axle
17. Third (Rear) Propeller Shaft
7-4
MAINTENANCE
MEMO
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7-5
MAINTENANCE
Maintenance Guide Table
The maintenance guide table is affixed to the reverse side
of the tool box cover. Lubricate and/or service the parts at
the intervals as instructed in the table so that all necessary
maintenance can be performed regularly.
 Symbol Marks
The following marks are used in the maintenance guide
table.
Grease
Hydraulic Oil
(Front Joint Pin, Cylinder Pin, Propeller Shaft)
Hydraulic Oil Filters

Engine Oil (Pilot Filter, Hydraulic Oil Tank Filter, Suction
Filter, Air Breather Element)
Gear Oil
Engine Oil Filter
(Final Drive, Differential Gear)
Coolant
Fuel
(Long-Life Coolant)
Transmission Oil Fuel Filter

(Transmission, Torque Converter) (Fuel Main Filter, Pre-Filter)
Transmission Oil Filter DEF/AdBlue® Supply Module Main Filter
7-6
MAINTENANCE
 Maintenance Guide Table
1 21 2 3 4, 5, 6, 7 Lubrication Interval 9
23
22
10
15
11
12
13
20 13
YA00045385_KC
17 19 18 17 2 16 14 20 12
Item Page Item Page

1 Grease (Front Joint Pin) 7-23 12 Grease (Axle Support pin) 7-27
2 Grease (Frame Hinge Pin) 7-26 13 Axle Gear Oil (Final drive, Differential gear) 7-43
3 Transmission Oil Filter 7-40 14 Transmission Oil 7-39
4 Hydraulic Oil Filter (Suction) 7-51 15 Engine Oil Filter 7-34
5 Hydraulic Oil Filter (Main) 7-51 16 Hydraulic Oil Filter (Pilot) 7-52
6 Air Breather Element 7-56 17 Grease (Steering Cylinder Pin) 7-25
7 Hydraulic Oil 7-48 18 Grease (Propeller Shaft) 7-29
8 Coolant (Long-Life Coolant) 7-79 19 Grease (Propeller Shaft Center Support) 7-29
9 Fuel Filter, Fuel Pre-Filter 7-68 20 Grease (Propeller Shaft Universal) 7-29
to 69 21 Grease (Brake Pedal) 7-30
10 Fuel (Diesel Fuel) 7-69 22 DEF/AdBlue® 7-127
11 Engine Oil 7-31 23 DEF/AdBlue® Supply Module Main Filter 7-130
7-7
MAINTENANCE
Preparations for Inspection and Maintenance

1 2 3
dWARNING: If ride control switch (3) is in the AUTO
position, the lift arm may unexpectedly rise. To
avoid an accident due to unexpected movement
of the lift arm, always turn ride control switch
(3) OFF before beginning the inspection and/or
maintenance of the machine.
dCAUTION: If the machine moves unexpectedly,

a serious accident may result. Be sure to apply the
parking brake when parking the machine.
Unless specified otherwise, park the machine by following

the procedures below before beginning the inspection
and/or maintenance work.
MNEC-07-001
1. Park the machine on a solid level surface.

2. Lower the working tools such as the bucket to the
ground. 4 5 6 7
3. Turn ride control switch (3) OFF.

4. Place forward / reverse lever (4) and forward / reverse
switch to neutral and place neutral lever lock (6) to
lock ( ) position.
5. Apply the parking brake (Turn parking brake (5) ON.)
6. Wedge the tires.
7. Run the engine at low idle speed for 5 minutes to
cool the engine. Turn key switch (7) OFF to stop
the engine. Again, turn key switch (7) ON and
place control lever lock switch (2) to the unlock ( MNEC-01-036
) position. Fully operate the lift arm control lever
(1) 3 to 4 strokes to release residual pressure in the
hydraulic system. If inspection and/or maintenance
5
must be performed with the engine kept running,
use a signal person.
8. Be sure to place control lever lock switch (2) to the
lock ( ) position.
9. Turn key switch (7) OFF and remove the key.
10. Start working only after putting an "UNDER
INSPECTION/MAINTENANCE" tag in a highly visible MNEC-01-058
place such as on the cab door or the control lever.
7-8
MAINTENANCE
dWARNING: Never attempt to maintain the machine

when the engine is running in order to prevent an
accident. If the engine must be run while working, do
the following.
 One person should take the operator's seat
to be ready to stop the engine any time while
communicating with other workers.
 When working around moving parts is unavoidable,
pay special attention to ensure that hands, feet, and
clothing do not become entangled. SA-2294
 If parts or tools are dropped or inserted into the fan
or the belt, they may fly off or be cut off. Do not drop
or insert parts and tools into the moving parts.
 Move control lever lock switch (2) to lock ( ) position
so that the front attachment will not move.
 Never touch the control levers and pedals.
If operating the control levers or pedals is
unavoidable, signal co-workers to move to a safe
place.
SA-026
MNEC-07-001
7-9
MAINTENANCE
Articulation Lock
dCAUTION: Before beginning to work near the

chassis center hinge, install articulation stopper
(lock bar) (2) to securely lock and prohibit
movement between the front and rear chassis.
Avoid accidents from unexpected movement of the
machine.
1. Align the front and rear chassis centers with each

other.
2. Remove β-form pin (5) to remove set pin (1) from the 1
MNEK-01-018
rear chassis hole.
3. Pull out and rotate articulation stopper (2) to align it

with the front chassis hole (3).
4. Install set pin (1) into the front chassis hole (3) and
the articulation stopper tip end hole. Install β-form
pin (5) to lock the articulation stopper (2) in position.
3 2
MNEK-01-019
7-10
MAINTENANCE
Inspection/Maintenance Access Side Cover 1 2
dCAUTION:
 Always close side covers (1) during driving and
operation.
 Do not keep side covers (1) open on a slope or when
a strong wind is blowing. Failure to do so may be
dangerous because side cover (1) may unexpectedly
close.
 Take care not to pinch your fingers when opening/
closing the side covers (1).
 When side cover (1) is opened, the cover may move
suddenly. Be careful not to come in contact with the
cover.
3 MNEK-01-009
 Before inspecting around the engine, be sure to
secure side cover (1) with holding rod (4).
 If the machine is equipped with the fenders (2) on
side covers (1), never ride on the fenders (2).
When opening side cover (1), pull latch (3).
fNOTE: When required to inspect the machine for a long time

with side cover (1) kept open, lock side cover (1) using the
holding rod (4) provided inside the side cover.
Side cover (1) has a holding groove. Engage the holding rod
(4) in the holding groove beforehand.
4
MNEK-01-010
7-11
MAINTENANCE
Rear Grille
dCAUTION:
 Open or close rear grille (2) only after stopping
the engine. Failure to do so may create a very
dangerous situation as entanglement with the
cooling fan may result.
 Before driving the machine, always check that MNEK-01-020
rear grille (2) is not open. 1
 Rear grille (2) may spring open. Take care not to

come in contact with the rear grille.
Opening the rear grille 2
Push open/close Button (1) laterally to open rear grille

(2) upward, allowing the fuel tank to be refilled and/or
the cooling fan to be cleaned.
Closing the rear grille

While holding the rear grille, slowly close the rear grille
downward until a "click" sound is heard.
MNEK-01-021
7-12
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.
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 Replacement Intervals

Fuel hose (Fuel tank to filter)
Fuel hose (Fuel tank to injection pump)
Oil filter hose (Engine to oil filter)
Heater hose (Heater to engine) Every 2 years or 4000 hours
Engine
Fuel hose (Engine to fuel tank) whichever comes first
Coolant filter hose (Engine to DCA coolant filter)
Heater hose (Engine to dosing module)
DEF/AdBlue® hose (Aftertreatment device)
Brake valve seals (Rubber parts) Every 1 year
Wet type brake (D-ring for piston) Every 4 years
Accumulator Every 2 years
Brakes
Stop light switch Every 2 years
Brake hose Every 2 years or 4000 hours
whichever comes first
Steering hose Every 2 years or 4000 hours
whichever comes first
Steering Mechanism
Steering cylinder seals (Rubber parts) Every 4 years
Steering valve seals (Rubber parts) Every 2 years
Pump suction hose
Hydraulic hose (Main pump to main valve)
Hydraulic hose (Fan pump to fan motor and fan valve)
Hydraulic hose (Pilot pump to charging valve)
Base Machine Hydraulic hose (Transmission high pressure circuit hose)
Hydraulic Hydraulic hose (Transmission cooler line hose) Every 2 years or 4000 hours
System Hydraulic oil tank return hose whichever comes first
Hydraulic oil cooler line hose
Hydraulic hose (Valve to hydraulic oil tank return hose)
Lift arm cylinder line hose
Front
Bucket cylinder line hose
Attachment
Pilot hose
Cab Seat belt Every 3 years
fNOTE: Be sure to replace seals, such as O-rings and gaskets,

when replacing hoses.
7-13
MAINTENANCE
Inspection and Maintenance Table

Check and/or carry out the maintenance at intervals of IMPORTANT
the specified operating hours below or the calender date, Severe applications require more frequent
whichever comes first. maintenance. Severe conditions include heavy dust,
extremely abrasive material, caustic chemicals,
extremely wet conditions or abnormally hot or cold
ambient temperatures.
: First time replacement or cleaning only

Operating hours
Section Item for check Page
10 50 100 250 500 1000 2000 4000 4500
Check Engine Oil Level  7-32
Check Coolant Level  7-77
Check DEF/AdBlue® Level  7-128
Check Accelerator Pedal Operation, and
 7-110
Exhaust Gas Color and Noise
Drain Fuel Filter  7-68
Check Fuel Level  7-65
Check Drive Belt  7-78
Check Fuel Hoses  7-73
Check Sound Absorbing Mat Around
 7-112
Engine
Check Crankcase Breather Tube  7-36
Check Air Inlet System  7-75
Replace Engine Oil and Oil Filter Cartridge 7-33

7-35
Engine
Clean Radiator/Oil cooler Cores and Other
*3  7-81
Cooling System
Replace Fuel Main Filter Element  7-69
Replace Fuel Pre-Filter Element  7-70
Drain Water and Sediment from Fuel Tank  7-67
Clean Fuel Pump Strainer  7-71
Check Drive Belt Tentioner Every 1 years or 1000 hours 7-79
Replace Crankcase Air Breather Element  7-37
Check Vibration Damper  7-39
Replace DEF/AdBlue® Supply Module Main
 7-131
Filter Element
Check and Adjust Valve Clearance Every 5000 hours 7-113
Replace Air Cleaner Element Indicator comes ON 7-74
Replace Coolant Every 2 years or 3000 hours 7-80
Check and Clean Aftertreatment Device As required, when regeneration indicator comes ON 7-125
fNOTE:
*3 Shorten maintenance intervals when the machine is operated under severe conditions or when the machine is
continuously operated for a long period of time.
7-14
MAINTENANCE

Operating hours
10 50 100 250 500 1000 2000 4000 4500
Transmission Check Transmission Oil Level  7-40
& Torque Replace Transmission Oil Filter Cartridge   7-41
Converter Replace Transmission Oil   7-41
Check Tire for Damage  7-94
Greasing (Axle support)  7-28
Check Tire (Tire Pressure)  7-94
Greasing (Propeller Shaft Pillow Block
 7-29
Bearing)
Check Wheel Bolt Torque   7-95
Clean Axle Housing Air Breather  7-46
Check Surroundings Around Axles and Axle
 7-46
Axle system Covers for Oil Leaks
Greasing (Second Propeller Shaft Spline) *3  7-30
Greasing (Third Propeller Shaft Spline) *3  7-30
Replace Axle Oil  7-45
Retighten Front Axle and Rear Axle Support
  7-113
Mounting Bolts
Greasing (Second (Front) Propeller Shaft) Every 12000 hours *3  7-28
Greasing (Second (Center) Propeller Shaft) Every 12000 hours *3  7-29
Greasing (Third (Rear) Propeller Shaft) Every 12000 hours *3  7-30
Check Steering Wheel Play  7-109
Steering
Greasing (Steering Cylinder) 
*1  7-26
system
Check Gas Pressure in Steering Accumulator  7-59
Check Parking Brake Force  7-91
Check Right and Left Brake Interlocking
 7-90
Performance
Check Accumulator Function, Gas Leakage,
 7-92
Brake system Looseness, and Damage
Greasing (Brake Pedal)  7-31
Greasing (Brake Pedal Linkage)  7-31
Check Brake Disks (Service and Parking)  7-93
Check Gas Pressure in Accumulator  7-93
fNOTE:
*1 Add grease daily during first 50 hours of operation. In case the machine is engaged in excavation in mud, water or
snow, add grease after each work shift.
7-15
MAINTENANCE

Operating hours
10 50 100 250 500 1000 2000 4000 4500
Check Hydraulic Oil Level  7-49
Check Bucket Teeth and Cutting Edge  7-107
Check Hoses and Lines for Leaks  7-60
Check Hoses and Lines for Cracks, Bends,
 7-60
Etc.
Greasing *1  *2   7-24
Check Ride Control Accumulator Function,
Gas Leakage, Looseness, and Damage  7-59
(Option)
Loading
Replace Hydraulic Tank Oil Return Filter  7-55
system
Replace Air Breather Element  7-57
Replace Pilot Oil Filter  7-53
Check Pilot Circuit Accumulator Function,
 7-58
Gas Leakage, Looseness, and Damage
Check Gas pressure in Ride Control
 7-59
Accumulator (Option)
Replace Hydraulic Oil and Clean Suction 7-50
*4 
Filter 7-52
Replace Pilot Circuit Accumulator Every 4000 hours or 2 years 7-59
Check Outer and Inner Rear View Mirrors  7-111
Check ROPS Cab Mounts, Resin Cab Roof,
 7-108
and Roof Mounting Bolts
Check and Replace Seat Belt and Lower
 Replace every 3 years 7-108
Chassis Tether
Clean Engine Room and Hood  7-112
Check Steps, Grab Handles and Handrails  7-111
Check Windshield Washer Fluid Level  7-108
Greasing (Center Pin)  7-27
Check Monitor Functions and Instrument
 7-86
Operation
Check Horn and Back Up Alarm  7-87
Electrical Check Work Lights  7-87
system Clean Rear View Camera Lens  7-112
Check Electrical Harnesses and Fuses  7-88
Check Battery Electrolyte Level  7-84
Check Electrolyte Specific Gravity  7-85
fNOTE:
*1 Add grease daily during first 50 hours of operation. In case the machine is engaged in excavation in mud, water or
snow, add grease after each work shift.
*2 After 50 hours of operation, carry out next greasing at the first 250 hours of operation. Then, carry out greasing every
500 hours of operation afterwards. Shorten greasing intervals when the machine is operated under severe conditions
or when the machine is continuously operated for a long period of time.
*4 Hydraulic oil changing interval differs according to the kind of hydraulic oil used.
7-16
MAINTENANCE

Operating hours
10 50 100 250 500 1000 2000 4000 4500
Clean/Replace Air Conditioner 7-100
*3  
Circulation/Fresh Air Filters 7-103
Check Air Conditioner Drive Belt  7-105
Check Refrigerant Level  7-106
Air
Check Air Conditioner Condenser  7-105
Conditioner
Check Air Conditioner  7-104
Check Air Conditioner Piping  7-104
Check Compressor and Pulley  7-106
Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours 7-106
Check Tightening Torque of Bolts and
Others   7-114
Nuts
fNOTE:
7-17
MAINTENANCE
Kind of Oils
Grease
Kind of Grease Multipurpose-type Lithium Grease
Application Chassis Lubrication, Front Attachment Joint Pins
Air Temperature -20 to 45 °C (-4 to 113 °F)
Oil Specification NLGI 2 EP
fNOTE:
 Be sure to use a lithium-based grease for universal joints and a propeller shaft spline.
If other types of chassis grease are used, premature wear and/or a noise emission may result.
 NLGI No. 2 grease is suitable for most temperatures and some auto-lube systems.
Use NLGI No. 1 or No. 0 grease for extremely low temperature.
Engine Oil
IMPORTANT: Use engine oil equivalent to DH-2 specified
in JASO or CJ-4, API. Failure to do so may reduce the
engine performance and/or shorten the engine service life.
Please be noted that all engine failures caused by
using engine oil other than specified are excluded from
Hitachi Warranty Policy.
Consult your nearest authorized dealer for the unclear points.
Kind of Oil Engine Oil
Application Engine Crank Case
Air Temperature -20 to 20 °C (-4 to 68 °F) -15 to 45 °C (5 to 113 °F)
API CJ-4, JASO DH-2
Oil Specification SAE10W-30 SAE15W-40
SAE10W-40
7-18
MAINTENANCE
Transmission Oil
Kind of Oil Engine Oil
Application Transmission and Torque Converter
Oil Specification API CF 10W Class
fNOTE: When the atmospheric temperature is below -20 °C: Contact your authorized dealer.
Axle Oil
Kind of Oil Gear Oil
Application Axle & Wet Disc Brake
High Gear Oil
Recommended Product Hitachi
TKTT15150-4th
Alternative Product TO-4 SAE50 Fluid, with 6% friction modifier
fNOTE:
 When using TO-4 SAE50 Fluid other than the listed recommended products, add 6% friction
modifier or "anti-chatter" additive to prevent or eliminate service brake application noise.
Recommended additive package for universal tractor fluid: HCM 9990A or Afton Hitec8703
or equivalent.
 The acceptable ambient temperature when using TO-4 SAE50 Fluid should fall within the
range -15 to 40 °C (5 to 104 °F).
 For extremely low ambient temperatures, lower viscosity or synthetic oils may be required.
7-19
MAINTENANCE
Hydraulic Oil
Kind of Oil Hydraulic Oil

Application Hydraulic System (Hydraulic Oil Tank)
Change Interval 4000 hours
Recommended Product Hitachi Super EX 46HN -
Alternative Product - JCMAS HK VG46W
fNOTE:
 Never mix hydraulic oils containing zinc with zinc-free hydraulic oils as hydraulic system component damage could
result.
 Use appropriate oil of viscosity depending on the temperature. Low temperature viscosity will differ depending on each
product. Contact each hydraulic oil manufacture directly.
Recommended Coolant
Kind of Coolant Long-Life Coolant

Application Radiator
Standard ASTMD-6210
Manufacturer/
Long Life Coolant C521
Recommended Products
7-20
MAINTENANCE
Service Refill Capacity
Location Liters Gallons

Fuel Tank (Diesel Fuel) 245 64
Engine Lubricant (Engine Oil) 25 6.6
Engine Coolant 33 8.7
Transmission 30 7.9
Axle (Front/Rear) 34/34 9/9
Hydraulic Oil 150 39.6
DEF Tank 25 6.6*
fNOTE: *: Refill quantity when the level gauge indicates "empty". The other shows the
maximum refill quantity to be required during level check, and may differ from the whole
system quantity.
7-21
MAINTENANCE
List of Consumable Parts

1. Filter Elements
Part No.
Engine Oil Filter YA00019107
Fuel Main Filter YL00008001
Fuel Pre-Filter Element YL00008002
Air Cleaner Element (outer) YA00018804
Air Cleaner Element (inner) YA00018805
Suction Filter 263F752091
Hydraulic Tank Oil Filter 4448401
Pilot Oil Filter 2655742471
Transmission Oil Filter YA00049017
Crankcase Air Breather Element YA00018806
DEF/AdBlue® Supply Module Main Filter YA00058284
Hydraulic Tank Air Breather Element 4437838
2. Drive Belts
Part No.
Air Conditioner Drive Belt 263F672001
7-22
MAINTENANCE
3. Combination Light and Other Light
Part No.
Head Light Assembly 4436232 (44890-60350)
Head Light Bulb (24 V, 70/75 W) 4434679
Unit 4434678
Turn Signal Light Assembly 2640242432
Turn Signal Light Clearance Light (24V 5W) 2640247301
Bulb
Turn Signal Light (24V 25W) 2640247291
Rear Combination Light Rear Combination Light Assembly 44881-60490
Work Light Assembly 4336570
Work Light
Bulb (24V 70W) 4285648
4. Slow Blow Fuses

Part No.
45A 4315323
65A 263G244421
70A 4315073
140A YA00021809
7-23
MAINTENANCE
A. Greasing
dWARNING: Apply the parking brake and the

articulation lock bar.
fNOTE:
 Until break-in operation is performed for more than
50 hours, lubricate the machine every day to get initial
operational concordance.
 If excavation is made in mud, water or snow, lubricate
the machine after operation is complete.
 Sufficiently add high quality grease through the grease
fittings. After removing contamination around the
grease fitting, add grease. After greasing, thoroughly 1
remove the old grease that was pushed-out from the
seals.
1. One point each to right and left bucket pins (1).

--- every 500 hours (250 hours at first time only)
M4GB-07-004
2. One point each to bucket link pins (2 and 3). 5

2 6
3. One point to bucket cylinder pin (4).

3
One point to bucket cylinder rod pin (5).

4. One point to lever (bell crank) pin (6).

M4GB-07-005
MNEC-07-006
4
7-24
MAINTENANCE
5. One point each to right and left lift arm cylinder rod pins
(7). 7
M4GB-07-005
6. One point each to right and left lift arm pivot pins (8).
7. One point each to right and left lift arm cylinder pins (9).
8 9 MNEC-07-006
7-25
MAINTENANCE
8. One point each to front right and left steering cylinder
pins (10 and 11).
--- every 250 hours
10- Cylinder left front
11- Cylinder right front
10 11 MNEC-07-007
9. One point each to right and left steering cylinder rod

pins (12 and 13). 12, 13
--- every 250 hours

Left rear (12)
Right rear (13)
M4GB-07-008
7-26
MAINTENANCE
10. One point each to upper and lower center hinge pins (14
and 15).
--- every 250 hours
Upper (14)
Lower (15)
14 MNEC-07-008
15
M4GB-07-010
7-27
MAINTENANCE
11. One point each to front and rear axle support pins (16
and 17).
--- every 10 hours
Front (16)
Rear (17)
MNEC-07-009
17 16
12. One point to second (front) propeller shaft universal (18).

--- every 12000 hours
fNOTE: When the machine is continuously operated under

severe conditions for a long time, shorten the greasing
intervals.
18 M4GB-07-013
7-28
MAINTENANCE
13. One point to propeller shaft center support (pillow unit)
(19).
--- every 250 hours
19
MNEC-07-007
14. One point to second (center) propeller shaft universal 20

front (20).
One point to second (center) propeller shaft universal

rear (22).
M4GB-07-014
22 MNEC-07-010
7-29
MAINTENANCE
15. One point to second (center) propeller shaft splines (21).
21 M4GB-07-014
24
16. Two points to third (rear) propeller shaft universal (23).
17. One point to third (rear) propeller shaft splines (24).

M4GB-07-017
23
7-30
MAINTENANCE
18. Two points to brake pedal (25)
25
M4FC-07-014
19. One point to brake pedal linkage (26)

26 M4FC-07-015
7-31
MAINTENANCE
B. Engine
Check Engine Oil Level
--- every 10 hours (before starting the engine)
2 1
IMPORTANT: Incorrect engine oil level may cause engine

problems (The oil level should be between the upper
and lower marks on oil level gauge (1)).
If engine oil level is too high, control the oil level to the
proper quantity before starting the engine.
Check oil level before starting the engine. Pull out oil level
gauge (1). Check for mixing of foreign matter or contamination
in the oil. Wipe oil level gauge (1) with cloth, re-insert it into
the pipe to the end, and then pull it out again. The oil level
should be between the upper and lower marks on oil level
gauge (1).
If oil level is below the lower limit mark, add the recommended MNEK-07-004
engine oil via oil filler (2).
If oil level exceeds the upper limit mark, remove drain plug (3),
and then drain oil.
Recheck oil level.
3
Specified Range
fNOTE: Level the engine when adding oil or inspecting oil

level.
When required to check oil level after operating the machine,
first stop the engine. Wait for more than 15 minutes. Then
check oil level.
(This means that the oil level will become stabilized after all
oil delivered to respective lubrication area returns to the oil
MNEK-07-002
pan.)
If the oil color changes, severe contamination and/or mixing
of foreign matter may be seen, change the oil.
dWARNING: Do not spill oil while changing oil. Spilled

fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammable materials may cause
fires.
7-32
MAINTENANCE
Change Engine Oil
--- every 500 hours
dWARNING: Immediately after the machine has been

operated, all engine parts are hot. Wait for the engine
3
to cool before starting any maintenance work. Failure

to do so may cause severe burns.
fNOTE: Improper disposal of waste oil can threaten the

earth's environment and ecology.
Dispose the waste oil and filters in accordance with the local
regulation and/or law.
Be sure to replace the engine oil filter when changing the
engine oil at the same time. MNEK-07-002
1. Park the machine following the same procedures as

described on page 7-8 for preparation of inspection/
maintenance work.
2. Clean the areas around the drain plug and the oil filter.
3. Arrange a 40 liter (11 gallons)- capacity container to
receive the drain oil. Clean cloth
4. Remove drain plug (3) provided on the fuel tank side to
allow oil to drain.
5. Drain oil from the oil filter cartridge.
Container
6. Allow oil to drain through a clean cloth to check that no
foreign matters such as metal pieces are included in the M4GB-07-020
oil.
7. Install a new oil filter.
(Refer to the descriptions for Replace Engine Oil
Filter.)
8. Securely tighten drain plug (3).
7-33
MAINTENANCE
9. Remove oil filler cap (2). Supply the specified amount of
engine oil.
Refer to "Engine Oil" on page 7-17. 4
Engine Oil amount : 25 liters (6.6 gallons)
4
10. Securely tighten oil filler cap (2).
11. Check for looseness of other oil filler caps (4).
12. Check that the oil level is between the maximum and
minimum level scales on oil level gauge (1). Then, start
the engine.
13. After starting the engine, check the sealing surfaces for
any oil leakage.
14. Keep the engine running at low idle speed for 5 minutes
and stop the engine. About 15 minutes later, recheck the
oil level. If necessary, add oil.
2 1
MNEK-07-005
7-34
MAINTENANCE
Replace Engine Oil Filter
--- every 500 hours (each time when engine oil is
changed)
dWARNING: Immediately after the machine has been

operated, all engine parts are hot. Wait for the engine
to cool before starting any maintenance work. Failure
to do so may cause severe burns.

described on page 7-8 for preparation of inspection/ 1
maintenance work.
MNEC-07-075
2. Clean the areas around the oil filter.
3. Before removing cartridge type element (1), loosen drain
plug (2) to drain oil from the cartridge. The oil is drained
through the drain hose. After draining the oil, tighten the
drain plug.
2
IMPORTANT:
 Take care not to allow foreign matter such as dirt to
enter the oil filter.
 Be careful not to damage the filter body when
removing or installing the filter.
 Never reuse a cartridge type element.
4. Remove cartridge type element (1) by turning it

counterclockwise with a filter wrench.
5. Pour new oil into new element (1), being careful not to MNEK-07-002
let it overflow.
6. After coating a new cartridge gasket with engine oil, turn
the cartridge clockwise until the gasket comes in contact
with the sealing surface.
7. Using the filter wrench, tighten the cartridge 3/4 to 1
turn more. Take care that if the cartridge is excessively
tightened, the cartridge may be deformed.
fNOTE: Install the cartridge with care so that the gasket is not
damaged due to twisting.
Check for any oil leakage at the filter mounting area.
8. Supply the specified amount of engine oil.

(Refer to the descriptions for Change Engine Oil.)
7-35
MAINTENANCE
Check Crankcase Breather Tube
--- every 10 hours (daily)
doperated,
WARNING: Immediately after the machine has been
all engine parts are hot. Wait for the engine
to cool down before starting any maintenance work.
Failure to do so may cause severe burns.
1
1. Park the machine following the same procedure as
maintenance work.
2. Check tube (1) for sludge, debris, or ice in the tube.
3. If sludge, debris, or ice is found clean the tube with
detergent and warm water or a solvent. Dry the tube
with compressed air.
4. Visually check the tube for cracks or damage. If damage
is found, replace the crankcase breather tube.
5. Check for any oil leakage or loose clamps at the MNEC-07-115
connection with the crankcase breather tube (1).
6. Check for loose clamp securing tube (1) to the engine.
7-36
MAINTENANCE
Replace Crankcase Air Breather Element 2
--- Every 2000 hours 1
dWARNING: Be sure to wear safety glasses when using

compressed air (0.2 MPa(30 PSI)).
3
fNOTE: The crankcase air breather element works as oil

separator.

maintenance work.
2. Remove oil filler cap (1).
MNEC-07-107
3. Remove bolts (2) from crankcase air breather cover (3).
4
fNOTE: Make a note of bolt (2) position for reference at
assembling work.
4. Remove crankcase air breather cover (3). 5
5. Remove air breather element (4) from rocker lever cover

(5).
Do not remove gasket from the rocker lever cover.
IMPORTANT: If gasket (6) sticks out from the rocker lever
cover (5) groove, install new gasket.
6. If any damage is found on the gasket, remove it by MNEC-07-108
pulling gasket tab (7).
6 6
dCAUTION: Be sure to wear safety glasses and gloves
when using detergent for cleaning.
MNEC-07-109
MNEC-07-110
7-37
MAINTENANCE
7. Clean the mounting surface of the air breather element
and O-ring on rocker lever cover (5). Wipe and dry 5
cleaned surface with clean cloth.
8. Clean the crankcase air breather cover. Dry the surface
with compressed air after cleaning.
9. Check the crankcase air breather cover for any damage;
replace it if necessary.
10. If gasket (6) is removed, install new gasket on the groove
of rocker lever cover (5).
fNOTE: Install gasket (6) in the order from A to E shown in

MNEC-07-111
the right illustration. Softly push gasket (6) when installing it.
Gasket (6) will not fit inside the groove if it is pushed hard with
the fingers. 6
11. Apply engine oil on the O-ring on air breather element
(4). Install air breather element (4) on rocker lever cover
(5).
12. Install crankcase air breather cover (3).
13. Mount bolts (2) on crankcase air breather cover (3) at the
same location as when they were removed.
Tightening torque: 7 N·m
14. Install oil filler cap (1).
MNEC-07-112
Oil
O-ring
MNEC-07-113
1
3
MNEC-07-107
7-38
MAINTENANCE
Check Vibration Damper
--- Every 2000 hours
maintenance work.
2. Check damper on the fan end of the engine crankshaft.
3. If any cracks, dent or deformation is found, consult your
authorized dealer for check and repair.
MNEC-07-116
MNEC-07-117
7-39
MAINTENANCE
C. Power Train
Check Transmission Oil Level
dWARNING: Check the oil level while running the

engine with care about the following points.
 Move forward/reverse lever to neutral and turn
parking brake switch ON. 1
 After leveling the bucket on the ground, move the

control lever lock switch to the lock ( ) position.
 Set the articulation lock bar.
IMPORTANT: Do not start the engine when the

transmission oil level is low. Damage to the
transmission may result. Do not use transmission oils 2
other than those listed in the "Transmission Oil". MNEK-07-003
The cap of filler port (1) has the breather function.
Never spray high pressure water to the cap and vicinity
of the cap. Water may enter into the transmission,
damage to the transmission may result. 2
Before starting the engine, check the transmission oil level

with oil level gauge (2). When the oil level is correct, the float
in the oil level gauge shall be in the center with the oil cooled.
Refill the oil as necessary from transmission oil filler port (1).
When checking oil level before operating the machine,

normally the float in gauge (2) must be higher than the COLD
MIN position. If the float is lower than the COLD MIN position,
M4GB-07-027
add oil through transmission oil filler port (1).
When the transmission oil temperature is in the normal range
of 80 °C to 90 °C (176 °F to 194 °F), the float in the gauge (2)
shall be between the HI and the LO notches at the HOT scale Transmission Oil
Temperature Gauge
on the oil level indication decal. If the float is outside the
appropriate range, add or drain oil so that the float enters the Appropriate oil
range between the HI and LO notches. temperature
(80 °C to 90 °C)
(176 °F to 194 °F)
MNEK-07-044
7-40
MAINTENANCE
Change Transmission Oil and Transmission Oil Filter
--- every 1000 hours (100 hours at first change only) 1 2 3
dWARNING:
 Unexpected movement of the machine may cause a
serious accident. When parking the machine, place
F-N-R lever (1) in neutral and neutral lever lock (3) in
the lock ( ) position. Then, apply parking brake (2)
and stop the engine.
 Before changing oil, install articulation lock bar (4)
to securely hold the front and rear chassis to avoid
MNEC-01-036
an accident due to unexpected machine movement.
Avoid accidents due to unexpected movement of the
machine.
IMPORTANT: Do not use transmission oils other than

those listed in the "Transmission Oil".
fNOTE: Be sure to replace the transmission oil filter when

changing the transmission oil at the same time.
1. Operate the machine until the transmission oil is heated

to the appropriate temperature (50 °C to 60 °C) (122 °F to
140 °F).
described on page 7-8 for preparation of inspection/ 4 MNEK-01-019
maintenance work.
3. Install articulation lock bar (4) to the front and rear of the
frame by following the procedures described on page Transmission Oil
7-10. Temperature Gauge
Oil temperature
(50 °C to 60 °C)
(122 °F to 140 °F)
MNEK-07-044
7-41
MAINTENANCE
IMPORTANT: The machine is equipped with a
turbocharged engine. Perform cool down operation
before stopping the engine. Failure to do so may cause
the lubricant on the turbocharger bearing surfaces
to desiccate due to the intense heat present inside
the turbocharger, possibly causing damage to the
turbocharger.
4. Turn the key switch OFF to stop the engine. Leave the
machine untouched for 10 minutes.
5. Prepare a container of more than 50 liters (13 gallons)
capacity to receive the drain oil.
5
fNOTE: Drain plug (5) is magnetized. If excessive amount of MNEC-07-013
metal pieces are found adhered to drain plug (5), contact your
authorized dealer.
6. Remove drain plug (5) from the transmission bottom to

drain the oil. Dispose of the drain oil in the proper way.
fNOTE: Do NOT apply sealant to drain plug (5).
7-42
MAINTENANCE
8. Using a filter wrench, turn cartridge filter (6)
counterclockwise to remove it.
9. Clean the filter-seating surface. After coating the new
cartridge filter gasket surface with new oil, lightly turn
the cartridge filter clockwise by hand until the cartridge
filter sealing surface comes in contact with the filter-
seating surface.
10. At this time, further tighten the cartridge filter 3/4 turns
using a filter wrench. Take care not to excessively tighten
the cartridge filter. Be careful not to damage filter
cartridge by overtightening.
8
11. Refill the specified amount of oil through transmission
oil filler port (7). 6 7 MNEC-07-014
Oil amount : 30 liters (7.9 gallons)
12. Start the engine and keep it running for two minutes.
13. Check that the oil level is within the specified range in oil
level gauge (8). If necessary, add oil.
fNOTE: Never reuse cartridge type element (6).

Install the cartridge with care so that the O-ring is not
damaged due to twisting.
Check for any oil leakage at the drain plug and the filter
mounting area.
7-43
MAINTENANCE
Change Axle Oil
dWARNING: Take care about the following points.

 Starting repair work immediately after operation
may cause burns. Wait for the oil to cool before
starting any maintenance work.
 Lock the front and rear frames with the articulation
lock bar.
IMPORTANT: Do not use axle oils other than those listed

in the "Axle Oil".
Check Oil Level

maintenance work.
frame by following the procedures described on page
7-10.
1 MNEK-01-019
3. Clean the vicinity of oil level plug (2).
4. Remove oil level plug (2). Clean the tip of dipstick (3)
connected to oil level plug (2) with a clean cloth.
2
Specified
Oil Level 4 Front Axle M4GB-07-037
M4GB-07-039
5. Make the plug lower surface contact to the axle seat

face. Oil level must be between marks H and L (4) on the
dipstick (3).
If necessary, add oil.
2
Rear Axle M4GB-07-038
7-44
MAINTENANCE
Change Axle Oil
maintenance work.
2. Install articulation lock bar to the front and rear of the
7-10.
3. Clean the areas around the drain plug and the oil filter.
4. Arrange a container of 50 liters capacity to receive the 1
drain oil.
Front Axle M4GB-07-035
5. Remove drain plug (1) to drain the oil.
7. Refill the specified amount of oil through oil level plug
(2) hole.
Oil amount
Front Axle Rear Axle
34 liters (9.0 gallons) 34 liters (9.0 gallons)
1
IMPORTANT: It takes time for oil to fully lubricate the
overall front axle.
After installing the plug, allow the machine to drive for
several minutes. Then, stop the engine and check the
axle for any oil leaks.
2
Front Axle M4GB-07-037
7-45
MAINTENANCE
Check Surroundings Around Axle and Covers for Oil
Leaks
Check the surroundings around the axle and covers for oil
leaks. If any oil leaks are found, check the bolts in the oil
leaking area for looseness. Retighten as needed.
M4GB-07-159
1
Clean Axle Housing Air Breather
--- every 500 hours
Front Axle Breather (1)
Rear Axle Breather (2)
1. Clean the vicinity around the air breather before

removing the air breather.
Open the machine front cover. Front axle air breather (1)
is located at the right side.
Open the machine side cover. Rear axle air breather (2) is
located at the left side.
MNEC-07-071
2. Put a cover on the air breather port to prevent foreign
matter from entering.
dCAUTION: Be sure to wear safety glasses when

cleaning the air breather with compressed air.
3. Clean the air breather using compressed air. If

completely contaminated, wash the air breather with a
cleaning solvent and reinstall it.
4. Take care not to allow foreign matter to enter into the
axle housing when reinstalling the air breather. 2
MNEC-07-076
7-46
MAINTENANCE
D. Hydraulic System
Inspection and Maintenance of Hydraulic
Equipment
1
d CAUTION: When checking and/or servicing the
hydraulic components, pay special attention to the
following points.
During operation, the parts of the hydraulic system
become very hot. Allow the machine to cool down
before beginning inspection or maintenance.
1. Park the machine following the same procedures as M4GB-07-044

maintenance work.
2. Begin servicing hydraulic components only after
components, hydraulic oil and lubricants are completely
cooled, and after releasing residual pressure.
2.1 Release internal pressure.
2.2 Be sure to relieve the air pressure from the hydraulic oil
tank by pressing air bleed valve (1).
2.3 Allow the machine to cool down. Note that servicing
heated and pressurized hydraulic components may
cause hot parts and/or oil to fly off or escape suddenly,
possibly resulting in personal injury.
Keep body parts and face away from plugs or screws
when removing them. Hydraulic components may be
pressurized even when cooled.
Never attempt to service or inspect the hydraulic
circuits on slopes. They are highly pressurized due to
self-weight.
7-47
MAINTENANCE
IMPORTANT:
 When connecting hydraulic hoses and pipes, take
special care to keep seal surfaces free from dirt and
to avoid damaging them. Keep these precautions in
mind.
 Wash hoses, pipes, and the tank interior with a
washing liquid and thoroughly wipe off before
reconnecting them.
 Only use O-rings that are free of damage or defects.
Be careful not to damage them during reassembly.
 Do not allow high pressure hoses to twist when
connecting them. The life of twisted hoses will be
shortened considerably.
 Carefully tighten low pressure hose clamps. Do not
overtighten them.
 When adding hydraulic oil, always use the same
brand of oil; do not mix brands of oil. As the machine
is filled with Hitachi Super EX 46HN or Genuine
Hydraulic Oil 5000 when it is shipped from the
factory, use it as a general rule. When selecting to
use another brand of oil listed in the table "Hydraulic
Oil", be sure to completely replace the oil in the
system.
 Do not use hydraulic oils other than those listed in
the table "Hydraulic Oil".
 Never run the engine without oil in the hydraulic oil
tank.
7-48
MAINTENANCE
Check Hydraulic Oil Level 1
IMPORTANT: If the oil level is not viewed in the level

gauge, immediately refill hydraulic oil up to the
appropriate level. Failure to do so may result in a
serious failure in the hydraulic system.
If the oil level is higher than the level gauge, drain oil
down to the appropriate level using a pump.

maintenance work. MNEC-07-017
2. Check oil level with level gauge (1) on hydraulic oil tank.
Oil must be between marks on the gauge. If necessary,
add oil. 1
fNOTE: During cold weather season, check the oil level after
warming up the hydraulic oil by referring to the instructions
described in the "Warm up operation" group.
M4GB-07-160
7-49
MAINTENANCE
Change Hydraulic Oil/Clean Hydraulic Oil Tank
Changing and cleaning procedure
dWARNING: Hydraulic oil becomes hot and pressurized

during operation. Severe burns may result if
skin comes in contact with escaping hydraulic oil
immediately after operation. Wait for the oil to cool
before starting any maintenance work.
IMPORTANT: Do not use hydraulic oils other than listed in

the "Hydraulic Oil".
1
MNEK-01-019
maintenance work.
7-10.
3. Before changing the hydraulic oil, be sure to relieve the
air pressure from the hydraulic oil tank (3) by pressing air
bleed valve (2).
IMPORTANT: When changing hydraulic oil, take care not

to permit foreign matter such as dirt, water, and /or 2 M4GB-07-044
sand to enter into the hydraulic oil tank.
3
4. Carefully pressure wash the area around the breather,
filter cover, and around the hydraulic tank. Dry the area
before removing any other covers.
5. Arrange a container of approx. 150 liters (40 gallons).

6. Remove cap (6) of drain valve (5).
5, 6
IMPORTANT: When connecting drainer (7), entwist it

slowly to avoid a large amount of oil from draining at a
time. Front Attachment
4 Side MNDB-07-023
7. Slowly entwist in the provided drainer (7) to the port to
drain oil.
fNOTE: Drain valve (5) opens by entwisting drainer (7). 5
8. Remove cleaning cover (4) on the bottom of hydraulic oil 7

tank (3). Clean the tank bottom with cleaning oil. Install
the cover to the original position after cleaning out tank.
MNDB-07-024
7-50
MAINTENANCE
9. Supply hydraulic oil through cover (8) hole on the top of 9 8
the hydraulic oil tank while checking the oil level at level
gauge (9).
Hydraulic oil tank : 100 liters (26.4 gallons)
capacity
Hydraulic system : 150 liters (39.6 gallons)
total capacity
10. Install cover (8) with bolts (6 used).

Tightening torque: 50 N·m (37 lbf·ft)
IMPORTANT: When changing hydraulic oil, take care not

MNEC-07-017
to permit foreign matter such as dirt, water, and/or
sand to enter into the hydraulic oil tank.
11. After changing hydraulic oil or replacing the return

filter, pilot filter and/or suction filter, bleed air from the
hydraulic system following the procedures below.
Bleed Air from the Hydraulic System

11-1.After supplying oil, start the engine.
11-2.Move the bucket and lift arm cylinders several times to
bleed air mixed in the hydraulic circuit. Do not operate
the cylinders to stroke end.
11-3.Rest the bucket on the ground to resume the hydraulic
oil level check position.
12. Stop the engine. Check for any oil leakage. Check the oil
level using level gauge (6).
7-51
MAINTENANCE
Clean Suction Filter
--- each time the hydraulic oil is changed.
IMPORTANT: This upper tank area must be very clean
prior to beginning this procedure. Failure to clean the
top of tank may lead to hydraulic system problems due
to system contamination.
A suction filter is located on the bottom of the hydraulic oil
tank.
Clean the suction filter when changing hydraulic oil.
1. After draining hydraulic oil, remove cover (1). Lift to 1 M4GB-07-044

take out rod (2). Put a cover over the oil supply port to
prevent foreign matter from entering. 1
When removing the suction filter, take care not to allow

trapped dust to fall into tank.
2
4
IMPORTANT: A few small particles in the strainer is
normal. Large metal, rubber pieces, or a large amount
of fine particles is abnormal. If found, contact your
authorized dealer.
2. Clean the suction filter and the hydraulic oil tank inside 3
with cleaning oil.
3. Supply the specified volume of oil through the oil supply
port while checking the oil level with the oil gauge. M4GB-07-048
4. Securely insert the suction filter into pipe (3) when
installing the suction filter. 5
5. Before installing cover (1), check that the rod top is

correctly inserted into support hole (4) on cover (1).
Then, install cover (1) with bolts.
6. Start the engine. While slowly raising or lowering the
arm and tilting the bucket forward and backward, check
for any abnormality. Stop the engine. Check the oil level
using level gauge (5).
MNEC-07-017
7-52
MAINTENANCE
Replace Pilot Oil Filter
1
Replace

during operation. Severe burns may result if
skin comes in contact with escaping hydraulic oil
immediately after operation. Wait for the oil to cool
before starting any maintenance work.

maintenance work.
7-10.
3. Before replacing the filter element, be sure to relieve the
air pressure from the hydraulic oil tank by pressing air
bleed valve (1).
4. Remove the inspection cover for left side rear frame. 2
5. Rotate the hexagonal section on the bottom of case (2)
counterclockwise using a spanner to remove case (2)
from head (3). MNEC-07-019
6. While turning element (5), remove the element 3

downward.
7. Replace O-ring (4) with a new one.
8. Sufficiently seat O-ring (4) and backup ring (6) in the
O-ring groove on case (2). 4
9. Coat the seal surface of new element (5) with hydraulic 6
oil. While turning element (5), completely install element
5
(5) into head (3) using care not to damage the element.
70MPD8-07-01
7-53
MAINTENANCE
10. Take care never to allow water and/or dust to enter the 3
filter case.
11. Install case (2) into head (3) while rotating case (2)
clockwise.
Tightening torque: 70 to 80 N·m (7 to 8 lbf·ft)
12. After replacing the filter, bleed air from the hydraulic
pump and check the oil level in the hydraulic oil tank.
(Refer to the descriptions for "Bleed air from the
hydraulic system" in item .)
If the machine is operated without bleeding the air 2
mixed in the hydraulic circuit, damage to the hydraulic
pump may result. 70MPD8-07-01
fNOTE: Replace the element at the regular intervals to

maintain clean hydraulic oil and extend the service life of the
hydraulic components.
7-54
MAINTENANCE
Replace Hydraulic Tank Oil Filter

during operation. 2
Severe burns may result if skin comes in contact
1
with escaping hydraulic oil immediately after
operation. Wait for the oil to cool before starting any
maintenance work.
Especially when removing the filter, be aware that the
remaining oil in the filter may spill. Use extra care.
M4GB-07-044

described on page 7-8 for preparation of inspection/ 3
maintenance work.
frame by following the procedures described on page 4
7-10.
3. Clean the vicinity around cover plate (1). 5
4. Arrange a container and workshop towels to receive the
spilled oil and the element. Relieve the air pressure from
the hydraulic oil tank by pressing air bleed valve (2). 6
5. Loosen bolts (3) (6 used) to remove cover (1) and O-ring

(4).
M4GB-07-051
When removing cover (1), slowly remove the cover while
3 1
pressing the cover downward so that spring (5) does not
fly off. Slowly permit cover to rise, then carefully remove.
6. Remove spring (5) and element (6).
7. Replace element (6) and O-ring (4) with new ones.
4
Install new element and O-ring in the hydraulic oil tank.
Before installing element (6), make sure that rubber (7) is 5
present.
6
8. Install cover (1) with bolts (3) (6 used).
7
M4GB-07-052
7-55
MAINTENANCE
9. After replacing the filter, bleed air from the hydraulic
pump and check the oil level in the hydraulic oil tank.
(Refer to the descriptions for "Bleed air from the
hydraulic system" in item .)
If the machine is operated without bleeding the air
mixed in the hydraulic circuit, damage to the hydraulic
pump may result.
fNOTE: Replace the element at the regular intervals to

maintain clean hydraulic oil and extend the service life of the
hydraulic components.
7-56
MAINTENANCE
Replace Air Breather Element
1
during operation.
Severe burns may result if skin comes in contact
with escaping hydraulic oil immediately after
operation. Wait for the oil to cool before starting any
maintenance work.
Replace
maintenance work.
2. Before replacing the filter element, be sure to relieve the
2
air pressure from the hydraulic oil tank by pressing air
bleed valve (1).
3. Rotate cover (3) clockwise approx. 1/4 turn. Remove cap 3
(2) by rotating it counterclockwise.
4. Rotate cover (3) counterclockwise and remove it.
Remove element (4). 4
5. Install new element (4). Tighten cover (3) clockwise.

After cover (3) come in contact with the inside element,
tighten the cover by 1/4 turn further.
6. Manually tighten cap (2) clockwise to the end. Hold cap
(2) in position by hand to prevent the cap from turning.
Tighten cover (3) counterclockwise 5 to 10° securely. 5
7. Take care not to allow water or dust to enter the
clearance (air discharge port) between cover (3) and M4GB-07-166
body (5).
fNOTE: Replace the element at the recommended regular

intervals to keep the hydraulic oil clean and to extend the
service life of the hydraulic components.
7-57
MAINTENANCE
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage
dWARNING:
 Allow only qualified personnel to handle the
accumulator.
 High-pressure nitrogen gas is enclosed in the
accumulator. (N2 is inert.) Caution is required to
prevent fires from occurring.
 Never strike the accumulator. Keep the accumulator
away from heat sources.
 Do not directly heat the accumulator. Do not weld MNEC-07-069
the accumulator housing.
 Be sure to release pressure before starting to work
C
on the pipe lines.
described on page 7-8 for preparation of inspection/ E B
maintenance work.
2. Raise the lift arm at the maximum height, and then set
the lift arm control lever in the Neutral (N) position. N N
3. Turn the key switch OFF to stop the engine.

4. Turn the key switch ON but do NOT start the engine. D A
5. Confirm the safety around the machine.
6. Place the lift arm control lever to FLOAT position (C) and G F
lower the bucket 1 m (3.3 ft) off the ground within 2
minutes after stopping the engine.
7. Place the lift arm control lever to the LOWER position (B)
and lower the bucket on the ground.
MNEC-03-003
8. Ensure the lift arm does not stop halfway. If the lift
arm stops halfway, the accumulator function may be
deteriorated. Consult your authorized dealer for check
and repair. C
E B
N
N
D A
M4GB-01-072
7-58
MAINTENANCE
Replace Pilot Circuit Accumulator
--- every 4000 hours or once every two years
whichever comes first.
Consult your authorized dealer for replace.
Check Ride Control Accumulator Function, Gas

Leakage, Looseness, and Damage (Option)
--- every 500 hours
dWARNING:
 Allow only qualified personnel to handle the
accumulator. MNEC-07-069

accumulator. (N2 is inert.) Caution is required to
prevent fires from occurring.
 Never strike the accumulator. Keep the accumulator
away from heat sources.
 Do not directly heat the accumulator. Do not weld
the accumulator housing.
 Be sure to release pressure before starting to work
on the pipe lines.
Let the machine travel with the ride control switch turned
AUTO and OFF to compare the machine's vertical vibration
during travel. Travel the machine at a speed faster than "Ride MNDB-07-020
Control Drive Speed Setting" displayed on the multi-monitor. If
the machine's vertical vibration is not dampened when letting
the machine travel with the ride control function activated, the
accumulator may be faulty. Consult your authorized dealer for
check and repair.
Check Gas Pressure in Ride Control Accumulator

(Option)
Check the gas pressure at a regular interval. Ask your
authorized dealer for checking.
Check Gas Pressure in Steering Accumulator

Check the gas pressure at a regular interval. Ask your nearest
authorized dealer for checking.
While steering the machine, if you feel pulsation or vibration
and machine does not turn smoothly, contact your nearest
authorized dealer for the gas pressure checking.
MNEC-07-114
7-59
MAINTENANCE
Check Hoses and Lines
--- every 250 hours
dWARNING: High pressure fluid can penetrate the

skin causing serious injury.
To avoid this hazard, search for leaks with a piece of
cardboard.
Protect hands and body from high-pressure fluids.
If an accident occurs, immediately see a doctor
familiar with this type of injury.
Any fluid injected into the skin must be surgically
removed within a few hours or serious infection SA-031
may result.
dWARNING: Hydraulic oil and lubricant leaks can

lead to fire that may result in serious injury.
To avoid this hazard :
 Park the machine on a solid, level surface.
Lower the bucket to the ground.
Stop the engine. Remove key from the key switch.
Push the control lever lock switch to the lock ( )
position.
 Check for missing or loose clamps, kinked
hoses, lines or hoses that rub against each other,
SA-292
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 abnormalities are found, repair them, as shown
in Tables 1-2.
 Tighten, repair or replace any missing, loose or
damaged clamps, hoses, lines, oil cooler, and
loose oil cooler flange bolts.
Do not bend or strike high-pressure lines. SA-044
Never install bent or damaged hoses or lines.
7-60
MAINTENANCE
Table 1. Hoses 3 2
Interval (hours) Check Points Abnormalities Remedies 1
Daily Hose covers Leak (1) Replace
2
3
Hose ends Leak (2) Replace M137-07-008
3 2 1
Fittings Leak (3) Retighten or replace 2

hose or O-ring
3
M115-07-145
Every 250 Hose covers Crack (4) Replace

hours 4
Hose ends Crack (5) Replace
M115-07-146
6
Hose covers Exposed reinforcement Replace
(6) 7
Hose covers Blister (7) Replace

M115-07-147
Hose Bend (8) Replace (Use proper

bend radius)
M115-07-148
Hose Collapse (9) Replace (Use proper
bend radius) 9
Hose ends and Deformation or Replace

fittings Corrosion (10)
10
M115-07-149
fNOTE: Refer to the illustrations in Fig. 1 for each check point location or for a description of Fig. 1
the abnormality. Use genuine Hitachi parts.
7-61
MAINTENANCE
Interval
Check Points Abnormalities Remedies
(hours) 13 12
Contact surfaces of Leak (11) Replace
flange joints 11
Bolts Loose or leak (11) Retighten or replace
Daily Check
O-ring
Welded surfaces on Leak (12) Replace M4GB-07-059
flange joints
Flange joint neck Crack (13) Replace
Welded surfaces on Crack (12) Replace 12
Every 250 13
flange joints
hours
Clamps Missing or deformation Replace or retighten
Loose bolts
M4GB-07-060
Fig.2
7-62
MAINTENANCE
Service Recommendations for Hydraulic Fittings 2 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
leakage.
3 6
1. Inspect fitting sealing surfaces (6). They must be free of M104-07-033
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) using
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, replace
O-ring (1) and check for correct O-ring position before
tightening the connection.
Tightening torque:
Tighten fittings to the torque values shown below.
Width across flats (mm) 27 36 41 50
Tightening N·m 95 180 210 350
torque: (lbf·ft) (70) (133) (155) (258)
7-63
MAINTENANCE
Metal Face Seal Fittings
7 9 8 10 5
Fittings are used on smaller hoses and consist of metal flare
(9) and metal flare seat (10).
1. Tighten fitting (7) by hand.
2. Tighten fitting (7) or nut (8) to the torque values shown.
Do not allow hose (5) to twist when tightening fittings.
Tightening torque: M202-07-051

Tighten fittings to the torque values shown below.
Width across flats
17 19 22 27 36
(mm)
Tightening N·m 25 30 40 80 180
torque: (lbf·ft) (18) (22) (30) (59) (133)
7-64
MAINTENANCE
E. Fuel System
Check Fuel Level
dWARNING:
fire hazards.
Fuel is flammable. Keep fuel away from
IMPORTANT: Always fill the fuel tank with the

specified diesel fuel. Failure to do so may cause
engine trouble and also making it difficult for
the engine to start. Use of diesel fuel with sulfur
content less than 15 mg/kg (15 ppm) is required.
Recommended Fuel About Biodiesel Fuel

Use only super high quality or high quality DIESEL FUEL Biodiesel fuel is made by refining various vegetable oils
(JIS K-2204) (ASTM 975D). Kerosene must NOT be used. or animal fats.
Use of poor quality fuel, tank cleaning solvents, IMPORTANT: When blended with Ultra-Low Sulfur
unapproved fuel additives, gasoline, kerosene or alcohol Diesel (ULSD) fuel it may be used only if:
refueled or mixed with specified fuel may deteriorate  It is used in blends of B5 (5% biodiesel/95%
performance of fuel filters and cause friction problems ULSD).
in the injectors. It also may affect other engine parts,  It is supplied by a BQ9000 Certified Marketer –
leading to malfunction. check www.bq9000.org.
 It meets the ASTM D6751 standard for B100
Using fuel other than ultra low-sulfur diesel fuel has
biodiesel before blending.
adverse effects on the engine and the aftertreatment
device, which may result in malfunction.  The biodiesel is properly stored and filtered prior
to use in the loader.
dCAUTION:
 Concentrations greater than B5 (5%) may cause
engine trouble that is not covered by warranty.
 Using biodiesel will increase fuel consumption
and reduce power compared to 100% ULSD.
 Biodiesel will experience restricted flow as
temperatures drop and may become waxy before
100% ULSD.
 Biodiesel storage can lead to water
contamination from absorption and microbial
growth greater than 100% USLD.
 The higher the concentration of biodiesel the
more likely damage to the engine and emissions
controls will occur.
 Biodiesel has a limited storage life and must be
used within 45 days of manufacture.
7-65
MAINTENANCE
Refueling 1

maintenance work.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.
dDANGER: Handle fuel carefully. Shut the engine off

before fueling. Do not smoke while you fill the fuel
tank or work on fuel system. MNEC-01-002
2. Check fuel gauge (1) of the monitor panel. Add fuel if

necessary.
2
IMPORTANT: Keep all dirt, dust, water and other foreign
materials out of the fuel system.
3. To avoid condensation, fill the tank at the end of

each day's operation. Take care not to spill fuel on the
machine or ground.
Fuel tank capacity: 245 liters (64 gallons)
4. Install and lock fill cap (2) immediately after fueling.
MNEK-01-013
7-66
MAINTENANCE
Drain Water and Sediment from Fuel Tank
Before starting to operate the machine, remove plug (2) from
the tip of drain valve (1) on the fuel tank bottom and open
drain valve (1) to drain water and/or sediment from the fuel 2
tank.
f NOTE: Drain valve (1) has vandal-proof plug (2).
MNEK-07-002
7-67
MAINTENANCE
Drain Fuel Filter
IMPORTANT: Drain fuel pre-filter daily before starting

operation. The engine may be damaged if failed.
Drained water should contain fuel. Follow the local
regulations when disposing it.
Fuel pre-filter (1) has water separator function, which drains

accumulated water.
fNOTE: Drain water when the engine trouble indicator

flashes.
Pre-Filter Main Filter
Draining Procedures
1. Connect black drain hose (5) located in the tool box to
MNEK-07-006
drain plug (3) under fuel pre-filter (1) and the case.
2. Loosen drain plug (3) to drain water. 4
Place a container to receive water for safety.

3. After draining water, securely tighten drain plug (3).
2
Bleed Air from the Fuel System

IMPORTANT: Air in the fuel system may make the engine 1
hard to start or make it run rough or not run at all.
After running the fuel tank dry, draining water from
fuel filter or fuel pre-filter (1) or replacing the fuel
filter, be sure to bleed the air from the fuel system.
If fuel contains high water content, check the fuel filter
earlier than the normal interval and drain water if
necessary.
3
1. Loosen air bleed plug (4), operate feed pump (2) until no
MNEK-07-007
air bubble is observed in the fuel from the air bleed plug.
2. After no air bubble is spouted from air bleed plug (4),
tighten air bleed plug (4) and operate the feed pump
until it becomes difficult to move.
3. Once the feed pump becomes difficult to move, push the
disk part of feed pump (2) back to the original position. 1
4. Start the engine. Check the fuel supply system for fuel
leaks.
MNDB-07-025
7-68
MAINTENANCE
Replace Fuel Main Filter Element
---every 500 hours
dCAUTION: Depending on the circumstance, diesel

fuel is flammable. When inspecting or performing
service or repairs on the fuel system, to reduce the
possibility of fire and resulting severe personal
injury, death, or property damage, never smoke or
allow sparks or flames (such as pilot lights, electrical
switches, or welding equipment) in the work area.
IMPORTANT:
 Be sure to use only genuine Hitachi elements for the
fuel main filter element and the pre-filter element.
Failure to do so may lower engine performance and/
or shorten the engine service life.
 Make sure that debris, water, steam, or cleaning
solution does not get inside the fuel system.
1. Remove cartridge filter (2) from fuel filter (1) by using a

filter wrench.
Arrange a container to receive fuel for safety and to
prevent ground from contamination.
2. Apply a thin film of clean fuel to the gasket of new
cartridge filter (2).
1, 2
3. Turn cartridge filter (2) clockwise by hand until the
gasket touches the contact area. MNEK-07-006
4. Using the filter wrench, tighten the cartridge 1/4 to 1/2

turn more.
Be careful not to overly tighten cartridge filter (2).
Deformation of the cartridge may result.
5. Bleed Air from the Fuel System
After replacing the fuel filter, bleed air from the fuel
system.
(Refer to "Bleed Air from the Fuel System" in item .) 2
M4GB-07-066
7-69
MAINTENANCE
Replace Fuel Pre-Filter Element
---every 500 hours
dCAUTION: Depending on the circumstance, diesel

fuel is flammable. When inspecting or performing
service or repairs on the fuel system, to reduce the
possibility of fire and resulting severe personal
injury, death, or property damage, never smoke or
allow sparks or flames (such as pilot lights, electrical
switches, or welding equipment) in the work area.
IMPORTANT:
 Be sure to use only genuine Hitachi elements for the
fuel main filter element and the pre-filter element.
Failure to do so may lower engine performance and/
or shorten the engine service life.
 Make sure that debris, water, steam, or cleaning
solution does not get inside the fuel system.
1. Remove cartridge filter (1) by using a filter wrench.

Arrange a container to receive fuel for safety and to
prevent ground from contamination.
2. Apply a thin film of clean fuel to the gasket of new
cartridge filter element (2).
1
3. Turn cartridge filter element (2) clockwise by hand until
the gasket touches the contact area.
MNEK-07-006
4. Using the filter wrench, tighten the cartridge 1/4 to 1/2
turn more.
Be careful not to overly tighten cartridge filter (1).
Deformation of the cartridge may result.
5. Bleed Air from the Fuel System
After replacing the fuel pre-filter, bleed air from the fuel
system.
2
(Refer to "Bleed Air from the Fuel System" in item .)
M4GB-07-066
7-70
MAINTENANCE
Clean Fuel Solenoid Pump Strainer
Cleaning
When the strainer is disassembled, be sure to replace
the gasket. Install the cover and the magnet only after
sufficiently cleaning them. After being assembled, closely
check the air-tightness of the strainer.
MNEK-07-002
7-71
MAINTENANCE
Disassembling/ Assembling
1. To remove cover (1), loosen with a wrench. 1 2 3 4 5
After cover (1) is removed, gasket (2), strainer (3), and
gasket (4) are easily removed in order.
2. Wash strainer (3) with solvent. Magnet

M1GR-07-004
3. Install the strainer in the reverse order of 36 mm 2.7 mm 1 mm
disassembling. At that time, install gasket (2) into 28 mm
cover (1) first. 3 2 4
Then, securely tighten cover (1) to pump (5) using a
wrench.
φ41
φ24
φ51
φ18
φ40
fNOTE: Wrench size: 17 mm
M1U1-07-006
IMPORTANT:
 Only clean and replace the strainer as well as Stretch gasket (4) to
gaskets (2) and (4) while servicing the fuel pump. remove.
Never attempt to disassemble other parts.
 Gasket (4) can get caught in the bore of pump (5),
making it difficult to remove the gasket, but do
not disassemble the cylinder of pump (5). If the Do not disassemble this part.
gasket is difficult to remove, do not disassemble
MDAA-07-053
other parts but stretch gasket (4) to remove it.
Use a new gasket (4) for assembling.
Gasket (4) is easily

removed by pulling
and stretching it.
MDAA-07-054
7-72
MAINTENANCE
Check Fuel Hoses 1 2
--- every 10 hours (daily) / every 250 hours
dWARNING: Fuel leaks can lead to fires that may result

in serious injury. 1
Check for kinked hoses, hoses that rub against each
other, and any fuel leaks. M4GB-07-071
Repair or replace any loose or damaged hoses. 3
Never reinstall bent or damaged hoses.
According to the check points shown below, check hoses for

oil leaks and damage. 4
If any abnormality is found, replace or retighten as instructed
in the table. M4GB-07-072
5
Hose
Interval
Check Points Abnormalities Remedies
(hours)
Every 10 Hose ends Leak (1)
Retighten or replace
hours (daily) Hose covers Wear, crack (2)
M4GB-07-073
Hose covers Crack (3) Replace
6
Every 250 Hose ends Crack (4) Replace
hours Hose Bend (5), Collapse (6) Replace
Hose fittings Corrosion (7) Replace
7
M4GB-07-074
7-73
MAINTENANCE
F. Air Cleaner
Replace Air Cleaner Element
1 2
Replace --- when the monitor indicator is lit.

Air cleaner (1) is comprised of double elements, the outer
element and inner element.
IMPORTANT: Do not reuse outer element (4). Replace it 3 3

when the indicator is lit.
Replace inner element (5) every after replacing outer
element (4) twice. Before reusing inner element (5),
ensure there is no damage on the filter surface, O-ring
and outer shape.

maintenance work.
IMPORTANT: Take care not to allow foreign matter such
as dirt to enter the engine when cleaning or replacing
elements.
MNEK-07-008
2. Remove clip band (3) and remove cover (2).
3. Hold the outer element release knob (6). Pull out outer 4
element (4) from the air cleaner to remove it.
4. Clean inside the air cleaner (1) with a wet cloth.
6
5. Hold inner element (5) release knob (7). Pull out inner
element (5) from air cleaner (1) to remove it.
6. Install inner element (5) and outer element (4) into air
cleaner (1).
IMPORTANT: An O-ring is fit on the circumference of
inner element (5). Push inner element (5) into the air
cleaner. Be sure there is no gap between the O-ring
and air cleaner.
7. Install cover (2) and tighten it with clip band (3). MNEK-07-030
8. Start the engine after the cleaning is done. Ensure the

indicator light is not ON. 5
MNEK-07-031
7-74
MAINTENANCE
Check Air Inlet System
Check pipes and hoses of the air inlet system for wear, damage
or loose connections and clamps. Replace damaged pipes and
hoses. Retighten loose clamps.
MNEC-07-121
MNEK-07-009
MNEK-07-010
7-75
MAINTENANCE
G. Cooling System
Coolant
Use fresh water or normal tap water as the coolant water.
Do not use strong acid or alkaline water. Use of the
genuine Long-Life Coolant (LLC) mixed by 33 to 50 % is
recommended.
If the air temperature is expected to fall below 0 °C (32

°F), fill the cooling system with Long-Life Coolant (LLC)
and soft water mix. As a general rule, the ratio of LLC
should be 50% as shown in the table below. If the ratio is
above 50%, the engine may overheat.
LLC Mixing Table
Coolant Capacity:
Air
Mixing ratio 33 liter (8.7 gallons)
temperature
% LLC Soft Water
°C (°F)
liter (gallon) liter (gallon)
50 16.5 (4.35) 16.5 (4.35)
dWARNING:
 Antifreeze is poisonous; if ingested, it can cause
serious injury or death. Induce vomiting and get
emergency medical attention immediately.
 When storing antifreeze, be sure to keep it in a
clearly marked container with a tight lid. Always
keep ANTIFREEZE out of the reach of children.
 Be careful of fire hazards. LLC is specified as a
dangerous substance in the fire protection law.
 If antifreeze is accidentally splashed into eyes,
flush with water for 10 to 15 minutes and get
emergency medical attention.
 When storing or disposing of antifreeze, be sure
to comply with all local regulations.
7-76
MAINTENANCE
Check Coolant Level 1
--- every 10 hours (daily) (before starting the engine)
dWARNING: Do not remove cap (2) until the coolant

temperature in the radiator is cool. Hot steam may
spout out, possibly causing severe burns. After the
coolant temperature cools, slowly loosen cap (2) to
release the inside air pressure before removing cap (2).
The coolant level must be at FULL (3) mark on expansion tank

(1).
If the coolant level is below the FULL (3) mark, remove cap (2)
from expansion tank (1) and refill coolant.
If expansion tank (1) is empty, add coolant to the radiator and MNEK-07-011
then to expansion tank (1).
 When refilling a long life coolant (LLC), use the same 3

brand product and the same mixture ratio as already
used in the machine.
 If only water is refilled, the mixture ratio in the long life
coolant (LLC) is diluted so that anti-rust and antifreeze
effect in the coolant will become deteriorated.
 Refer to page 7-75 for the coolant specifications.
MDAK-07-048
MNEK-07-012
7-77
MAINTENANCE
Check Drive Belt
Check the drive belt for any abnormality. If any cracks are
found, replace the belt with a new one.
OM0099
7-78
MAINTENANCE
Check Drive Belt Tensioner
--- every 1000 hours or once a year
maintenance work.
2. Install articulation lock bar to the front and rear of the 1
7-10.
3. Open the side cover to access the engine.
4. With the belt installed, verify that neither tensioner arm
stop is in contact with the spring casing stop. If either
stop is touching, drive belt (1) must be replaced. MNEC-07-116
2
After replacing the belt, if the tensioner arm stops
are still in contact with the spring case stop, the belt
3
tensioner must be replaced.
5. Check tensioner (2) for cracks on arm, pulley, and stops. If
any cracks are observed, the drive belt tensioner must be 2
replaced.
fNOTE: Consult your nearest authorized dealer for the drive

belt tensioner replacement.
1
6. Check belt tensioner pulley (3) for any dirt or damage.
If ir is dirty or damaged, contact your nearest authorized
dealer for cleaning or replacement.
7. Check the location of drive belt on belt tensioner pulley

(3).
The belt must be centered on, or close to the middle of,
the pulley. 90Z7B-7-77-2
Misaligned belts, either too far forward or backward, can
cause belt wear, belt roll-off failures, or increase uneven
tensioner bushing wear.
90Z7B-7-77-3
3
7-79
MAINTENANCE
Change Coolant
--- every 2000 hours or two years
dCAUTION: Do not remove the expansion tank cap (1)

until the coolant temperature in the radiator is cool.
Hot steam may spout out, possibly causing severe 1
burns. After the coolant temperature cools, slowly
loosen cap (1) to release the inside air pressure before
removing cap (2).
IMPORTANT: Use Hitachi genuine coolant. Change the
coolant every two years or 2000 hours whichever
comes first.

maintenance work.
MNEK-07-012
7-10.
3. Remove expansion tank cap (1). Open radiator drain cock
(2) and drain the coolant.
4. Close radiator drain cock (2). Supply low impurity soft
water or tap water together with the specified LLC up
to the radiator filler port. When adding coolant, do so
slowly to avoid mixing in the system.
Start the engine and sufficiently bleed air from the
cooling system.
fNOTE: When refilling a long-life coolant, pour it at flow rate

14 L/min (3.7 gpm) or below. If flow rate is larger than the 2
above, air does not bleed, being unable to fill the specified
amount.
MNEK-07-013
5. After adding coolant, operate the engine for several

minutes. Check the coolant level again and add coolant
if necessary.
7-80
MAINTENANCE
Clean Radiator/Oil Cooler and Other Cooling System
--- every 500 hours or when the core is clogged.
dCAUTION: Wear goggles or safety glasses when using

compressed air [less than 0.2 MPa (30 PSI)].
3
IMPORTANT: If compressed air with the pressure of more

than 0.2 MPa (30 PSI) or tap water with high delivery
pressure is used for cleaning, damage to the radiator/
oil cooler fins may result.
Keep the nozzle away from the core surface more than
500 mm (20 in).
Over the Side Cover

Check and clean air conditioner condenser (2) and torque
converter oil cooler (3).
Over the Rear Grille

Check and clean radiator (4), hydraulic oil cooler (5) and
intercooler (6), and hydraulic driven fan (7) by releasing lock
(8) and opening the hydraulic driven fan. MNEK-07-019
2
If dirt or dust is accumulated on them, cooling system
performance decreases. Clean the radiator/oil cooler cores
with compressed air pressure (lower than 0.2 MPa (30 PSI))
or tap water. It will prevent a reduction in cooling system
performance.
4 5 6 8 7
MNEK-07-015
7-81
MAINTENANCE
H. Electrical System
IMPORTANT:
 Improper radio communication equipment and
associated parts, and/or improper installation
of radio communication equipment affects the
machine's electronic parts, causing involuntary
movement of the machine.
Improper installation of electrical equipment 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.
Batteries
dWARNING:
 Battery gas can explode. Keep sparks and flames SA-036
away from batteries.
 Do not keep tools, metals or flammable materials
around the battery or inside the battery room. If a
metal tool is placed across the battery terminal and a
vehicle component such as the engine block, sparks
may be created, possibly resulting in fire and/or
explosion.
 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.
 Charge the batteries in a well ventilated location.
 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.
MNEK-07-016
7-82
MAINTENANCE
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, call 911, then:

1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. If splashed in eyes, flush with water for 10 to 15
minutes. Get medical attention immediately.
If acid is swallowed, call 911, then:

1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
IMPORTANT: Add water to batteries when cool weather

before you begin operating your machine for the day,
or else charge the batteries.
IMPORTANT: If the battery is used with the electrolyte

solution level lower than the specified level, the
battery performance may deteriorate quickly.
IMPORTANT: Do not refill electrolyte solution more than

the specified upper level. Electrolyte solution may
spill, damaging painted surfaces and/or corroding
other machine parts.
fNOTE: In case electrolyte solution is filled above the specified

upper level line or beyond the bottom end of the sleeve,
remove the excess electrolyte solution until the electrolyte
solution level is down to the bottom end of the sleeve by using
a pipette.
After neutralizing the removed electrolyte solution with
sodium bicarbonate, flush it with plenty of water, otherwise,
consult the battery manufacturer.
7-83
MAINTENANCE
Electrolyte Level Check --- every 100 hours (monthly)
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.
Do not use a dry towel. Static electricity may be U.L (Upper Level)
developed, causing the battery gas to explode. Check L.L (Lower Level)
if the electrolyte level is between U.L (Upper Level) and
M146-07-109
L.L (Lower Level).
If the electrolyte level is lower than the middle level
between the U.L and L.L, immediately refill with Filler Port
distilled water or commercial battery fluid.
Be sure to refill with distilled water before recharging
(operating the machine). Sleeve
After refilling, securely tighten the filler caps. Upper Level
Lower Level
3.2 When impossible to check the level from the battery Separator Top
side or no level check mark is indicated on the side: M146-07-110
After removing the filler plug from the top of the Correct
battery. Check the electrolyte level by viewing through Since the electrolyte solution surface touches the bottom
the filler port. It is difficult to judge the accurate end of the sleeve, the electrolyte solution surface is raised
electrolyte level in this case. When the electrolyte due to surface tension so that the electrode ends are seen
curved.
level is at the U.L, the level is judged to be proper.
Referring to the illustrations at the right side, check M146-07-111
Lower
the level. When the electrolyte level is lower than the
When the electrolyte solution surface is lower than the
bottom end of the sleeve, refill with distilled water or bottom end of the sleeve, the electrode ends are seen
commercial battery fluid up to the bottom end of the straight.
sleeve.
M146-07-112
After refilling, securely tighten the filler caps.
Be sure to refill with distilled water before recharging
(operating the machine).
3.3 When an indicator is available to check the level, follow
its check result.
4. Always keep the area 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
7-84
MAINTENANCE
Check Electrolyte Specific Gravity
--- every 250 hours If you spill acid on yourself, call 911, then:
1. Flush your skin with water.
dCAUTION: Battery gas can explode. Keep sparks
and flames away from batteries. Use a flashlight 2. Apply baking soda or lime to help neutralize the
and a mirror to check the battery electrolyte acid.
solution level.
3. If splashed in eyes, flush with water for 10 to 15
Sulfuric acid in battery electrolyte solution is minutes. Get medical attention immediately.
poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if splashed If acid is swallowed, call 911, then:
into the eyes. 1. Drink large amounts of water or milk.
Never check the battery charge by placing a metal 2. Then drink milk of magnesia, beaten eggs, or
object across the posts. Use a battery tester or vegetable oil.
hydrometer.
3. Get medical attention immediately.
Always remove the grounded (-) battery lead first
and attach it last.
IMPORTANT: Check the specific gravity of the
Avoid hazard by: electrolyte when it is cool, not immediately after
1. Filling batteries in a well-ventilated area. operation.
2. Wearing eye protection and rubber gloves.
Check the electrolyte specific gravity in each battery cell.
3. Avoiding breathing fumes when electrolyte The lowest limit of the specific gravity for the electrolyte
solution is added. varies depending on electrolyte temperature. The
4. Avoiding spilling or dripping electrolyte solution. specific gravity should be kept within the range shown
below. Charge the battery if the specific gravity is below
5. Using proper booster battery starting procedures. the limit.
Recommended range of specific gravity by electrolyte temperature

40 °C
(104 °F)
20 °C
(68 °F) Working Range
0 °C
(32 °F)
Fluid temp.
–20 °C
(–4 °F)
–40 °C
(–40 °F)
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
7-85
MAINTENANCE
Replace Batteries
IMPORTANT: Before adjusting electrical system or
welding on the machine, disconnect the negative
side of the battery, or turn the battery disconnect
switch to OFF position.
Your machine has two 12-volt batteries with negative (-)

ground.
If one battery in a 24-volt system has failed but the other
is still good, replace the failed battery with an operable
battery of the same type. 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.
Check Monitor Functions and All Other

Instrument Operation
Run the engine at low idle when checking the instruments.
The monitor indicates alarm, caution and confirmation
status in red, orange, and normal operative condition in
blue or green respectively. Check each gauge or meter if its
needle is moved with the key switch ON. The needle shall
be moved to the blue range when normal and to the red
range when abnormal. Refer to the Group of Operator’s
Station in Section 1 for more information.
7-86
MAINTENANCE
Check Work Lights
dCAUTION: If any burned-out light is found,

immediately replace it with a new one.
Visually check all work lights that they normally light and/or
flash from the front and rear sides of the machine.
MNEK-07-039
Check Horn and Backup Alarm

dWARNING: Before checking the horn and/or the

backup alarm, always apply the parking brake and
1
clear the machine's vicinity of other personnel.
Horn (1) is located on the front chassis.

The horn switch button is located at the steering wheel center
and on the right console. If the machine is equipped with a
multi-function joystick lever, the horn switch is located on the
multi-function joystick lever. Backup alarm (2) is located at the
left side of the rear grille. Check that backup alarm (2) correctly MNEK-07-039
sounds by operating either the forward/reverse lever or the
forward/reverse switch to the reverse drive side.
MNEK-07-040
7-87
MAINTENANCE
Check Electrical Harnesses and Fuses
--- every 50 hours
dCAUTION: If dirt or dust is adhered on the wirings or

relays, it may cause fire on the machine.
Check the electrical harness and terminals of the batteries,

starter motor, and alternator for loose connection and/or short
circuit (broken shield). Remove dirt or dust if necessary.
If any burned mark or an abnormal smell is noticed at a
harness, consult your nearest authorized dealer.
Replace Fuse:
1. If any electrical equipment becomes inoperable, first
check the fuses in the fuse boxes (A, B) located in the left
Fuse Box B
console in the operator's station.
2. One spare fuse for each respective fuse capacity is
provided in the fuse boxes (A, B). Fuse Box A
3. Finally, check slow blow fuses (1) (2) located on the
Relay Boxes
inside of the battery box.
MNEK-07-017
1- 70A, 140A
2- 45A, 65A (2 used)
1 2
MNEK-01-015
7-88
MAINTENANCE
Fuse Box A
10- PARKING 20- OPTION 4 (JSS)
5A (10 A)
9- AC1 19- OPTION 3 (ACC2)
10 A (15 A)
8- STOP LAMP 18- DEF HEATER
5A 15 A
7- BACKUP ALARM 17- DEF SUPPLY
5A 15 A
6- HEAD LAMP LH 16- DEF SENSOR
5A 15 A
5- WORKING LAMP FRONT 15- AC2
20 A 20 A
4- WIPER FRONT 14- ROTARY BEACON Fuse Box A Fuse Box B
15 A 10 A
MNEC-01-031
3- 24 V CIGAR SOCKET 13- SEAT HEATER
10 A 20 A
2- HEAD LAMP RH 12- OPTION 2 (ACC1)
5A (20 A)
1- FUEL PUMP 11- RADIO (USA)
5A 10 A
Fuse Box B
10- ECM 20- SECONDARY STEERING
30 A 5A
9- TCU 19- HIGH BEAM
10 A 10 A
8- CONTROLLER 18- WIPER REAR
10 A 10 A
7- FLASHER 17- WORKING LAMP REAR
10 A 20 A
6- HORN 16- LOADER CONTROL
10 A 5A
5- OPT C/U 15- MC
5A 10 A
4- OPTION 1 (BT) 14- TCU POWER
(15 A) 10 A
3- CAB DOME LAMP 13- POWER ON
5A 10 A
2- LIGHTING SW 12- POSITION 2
10 A 5A
1- DC/DC POWER ON 11- POSITION 1
20 A 5A
7-89
MAINTENANCE
I. Brake System
Check Right and Left Brake Interlocking
Performance
dWARNING:
 Put up a no admission notice for the range of 100
m (110 yd) ahead in the forward machine travel
direction. Arrange a safety monitor person.
 Do not allow dust and/or soil to accumulate in
vicinity (3) of the brake pedal. The brake may lose
traction. MNEC-01-036
1
While stepping on brake pedal (1), check the pedal movement,

the brake performance, and the play in the pedal stroke for 2
any abnormality.
If dust and/or soil accumulates in vicinity (3) of the brake
pedal, remove the accumulated dust and/or soil.
Check Brake Performance

The machine must be stopped within 5 m (16.4 ft) range
after the brake is applied while driving at the speed of 20
km/h (12.4 mph) on a flat dry paved surface road.
1
Check Play in Brake Pedal Stroke
3
Measure the pedal stroke at pedal tip (2) by pressing the MNEC-07-042
pedal with your hand until you feel an intermittent feed
back from the pedal.
Correct Play (2) : 7 to 16 mm (0.3 to 0.63 in)
If the play is outside the specified range, consult your
nearest authorized dealer.
If abnormal pedal operation and/or performance is noticed,
consult your nearest authorized dealer. Get the machine
checked and repaired.
7-90
MAINTENANCE
Check Parking Brake Force
dWARNING: Check the machine in a place where

no one is present or ahead in the drive traveling
direction. Keep bystanders away from the machine.
After confirming the service brakes work normally, test the 1

parking brake.
1. Move the machine to a safe open place on a 20 %

(11.3 degrees) inclining dry surface slope.
2. Stop the machine with the service brake.
3. Turn ON parking brake switch (1).
4. Release the service brakes.
5. The machine should not move.
MNEC-01-036
IMPORTANT: If machine moves when parking brake
switch is ON, there is some problem with parking
brake. Consult your nearest authorized dealer. Do
not operate until problem has been corrected.
7-91
MAINTENANCE
Check Accumulator Function, Gas Leakage,
Looseness, and Damage
--- every 500 hours
dWARNING: Allow only qualified personnel to

service the accumulator.
accumulator. (N2 is inert, and will not burn.)
 Never strike the accumulator. Keep the
accumulator away from heat sources.
 Do not weld the accumulator housing.
 Be sure to release oil pressure before starting to
work on the brake circuit.
MNDB-07-001
1. Check that alarm function is activated:
Check that when the brake pedal is strongly stepped
more than 5 strokes with the key switch ON and the
engine stopping, the monitor indicators come ON.
2. Note that alarm function is deactivated:
Start the engine. Run the engine at middle speed
to pressurize the accumulator. Check that when the
pressure builds in the accumulator, the alarm buzzer
stops sounding and the brake oil pressure indicator
goes OFF.
3. Note how many times the brake pedal is stepped:
Check that the brake pedal can be stepped more
than 5 strokes before the brake oil pressure indicator
comes ON with the key switch ON, the engine
stopping, and brake oil pressure gauge in the right of
the monitor display indicates the maximum level.
Three points described above must be confirmed

as operational. Besides the above points, check the
accumulator for gas leakage, looseness, and damage. If any
abnormality is found, immediately consult your nearest
authorized dealer.
7-92
MAINTENANCE
Check Gas Pressure in Accumulator
Check the gas pressure at a regular interval. If the machine
is operated with the gas pressure lower than specified value,
normal brake operation and/or loading operation may not be
achieved, possibly creating very hazardous situations. Ask your
nearest authorized dealer for checking.
Check Brake Disks (Service and Parking)

Service brake (1) is a closed wet type brake.
Parking brake (2) is a dry type disk brake. Parking brake (2) is
mounted on the transmission side.
Consult your nearest authorized dealer for checking.
M4GB-07-101
1
2 M4GB-06-004
7-93
MAINTENANCE
J. Tire
Check and Replace Tire (Tire Pressure)
Check appearance --- 10 hours (daily)
Check tire pressure when appearance is
questionable or each week (50 hours)
Replace --- as necessary
dWARNING:
 Secure the front and rear chassis with the
articulation lock bar and pins.
 When inflating tires, stand behind the tread and use
the self-attaching chuck with a line extension.
 Avoid welding near tires, which could potentially
cause the tires to explode.
 A tire may explode if it is smoking due to intense
heat such as if the machine catches fire.
 Never weld on rims. Replace defective rims.
IMPORTANT:
 Always maintain the correct tire pressure.
 Even if only one tread pattern has worn out, replace
the tire with new one. Tires must be evenly sized.
Before operating the machine, check the tires for
damage. SA-249
 When replacing one tire, use a new tire having the
same tread pattern and specification as the other
tires.
 Tires must be evenly sized.
Check Air Pressure

1. Measure air pressure when the tires are cool before
operating the machine.
Standard Tire Standard Air Pressure

20.5R25 (L3) 400 kPa (4.00 kgf/cm2) (58 PSI)
2. Check tires for damage and/or excessive wear.
Check Tire for Damage

dWARNING: If tire has external damaged such as deep

cuts, an accident due to puncture or burst of the tire
may occur, possibly resulting in injury or death.
Check the external appearance of tires for damage.
7-94
MAINTENANCE
Check Wheel Bolt Torque
(Right) (Wrong)
Be sure to check the wheel bolt torque by turning the bolt in
the tightening direction.
Replace Tire
dWARNING: Secure the front and rear frames with the

articulation lock bar and pins. Front
IMPORTANT: Height of the machine may change

according to the types of tires to be installed.
M4GB-07-104
Do not change the specifications of the registered
machine by using unauthorized tire sizes.

maintenance work.
7-10.
3. Loosen all wheel bolts one turn.
Note which way the tread pattern is facing.
4. After jacking up the machine, securely support the M4GB-07-102
machine with blocks.
5. Remove the wheel bolts. Replace the tire.
6. With the tire raised off the ground, lightly tighten the
wheel bolts in order as illustrated to the right.
7. Lower the machine. Retighten the wheel bolts to
specification in the order as illustrated to the right.
7-95
MAINTENANCE
Recommended Tire Air Pressure (Bias ply tire)
Size Pattern Air pressure
325 kPa
20.5-25-12PR L-3 (3.25 kgf/cm2)
(47 PSI)
325 kPa
20.5-25-16PR L-3 (3.25 kgf/cm2)
(47 PSI)
Adjust air pressure according to the job site conditions
Tire Sizes to be Used

Adjust tire pressure in conformity with the work mode the
machine is engaged in.
Consult your nearest authorized dealer or tire manufacturer for
more detailed information.
Driving on Public Roads: Standard Pressure

 Loading/excavation on normal ground surface: Standard
or slightly higher than standard pressure
 Heavy-duty excavation: Higher pressure in the standard
pressure range
 Operation on soft or sandy terrain: Slightly lower than
standard pressure
fNOTE: Apply the same air pressure to snow tires.

For radial tires, tires with other patterns, or special operating
conditions consult the tire manufacture.
For liquid tire ballast consult your nearest authorized dealer
or the tire dealer.
7-96
MAINTENANCE
Oscillation Stopper
IMPORTANT: Use oscillation stopper (1) that for the tire 1
size and tread pattern.
According to the size and tread pattern of tires, the

clearance between the machine parts and top of tire (A)
may become narrower, interference can occur between the
tire and the machine parts.
When size and tread pattern of tires are changed, install the
correct oscillation stopper (1) by referring the list below.
Tire Size Tread Pattern Oscillation Stopper

M4GB-07-162
20.5-25-12, 16PR L-3 ×
L-4
20.5 R 25 L-5 ×
A
: Use
×: Not use
fNOTE: The oscillation stopper is available at your nearest

authorized dealer.
M4GB-07-163
7-97
MAINTENANCE
Tire Rotation
Rotate tires when uneven or abnormal wear is recognized
on either front or rear, or right and left tire. Tire rotation is
recommended to achieve uniformity of wear on tires or
equalization of tire service life.
Rotation Procedure
dWARNING: Install tire with no external damage such

as score and abnormal wear.
(Right) (Wrong)
Failure to do so may cause the puncture or the tire to
blowout, possibly resulting in personal injury or death
since tire load is increased when the machine is loaded
or braked during operation.
 Switch tires only between the front and rear positions. Do

not switch the tires between diagonal positions. Front
 Align the tire rotation direction with the tire tread design
pattern. Especially traction tread design pattern (optional)
will affect not only economy of tire but also safety of
operation. M4GB-07-104
How to Check Wear Amount (Tread Design Groove

Depth):
Measure the groove depth at 1/4 tread width position
1
[shown with  mark (1) in the figure].
Tread width
Use limit of the groove depth shall be approx. 85 % of the
new tire groove depth. If extreme uneven wear or exposed
rubbing strips are found, replace the tire even before
reaching 85 %. Groove
depth
IMPORTANT: If the machine is operated with such tires at
either rear or front being extremely worn or different
in type, construction, or size, the travel driving system
such as axles or transmission will be adversely affected
Tread width
in their performance and/or endurance.
When replacing tires, be sure to use the same tires MNEC-07-122
in type, construction and size to the four wheels. It is
recommended to replace tires of the four wheels at the
same time.
7-98
MAINTENANCE
Removal and Installation of Tire
dWARNING: A wheel and tire assembly is a very

heavy part so that removal and installation of a
tire is hazardous and difficult work. In addition,
a crane to lift a tire is required when removing or
installing the tire to the wheel. Consult your nearest
authorized dealer or a professional tire sales shop
for tire removal and installation work. When jacking
up the machine, observe the following points.
 Select dry, solid and flat ground for a work site.

 Work in a group of more than two persons. One
person to mainly do the work and others to work as
assistants and/or ensure safety.
 Do not use the bucket to raise the front wheels.
 Do not raise the machine off the ground higher
necessary.
 When one axle is raised off the ground, block the tires
at the axle that is still in contact with the ground.
 After the machine is raised off ground, be sure to
block the machine using rigid supports. If wooden
blocks are used for "cribbing" support, use only hard
wood blocks. Never use soft wood for support. Never
leave the machine to be supported only by jacks.
 The rear wheels oscillate. Insert wooden blocks
between the axle and the frame to stop oscillation.
 When removing the wheel bolts, lift the wheel with
a crane so that the wheel bolt remaining at the top
position is removed lost.
 Wheel bolt tightening torque: 890 N·m (91 kgf·m, 655
lbf·ft)
Tire Wheel:
dWARNING: Use only reliable and professional

tire repair shops to do tire repair or replacements.
Only authorized professional repair shops should
be permitted to assemble and inflate tires. Rusty
rims that have been deeply corroded must not be
reused. Replace them with new rims.
7-99
MAINTENANCE
K. Air Conditioner
Clean/Replace Air Conditioner Circulation/Fresh Air
Filters
Clean filters
--- every 100 hours (or once a week whichever comes
first)
Replace filter
--- after cleaning filters 10 times (or when the filters
are severely clogged)
fNOTE: If the machine is operated at a dusty job site, clean or

replace the filter element earlier than the normal interval.
Clean Fresh Air Filter

1. Remove the filter:
The fresh air filter is installed behind cover (1) on the
left rear side of the cab exterior. Open cover (1) with the
starter key. 1
Loosen wing nuts (3) and remove plate (2). Remove fresh
air filter (4).
dCAUTION: When using compressed air pressure, wear

safety glasses or goggles.
MNEC-01-505
IMPORTANT: If compressed air delivery pressure is

2
high, damage to the filter fins may result. Always use
compressed air at the lower pressure than 0.2 MPa (30
PSI). Keep the nozzle more than 500 mm (20 in) away
from the core surface.
2. Clean fresh air filter (4).

Clean fresh filter (4) using compressed air or by washing 3
with water.
Washing procedure with water is as follows: 4
2.1 Use tap water.
2.2 Submerge the filter in water containing a neutral
detergent for about 5 minutes. MNEC-07-043
2.3 Clean the filter with water again.

2.4 Sufficiently dry the filter.
7-100
MAINTENANCE
IMPORTANT: Inappropriate installation of the filter may
cause dust to enter into the air conditioner, causing
malfunction or breakdown of the air conditioner.
Before installing the filter element, clean off dust
around the mounting area; install the filter element
with extra care.
3. Install the cleaned fresh air filter or a new filter by

following the filter removal procedure described in step
1 in the reverse order.
7-101
MAINTENANCE
Clean and Replace Double Filter (Option)
--- When cleaning fresh air filter
1. Remove the double filter:
The double filter is installed behind cover (1) on the left
rear side of the cab exterior. Open cover (1) with the
starter key.
Loosen wing nuts (3) and remove plate (2) with double 1
filter (7).
Remove bolts (5) (4 used), plate (6), and double filter (7)
from plate (2).

MNEC-01-505
IMPORTANT: If compressed air delivery pressure is 2

PSI). Keep the nozzle more than 500 mm (20 in) away
from the core surface.
2. Clean double filter (7). 3

Clean double filter (7) using compressed air or by
washing with water.
4
Washing procedure with water is as follows:
2.1 Use tap water.
2.2 Submerge the filter in water containing a neutral MNEC-07-043
detergent for about 5 minutes.
3. Install the cleaned double filter or a new filter by 4
2
1 in the reverse order. 7
6
5
MNHE-07-048
7-102
MAINTENANCE
Clean Circulation Air Filter
1. Remove the filter:
Remove screw (6) under cup holder (5) and tilt the cup
holder forward. Hold handle (7) and pull handle (7)
toward you to remove circulation air filter (8).

5
IMPORTANT: If compressed air delivery pressure is

6 M4GB-07-108
PSI). Keep the nozzle away from the core surface more
than 500 mm (20 in).
8
2. Clean circulation air filter (8). 7
Clean circulation air filter (8) using compressed air or by

washing with water.
Washing procedure with water is as follows:
2.1 Use tap water.
2.2 Submerge the filter in water containing a neutral
detergent for about 5 minutes.
MNEC-07-044
IMPORTANT: Inappropriate installation of the filter may

cause dust to enter into the air conditioner, causing
malfunction or breakdown of the air conditioner.
Before installing the filter element, clean off dust
around the mounting area; install the filter element
with extra care.
Keep cab doors closed when operating machine.
3. Install the cleaned circulation air filter or a new filter by

1 in the reverse order.
7-103
MAINTENANCE
Check Air Conditioner
--- every 6 months
Check the air conditioner switch panel, air conditioner unit,
and condenser mounting areas for any abnormality, and check
hoses for any damage.
fNOTE: When the season to use the air conditioner comes

close, check the air conditioner to get it ready to use at all
times.
When not required to use the air conditioner for a long period
of time, operate the air conditioner in the cooling mode once
a week to prevent lack of lubrication.
dWARNING: Do not clean the compressor and receiver

tank with steam.
The refrigerant gas pressure will increase, possibly
causing the hoses to break.
Check Air Conditioner Piping

--- every 6 months
dCAUTION: If any leakage is found, repair or replace

the corresponding pipes. Tighten the joint bolts to
specification.
Do not overly tighten piping.
Check the piping for abnormal deformation and/or damage.

If a pipe joint is contaminated with oil, refrigerant leakage may
be suspected. Check for leakage using a gas leak detector.
7-104
MAINTENANCE
Check Air Conditioner Condenser
--- every 6 months
If condenser (1) is covered with dirt and/or insects, air
conditioner cooling performance will be reduced. 1
Remove dirt or stain from fins of condenser (1) using tap water.
If the condenser has been severely contaminated, use a soft
brush. Do not use a hard brush, which may damage the fins.
Check Air Conditioner Drive Belt

--- every 6 months
Check the belt for abnormal deflection and damage.
Check drive belt tension by depressing the midpoint shown MNEK-07-019
with  mark in the illustration with the thumb. Deflection must
be as follows with a depression force of approximately 98 N
(22 lbf ).
Deflection : approx. 6 mm (0.24 in)
2 3
Belt Tension Adjustment Procedure
1. Loosen lock nut (2) of tension pulley (4).
2. Move tension pulley (4) to adjust belt tension by turning 4
belt tension adjustment bolt (3).
3. Securely tighten nut (2).
M4GB-07-111
7-105
MAINTENANCE
Check Refrigerant
--- every 6 months
Start the engine and run at approximately 1500 min-1 (rpm).
Turn the air conditioner switch to ON. Set the blower switch
to HI and set the temperature control switch to the coolest
position (18 °C on the monitor screen). Operate the air
conditioner 2 to 3 minutes. Check if cool air comes out from
the vent in the cab.
Type Refrigerant No. Quantity kg

HFC R134a 0.9±0.05
IMPORTANT: If recovery or refill of refrigerant is required
during the machine maintenance (including disposing
the machine), contact your refrigerant supplier or your
authorized dealer.
Replace Air Conditioner Receiver Dryer

--- every 6000 hours or three years
IMPORTANT: Do not release refrigerant into the
atmosphere as this is illegal. Comply with refrigerant
regulations.
Before charging refrigerant, all the refrigerant must be
recovered from the system. Consult your nearest authorized
dealer to replace receiver dryer (1) or to charge the refrigerant.
90Z7-OM0144
Check Compressor and Pulley

--- once a year
Check the compressor and its vicinity for abnormality in
operation, oil stain, or refrigerant leakage. Check the pulley for
abnormal noise.
Check the belt for abnormal deflection and damage.
Check Compressor:
After operating the air conditioner for 5 to 10 minutes,
check temperature at both the high pressure pipe and the
low pressure pipe.
Normally, the high pressure pipe must be hot and the low
pressure pipe must be cool.
MNEK-07-020
7-106
MAINTENANCE
L. Miscellaneous 2
Check Bucket Teeth and Cutting Edge

Check bucket teeth for wear and looseness.
Replace
dWARNING:
of metal.
Guard against injury from flying pieces
Wear goggles or safety glasses, hard hat and face

shield.
Cutting Edge
1. Lift the bucket so its bottom is level. Lift the bucket to 4
an appropriate height and wedge a block under it so 1
the bucket will not come down. Stop the engine.
M4GB-07-116
2. Loosen bolts (1) and nuts (2). Remove cutting edge (4).
3. Install new cutting edge (4). If the reverse side of a
cutting edge is not worn much, use it again with the
face reversed. If both sides are worn out, replace it with
a new one.
4. Tighten nuts (2).
Tightening torque
Cutting edge : 1068 N·m (788 lbf·ft)
5. Retighten mounting nuts (2) after a few hours of

operation.
Bucket Teeth
1. Lift the bucket so its bottom is level. Lift the bucket to
Lock MNEK-07-041
an appropriate height and wedge a block under it so
the bucket will not come down. Stop the engine. Unlock
prybar
2. Insert a prybar into the locking part of the tooth,
unlock it and remove the point.
3. Remove the point of the tooth. MNEK-07-045
4. Mount a new point and lock it with the prybar.

5. After operating the machine for several hours, check MNEK-07-046
and make sure there are no problems with the Point
mounting of the point.
7-107
MAINTENANCE
Check and Replace Seat and Seat Belt
Check appearance --- every 10 hours (daily) 2
Replace --- every 3 years
1
Examine buckle (1), attaching hardware (2) and seat belt web.
Replace the seat belt web, buckle, or attaching hardware if
they are damaged, or worn. Also check the wind-up condition
of the seat belt.
Replace seat belt every 3 years, regardless of appearance.
Inspect the seat for large play or damage. Replace it if
necessary.
90Z7-7-96-1
Check ROPS Cab, Resin Cab Roof, and Roof Mounting 4

Bolts
3
Check the appearance of ROPS cab (3) and resin cab roof (4)
for any abnormal damage or deformation.
M4GB-07-118
Check Windshield Washer Fluid Level

IMPORTANT: Keep all dirt, dust and other foreign

materials out of the tank.
Use anti-freeze type washer fluid in cold weather.
Check the fluid level. If necessary, add the fluid.
fNOTE: The location of the windshield washer fluid tank

differs depending on the machine models.
MNEK-07-021
7-108
MAINTENANCE
Check Play Amount in Steering Wheel Movement
dWARNING: Pinch point. When the steering wheel

is turned, the clearance between the front and rear
chassis closes, creating a hazardous situation. Keep
personnel away from the chassis articulation point
during inspection.
Check that play (1) in steering wheel movement is correct

1
and that steering column tilt telescopic lever (2) and pedal
(3) are held securely. In addition, check that the chassis
steering stoppers come in contact with the opposing
chassis surface stopper when the steering wheel is fully
turned and that the steering cylinders operate normally.
1. Start the engine. Turn the parking brake switch ON.

2. Slightly lift the bucket above the ground. Place the
control lever lock in the lock ( ) position.
3. While running the engine at slow speed, MNEC-07-050
slightly rotate the steering wheel clockwise and
counterclockwise. Measure the beginning movement
distance along the steering wheel circumference
until both right and left steering cylinders start
moving (check the movement of the bucket and/or
tires).
Play amount (1): 5 to 15 mm (0.2 to 0.6 in)
fNOTE: If too much steering wheel play is found or if the

steering wheel does not move smoothly, consult your
nearest authorized dealer for checking.
2 3 MNEC-01-037
7-109
MAINTENANCE
Check Accelerator Pedal Operation, and Exhaust Gas
Color and Noise
dWARNING: Move the forward/reverse lever to neutral.

Apply the parking brake. After horizontally resting the
bucket on the ground, set the wheel stoppers.
While slowly stepping on accelerator pedal (1), check that

the engine speed smoothly increases. While slowly returning
accelerator pedal (1), check that the engine speed smoothly
decreases.
If dust and/or soil accumulate in vicinity of accelerator pedal
(1), remove them. 1 MNEC-01-037
Exhaust Gas Color and Noise
dDANGER: Ventilate the shop with fresh air when

carrying out warm-up operation indoors. Failure to
do so may cause intoxication by exhaust gas, possibly
resulting in personal death accident.
IMPORTANT: This machine is equipped with an engine

that meets Tier 4 emission requirements. Never
attempt to modify the inlet and exhaust system.
Exhaust gas color is normally transparent or light blue.

Although exhaust gas color slightly becomes white
immediately after the engine is started or quickly
accelerated, this symptom is not abnormal.
If the exhaust gas color turns black, white, brown, or gray,
check the engine oil level and the fuel supply system for any
abnormality. In addition, check that no abnormal noise is
heard coming from the engine or the muffler.
7-110
MAINTENANCE
Check Rearview Mirror and Inside Rearview Mirror
1
Check that inside rearview mirror (1) and rearview mirror (2)
are adjusted correctly. Check inside rearview mirror (1) and
rearview mirror (2) for contamination or damage to the mirror
glass. Clean if needed.
2
M4GB-01-126
2 2
MNEK-07-039
4 4
4 4
Check Steps and Handrails for Damage and
Looseness
Check steps (3) and handrails (4) for damage, looseness and
contamination. If oil, grease or mud are on the steps and/or
handrails (4), remove it.
If the steps (3) and/or handrails (4) become damaged or
loosened, immediately replace.
3
Do not repair handrails or steps. Repairs can fail unexpectedly.
Be sure to replace damaged steps or handrails.
MPD8-01-001
3
4 4 4
MPD8-01-002
3
7-111
MAINTENANCE
Clean Engine Compartment and Hood
dCAUTION: Dust or chips accumulated in the engine

compartment or around the hood may come in contact
with high temperature sections near the engine or
hood, possibly causing fires.
Remove the accumulated dust and chips from the hood.

Open the side access cover and check if dust and/or chips are
accumulated in the engine compartment and/or the areas
above the engine. Remove the accumulated chips and/or dust MNEK-07-032
if any.
Check Sound Absorbing Mat Around Engine

dCAUTION: If the sound absorbing mat in the engine

compartment becomes unglued, the mat may come in
contact with high temperature sections of the engine,
possibly resulting in fires.
Check if the sound absorbing mat around the engine is

unglued. If any part of the mat is found unglued, immediately
contact your nearest Hitachi dealer for repair.
MNEK-07-022
Cleaning of Rear View Camera Lens

--- every 10 hours
Oil, dust, moisture band, or others may obscure the image
from the camera lens. Rear view
camera
If image is not clear, clean the lens by following below
procedure.
1. Gently wipe surface of the camera lens with a damp

cloth.
IMPORTANT: Never use organic solvent.

Do not apply excessive force as it may damage the
camera.
MNEK-01-006
7-112
MAINTENANCE
Check and Adjust Valve Clearance
Consult your nearest authorized dealer for check and repair.
Retighten Front Axle and Rear Axle Support

Mounting Bolts
Check front and rear axle support mounting bolts for
looseness.
Tightening torques of the front axle and rear axle

support mounting bolts
Rear Axle Support Mounting

Front Axle Mounting Bolt
Bolt
785±150 N·m
890±170 N·m (656±125 lbf·ft)
(579±111 lbf·ft)
7-113
MAINTENANCE
Tightening and Retightening Torque of Nuts and
Bolts
Check tightness after the first 50 hours then every 2000 hours.
The nuts and bolts other than those shown in the table below
shall be tightened in accordance with the torque values shown
in the table on page 7-114.
Tighten or retighten nuts and bolts used on this machine in
accordance with the torque values shown in the following
table.
Check nuts and bolts for looseness and missing daily before
and after operation. If any loose or missing nuts and/or bolts
are found , retighten or supply replacement parts.
Bolt Wrench Torque

Locations Quantity
Diameter Size N·m (lbf·ft)
785±150
1 Front axle mounting bolt 24 8 36
(579±11)
890±170
2 Rear axle support mounting bolt 24 8 36
(656±125)
3 Wheel rim mounting bolt 24 60 36 890 (656)
Axle side 12 12 17 *145 (107)
4 Propeller shaft mounting bolt **1/2-20
Transmission side 8 3/4 inch *145 (107)
UNF-2A
5 Propeller shaft support bearing mounting bolt 20 2 30 206 (152)
6 Transmission mounting bolt: Bracket 20 4 30 *401 (296)
7 Transmission mounting bolt: Cushion rubber 18 2 27 315 (232)
8 Engine mounting bolt: Bracket 12 10 19 *110 (82)
9 Engine mounting bolt: Cushion rubber 18 2 27 315 (232)
10 Aftertreatment device mounting nut (Double) 10 16 17 20 (14.8)
11 Counterweight mounting bolt 30 4 46 1510 (1114)
12 Top center pin upper flange lock 16 7 24 *205 (151)
13 Bottom center pin lock 16 1 24 210 (155)
16 9 24 210 (155)
14 Loader front pin lock
12 4 19 90 (66)
15 Steering cylinder pin lock 12 4 19 90 (66)
16 Radiator frame mounting bolt 16 6 24 *210 (155)
17 Radiator mounting bolt 8 2 12 17.6 (13)
18 Intercooler mounting bolt 8 1 12 17.6 (13)
19 Oil cooler mounting bolt 10 2 17 36.2 (27)
20 Torque converter cooler mounting bolt 10 4 17 36.2 (27)
21 Air conditioner condenser mounting bolt 8 4 13 12.5 (9.2)
SOCKET 24.5to29.4
22 Air conditioner compressor mounting bolt 8 4
6 (18to21.7)
23 Cab cushion rubber mounting bolt 16 4 24 *205 (151)
24 Cutting edge mounting bolt **1" 12 37.47 1068 (788)
25 Wear plate mounting bolt **1" 4 37.47 1068 (788)
*: LOCTITE #263 is used.
**: The unit of figure is "inch".
7-114
MAINTENANCE
Tightening Torque Chart
Hexagon Wrench Socket Bolt
Bolt Dia. Wrench Size Wrench Size

Socket Bolt
mm (in)
mm mm
N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft)
3.3 to 4.2 10 5
6 (0.24)
(2.4 to 3.1)
8 (0.31) 30 (22) 20 (14.8) 10 (7.4) 13 20 (14.8) 6
10 (0.39) 65 (48) 50 (36.9) 20 (14.8) 17 50 (36.9) 8
12 (0.47) 110 (81) 90 (66.4) 35 (25.8) 19 90 (66.4) 10
14 (0.55) 180 (133) 140 (104) 55 (40.6) 22 140 (104) 12
16 (0.63) 270 (199) 210 (155) 80 (59) 24 210 (155) 14
18 (0.71) 400 (295) 300 (221) 120 (88.5) 27 300 (221) 14
20 (0.79) 550 (406) 400 (295) 170 (125) 30 400 (295) 17
22 (0.87) 750 (553) 550 (406) 220 (162) 32
24 (0.94) 950 (700) 700 (516) 280 (207) 36
27 (1.06) 1400 (1033) 1050 (774) 400 (295) 41
30 (1.18) 1950 (1438) 1450 (1069) 550 (406) 46
33 (1.30) 2600 (1918) 1950 (1438) 750 (553) 50
36 (1.42) 3200 (2360) 2450 (1807) 950 (700) 55
dCAUTION: If counterweight mounting bolts are

loosened, consult your nearest authorized dealer.
IMPORTANT:
 Apply lubricant to bolts and nuts to lower friction
except plated bolts and nuts.
 Remove soil, dust, and/or dirt from the nut and bolt
thread surfaces before tightening.
 Tighten nuts and bolts to specifications. If tightened
with excessively low or high torque, missing or
breakage of nuts and/or bolts may result.
7-115
MAINTENANCE
1. Front axle mounting bolt
Bolt dia. mm 24
Quantity 8
M4GB-07-124
2. Rear axle support mounting bolt
Bolt dia. mm 24
Quantity 8
M4GB-07-125
MNEC-07-052
3. Wheel rim mounting bolt
Bolt dia. mm 24
Quantity 60
M4GB-07-127
7-116
MAINTENANCE
4. Propeller shaft mounting bolt
Axle side
Bolt dia. mm 12
Quantity 12
Transmission side
1/2-20
Bolt dia. inch
UNF-2A
Quantity 8
M4GB-07-017
fNOTE: Apply LOCTITE#263.
5. Propeller shaft support bearing mounting bolt
Bolt dia. mm 20
Quantity 2
MNEC-07-053
6. Transmission mounting bolt: Bracket
Bolt dia. mm 20
Quantity 4
MNDB-07-010
7-117
MAINTENANCE
7. Transmission mounting bolt: Cushion rubber
Bolt dia. mm 18
Quantity 2
MNEC-07-054
8. Engine mounting bolt: Bracket
Bolt dia. mm 12
Quantity 10
8
9. Engine mounting bolt: Cushion rubber
Bolt dia. mm 18
Quantity 2
MNEC-07-093
7-118
MAINTENANCE
10. Aftertreatment device mounting nut (Double)
Bolt dia. mm 10 (Nut)

Quantity 16
MNEK-07-023
MNEK-07-024
11. Counterweight mounting bolt
Bolt dia. mm 30
Quantity 4
MNEK-07-040
12. Top center pin upper flange lock
Bolt dia. mm 16
Quantity 7
MNEK-07-047
7-119
MAINTENANCE
13. Bottom center pin lock
Bolt dia. mm 16
Quantity 1
MNEK-07-043
14. Loader front pin lock
Bolt dia. mm 16 12
Quantity 9 4
M4GB-07-137
MNEC-07-006
15. Steering cylinder pin lock
Bolt dia. mm 12
Quantity 4
MNEK-07-043
7-120
MAINTENANCE
16. Radiator frame mounting bolt
Bolt dia. mm 16
Quantity 6
MNEK-07-025
17. Radiator mounting bolt
Bolt dia. mm 8
Quantity 2
MNEK-07-026
7-121
MAINTENANCE
18. Intercooler mounting bolt
Bolt dia. mm 8
Quantity 1
MNEK-07-027
19. Oil cooler mounting bolt
Bolt dia. mm 10
Quantity 2
MNEK-07-027
20. Torque converter cooler mounting bolt
Bolt dia. mm 10
Quantity 4
MNEK-07-028
21. Air conditioner condenser mounting bolt
Bolt dia. mm 8
Quantity 4
MNEK-07-029
7-122
MAINTENANCE
22. Air conditioner compressor mounting bolt
Bolt dia. mm 8
Quantity 4
MPD8-07-001
23. Cab cushion rubber mounting bolt
Bolt dia. mm 16
Quantity 4
MNEC-07-066
7-123
MAINTENANCE
24. Cutting edge mounting bolt
Bolt dia. inch 1"

Quantity 12
M4GB-07-116
25. Wear plate mounting bolt
Bolt dia. inch 1"

Quantity 4
M4GB-07-150
7-124
MAINTENANCE
M. Aftertreatment Device
Check and Clean Aftertreatment Device
--- as required
IMPORTANT: 1
 Check and clean flammable materials on the area
around the Aftertreatment device.
1
 Condensation for dew may blow out from the
exhaust outlet of the afterfreatment device and
black deposition may be observed; it is not a
malfunction.
Do not disassemble the base machine support parts and

sensors.
When the machine is operated in dusty areas, refer to
the page 9-1 "Maintenance Under Special Environmental
Conditions". MNEK-07-037
1. Open the right and left side cover. 3

4
2. Check exhaust pipe (1) for cracks.
2
Check the aftertreatment device units for loose or
disconnection.
3
3. Check the connectors and harnesses of NOx sensors

(2), temperature sensors (3) and dosing module (4) for
abnormality.
2
4. Close the side cover.

3
MPD8-07-002
7-125
MAINTENANCE
N. Urea SCR System
dWARNING: Fill specified DEF/AdBlue® into the DEF/

AdBlue® tank.
If improper DEF/AdBlue® is refilled, fire or system
failure may result. If improper liquid is refilled in the
DEF/AdBlue® tank, consult your authorized dealer for
check or repair.
Specified DEF/AdBlue®
Refill DEF/AdBlue® which meets Japanese Industrial Standards
(JIS K2247), International Organization for Standardization (ISO
22241) or Deutsche Industrie Normen (DIN 70070). If improper
liquid (diesel oil, kerosene or gasoline) is refilled in the DEF/
AdBlue® tank, fire or system failure may result. The specified
DEF/AdBlue® is colorless and odorless solution (urea 32.5 %,
water 67.5 %) which begins to freeze at -11 °C (12 °F). It is
recommended storing DEF/AdBlue® at temperature between -10
and 40 °C (14 and 104 °F).
In some cases, specified urea solution is referred to by one or

more of these names:
 Aqueous Urea Solution 32
 AUS 32
 NOx Reduction Agent
 Catalyst Solution
f NOTE: AdBlue® is produced from suppliers which are licensed
by the VDA (Verband der Automobilindustrie e.V).
Diesel Exhaust Fluid (DEF) is certified by the API (American
Petroleum Institute) Diesel Exhaust Fluid Certification
Program.
dCAUTION:
 DEF/AdBlue® is colorless and harmless solution. It is
harmless when contacting with the body, however,
it may cause skin to become inflamed depending on
the constitution of the individual. Flush DEF/AdBlue®
with clean water when it contacts on the skin.
 If you swallow DEF/AdBlue® by mistake, drink 1 or 2
cups of water or milk and seek immediate medical
attention.
 If DEF/AdBlue® is accidentally splashed into eyes,
flush with water for 15 minutes or longer and get
emergency medical attention.
7-126
MAINTENANCE
IMPORTANT:
 Use dedicated container recommended by the
business entity who is handling DEF/AdBlue® to
store DEF/AdBlue®. Do not use general container, a
container used for other purpose and contaminated
container because the quality of DEF/AdBlue®
deteriorates.
 The DEF/AdBlue® is non-combustible, however, move
DEF/AdBlue® to a safe place when fire occurs.
 Wash out spilled DEF/AdBlue® with clean water.
 Seal the container and store it in a well ventilated
place. If DEF/AdBlue® freezes, the quality does not
change just after freezing.
 As long as sealed by an airtight stopper, unless water
evaporates DEF/AdBlue® will not deteriorate within
the guarantee period.
 Do not pour waste DEF/AdBlue® and its containers
onto the ground, and do not allow waste to flow into
rivers and/or lakes. When disposing DEF/AdBlue®,
make sure to let authorized industrial waste disposal
contractor dispose of it appropriately.
7-127
MAINTENANCE
Check DEF/AdBlue®
Park the machine on a level surface. Lower the bucket to the
ground. Check the DEF/AdBlue® level with DEF/AdBlue® gauge
(1). 1
If necessary, stop the engine and add DEF/AdBlue®.
Refill DEF/AdBlue®
dCAUTION: MNEK-01-103EN
 Refill DEF/AdBlue® which meets Japanese Industrial

Standards (JIS K2247), International Organization for
Standardization (ISO 22241) or Deutsche Industrie
Normen (DIN 70070) in DEF/AdBlue® tank (2). If
low density DEF/AdBlue® is refilled, alarm will be
generated, restricting machine operation. Do not
dilute DEF/AdBlue® with water.
 Wear safety equipment such as safety glasses or
goggles, rubber gloves appropriate to the job. Wash
DEF/AdBlue® with clean water when it contacts on 3
the skin. If DEF/AdBlue® is accidentally splashed into
eyes, flush with water for 15 minutes or longer and
get emergency medical attention.
2
1. Park the machine according to the instruction on

"Preparations for Inspection and Maintenance" (7-8).
2. DEF/AdBlue® tank (2) is located in the cover at left rear of
the machine. Open the DEF/AdBlue® tank cover.
3. Clean dust and mud around the filler port of DEF/
AdBlue® tank with clean cloth.
4. Remove cap (3) from DEF/AdBlue® tank (2) and refill DEF/
AdBlue®. Be sure to stop refilling before the “FULL” line
(4).
IMPORTANT:
 Take care not to allow dust and/or water to enter the 4
DEF/AdBlue® tank when refilling. MNEK-07-033
 If DEF/AdBlue® is filled above the “FULL” line, the

system may be damaged during operation or tank
(2) may be broken when frozen.
7-128
MAINTENANCE
5. Install cap (3) after refilling DEF/AdBlue®. Close the DEF/
AdBlue® tank cover.
IMPORTANT: 3
 Do not get on top of DEF/AdBlue® tank (2) or sensors
and piping on the tank. Failure to do so may damage
the machine. 2
 White deposits may be observed when DEF/AdBlue®
is dried naturally; it is normal. Wash out DEF/AdBlue®
deposits with soft water. Never use a high pressure
washer.
fNOTE:
 Wipe spilled DEF/AdBlue® and wash spilled area with plenty
of water.
 The sound of flowing water may be heard from the tank
after the engine stops. It is the sound of returning DEF/
AdBlue® from piping to the tank, not a malfunction.
 DEF/AdBlue® will freeze at low temperature, and
deteriorate (ammonification) at high temperature. It 4
MNEK-07-033
is recommended storing DEF/AdBlue® at temperature
between -10 and 40 °C (14 and 104 °F).
 Use dedicated container (purchased container) to store or
carry DEF/AdBlue®. Alternatively use a polyethylene resin
tank, or stainless steel tank.
7-129
MAINTENANCE
Change DEF/AdBlue®
---As required
2
d CAUTION: Wear safety equipment such as safety
glasses or goggles, rubber gloves appropriate to
the job. Wash DEF/AdBlue® with clean water when it
contacts with the skin. If DEF/AdBlue® is accidentally
splashed into eyes, flush with water for 15 minutes or
longer and get emergency medical attention.
IMPORTANT: When contaminated or deteriorated DEF/
AdBlue® is used, malfunction may result. Change DEF/
AdBlue® periodically to keep cleanliness in the tank.
1. Remove bolts (1) and washers and remove cover (2).

2. Place a 50 liter (13 gallons) or larger capacity container
under drain plug (3).
3. Slowly loosen drain plug (3) to drain DEF/AdBlue®. 1
4. Tighten drain plug (3) after draining DEF/AdBlue®. MNEK-07-034
Wrench size: 6 mm
Tightening torque: 5 to 7 N·m (3.7 to 5 lbf·ft)
5. Fix cover (2) with bolts (1) and washers.
6. Remove the cap from DEF/AdBlue® tank and refill DEF/
AdBlue®.
(Refer to 1 “Check DEF/AdBlue®”.)
DEF amount: 25.1 liters (6.6 gallons)
3
MNEK-07-035
7-130
MAINTENANCE
Replace DEF/AdBlue® Supply Module Main Filter DEF/AdBlue® Supply Module

A filter (2) is mounted in the DEF/AdBlue® supply module.
Periodically replace filter (2).
dCAUTION: Use rubber glove and goggles or safety

glasses for protection during operation. Wash DEF/
AdBlue® with clean water when it contacts on the skin.
IMPORTANT:
 Take care not to allow dirt and/or water to enter the
DEF/AdBlue® tank while replacing filter (2).
 Check for leaks around the mounting position after
replacement.
 White deposition may be observed when DEF/
AdBlue® is dried naturally; it is normal. Wash out
DEF/AdBlue® deposition with clean water. Never use
1 MNEK-07-036
a high pressure washer.
1. Park the machine according to the instruction on

Preparations for Inspection and Maintenance (7-8).
2. Open the side cover.
3. Remove cap (1) from the DEF/AdBlue® supply module by
using a 27 mm bihexagon wrench.
4. Pull out filter (2) inside the supply module. As it is tightly
mounted, it can not be pulled by hands. Use tools such
as a pliers. Replace filter (2) assembly when replacing
filter (2) of DEF/AdBlue® supply module.
2
5. Install new filter (2), and tighten cap (1) with 20±5 N·m
(14.8±3.7 lbf·ft) torque.
1
MDC1-07-044
7-131
MAINTENANCE
MEMO
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7-132
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
Maintenance Under Special Environmental Conditions
dWARNING: Before operating the machine in a

river, check the riverbed conditions in advance.
dWARNING: Avoid driving the machine into a
river where the riverbed is steep and deep or the
stream is rapid.
Operating Precautions for Maintenance

Conditions
Muddy Soil, Rainy Before Operation: : Check tightness of plugs and all drain cocks.
or Snowy Weather After Operation : Clean the machine and check for cracks and damage. Check for loose or
missing bolts and nuts. Lubricate all necessary parts.
If the machine should be submerged in water more than approximately 450
mm, water may get into the brake device (like the park brake), resulting in
poor braking performance. Watch out when starting/stopping the machine.
Near the Ocean Before Operation: : Check tightness of plug and all drain cocks.
(or near chemical After Operation : Thoroughly clean the machine with fresh water to wash off salt.
treatment place) Service electrical equipment often to prevent corrosion.
Dusty Air Cleaner : Clean the element regularly at shorter service intervals when indicator
Atmosphere illuminates.
Radiator : Clean the oil cooler and the radiator cores.
Fuel, DEF/AdBlue® : Clean the filter element and strainer regularly at shorter service intervals.
Aftertreatment Device, : Clean them frequently to prevent deposits or dirt.
Engine Apply “Aftertreatment Device Regeneration Inhibit” setting as needed.
Electrical Equipment : Clean them regularly, in particular, the commutator surface of the alternator
and starter.
Rocky Ground Chassis : Check for damage on tires, for loose, cracked, worn, and damaged bolts and
nuts.
Front Attachment: : Standard attachment may be damaged when digging rocky ground. Use a
heavy duty bucket. Consult your nearest authorized dealer.
Freezing Weather Fuel : Use high quality fuel suitable for low temperature.
Check the fuel tank breather pipe freezing.
Lubricant : Use high quality low viscosity hydraulic oil and engine oil.
Engine Coolant : Be sure to use antifreeze.
Battery : Fully charge the batteries regularly at shorter service intervals. If not
charged fully, electrolyte may freeze.
Tires and Chassis : Keep fires and chassis clean. Park the machine on a hard surface to prevent
the tires from freezing to the ground.
DEF/AdBlue® : Keep 80% of tank capacity when storing at -10°C (12°F) or lower. The DEF/
AdBlue® tank maybe broken if DEF/AdBlue® is frozen.
When handling Engine compartment : Remove old paper and/or waste accumulated around the radiator and
old paper and/or in the engine compartment, possibly causing overheating or fires of the
industrial waste machine if not removed.
Air cleaner : Clean the element at shorter intervals.
Fuel system : Clean and replace the elements and the filters at shorter intervals.
Loader chassis : Remove the accumulated paper and/or waste from the surroundings
around the loader chassis and the attachment. Failure to do so may cause
damage of the machine.
Radiator : Wash as frequently as possible to prevent corrosion due to chemical
materials.
IMPORTANT: If material to be handled is a substance that causes corrosion such as salt or chemical, consult your
nearest authorized dealer. Special modification or treatment may be needed for the machine. If the machine
continues to be used, malfunction may occur due to corrosion.
Consult your nearest authorized dealer when the machine is operated under special condition (s).
9-1
Precautions for Maintenance During Cold

Weather Season
Before the atmospheric temperature below -0 °C (32 °F), note
the following points.
 Water and oil in the machine will freeze. Never use water
without antifreeze. Use correct windshield washing solution
so that windshield washer tanks and pumps will not freeze.
 Road surfaces may freeze so that tires may slip.
 Oil viscosity changes and oil thickens.
Keeping the above points in mind, follow the below:

1. Refill fluids such as water and lubricants prior to
operation (except fuel).
2. Mix LLC (long life coolant) in the radiator (coolant). When
this machine is shipped from the factory, LLC is supplied.
3. Change the engine oil to cold weather type oil.
4. Use fuel (#1 diesel fuel). To prevent condensation on the
inside wall in the fuel tank, fully refill the fuel tank with
#1 diesel fuel after each shift.
5. If the electrolyte solution in the battery case freezes,
damage to the battery case may result. Keep the
batteries fully charged. After completing work, turn all
lights OFF. When finished with work, run the engine at
low idle for a few minutes to cool down. This will help
rebuild battery charge when lights and other equipment
are off.
In extreme cold, remove the batteries and store them
in a warm indoor place. When it is possible to measure
and adjust the specific gravity of the electrolyte solution,
increase the specific gravity of the electrolyte up to
1.280. Do not increase more than 1.280.
After taking the measures as recommended above, start

operation of the machine.
9-2
dDANGER: Ventilate the area with fresh air when

carrying out warm-up operation indoor. Failure to do
so may cause asphyxiation from exhaust gas, resulting
in death or severe injury.
6. After preheating, start and warm up the engine.

7. After warming up the engine, warm up the loading
hydraulics. Slowly operate the control levers to move the
cylinders full stroke several times. Do not force cylinders
to go to the end of their stroke.
8. Road surfaces covered with snow, especially when snow
has been compacted, will be frozen. Use tire chains on all
four wheels.
9. Take anti-freeze measures after completing operation.
 Spray keyholes with light oil. Cover the keyhole by
sticking a tape on.
 Rubber parts such as wiper blades may freeze. Keep other
parts away from the rubber parts. Warm up cab prior to
use of wipers.
 Remove packed snow from around the axles, articulation
joint and inside the machine with a bar or brush. Be
careful not to damage electrical wiring.
 In case it is impossible to store the machine indoors, park
the machine on a level dry surface and cover the machine
with a large machine cover.
 Keep 80% of tank capacity when storing DEF/AdBlue®.
The DEF/AdBlue® tank maybe broken if frozen.
f NOTE: DEF/AdBlue® starts freezing at -10°C (12°F). Freezing
does not affect its performance once thawed.
9-3

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MAINTENANCE

Correct Maintenance and Inspection Procedures

Inspect machine daily before starting.

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

Check the Hour Meter Regularly

This manual recommends grouping the intervals into three

Check and maintenance intervals shown in this manual

1. Bolt on Cutting Edge 18. Transmission

Hydraulic Oil Filters

Transmission Oil Fuel Filter

Transmission Oil Filter DEF/AdBlue® Supply Module Main Filter

Item Page Item Page

Preparations for Inspection and Maintenance

dCAUTION: If the machine moves unexpectedly,

Unless specified otherwise, park the machine by following

1. Park the machine on a solid level surface.

3. Turn ride control switch (3) OFF.

dWARNING: Never attempt to maintain the machine

dCAUTION: Before beginning to work near the

1. Align the front and rear chassis centers with each

3. Pull out and rotate articulation stopper (2) to align it

Inspection/Maintenance Access Side Cover 1 2

When opening side cover (1), pull latch (3).

fNOTE: When required to inspect the machine for a long time

 Rear grille (2) may spring open. Take care not to

Opening the rear grille 2

Push open/close Button (1) laterally to open rear grille

Closing the rear grille

Periodic Replacement of Parts

Periodic Replacement Parts Replacement Intervals

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

Inspection and Maintenance Table

: First time replacement or cleaning only

: First time replacement or cleaning only

: First time replacement or cleaning only

: First time replacement or cleaning only

Kind of Oil Hydraulic Oil

Kind of Coolant Long-Life Coolant

Location Liters Gallons

List of Consumable Parts

4. Slow Blow Fuses

dWARNING: Apply the parking brake and the

1. One point each to right and left bucket pins (1).

2. One point each to bucket link pins (2 and 3). 5

3. One point to bucket cylinder pin (4).

One point to bucket cylinder rod pin (5).

4. One point to lever (bell crank) pin (6).

--- every 500 hours (250 hours at first time only)

9. One point each to right and left steering cylinder rod

--- every 250 hours

12. One point to second (front) propeller shaft universal (18).

fNOTE: When the machine is continuously operated under

14. One point to second (center) propeller shaft universal 20

One point to second (center) propeller shaft universal

17. One point to third (rear) propeller shaft splines (24).

19. One point to brake pedal linkage (26)

IMPORTANT: Incorrect engine oil level may cause engine

fNOTE: Level the engine when adding oil or inspecting oil

dWARNING: Do not spill oil while changing oil. Spilled