PART NO.

WNDB-EN-01

ZW180-5B • ZW180PL-5B
Workshop Manual

WHEEL LOADER
WORKSHOP MANUAL
180-5B
180PL-5B
Wheel Loader
URL:http://www.hitachi-c-m.com

WNDB-EN-01

Service Manual consists of the following separate Part No.

Technical Manual (Operational Principle) : Vol. No.TONDB-EN
Technical Manual (Troubleshooting) : Vol. No.TTNDB-EN
PRINTED IN JAPAN (K) 2015, 12 Workshop Manual : Vol. No.WNDB-EN
 INTRODUCTION
To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
The machine specification and description according to Form” at the end of this manual. (Note: Do not tear off
destination may be explained on this manual. the form. Copy it for usage.):
 Technical Information Center Hitachi Construction
 Be sure to thoroughly read this manual for correct Machinery Co., Ltd.
product information and service procedures.  TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: HCM-TIC-GES@hitachi-kenki.com

Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.

Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures.  Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / disassemble procedures.

Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:

Example:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group

IN-01
 INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential dCAUTION:
for personal injury of machine damage. Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate
fNOTE:
Indicates supplementary technical information or know-
lifting techniques and equipment when lifting heavy
how.
parts.

Units Used
SI Units (International System of Units) are used in this Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
manual. MKSA system units and English units are also
indicated in parentheses just behind SI units. A table for conversion from SI units to other system units
is shown below for reference purposes.

Quantity To Convert From Into Multiply By

Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3 yd3 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm 2
10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min -1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0

fNOTE: The numerical value in this manual might be

different from the above-mentioned table.

IN-02
 SYMBOL AND ABBREVIATION
Symbol and Abbreviation

Symbol / Name Explanation

Abbreviation
TO Technical manual (Operational principle)Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
VGS Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged
system to supercharge the exhaust energy while running
the engine at slow idle speed. VGS optimizes the turbine
rotation, improves the performance at slow-speed torque
and the acceleration, reduces fuel consumption, and reduces
particulate matter (PM) by adjusting the nozzle opening of
turbine housing.
TCU Transmission Control Unit Transmission control unit. TCU control transmission
according to the machine operating condition.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment.

SY-1
 SYMBOL AND ABBREVIATION

Symbol / Name Explanation

Abbreviation
DPF Diesel Particulate Filter DPF is a filter which removes particulate matter (PM)
including the toxic substance of exhaust gas of the diesel
engine. Exhaust particulate removal equipment.
DPD Diesel Particulate Diffuser DPD is an exhaust emission control system, a type of DPF,
which cleans up particulate matter (PM) of diesel engine
exhaust gas. DPD is a ceramic filter which traps and filters
PM of exhaust gas. DPD burns up accumulated PM when PM
increases and regenerates the filter.
DOC Diesel Oxidation Catalyst Oxidation catalyst for the diesel engine. Diesel oxidation
catalyst oxidizes unburnt fuel and raises exhaust
temperature.
CSF Catalyzed Soot Filter Filter. The filter traps, burns, and remove particulate matter
(PM) by using high-temperature-exhaust gas with diesel
oxidation catalyst. Catalyst is applied onto the filter. This
advances PM burning.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the
intake manifold and combines it with intake-air. Therefore,
combustion temperature is lowered and generation of oxide
of nitrogen (NOx) is controlled.

SY-2
 SAFETY
Recognize Safety Information
 These are the SAFETY ALERT SYMBOLS.

 When you see these symbols on your machine or in this

manual, be alert to the potential for personal injury.
 Follow recommended precautions and safe operating
practices.

SA-688

Understand Signal Words

 On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.

 DANGER indicates an imminently hazardous situation

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

 CAUTION also calls attention to safety messages in this

manual.

 To avoid confusing machine protection with personal SA-1223

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

 f NOTE indicates an additional explanation for an

element of information.

SA-1
 SAFETY
Follow Safety Instructions
 Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
 Learn how to operate the machine and its controls correctly
and safely.
 Allow only trained, qualified, authorized personnel to
operate the machine.
 Keep your machine in proper working condition. SA-003
 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Never attempt to modify or disassemble the inlet/exhaust
parts and the muffler filter. Avoid giving shocks on the
muffler filter by striking elements with other objects or
dropping the elements. Failure to do so may affect the
exhaust gas purifying device, possibly damaging it or
lowering its performance.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.

SA-2
 SAFETY
Prepare for Emergencies
 Be prepared if a fire starts or if an accident occurs.

 Keep a first aid kit and fire extinguisher on hand.

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

Wear Protective Clothing

 Wear close fitting clothing and safety equipment
appropriate to the job.

You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
SA-438
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.

 Avoid wearing loose clothing, jewelry, or other items that

can catch on control levers or other parts of the machine.

 Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones while
operating the machine.

SA-3
 SAFETY
Protect Against Noise
 Prolonged exposure to loud noise can cause impairment or
loss of hearing.

 Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.

SA-434

Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.

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

described in the “Inspect Machine Daily Before Starting”
section in the operator’s manual.

SA-435

SA-4
 SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not mess up around the operator's seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
accelerator pedal, brake pedals, control lever lock switch
or control levers, which may result in serious injury or
death.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
 Keep all flammable objects and/or explosives away from
the machine.
 After using the ashtray, always cover it to extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
 Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact
with the accelerator or brake pedals during operation,
resulting in serious injury or death.

SA-5
 SAFETY
Use Handrails and Steps
 Falling is one of the major causes of personal injury.
 When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.

 Do not use any controls as handholds.

 Never jump on or off the machine. Never mount or
dismount a moving machine.
 Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
 Never get on and off the machine with tools in your
hands.
SA-439

Never Ride Attachment

 Never allow anyone to ride attachment or the load. This is
an extremely dangerous practice.

Adjust Operator’s Seat

 A poorly adjusted seat for either the operator or the work
at hand may quickly fatigue the operator leading to
misoperations.

 The seat should be adjusted whenever changing the

operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror SA-462
is broken, immediately replace it with a new one.

SA-6
 SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open / close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the control lever lock switch to the lock ( ) position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.

 Before leaving the machine, be sure to first lower the front

attachment to the ground and then move the control
lever lock switch to the lock ( ) position. Turn the key
switch OFF to stop the engine.
 Before leaving the machine, close all windows, doors, and
access covers and lock them up.

Fasten Your Seat Belt

 If the machine should overturn, the operator may become
injured and / or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.

 Prior to operating the machine, thoroughly examine

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

SA-7
 SAFETY
Move and Operate Machine Safely
 Bystanders can be run over.

 Take extra care not to run over bystanders. Confirm the

location of bystanders before moving, or operating the
machine.
 Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
 Use a signal person when moving, or operating the
machine in congested areas. Coordinate hand signals
before starting the machine.
 Use appropriate illumination. Check that all lights are SA-398
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
 Ensure the cab door, windows, doors and covers are
securely locked.
 Check the mirrors and the monitor in the CAB for
problems.
If there is any problem, replace the problem part(s) or
clean the mirror, camera and the monitor.
Refer to Rear View Monitor section on the cleaning of the
camera and the monitor.

Handle Starting Aids Safely

Starting fluid:

 Starting fluid is highly flammable.

 Keep all sparks and flame away when using it.

 Keep starting fluid well away from batteries and cables.
 Remove container from machine if engine does not need
starting fluid.
 To prevent accidental discharge when storing a
pressurized container, keep the cap on the container, and
store it in a cool, well-protected location.
 Do not incinerate or puncture a starting fluid container.
SA-293

SA-8
 SAFETY
Operate Only from Operator’s Seat
 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.

 Start the engine only when seated in the operator's seat.

 NEVER start the engine while standing on the tire or on
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-431

Jump Starting
 Battery gas can explode, resulting in serious injury.

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

instructions shown in the “OPERATING ENGINE” chapter in
the operator’s manual.
 The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
 Never use a frozen battery.
 Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032

SA-9
 SAFETY
Investigate Job Site Beforehand
 When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.

 Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
 When working on an incline or on a road shoulder,
employ a signal person as required. SA-447
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.

SA-10
 SAFETY
Equipment of Head Guard, ROPS, FOPS
In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)
Any modification of the ROPS structure will modify its
performances and its certification will be lost.

ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure

SA-521

Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.

SA-481

SA-11
 SAFETY
Keep Riders Off Machine
 Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.

 Only the operator should be on the machine. Keep riders

off.
 Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-427

Drive Safely
 Beware of the possibility of slipping and / or turning over
the machine when driving on a slope.

 When driving on level ground, hold the bucket at mark

(A) 300 mm (12 in) above the ground as illustrated.
 Avoid traveling over any obstacles.
 Drive the machine slowly when driving on rough terrain.
 Avoid quick direction changes. Failure to do so may cause
the machine to turn over.
 If the engine stops while driving, the steering function
becomes inoperative. Immediately stop the machine by
applying the brake to prevent personal accident.
SA-448

SA-12
 SAFETY
Drive Machine Safely (Work Site)
 Before driving the machine, always confirm that the
steering wheel / and forward / reverse lever (switch)
direction corresponds to the direction you wish to drive.

 Be sure to detour around any obstructions.

 Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
SA-449
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 200 to 300 mm
(approximately 8 to 12 in) (A) above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.

 Driving across the face of a slope or steering on a slope

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

SA-450

WRONG

SA-451

SA-13
 SAFETY
Drive Safely with Bucket Loaded
 If the machine is incorrectly operated while driving with the
bucket loaded, turning over of the machine may result. Be
sure to follow all the instructions indicated below.

 When driving the machine on a job site with the bucket

loaded, hold the bucket as low as possible to keep the
machine balanced and to have good visibility.
 Do not exceed the rated load capacity. Always operate
the machine within the rated load capacity.
 Avoid fast starts, stops, and quick turns. Failure to do so
may result in personal injury and / or death.
 Avoid rapid drive direction changes which could possibly SA-400
cause personal injury and / or death.

Drive on Snow Safely

 Beware of the possibility of slipping or turning over the
machine when driving on frozen snow surfaces.

 The machine may slip more easily than expected on

frozen snow surfaces even if the inclination is small.
Reduce speed when driving. Avoid fast starts, stops and
quick turns.
 Road shoulder and / or set-up utilities covered with snow
are difficult to locate. Be sure where they are before
removing snow.
SA-452
 Be sure to use tire chains when driving on snow.
 Avoid applying the brake for quick stops on snow. If a
quick stop is required, lower the bucket to the ground.

SA-14
 SAFETY
Travel on Public Roads Safely
 This machine is not allowed to drive on public roads with
the bucket loaded.

 Be sure to empty the bucket.

 Hold the bucket at mark (A) 300 mm (12 in) above the
road surface as illustrated.

SA-453

Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.

To avoid rollaways:
 Select level ground when possible to park machine.
 Do not park the machine on a grade.
 Lower the bucket to the ground.
 Put the forward / reverse lever (switch) in neutral, and pull
up the parking brake switch (lever) in the ON (parking
brake) position. SA-457
 Run the engine at low idle speed without load for 5
minutes to cool down the engine.
 Stop the engine and remove the key from the key switch.
 Turn the control lever lock switch to the lock ( ) position.
 Block both tires and lower the bucket to the ground.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.

SA-458

SA-15
 SAFETY
Avoid Accidents from Backing Up and Turning
 Make sure no one is working under or close to the machine
before backing up or turning the machine to avoid personal
injury and / or death by being run over or entangled in the
machine.

 Keep all personnel away from the machine by sounding

the horn and / or using hand signals. Use extra care to be
sure no one is in from the articulation area before turning
the machine.
 Keep windows, mirrors, and lights in good condition.
 Reduce travel speed when dust, heavy rain, fog, etc.,
reduce the visibility.
 In case good visibility is not obtained, use a signal person SA-383
to guide you.

SA-312

SA-16
 SAFETY
Avoid Positioning Bucket or Attachment Over
Anyone
 Never allow the bucket or attachment to pass over co-
workers and / or the dump truck operator’s cab. Falling soil
from the bucket or contact with bucket or attachment may
cause serious personal accidents and / or damage to the
machine.

 Avoid carrying the bucket or attachment over the co-

workers to ensure safe operation.
SA-518

Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS
PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE
MACHINE IS PREDICTED, SECURELY HOLD THE STEERING
WHEEL TO PREVENT YOUR BODY FROM BEING THROWN
OUT OF THE MACHINE.
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
SA-463
FASTEN YOUR SEAT BELT
 The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.

To avoid tipping:
 Be extra careful before operating on a grade.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the
machine.
 Reduce operating speeds to avoid tipping or slipping.
 Avoid changing direction when traveling on grades.
 NEVER attempt to travel across a grade steeper than 5
degrees if crossing the grade is unavoidable.
 Reduce swing speed as necessary when swinging loads.

 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become

soft and make ground travel unstable.

SA-17
 SAFETY
Never Undercut a High Bank
 The edges could collapse or a land slide could occur causing
serious injury or death.

SA-519

Dig with Caution

 Accidental severing of underground cables or gas lines may
cause an explosion and / or fire, possibly resulting in serious
injury or death.

 Before digging, check the location of cables, gas lines, and

water lines.
 Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
 If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
SA-396
 Contact your local “diggers hot line” if available in your
area , and / or the utility companies directly.
Have them mark all underground utilities.

Perform Truck Loading Safely

 Do not operate the machine involuntarily. Unexpected
machine movement may cause personal injury and / or
death.

 Do not lower the bucket with the lift arm control lever
in the FLOAT position. The bucket may free fall, possibly
causing personal injury and / or death.
 Always select a level surface for truck loading.
SA-397

SA-18
 SAFETY
Avoid Power Lines
Serious injury or death can result from contact with electric
lines.

Never move any part of the machine or load closer to any

electric line than 3 m (10 ft) plus twice the line insulator
length.

SA-455

Precautions for Operation

 If the front attachment or any part of the machine comes in
contact with an overhead obstacle, both the machine and
the overhead obstacle may become damaged, and personal
injury may result.

 Take care to avoid coming in contact with overhead

obstacles with the bucket or arm during operation.

Precautions for Lightning

 The machine is vulnerable to lightning strikes.

 In the event of an electrical storm, immediately stop

operation, and lower the bucket to the ground. Evacuate
to a safe place far away from the machine.
 After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only after
repairing them.

SA-19
 SAFETY
Object Handling
CRANING OPERATION USING THE MACHINE IS NOT
ALLOWED.
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
resulting in serious injury or death.

Never attach a sling or chain to the bucket teeth or to the

attachment (fork or grapple for example). They may come
off, causing the load to fall.

SA-132

Protect Against Flying Debris

 If flying debris hit eyes or any other part of the body, serious
injury may result.

 Guard against injury from flying pieces of metal or debris;

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

SA-432

SA-20
 SAFETY
Park Machine Safely
To avoid accidents:
 Park the machine on a firm, level surface.
 Lower bucket to the ground.
 Put the forward / reverse lever (switch) in neutral, and
turn the parking brake switch (lever) ON (parking brake)
position.
 Run the engine at low idle speed without load for 5
minutes.
 Turn key switch to OFF to stop engine.
 Remove the key from the key switch.
SA-456
 Turn the control lever lock switch to the lock ( ) position.
 Close windows, roof vent, and cab door.
 Lock all access doors and compartments.

Store Attachments Safely

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.

 Securely store attachments and implements to prevent

falling. Keep children and bystanders away from storage
areas.

SA-034

SA-21
 SAFETY
Transport Safely
 Take care that the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.

 Observe the related regulations and rules for safe

transportation.
 Select an appropriate truck or trailer for the machine to Less than 15 °
be transported.
 Be sure to use a signal person.
SA-454
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight.
3. Use the low speed gear.
4. Never steer the machine while being on the ramp. If the
traveling direction must be changed while being on the
ramp, unload the machine from the ramp, reposition the
machine on the ground, then try loading again.
5. After loading, install the lock bar to securely hold the
articulation mechanism.
6. Wedge the front and rear of tires. Securely hold the
machine to the truck or trailer deck with wire ropes.

Be sure to further follow the details described in the

TRANSPORTING chapter.

SA-22
 SAFETY
Handle Fluids Safely−Avoid Fires
 Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and / or a fire may occur, possibly resulting in
serious injury or death.

 Do not refuel the machine while smoking or when near

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

 All fuels, most lubricants, and some coolants are flammable.

SA-018
 Store flammable fluids well away from fire hazards.
 Do not incinerate or puncture pressurized containers.
 Do not store oily rags; they can ignite and burn
spontaneously.
 Securely tighten the fuel and oil filler caps.

SA-019

SA-23
 SAFETY
Practice Safe Maintenance
To avoid accidents:
 Understand service procedures before starting work.
 Keep the work area clean and dry.
 Do not spray water or steam inside cab.
 Never lubricate or service the machine while it is moving.
 Keep hands, feet and clothing away from power-driven
parts.

Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Run the engine at low idle speed without load for 5
SA-028
minutes.
4. Turn the key switch to OFF to stop engine.
5. Relieve the pressure in the hydraulic system by moving
the control levers several times.
6. Remove the key from the key switch.
7. Attach a “Do Not Operate” tag on the control lever.
8. Turn the control lever lock switch to the lock ( ) position.
9. Lock bar connects the front and rear frames.
10. Allow the engine to cool.

 If a maintenance procedure must be performed with the SA-312

engine running, do not leave machine unattended.
 Never work under a machine raised by the lift arm.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter of this manual.
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (-) before making
adjustments to electrical systems or before performing
SA-134
welding on the machine.

SA-527

SA-24
 SAFETY
 Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
 Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid,
or window washer fluid may catch fire.

SA-037

Warn Others of Service Work

 Unexpected machine movement can cause serious injury.

 Before performing any work on the machine, attach a “Do

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

SS2045102

Support Machine Properly

 Never attempt to work on the machine without securing
the machine first.

 Always lower the attachment to the ground before you

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

SA-527

SA-25
 SAFETY
Stay Clear of Moving Parts
 Entanglement in moving parts can cause serious injury.

 To prevent accidents, care should be taken to ensure that

hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.

SA-026

Support Maintenance Properly

 Explosive separation of a tire and rim parts can cause
serious injury or death.

 Do not attempt to mount a tire unless you have the

proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
 Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
 When inflating tires, use a chip-on chuck and extension
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
if available.
 Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
 Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and
SA-249
may result in tire explosion.

SA-26
 SAFETY
Prevent Parts from Flying
 Travel reduction gears are under pressure.

 As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
 GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.

SA-344

Prevent Burns
Hot spraying fluids:

 After operation, engine coolant is hot and under pressure.

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

 Avoid possible injury from hot spraying water. DO NOT

remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to SA-039
release all pressure before removing the cap.

Hot fluids and surfaces:

 Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.

 Wait for the oil and components to cool before starting

any maintenance or inspection work.

SA-225

SA-27
 SAFETY
Replace Rubber Hoses Periodically
 Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.

 Periodically replace the rubber hoses. (See the page of

“Periodic replacement of parts” in the operator’s manual.)

 Failure to periodically replace rubber hoses may cause a fire,

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

Avoid High-Pressure Fluids

 Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.

 Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
SA-031
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours, or
gangrene may result.

SA-292

SA-044

SA-28
 SAFETY
Prevent Fires
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to fires.
 Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
 Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
 Do not bend or strike high-pressure lines.
 Never install bent or damaged lines, pipes, or hoses.
 Replace fuel hoses and hydraulic hoses periodically even
SA-019
if there is no abnormality in their external appearance.

Check for Shorts:

 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
 Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.

SA-29
 SAFETY
Clean up Flammables:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammables immediately. Check and clean high
temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammables away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammables such as
dead leaves from entering. However, flammables which
have passed through the wire screen may cause fires.
Check and clean the machine every day and immediately
remove accumulated flammables.

Check Key Switch:

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

Check Heat Shields:

 Damaged or missing heat shields may lead to fires.
 Damaged or missing heat shields must be repaired or
replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as mufflers may cause fire. Always close the engine cover
while operating the machine.

SA-30
 SAFETY
Evacuating in Case of Fire
 If a fire breaks out, evacuate the machine in the following
way:

 Stop the engine by turning the key switch to the OFF

position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 In an emergency, if the cab door can not be opened,
break the front or rear window panes with the emergency
evacuation hammer to escape from the cab. Refer to the
explanation pages on the Emergency Evacuation Method. SA-393

SS-1510

Beware of Exhaust Fumes

 Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.

 If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
 PM (Particle Matter) combustion may generate white
smoke during muffler filter regeneration. Do not attempt
to do muffler filter manual regeneration in a badly
ventilated indoors. SA-016

Precautions for Welding and Grinding

 Welding may generate gas and / or small fires.

 Be sure to perform welding in a well ventilated and

prepared area. Store flammable objects in a safe place
before starting welding.
 Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.

 Grinding on the machine may create fire hazards. Store

flammable objects in a safe place before starting grinding.

 After finishing welding and grinding, recheck that there are

SA-818
no abnormalities such as the area surrounding the welded
area still smoldering.

SA-31
 SAFETY
Avoid Heating Near Pressurized Fluid Lines
 Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
 Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
 Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc..

Avoid Applying Heat to Lines Containing SA-030

Flammable Fluids
 Do not weld or flame cut pipes or tubes that contain
flammable fluids.
 Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.

Precautions for Handling Accumulator and Gas

Damper
High-pressure nitrogen gas is sealed in the accumulator and
the gas damper. Inappropriate handling may cause explosion,
possibly resulting in serious injury or death.

Strictly comply with the following items:

 Do not disassemble the unit.
 Keep the units away from open flames and fire.
 Do not bore a hole, do not cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing the unit, sealed gas must be released.
Consult your nearest Hitachi dealer.

SA-32
 SAFETY
Remove Paint Before Welding or Heating
 Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.

 Avoid potentially toxic fumes and dust.

 Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
 Remove paint before welding or heating:

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

Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.

Beware of Asbestos and Silicon Dust and Other

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer.
Inhalation of silicon dust and other contamination may
cause sickness.

 Depending on the work site conditions, the risk

of inhaling asbestos fiber, silicon dust or other
contamination may exist. Spray water to prevent asbestos
fibers, silicon dust or other contamination from becoming
airborne. Do not use compressed air.
 When operating the machine in a work site where SA-029
asbestos fibers, silicon dust or other contamination
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contamination.
 Keep bystanders out of the work site during operation.
 Asbestos might be present in imitation parts. Use only
genuine Hitachi Parts.

SA-33
 SAFETY
Prevent Battery Explosions
 Battery gas can explode.

 Keep sparks, lighted matches, and flame away from the

top of battery.
 Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
 Do not charge a frozen battery; it may explode. Warm the
battery to 16 °C (60 °F) first.
 Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the
battery may result.
 Loose terminals may produce sparks. Securely tighten all
SA-032
terminals.
 Connect terminals to the correct electrical poles. Failure
to do so may cause damage to the electrical parts or fire.

 Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into eyes,
possibly resulting in blindness.
 Be sure to wear eye protection when checking electrolyte
specific gravity.

Service Air Conditioning System Safely

 If spilled onto skin, refrigerant may cause a cold contact
burn.

 Refer to the instructions described on the container for

proper use when handling the refrigerant.
 Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
 Never touch the refrigerant.

SA-405

SA-34
 SAFETY
Handle Chemical Products Safely
 Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.

 A Material Safety Data Sheet (MSDS) provides specific

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

Dispose of Waste Properly

 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.

 Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.
 Do not pour waste onto the ground, down a drain, or into
any water source.
 Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to SA-226
recover and recycle used air conditioning refrigerants.
 Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.

SA-35
 SAFETY
Notes for Muffler Filter
Muffler Filter
The muffler filter removes particle matters (PM) in
the exhaust gas. The muffler filter traps PM, and it is
automatically regenerated by burning PM when the set
amount of PM is accumulated in the filter. Follow the
instructions below to prevent the muffler filter from being
damaged.

dWARNING: Exhaust gas from the muffler filter, muffler

and exhaust piping becomes hot during and right
after engine running and filter regeneration (burning
PM). Keep away from the direction of the exhaust
piping and its vicinity during the filter regeneration.
Be careful not to let your skin contact with any hot gas
from the exhaust piping. It may cause severe burns.

Do not directly touch water coming out of the muffler filter.

The water is mildly-acidic by oxidation catalyst mounted
in the muffler filter. If filter water spills on your skin,
immediately flush it out with clean water.

Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.

SA-36
 SAFETY
Precaution for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which is
situated at the back of the driver's seat. There is a possibility
that a medical device, including an implantable device
such as a cardiac pacemaker, would be affected and would
malfunction by the electrical waves emitted from the
communication terminal equipment.

Any person affixed with a medical device such as the above

should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.662 inches) apart at MNEC-01-046
all times. If such condition cannot be met, please contact our
company's nearest dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.

Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipments:
E-GSM900 0.573 W/Kg (914.80 MHz)
DCS-1800 0.130 W/Kg (1710.20 MHz)
WCDMA Band I 0.271 W/Kg (1950.00 MHz)

* This data was measured by having each type of

communication terminal equipment, such as the
communication terminal equipment used with this machine,
and a human body set apart by 3 cm (1.18 inches).
* SAR is a measure of the amount of radio frequency energy
absorbed by the body when using a wireless application such
as a mobile phone.

In Japan: * Under the Japanese Radio Act and other relevant

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).

In EU Member nation: * Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).

SA-37
 SAFETY
 Never attempt to disassemble, repair, modify or displace the
communication terminal, antennas or cables. Failure to do
so may result in damage and/or fire to the base machine or
to the communication terminal. (When required to remove
or install the communication terminal, consult your nearest
Hitachi dealer.)

 Do not pinch or forcibly pull cables, cords or connectors.

Failure to do so may cause short circuit or broken circuit
that may result in damage and/or fire to the base machine
or to the communication terminal.

SA-38
 SAFETY
Before Returning the Machine to the Customer
 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced.

SA-435

SA-39
 SAFETY
(Blank)

SA-40
 SECTION AND GROUP SECTION 1 GENERAL INFORMATION
CONTENTS Group 1 Precautions for Disassembling and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Pressure Release Procedure
Group 6 Preparation
WORKSHOP MANUAL
SECTION 2 MAINTENANCE STANDARD
Group 1 Body
Group 2 Travel System
Group 3 Front Attachment
Group 4 Front Attachment (Parallel Link)
SECTION 3 BODY
Group 1 Cab
Group 2 Counterweight
Group 3 Center Hinge
Group 4 Engine
Group 5 Radiator Assembly
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Pilot Valve
Group 11 Brake Charge Valve
Group 12 Manifold Valve
Group 13 Solenoid Valve
All information, illustrations and
specifications in this manual are based on Group 14 Priority Valve
the latest product information available Group 15 Cooling Fan System
at the time of publication. The right is
reserved to make changes at any time Group 16 Ride Control Device
without notice. Group 17 Parallel Link (Special Parts)

COPYRIGHT(C)2015
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
 SECTION 4 TRAVEL SYSTEM
SECTION AND GROUP
CONTENTS Group 1 Tire
Group 2 Drive Unit
Group 3 Axle
Group 4 Propeller Shaft
Group 5 Brake Valve
Group 6 Steering Device
WORKSHOP MANUAL Group 7 Emergency Steering Device
SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
Group 3 Front Attachment (Parallel Link)
Group 4 Cylinder (Parallel Link)

All information, illustrations and

specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.

COPYRIGHT(C)2015
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle) TECHNICAL MANUAL (Troubleshooting)
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specifications Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Machine Performance Test
Group 1 Controller Group 5 Component Test
Group 2 Control System Group 6 Adjustment
Group 3 ECM System SECTION 5 TROUBLESHOOTING
Group 4 Hydraulic System Group 1 Diagnosing Procedure
Group 5 Electrical System Group 2 Monitor
SECTION 3 COMPONENT OPERATION Group 3 e-Service
Group 1 Pump Device Group 4 Component Layout
Group 2 Control Valve Group 5 Troubleshooting A
Group 3 Cooling Fan System Group 6 Troubleshooting B
Group 4 Steering Valve Group 7 Air Conditioner
Group 5 Priority Valve
Group 6 Pilot Valve
Group 7 Brake Charge Valve
Group 8 Manifold Valve
Group 9 Drive Unit
Group 10 Axle
Group 11 Brake Valve
Group 12 Ride Control Valve
Group 13 Others
SECTION 1

GENERAL
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling..................................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Painting..............................................................................W1-3-1-1
Painting (Parallel Link)...................................................W1-3-2-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1
Bleeding Air from Hydraulic System........................W1-4-1-2
Bleeding Air from Fuel System...................................W1-4-1-3
Bleeding Air from Radiator..........................................W1-4-1-4
Bleeding Air from Brake (Axle)...................................W1-4-1-5
Group 5 Releasing Pressure
Front Attachment Hydraulic Circuit Pressure
Release Procedure.....................................................W1-5-1-1
Ride Control Accumulator Pressure Release
Procedure.....................................................................W1-5-1-2
Parking Brake Accumulator Pressure Release
Procedure.....................................................................W1-5-1-3
Group 6 Preparation
Preparation before Inspection and
Maintenance...............................................................W1-6-1-1

NDBW-1-1
(Blank)

NDBW-1-2
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Disassembling and  If a part or component cannot be removed after

Assembling removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), then take the
Precautions for Disassembling appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and tag
 Clean the Machine
them if necessary.
Thoroughly wash the machine before bringing it
 Store common parts, such as bolts and nuts with
into the shop. Bringing a dirty machine into the shop
reference to where they are to be used and in a
may cause machine components to be contaminated
manner that will prevent loss.
during disassembling / assembling, resulting in
 Inspect the contact or sliding surfaces of
damage to machine components, as well as decreased
disassembled parts for abnormal wear, sticking, or
efficiency in service work.
other damage.
 Measure and record the degree of wear and
 Inspect the Machine
clearances.
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
 Precautions for Assembling
incorrect disassembling of components as well as
 Be sure to clean all parts and inspect them for any
personal injury.
damage. If any damage is found, repair or replace
Check and record the items listed below to prevent
part.
problems from occurring in the future.
 Dirt or debris on the contact or sliding surfaces may
 The machine model, machine serial number, and
shorten the service life of the machine. Take care not
hour meter reading.
to contaminate any contact or sliding surfaces.
 Reason for disassembly (symptoms, failed parts, and
 Apply appropriate lubricant oil onto parts in order to
causes).
prevent them from seizing.
 Clogging of filters and oil, water or air leaks, if any.
 Be sure to replace O-rings, backup rings, oil seals, and
Capacities and condition of lubricants.
floating seals with new ones once they have been
 Loose or damaged parts.
disassembled. Apply grease before installing
 Be sure that liquid-gasket-applied surfaces are clean
 Prepare and Clean Tools and Disassembly Area
and dry.
Prepare the necessary tools to be used and the area for
 If an anti-corrosive agent has been used on a new
disassembling work.
part, be sure to thoroughly clean the part to remove
the agent.
Precautions for Disassembling and Assembling
 Fit the matching marks made when disassembling
 Precautions for Disassembling and assemble them.
 Cap the open ends in case the hoses and pipes  Be sure to use the designated tools to assemble
have been disconnected. In addition, attach an bearings, bushings, and oil seals.
identification tag onto the connectors, hoses, and  Keep a record of the number of tools used for
pipes for assembling. disassembly / assembly. After assembling is
 Before disassembling, clean the exterior of the completed, count the number of tools so as to make
components and place on a workbench. sure that no forgotten tools remain in the assembled
 Drain hydraulic oil and gear oil from the hydraulic machine.
components and reduction gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling if
necessary.
 Be sure to use the specified special tools when
instructed.

W1-1-1-1
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Using Floating Seal 1

1. In general, replace the floating seal with a new one

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding
surface (e) of seal ring (1). W178-02-11-001
2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) for tears, breaks, deformation, or
hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following to prevent
trouble.
 Clean the floating seal and seal mounting bores with
cleaning solvent. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a - Correct c - Twist of O-Ring
 After installing the floating seal, check that O-ring b - Incorrect d - Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
(e) and (f ) at point (A) and (B), as illustrated. If these
distances differ, correct O-ring (2) seating. a A b A

B B

A=B A≠B

W178-02-11-003

a - Correct e - Sliding Surface

b - Incorrect f - Seal Mating Surface

W1-1-1-2
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings a
safely.
 Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
 Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load with
a temperature of 100 °C (212 °F) or more, reduce the
load weight.
 Do not lift acid or alkali chemicals. W102-04-02-016
 Take care not to allow the sling to become wet. The
a - Correct Eyehole Lifting
load may slip.
Method
 When required to use more than one sling, use slings
with the same width and length to keep the lifted b
load balanced.
 When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
 Avoid using twisted, bound, connected, or hitched
slings.
 Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
 When removing the slings from under the load, take
care not to damage the nylon slings. Avoid contact W105-04-01-008
with protrusions.
 Avoid dragging slings on the ground, throwing b - Incorrect Eyehole Lifting
Method
slings, or pushing slings with a metal object.
 When using with other types of slings (wire rope) or
accessories (shackle), protect the joint so that the
nylon sling is not damaged.
 Store the nylon slings indoors so that they won’t
deteriorate with heat, sun light, or chemicals.

c W162-01-01-009

c - Bent of Sling

W1-1-1-3
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

dCAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may result.
Be sure to visually check the nylon sling for any
damage before using.

2. Before using a nylon sling, visually check the nylon

sling for any damage corresponding to examples
shown to the right. If any damage is found, cut and
discard the sling.
Even if no damage is found, do not use slings older
than 7 years.

Damaged Appearance a
a

W162-01-01-002 W162-01-01-006
e
a - Broken Sewing Thread a - Broken Sewing Thread e - Separation of Belt

b f

W162-01-01-003 W162-01-01-007
b
b - Scuffing b - Scuffing f - Scoring

c
c g

W162-01-01-004
W162-01-01-008
c - Fuzz d - Broken Sewing Thread
c - Fuzz g - Broken Warp

W162-01-01-005

a - Broken Sewing Thread

W1-1-1-4
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Maintenance Standard Terminology

“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification. Allowable errors will be
indicated if necessary.

“Allowable Limit”
1. Normal machine performance cannot be
accomplished after exceeding this limit.
2. Repair or adjustment is difficult after exceeding this
limit.
3. Repair or adjustment is impossible after exceeding
this limit.
Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.

W1-1-1-5
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

(Blank)

W1-1-1-6
 SECTION 1 GENERAL
Group 2 Tightening

Tightening Bolts and Nuts

dCAUTION: Use tools appropriate for the work

to be done. Makeshift tools and procedures
can create safety hazards. For loosening and
tightening nuts and bolts, use correct size tools.
Otherwise, tightening tools may slip, potentially
causing personal injure.
IMPORTANT:
 Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it) WDAA-01-02-001
 Clean the bolt and nut threads and remove dirt
or corrosion before installing.

Bolt Types
Tighten the nuts or bolts correctly to the torque
specifications.
As the different types and grades of bolt are used,
use and tighten the correct bolts correctly when
assembling the machine or components.

Specified Tightening Torque Chart

2013/09
Bolt Hexagon Head Bolt Socket Bolt
Dia. Wrench Socket Bolt Wrench
mm Size mm Size mm

WDAA-01-02-002 WDAA-01-02-003 WDAA-01-02-004

N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft)
6 3 to 4 (2.2 to 3) 10 5
8 30 (22) 20 (15) 10 (7.4) 13 20 (15) 6
10 65 (48) 50 (37) 20 (15) 17 50 (37) 8
12 110 (81) 90 (66) 35 (26) 19 90 (66) 10
14 180 (133) 140 (103) 55 (41) 22 140 (103) 12
16 270 (200) 210 (155) 80 (59) 24 210 (155) 14
18 400 (300) 300 (220) 120 (89) 27 300 (220) 14
20 550 (410) 400 (300) 170 (125) 30 400 (300) 17
22 750 (550) 550 (410) 220 (162) 32
24 950 (700) 700 (520) 280 (205) 36
27 1400 (1030) 1050 (770) 400 (300) 41
30 1950 (1440) 1450 (1070) 550 (410) 46
33 2600 (1920) 1950 (1440) 750 (550) 50
36 3200 (2360) 2450 (1810) 950 (700) 55

W1-2-1-1
 SECTION 1 GENERAL
Group 2 Tightening

IMPORTANT: The following items are applied to both

fine and coarse pitch threads.
 Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it)
 Torque tolerance is ±10 %.
 Use the bolts of correct length. The bolts that
are too long cannot be tightened as the bolt tip
comes into contact with the bottom of bolt hole.
Also the bolts that are too short cannot develop
sufficient tightening force.
 The torque given in the chart on the previous
page are for general use only, however,
a different torque is given for a specific
application. Use the specified torque.
 Clean the nut and bolt threads and remove dirt
or corrosion before installing.

Tightening Order
When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.

a b c

1 12 9 4 1 6 7 14
1.4 6 3

4 5
2 13 8 5 2 3 10 11
2.3

W105-01-01-003

a - Equally tighten upper and b - Tighten diagonally c - Tighten from center

lower alternately diagonally

W1-2-1-2