Page 1 PART NO. ENMPTC-NA1-3 Operator's Manual 150PL Wheel Loader URL:https://www.hitachicm.com Serial No. 005201 and up This book is printed on recycled paper. PRINTED IN JAPAN (E) 2022, 09...
Page 2 INTRODUCTION Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support service your machine correctly. Failure to do so could program for customers who operate and maintain their result in personal injury or machine damage.
Page 3 MACHINE NUMBERS INDEX SAFETY SAFETY SIGNS COMPONENTS NAME GETTING ON/OFF THE MACHINE OPERATOR’S STATION BREAK-IN OPERATING ENGINE DRIVING MACHINE OPERATING MACHINE TRANSPORTING MAINTENANCE MAI N TENANCE UNDER SPECI A L ENVI R ONMENTAL CONDI T I O NS STORAGE TROUBLESHOOTING SPECIFICATIONS SPECIFICATIONS OPTIONAL ATTACHMENTS...
Page 5: Table Of Contents
CONTENTS MACHINE NUMBERS ................1 Evacuating in Case of Fire ............S-32 Beware of Exhaust Fumes............S-32 SAFETY ....................S-1 Precautions for Welding and Grinding ......... S-32 Recognize Safety Information ............S-1 Avoid Heating Near Pressurized Fluid Lines ....... S-33 Understand Signal Words .............S-1 Avoid Applying Heat to Lines Containing Flammable Follow Safety Instructions ............S-2 Fluids ...................
Page 6 CONTENTS HST Oil Temperature Indicator (Red) ........1-17 Neutral Lever Lock (for the Forward/Reverse Lever) ..1-52 Secondary Steering Indicator (Yellow) (Optional) .... 1-18 Steering .................... 1-52 Seat Belt Indicator (Red) ............1-18 Horn Switch ..................1-52 Water Separator Indicator (Red) ..........1-18 Turn Signal Lever ................
Page 7 CONTENTS DRIVING MACHINE ...............4-1 Off-Season Air Conditioner Maintenance ...... 1-94 Adjusting Operator's Seat (Air Suspension Type Seat) ... 1-95 Driving the Machine ...............4-1 Components Name ..............1-95 Starting to Move ................4-2 Rear Tray ..................1-96 Parking Brake Switch ..............4-4 Electric Power Output (12 VDC Electrical Outlet) ..... 1-96 Drive Speed Change...............4-5 Fuse Box ...................
Page 8 CONTENTS Periodic Replacement of Parts ..........7-16 Check Drive Belt Tensioner ..........7-76 Kind of Oils ..................7-18 Change Coolant ............... 7-77 List of Consumable Parts ............7-22 Clean Radiator/Oil Cooler and Other Cooling A. Greasing ..................7-25 System ................... 7-78 B.
Page 9 CONTENTS Refill DEF/AdBlue® ..............7-125 Replace DEF/AdBlue® Supply Module Main Filter ..7-128 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS ..................9-1 Maintenance Under Special Environmental Conditions ...9-1 Precautions for Maintenance During Cold Weather Season ....................9-2 STORAGE ..................10-1 Storing the Machine ..............10-1 TROUBLESHOOTING ..............11-1 Troubleshooting ................
Page 10 CONTENTS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 11: Machine Numbers
MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.
Page 12 MACHINE NUMBERS Aftertreatment Device 1. SCR TYPE MFG. NO. MPTC-00-002 2. DOC TYPE MFG. NO. MPTC-00-003...
Page 13: Safety
SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices. SA-2644 Understand Signal Words ...
Page 14: Follow Safety Instructions
 Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine...
Page 15: Prepare For Emergencies
SAFETY Prepare for Emergencies  Be prepared for a fire or an accident.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly. ...
Page 16: Protect Against Noise
SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine ...
Page 17: General Precautions For The Cab
SAFETY General Precautions for the Cab  Before entering the cab, thoroughly remove all dirt and/ or oil such as mud, grease, soil or stones from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.
Page 18: Use Handrails And Steps
SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as handholds. ...
Page 19: Ensure Safety Before Rising From Or Leaving Operator's Seat
SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position.
Page 20: Move And Operate Machine Safely
SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped).
Page 21: Operate Only From Operator's Seat
SAFETY Operate Only from Operator’s Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  Never start the engine while standing on the tire or on ground.
Page 22: Investigate Job Site Beforehand
SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.
Page 23: Equipment Of Head Guard, Rops, Fops
SAFETY Equipment of Head Guard, ROPS, FOPS If the machine is operated in areas where the possibility of falling stones or debris, 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 performance and its certification will be lost.
Page 24: Keep Riders Off Machine
SAFETY Keep Riders Off Machine  Riders on the machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.
Page 25: Drive Machine Safely (Work Site
SAFETY Drive Machine Safely (Work Site)  Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions. ...
Page 26: Drive Safely With Bucket Loaded
SAFETY Drive Safely with Bucket Loaded  If the machine is 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.
Page 27: Travel On Public Roads Safely
 Be sure to empty the bucket.  Hold the bucket at mark (A) above the road surface as illustrated. Height A ZW140-6: 350~400 mm (13.8~15.7 in) ZW150-6, 150PL-6: 420~470 mm SA-453 (16.5~18.5 in) Avoid Injury from Rollaway Accidents  Death or serious injury may result if you attempt to mount...
Page 28: Avoid Accidents From Backing Up And Turning
SAFETY Avoid Accidents from Backing Up and Turning  Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine.
Page 29: Avoid Positioning Bucket Or Attachment Over Anyone
SAFETY Avoid Positioning Bucket or Attachment Over Anyone  Never allow the bucket or attachment to pass over co- workers and/or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket or attachment may cause serious personal accidents and/or damage to the machine.
Page 30: Never Undercut A High Bank
SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death. SA-519 Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.
Page 31: Avoid Power Lines
SAFETY Avoid Power Lines Serious injury or death can result from contact with electric lines. When operating near an electric line, never move any part of the machine or load to within 3 m (10 ft) plus twice the line insulator length of overhead wires.
Page 32: Object Handling
SAFETY Object Handling CRANING OPERATION USING THE MACHINE IS NOT ALLOWED.  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example).
Page 33: Protect Against Flying Debris And Falling Object
SAFETY Protect Against Flying Debris and Falling Object  During hammer operation, debris from earth, rock or metal may fly in all directions, resulting in a serious personal injury or death.  When driving the connecting pins in or out, wear goggles or safety glasses, hard hat and face shield.
Page 34: Park Machine Safely
SAFETY Park Machine Safely To avoid accidents:  Park the machine on a firm, level surface.  Lower bucket to the ground.  Put the forward / reverse lever (switch) in neutral, and turn the parking brake switch ON (parking brake) position.
Page 35: Transport Safely
SAFETY Transport Safely  Be aware 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. Less than 15 ° ...
Page 36: Handle Fluids Safely−Avoid Fires
SAFETY Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.
Page 37: Practice Safe Maintenance
SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving. ...
Page 38: Warn Others Of Service Work
SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. If the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
Page 39: Stay Clear Of Moving Parts
SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. SA-026 Support Maintenance Properly ...
Page 40: Prevent Parts From Flying
SAFETY Prevent Parts from Flying  Travel reduction gears are under pressure.  As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.  GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.
Page 41: Replace Rubber Hoses Periodically
SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. ...
Page 42: Prevent Fires
SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
Page 43 SAFETY Clean up Flammable Materials:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammable materials immediately.
Page 44: Evacuating In Case Of Fire
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. ...
Page 45: Avoid Heating Near Pressurized Fluid Lines
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. ...
Page 46: Remove Paint Before Welding Or Heating
 Keep bystanders out of the work site during operation.  Asbestos might be present in non-genuine parts. Use only genuine Hitachi Parts. S-34...
Page 47: Prevent Battery Explosions
SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. ...
Page 48: Handle Chemical Products Safely
 Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Hitachi equipment includes such items as oil, fuel, coolant, DEF/AdBlue®, 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.
Page 49: Notes On Aftertreatment Device
SAFETY Notes on Aftertreatment Device About Aftertreatment Device The aftertreatment device removes particulate matter (PM) and NOx (Nitrogen Oxide) from the exhaust gas. Follow the instructions below to prevent the aftertreatment device from being damaged. WARNING: Exhaust gas from the aftertreatment device, muffler, exhaust piping and tail piping becomes hot during and right after engine running and regeneration of aftertreatment device.
Page 50: Precautions For Communication Terminal
SAFETY Precautions for Communication Terminal Equipment This machine is installed with a communication terminal emitting radio waves behind the operator's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, could be affected and malfunction due to the electrical waves emitted from the communication terminal.
Page 51 SAFETY  Do not 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. (Before removing or installing the communication terminal, consult your authorized dealer.) ...
Page 52: Safety Signs
SAFETY SIGNS All safety signs and their locations affixed on the machine are illustrated in this group. Make sure of the contents described in the safety signs through reading actual ones affixed on the machine to ensure safe machine operation. Always keep the safety signs clean.
Page 53 SAFETY SIGNS 1. Bucket 23. Hood CAUTION: Sign indicates a fall hazard. Sign indicates a hazard of falling. Do not stand on this place. 4478724370 2. Both Sides of Lift Arm DANGER: Crush Hazard During operation, loads may spill from the bucket and/ or the bucket may suddenly fall.
Page 54 SAFETY SIGNS 4. Cab Inside Right Front Column (First safety sign from the top) WARNING Prior to operation, maintenance, disassembling, and transportation of the machine, be sure to read and understand the Operator’s Manual. 4478724940 5. Cab Inside Right Front Column (2nd safety sign from the top) DANGER: Electrocution Hazard...
Page 55 SAFETY SIGNS 7. Cab Inside Right Front Column (4th safety sign from the top) WARNING: Rollover Hazard To minimize the injury due to an overturning accident, be sure to fasten the seat belt prior to operating the machine. 4478724970 8. Cab Inside Left Front Column WARNING: Runover Hazard Be sure that the backup alarm is operable when the machine is put in reverse.
Page 56 SAFETY SIGNS 10. Both Sides Top of Fan Guard Sign indicates a hazard of rotating parts, such as fan. Turn off before inspection and maintenance. 4478724380 11. Hood and Both Sides of Oil Cooler 24. 30. Engine Housing WARNING: Burn Hazard Avoid skin contact with highly heated parts such as the engine, muffler, etc.
Page 57 SAFETY SIGNS 13. Inside Battery Box CAUTION: Chemical Burn Hazard Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness. Take care not to touch electrolyte. 4478725000 14. Inside Battery Box WARNING: Explosion Hazard Sign indicates an explosion hazard. Keep fire and open flames away from this area.
Page 58 SAFETY SIGNS 15. Inside Battery Box CAUTION: Shock Hazard Sign indicates an electrical hazard from handling the cable. Read the manual for safe and proper handling. 4478724350 16. Both Sides Bottom of Rear Frame Side Cover WARNING: Entanglement Hazard Sign indicates a hazard of rotating parts, such as belt. Turn off before inspection and maintenance.
Page 59 SAFETY SIGNS 18. Hydraulic Oil Tank WARNING: Burn Hazard Sign indicates a burn hazard from compressed air and spurting hot oil if the oil inlet is uncapped during or right after operation. Read the manual for safe and proper handling. 4478725030 19.
Page 60 SAFETY SIGNS 21. Both Sides of Counterweight WARNING: Runover Hazard Avoid injury from backing-over accident. Keep everyone far away from the machine during operation. 4478724400 25. Transmission Maintenance Cover 31. Inside of Left Front Frame WARNING: Oil injection hazard. The accumulator has been charged with high-pressure nitrogen gas.
Page 61 SAFETY SIGNS 27. Articulate Lock Bar WARNING: Crush Hazard The articulation area becomes a pinch point when steering the machine. Keep all personnel away from the articulation area during operation of the machine. 4478724410 28. Cab Inside Right Console To those persons fixed with any medical device. Including implantable device such as a cardiac pacemaker.
Page 62 SAFETY SIGNS 30. Inside DEF/AdBlue® Tank Box IMPORTANT: Avoid Contamination  The DEF/AdBlue® tank should be filled with DEF/AdBlue® only. Do not mix any other liquid like water, oil, fuel. label 44774-27240 S-50...
Page 63: Components Name
COMPONENTS NAME Components Name ZW140-6/ZW150-6 1- Cutting Edge (BOC) 2- Bucket 3- Lever 9, 10 4- Bucket Cylinder 5- Front Combination Light (Headlight/Turn Signal/Clearance Light/Hazard Light) 6- Outside Rear View Mirror 7- Front Work Light 8- ROPS Cab 9- Fuel Filler Port MPTC-01-012 10- DEF/AdBlue®...
Page 64 COMPONENTS NAME Components Name ZW150PL-6 1- Cutting Edge (BOC) 2- Bucket 9, 10 3- Lever 4- Bucket Cylinder 5- Front Combination Light (Headlight/Turn Signal/Clearance Light/Hazard Light) 6- Outside Rear View Mirror 7- Front Work Light 8- ROPS Cab 9- Fuel Filler Port MPTC-01-002 10- DEF/AdBlue®...
Page 65: Getting On/Off The Machine
GETTING ON/OFF THE MACHINE Getting ON/OFF the Machine Footholds (1) and handrails (2) are provided in and around the machine. These are used to get on and off the cab safely as well as to do inspection and maintenance of the machine safely. Never jump on or off the machine as it is very dangerous.
Page 66: Operator's Station
Standardization (ISO). If improper liquid (diesel oil, kerosene or gasoline) is refilled in the DEF/AdBlue® tank, fire or system failure may result.  Use only genuine Hitachi engine oil. Using engine oil other than Hitachi genuine oil may result in malfunction of the aftertreatment device.
Page 67 OPERATOR'S STATION  Do not modify the machine without authorization. Never attempt to modify the air inlet and exhaust parts such as the air duct, aftertreatment device and the exhaust piping. Also never attempt to disassemble the aftertreatment device. Avoid giving shocks on the aftertreatment device by striking elements with other objects or dropping the device.
Page 68 OPERATOR'S STATION  If auto regeneration did not complete, an aftertreatment device regeneration request will blink on the monitor. (Refer to the page 1-16) Perform manual regeneration following the specified procedure. (Refer to the page 1-74)  When the machine is operated without performing manual regeneration, the aftertreatment device may be damaged.
Page 69: Cab Features
OPERATOR'S STATION Cab Features 1- Front Defroster 2- Front Console 3- Operator's Seat 4- Right Console 5- Document Holder 6- Hot/Cool Box 7- Rear Defroster 8- Glove Compartment 9- Cup Holder 10- Floor Mat MNEC-01-035...
Page 70: Front Console
OPERATOR'S STATION Front Console 1- Air Conditioner Front Vent 2- Hazard Switch 3- Work Light Switch 4- Parking Brake Switch 5- Neutral Lever Lock (for the Forward/Reverse Lever) 6- Steering Wheel 7- Monitor Panel 8- Horn Switch MNDB-01-001 9- Accelerator Pedal 10- Brake/Inching Pedal (Both right and left sides are interlocked.) 11- Front/Rear Wiper Switch...
Page 71: Right Console
9- Power Mode Switch 10- Forward/Reverse Selector Switch 11- Fan Reverse Rotation Switch 12- Auxiliary 13- Quick Cupler Switch (ZW140-6/150-6: Optional) 14- Secondary Steering Operation Check Switch (Optional) 15- Aftertreatment Device Regeneration Switch 16- Lift Arm Auto Leveler Switch (Upward Set)
Page 72: Fingertip Control Type
MNDB-01-004 9- Forward/Reverse Selector Switch 10- Fan Reverse Rotation Switch 11- Auxiliary 12- Quick Cupler Switch (ZW140-6/150-6: Optional) 13- Secondary Steering Operation Check Switch (Optional) 14- Aftertreatment Device Regeneration 15- Lift Arm Auto Leveler Switch (Upward Set) 16- Lift Arm Auto Leveler Switch (Downward Set)
Page 73: Monitor Panel
OPERATOR'S STATION Monitor Panel MPTC-01-019 1- Left Turn Signal Indicator 21- Monitor Display Mode Selector 2- High Beam Indicator 22- Aftertreatment Device Regeneration inhibited Indicator 3- Work Light Indicator 23- Monitor Display Selector (Up) 4- Right Turn Signal Indicator 24- Preheat Indicator 5- Aftertreatment Device Warning Indicator 25- Monitor Display Selector (Down) 6- Aftertreatment Device Regeneration inhibited...
Page 74: Service Indicator
OPERATOR'S STATION Service Indicator WARNING: Prevent possible casualty and/or machine damage. If the service indicator flashes and the alarm buzzer sounds, immediately stop machine operation. Then, check and service the section displaying the trouble. The service indicator comes ON and the alarm buzzer sounds if one of the following cases below occurs.
Page 75: Parking Brake Indicator (Red)
OPERATOR'S STATION Parking Brake Indicator (Red) The parking brake indicator will light when the parking brake is applied. If the forward/reverse lever is moved to either the forward (F) or the reverse (R) position when the parking brake is applied, the alarm buzzer will sound.
Page 76: Low Steering Oil Pressure Indicator (Red) (Optional)
OPERATOR'S STATION Low Steering Oil Pressure Indicator (Red) (Optional) IMPORTANT: The secondary steering system shall only be used provisionally when the steering oil pressure dropped. If continuously used, it may damage the system. If the steering oil pressure decreases, the low steering oil pressure indicator and the service indicator will light, and the alarm buzzer will sound.
Page 77: Engine Trouble Indicator (Red)
OPERATOR'S STATION Engine Trouble Indicator (Red) If any serious abnormality occurs in the engine and/or engine related parts, the red indicator will light. If the engine trouble indicator and the service indicator light, immediately move the machine to a safe area, set the machine in the park position and stop the engine.
Page 78: Aftertreatment Device Warning Indicator
OPERATOR'S STATION Aftertreatment Device Warning Indicator Aftertreatment Device Regeneration Request (Blinking Yellow) Aftertreatment device regeneration is needed. Set the machine in a regeneration condition, turn the regeneration switch to the manual regeneration position. MPTC-01-019 MNDF-01-036 Aftertreatment Device Regeneration Inhibited Warning Indicator Aftertreatment Device Regeneration Inhibited Warning (Yellow) As the regeneration inhibition has been set, manual...
Page 79: Air Filter Restriction Indicator (Red)
OPERATOR'S STATION Air Filter Restriction Indicator (Red) If the air cleaner element becomes clogged, the air filter restriction indicator and the service indicator light. Immediately stop the engine and inspect the air cleaner element. Replace the element, if necessary. M4GB-01-023 Preheat Indicator (Yellow) The engine is being preheated as long as the preheat indicator stays ON.
Page 80: Secondary Steering Indicator (Yellow) (Optional)
OPERATOR'S STATION Secondary Steering Indicator (Yellow) (Optional) IMPORTANT: The secondary steering system shall be provisionally used. If continuously used, damage to the system may result. If the secondary steering system operates, the secondary steering indicator will come ON. Move the machine to a safe area and stop the machine.
Page 81: Coolant Temperature Gauge
OPERATOR'S STATION Coolant Temperature Gauge The engine coolant temperature is indicated with a needle. When the needle stays in range (1) during operation, the coolant temperature is normal. If the engine coolant temperature becomes abnormally high, the service indicator will flash and the alarm buzzer will sound. Stop machine operation and run the engine at low idle to lower the coolant temperature.
Page 82: Turn Signal Indicator (Green)
OPERATOR'S STATION Turn Signal Indicator (Green) When the turn signal lever is operated, the turn signal and the turn signal indicator start flashing. M4GB-01-032 High Beam Indicator (Blue) When the head lights are used at the high beam position, the indicator will light.
Page 83: Clearance Light Indicator (Green)
OPERATOR'S STATION Clearance Light Indicator (Green) When the clearance lights are turned ON, this indicator will light. M4GB-01-035 Control Lever Lock Indicator (Red) When the control lever lock switch is in ON position, the control lever lock indicator will light. MNEC-01-004 Power Mode Indicator (Green) When the power mode switch is in ON position, the power...
Page 84: Maintenance Indicator (Yellow)
OPERATOR'S STATION Maintenance Indicator (Yellow) Indicates that the maintenance times for the following items are approaching. Each time the ignition key is turned ON, the indicator comes ON for 30 seconds. The indicator lights 20 hours before the specified maintenance time arrives. Items to be indicated: ...
Page 85: Monitor Display
OPERATOR'S STATION Monitor Display 1- Monitor Display 2- Monitor Display Mode Selector 3- Monitor Display Selector (Up) 4- Monitor Display Selector (Down) 5- Speedometer 6- Information Display 7- Traction Control Indicator MPTC-01-019 8- Forward/Reverse and Shift Position Indicator 9- Ride Control Indicator 10- ECO Indicator 11- DEF/AdBlue®...
Page 86: Forward/Reverse And Shift Position Indicator
OPERATOR'S STATION Forward/Reverse and Shift Position Indicator Forward/Reverse and Shift Position Indicator (1) displays the machine driving status (selected FNR lever and shift positions). MPTC-01-020  FNR (Forward/Reverse) Position Indicator FNR position indicator (2) displays the selected position of forward (F)/neutral (N)/reverse (R) lever (3). (Letters F-N-R are constantly displayed.) MPTC-01-022 MNDB-01-002...
Page 87 OPERATOR'S STATION  Traction Control Indicator When traction control switch (2) is ON, traction control indicator (1) lights. MPTC-01-022 MNDB-01-005  Shift Position Indicator When forward/reverse lever (4) is in either the forward or reverse position, shift position indicator (3) displays the actually selected shift stage.
Page 88: Speedometer
OPERATOR'S STATION Speedometer Speedometer (1) indicates the present machine driving speed. While information display (2) is indicating the drive distance, each time monitor display mode selector (3) is pressed, the indicated speed unit alternates between “km/h” and “MPH. ” MPTC-01-019 MPTC-01-020 1-26...
Page 89: Ride Control Indicator
OPERATOR'S STATION Ride Control Indicator Ride control indicator (1) lights when ride control switch (2) is turned ON. MPTC-01-020 ECO Indicator MNDB-01-005 ECO indicator (3) lights when the engine runs in energy efficient condition. It becomes OFF when the driving speed is 2 km/h or lower or under heavy driving load.
Page 90: Def/Scr System Alarm
OPERATOR'S STATION DEF/SCR System Alarm When the DEF/AdBlue® level becomes low and/or the Urea SCR system malfunctions, the engine performance is controlled depending on the status. The operator is alerted with alarm indicators and buzzer. Move and park the machine in a safe place and follow troubleshooting guide for the accompanied alarms.
Page 91: Urea Scr System Malfunction
OPERATOR'S STATION Urea SCR System Malfunction Alarm Indicator Buzzer Status/Inducement Buzzer sounds once. Urea SCR system is broken. (Red, light) Urea SCR system is broken. Buzzer sounds every 3.8 seconds. Engine output is restricted. (Red, slow blink) (Yellow) Buzzer sounds every 1.2 seconds. (Red, slow blink) Urea SCR system is broken.
Page 92: Machine Information Display
OPERATOR'S STATION Machine Information Display When the key switch is turned ON, machine information area (4) displays the machine information. When the key switch is turned ON, the machine information display indicates engine start-ready screen (5). Each 0.5 seconds, the most left side indication is counted down as shown in display illustration (6).
Page 93: Shifting Item To Be Indicated On Machine Information Display
OPERATOR'S STATION Shifting Item to be Indicated on Machine Information Display Press monitor display selector (2) to shift the display item one a time in order from the clock display on the machine information display. MPTC-01-019  Clock (24H) : When monitor display selector ( )(2) is pressed once: : When monitor display selector ( )(3) is pressed once:...
Page 94 OPERATOR'S STATION IMPORTANT: Each time the oil is changed and/or oil filter is replaced, reset the displayed monitor time by pressing monitor display mode selector (1) for more than 2 seconds. Beware not to press monitor display mode selector (1) when the display is indicating the time to change or replace.
Page 95 OPERATOR'S STATION MPTC-01-019 : When monitor display selector ( )(2) is pressed once: : When monitor display selector ( )(3) is pressed once:  Hydraulic Oil Filter 1 Hour Meter Hydraulic Oil Filter 1 Screen E and time screen F indicating the remaining hours Hour Meter up to hydraulic tank oil filter replacement are alternately displayed.
Page 96 OPERATOR'S STATION MPTC-01-019  Transmission Oil Hour Meter : When monitor display selector ( )(2) is pressed once: Screen K and time screen L indicating the remaining hours up : When monitor display selector ( )(3) is pressed once: to transmission oil change are alternately displayed. Transmission Oil When the remaining hour reading becomes 0 hour, Hour Meter...
Page 97 OPERATOR'S STATION MPTC-01-019  Engine Oil Filter Hour Meter : When monitor display selector ( )(2) is pressed once: Screen Q and time screen R indicating the remaining hours up : When monitor display selector ( )(3) is pressed once: to engine oil filter replacement are alternately displayed.
Page 98 OPERATOR'S STATION MPTC-01-019  DEF/AdBlue® Supply Module Main Filter Hour Meter : When monitor display selector ( )(2) is pressed once: Screen W and time screen X indicating the remaining hours : When monitor display selector ( )(3) is pressed once: up to DEF/AdBlue®...
Page 99: Resetting Of Oil Change And Filter Replacement Intervals
OPERATOR'S STATION Resetting of Oil Change and Filter Replacement Intervals Reset oil change and/or oil filter replacement intervals as needed: Hydraulic Oil Change Interval Hour Meter Oil change intervals can be reset to “2000.0”, “1500.0”, or “1000.0”. The interval set when the machine was shipped from the factory is “2000.0”.
Page 100: Hydraulic Oil Filter 1 Replacement Interval Hour Meter
OPERATOR'S STATION Hydraulic Oil Filter 1 Replacement Interval Hour Meter Hydraulic oil filter replacement intervals can be reset to “1000.0” or “500.0”. The interval set when the machine was shipped from the factory is “1000.0”. While displaying the change interval hours, keep pressing switch (1).
Page 101: Hydraulic Oil Filter 2 Replacement Interval Hour Meter
OPERATOR'S STATION Hydraulic Oil Filter 2 Replacement Interval Hour Meter Hydraulic oil filter replacement intervals can be reset to “2000.0”, “1500.0”, or “1000.0”. The interval set when the machine was shipped from the factory is “2000.0”. While displaying the change interval hours, keep pressing switch (1).
Page 102: Hydraulic Oil Filter 3 Replacement Interval Hour Meter
OPERATOR'S STATION Hydraulic Oil Filter 3 Replacement Interval Hour Meter Hydraulic oil filter replacement intervals can be reset to “500.0”, “250.0”, or “100.0”. The interval set when the machine was shipped from the factory is “500.0”. While displaying the change interval hours, keep pressing switch (1).
Page 103: Transmission Oil Change Interval Hour Meter
OPERATOR'S STATION Transmission Oil Change Interval Hour Meter Oil change intervals can be reset to “1000.0”, “500.0”, or “250.0”. The interval set when the machine was shipped from the factory is “1000.0”. While displaying the change interval hours, keep pressing switch (1).
Page 104: Transmission Oil Filter Replacement Interval Hour Meter
OPERATOR'S STATION Transmission Oil Filter Replacement Interval Hour Meter Transmission oil filter replacement intervals can be reset to “500.0”, “250.0”, or “100.0”. The interval set when the machine was shipped from the factory is “500.0”. While displaying the replacement interval hours, keep pressing switch (1).
Page 105: Engine Oil Change Interval Hour Meter
OPERATOR'S STATION Engine Oil Change Interval Hour Meter Oil change intervals can be reset to “500.0”, “250.0”, or “200.0”. The interval set when the machine was shipped from the factory is “500.0”. While displaying the change interval hours, keep pressing switch (1).
Page 106: Engine Oil Filter Replacement Interval Hour Meter
OPERATOR'S STATION Engine Oil Filter Replacement Interval Hour Meter Filter replacement intervals can be reset to “500.0”, “250.0”, or “200.0”. The interval set when the machine was shipped from the factory is “500.0”. While displaying the replacement interval hours, keep pressing switch (1).
Page 107: Oil Separator Element Replacement Interval Hour Meter
OPERATOR'S STATION Oil Separator Element Replacement Interval Hour Meter Oil separator element replacement intervals can be reset to “2000.0”, “1500.0”, or “1000.0”. The interval set when the machine was shipped from the factory is “2000.0”. While displaying the replacement interval hours, keep pressing switch (1).
Page 108: Fuel Filter Replacement Interval Hour Meter
OPERATOR'S STATION Fuel Filter Replacement Interval Hour Meter Filter replacement intervals can be reset to “500.0” or “250.0”. The interval set when the machine was shipped from the factory is “500.0”. While displaying the replacement interval hours, keep pressing switch (1). NOTE: When switch (1) is released, time resetting is completed.
Page 109: Def/Adblue® Supply Module Main Filter Replacement Interval Hour Meter
OPERATOR'S STATION DEF/AdBlue® Supply Module Main Filter Replacement Interval Hour Meter Filter replacement intervals can be reset to “4500.0” or “3000.0”. The interval set when the machine was shipped from the factory is “4500.0”. While displaying the replacement interval hours, keep pressing switch (1).
Page 110: Axle Oil Change Interval Hour Meter
OPERATOR'S STATION Axle Oil Change Interval Hour Meter Oil change intervals can be reset to “2000.0”, “1500.0”, or “1000.0”. The interval set when the machine was shipped from the factory is “2000.0”. While displaying the change interval hours, keep pressing switch (1).
Page 111: Clock Setting Mode
OPERATOR'S STATION Clock Setting Mode The clock display on the machine information display screen can be set in the clock setting mode. NOTE: If battery power is interrupted for an extended period of time, the time display screen may indicate “Year of 2000, Month of 1, day of 1, and time of 00:00”...
Page 112: Switches, Steering Wheel And Pedals
OPERATOR'S STATION Switches, Steering Wheel and Pedals 1- Air Conditioner Front Vent 2- Hazard Switch 3- Work Light Switch 4- Parking Brake Switch 5- Neutral Lever Lock (for the Forward/Reverse Lever) 6- Steering Wheel 7- Monitor Panel 8- Horn Switch MNDB-01-001 9- Accelerator Pedal 10- Brake/Inching Pedal (Both right and left sides are...
Page 113: Forward/Reverse Lever/ Shift Switch
OPERATOR'S STATION Forward/Reverse Lever/ Shift Switch 1, 2 IMPORTANT: The forward/reverse lever and shift switch are designed to operate with low effort. Do not press and twist the lever and switch firmly. Damage to the lever and switch may result. Forward/Reverse Lever Changes the machine drive direction from forward to reverse and vice versa.
Page 114: Neutral Lever Lock (For The Forward/Reverse Lever)
OPERATOR'S STATION Neutral Lever Lock (for the Forward/Reverse UNLOCK Lever) WARNING: When the machine is parked or serviced, be sure to place neutral lever lock (1) in the LOCK position. The neutral lever lock makes the forward/reverse lever immovable so that the machine does not start moving even if a body part comes in contact with the forward/reverse lever by mistake.
Page 115: Turn Signal Lever
OPERATOR'S STATION Turn Signal Lever Indicates the drive change direction to persons and/or other vehicles by operating turn signal lever (7). Return turn signal lever (7) to neutral manually. L- Left Turn R- Right Turn MNDB-01-003 1-53...
Page 116: Light Switch
OPERATOR'S STATION Light Switch Light switch (1) has three positions, OFF, Small, and Main. As shown below, each light comes ON ( ) or OFF ( according to the selected position of the light switch. 2- Headlight 3- Turn Signal / Hazard Light / Clearance Light 4- Turn Signal/Hazard Light 5- Brake Light/Tail Light MNDB-01-003...
Page 117: High-Low Beam Switch
OPERATOR'S STATION High-Low Beam Switch Shifts the direction of the headlight beam high and low. CAUTION: Travel the machine with the headlight in the low beam position when other vehicles are present in the vicinity. By bringing down signal lever (7) with the headlight ON, the headlight beam turns upward, and high beam indicator (8) comes ON.
Page 118: Wiper Switch
OPERATOR'S STATION Wiper Switch Wiper Operation IMPORTANT: The windshield surface, the wiper blade, the wiper motor and the relay may be damaged due to dry or frozen condition of the wiper and the windshield.  Before operating the windshield wiper, remove snow or dust from the windshield surface and defrost the frozen windshield.
Page 119: Front/Rear Wiper Switch
OPERATOR'S STATION Front/Rear Wiper Switch Operate wiper switch (1) to move the front and rear windshield wipers. IMPORTANT: The washer motor may become damaged if washer fluid is continuously used for more than 20 seconds or the wiper switch is operated with no fluid in the washer tank.
Page 120: Hazard Switch
OPERATOR'S STATION Hazard Switch IMPORTANT: Do not hold hazard switch (1) in the " " position for a long time with the engine stopped. The batteries will become discharged. When a machine failure occurs, use this switch to inform other vehicles that the machine is in an emergency situation.
Page 121: Work Light Switch
OPERATOR'S STATION Work Light Switch Press the mark on switch (1) while the light switch is in " " or " " position to turn front work lights (2) ON. Rear work lights (3) stay OFF. When the side with mark switch (1) is pressed, both front work lights (2) and rear work lights (3) are turned ON.
Page 122: Parking Brake Switch
OPERATOR'S STATION Parking Brake Switch WARNING:  To prevent accidents due to running away of the machine, after parking the machine or before leaving the machine, be sure to apply the parking brake.  Never apply the parking brake while traveling the machine.
Page 123: Accelerator Pedal
OPERATOR'S STATION Accelerator Pedal When accelerator pedal (3) is stepped on, the engine speed increases. When released, the engine speed decreases. NOTE: The engine speed may change due to the machine control regardless of the operation of the accelerator pedal. Brake/Inching Pedal WARNING: MNDB-01-001...
Page 124: Tilt, Telescopic Lever/Steering Column Tilt Pedal
OPERATOR'S STATION Tilt, Telescopic Lever/Steering Column Tilt Pedal WARNING:  Before operating the machine, be sure that the steering wheel is locked.  Do not operate tilt, telescopic lever (1) and steering column tilt pedal (2) during operation.  Before operating the machine, adjust the steering column inclination so as to match the operator's physical constitution.
Page 125: 1St Speed Select Switch
OPERATOR'S STATION 1st Speed Select Switch Maximum speed can be selected from 7 km/h to 13 km/h (4.3 to 8.1 mph) range by operating 1st speed select switch (2) while shift switch (1) is in the 1st speed position. NOTE: Maximum speed can be selected from 0 km/h to 7 km/h (0 to 4.3 mph) range when creep mode switch (3) is in the ON position.
Page 126: Auto Shut-Down (Idling Stop) Switch
OPERATOR'S STATION Auto Shut-Down (Idling Stop) Switch WARNING: This function automatically stops the engine. Take extra care on the work and work environment when using this function. When auto shut-down (idling stop) switch (1) is set in ON, the engine automatically stops after the preset time at the state in which the machine is parking.
Page 127: Right Console / Switches
9- Power Mode Switch 10- Forward/Reverse Selector Switch 11- Fan Reverse Rotation Switch 12- Auxiliary 13- Quick Cupler Switch (ZW140-6/150-6: Optional) 14- Secondary Steering Operation Check Switch (Optional) 15- Aftertreatment Device Regeneration Switch 16- Lift Arm Auto Leveler Switch (Upward Set)
Page 128: Multi-Function Joystick Lever
OPERATOR'S STATION Multi-Function Joystick Lever The multi-function joystick lever is used to operate the lift arm and/or bucket. Lever Bucket Operation Position Float: The lift arm free falls and can be moved as loads are applied. Lift Arm Lower Hold: The lift arm is stopped and held in that position.
Page 129: Right Console / Switches
OPERATOR'S STATION Right Console / Switches Fingertip Control Type 1- Bucket Control Lever 2- Lift Arm Control Lever 3- Auxiliary Control Lever (Optional) 4- Forward/Reverse Switch 5- Control Lever Lock Switch 6- Creep Mode Switch 7- Traction Control Switch 8- Power Mode Switch MNDB-01-004 9- Forward/Reverse Selector Switch 10- Fan Reverse Rotation Switch...
Page 130: Control Lever
OPERATOR'S STATION Control Lever The lift arm control lever and the bucket control lever are used to operate the lift arm and/or bucket. Lift Arm Control Lever (1) Lever Lift Arm Operation Position Float: The lift arm free falls and can be moved as loads are applied.
Page 131 OPERATOR'S STATION  When pushing down the lift arm control lever to the "Float" position (C), the lift arm moves to the position preset at lower kickout and is held in the position. When the lift arm moves to the preset position, the lift arm control lever automatically moves to "Neutral"...
Page 132: Control Lever Lock Switch
OPERATOR'S STATION Control Lever Lock Switch WARNING:  Before leaving the operator's seat, be sure to stop the engine. Then, set control lever lock switch (1) to the LOCK ( ) position.  Always check to be sure that the control lever lock switch is set in the LOCK ( ) position before transporting the machine or leaving the machine at the end of the shift.
Page 133: Armrest Adjust Handle
OPERATOR'S STATION Armrest Adjust Handle The armrest is provided so that the operator can operate the lever with an arm on the armrest, for comfort and ease. Loosen handle (1) and position the armrest height to fit the operator's preference, tighten handle (1) to fix the armrest. L : Loosen R : Tighten MNDB-01-005...
Page 134: Creep Mode Switch
OPERATOR'S STATION Creep Mode Switch Maximum speed can be selected from 0 km/h to 7 km/h (0 to 4.35 mph) range by turning ON creep mode switch (3) and then operating 1 speed select switch (2) while shift switch (1) is in the 1st speed position.
Page 135: Traction Control Switch
OPERATOR'S STATION Traction Control Switch When traction control switch (1) is turned ON, indicator (2) is lit. This function prevents tire slip and improves working efficiency by controlling the maximum tractive force when digging load is high. ON : This mode is suited for removing snow. Maximum tractive force is reduced.
Page 136: Power Mode Switch
OPERATOR'S STATION Power Mode Switch Operating power mode switch (1) turns the power mode function ON and OFF. Power Mode Material OFF Mode  Crushed Rocks in Smaller (Loading work with Diameter more emphasis on fuel  Gravel consumption)  Stone ...
Page 137: Aftertreatment Device Regeneration Switch
OPERATOR'S STATION Aftertreatment Device Regeneration Switch Aftertreatment device regeneration switch (1) is a three- position switch. It selects auto-regeneration, manual regeneration and regeneration inhibited of the aftertreatment device. Manual Regeneration : If the switch is in this position, the manual regeneration is performed when the aftertreatment device regeneration request is displayed.
Page 138: Manual Regeneration Procedure
OPERATOR'S STATION Manual Regeneration Procedure IMPORTANT:  Manual regeneration that is performed when the aftertreatment device regeneration request is displayed restores aftertreatment device function. This is not a malfunction.  If the machine is continuously operated despite the aftertreatment device regeneration request is displayed, aftertreatment device alarm and engine trouble alarm will be displayed, and the buzzer sounds.
Page 139 OPERATOR'S STATION CAUTION: The manual regeneration does not start unless the accelerator pedal is OFF, forward/reverse lever is in Neutral, parking switch is ON, and the front attachment lock switch is ON. When touching the accelerator pedal, forward/reverse lever, parking switch and the front attachment lock switch, the regeneration process is aborted.
Page 140: Aftertreatment Device Regeneration Inhibited
OPERATOR'S STATION Aftertreatment Device Regeneration Inhibited IMPORTANT: The aftertreatment device regeneration can be inhibited to prevent auto regeneration while operating the machine in a dusty area or indoors. When aftertreatment device regeneration switch (1) is in regeneration inhibited (4) position, the auto regeneration will not be performed.
Page 141: Ride Control Switch
OPERATOR'S STATION Ride Control Switch WARNING:  To ensure safety, operate the ride control switch only after parking the machine with the bucket lowered to the ground.  When operating the machine with the front attachment in the float position (scooping, grading, or snow removal), always turn the ride control switch OFF.
Page 142: Fan Reverse Rotation Switch
OPERATOR'S STATION Fan Reverse Rotation Switch Fan reverse rotation switch (1) reverses the hydraulic driven fan. In case the radiator is clogged, rotate the hydraulic driven fan in reverse direction to blow out the clogged dust. Carry out the fan reverse rotation regularly to prevent the cooling system from clogging.
Page 143: Auto
OPERATOR'S STATION AUTO When fan reverse rotation switch (1) is set to AUTO position, the fan automatically reverses rotation and then returns to the normal direction. Normal rotation  Reverse rotation  Normal rotation ... The fan rotates in the normal direction for 10 minutes for the first time;...
Page 144: Forward/Reverse Selector Switch
OPERATOR'S STATION Forward/Reverse Selector Switch Forward/reverse selector switch (2) is a switch that activates forward/reverse switch (1) on the control lever. When forward/ reverse selector switch (2) is in ON position, the machine travels in forward or reverse direction by pressing (F) or (R) button of forward/reverse switch (1).
Page 145: Secondary Steering Operation Check Switch (Optional)
OPERATOR'S STATION Secondary Steering Operation Check Switch (Optional) Push secondary steering operation check switch (1) to check whether the secondary steering pump operates. The secondary steering pump operates while pushing the ON side of the switch. In the meantime, secondary steering alarm (2) will be displayed on the monitor screen.
Page 146: Dual Lift Arm Auto Leveler
OPERATOR'S STATION Dual Lift Arm Auto Leveler The lift arm auto leveler is a device that automatically stops the lift arm at the preset position while lowering or raising the lift arm. It is convenient to change the setting of stop position by using this function when the machine is constantly used in a specific way for cargo handling work.
Page 147: Cigar Lighter (24 Vdc Electrical Outlet)
WARNING: Never touch other than the knob part. Otherwise, it may result in severe burns. CAUTION: Do not power anything other than a genuine Hitachi Construction Machinery electrical device from the cigar lighter port. IMPORTANT: In case the cigar lighter does not pop out...
Page 148: Ash Tray
OPERATOR'S STATION Ash Tray WARNING: Take precautions against fires. Use ash tray (1) when smoking in the cab. MNDB-01-003 1-86...
Page 149: Auto Air Conditioner
OPERATOR'S STATION Auto Air Conditioner Feature  Full Auto-Temperature Control: Automatically controls the cab temperature to maintain the temperature set by the temperature control switch regardless of outside air temperature and insolation.  Max. Cooling and Heating: Maximum cooling or heating can be obtained by pressing the top side mark "...
Page 150: Components Name
OPERATOR'S STATION Components Name 1- Control Panel 2- Front Vent 3- Rear Vent 4- Foot Vent 5- Defroster Vent 6- Power OFF Switch 7- Blower Switch MNDB-01-011 8- Liquid-Crystal Display (LCD) 9- Temperature Control Switch 10- Mode Switch 11- AUTO Switch 12- Air Conditioner Switch 13- Circulation/Fresh Air Switch 14- Defroster Switch...
Page 151: Controller Part Name And Function
OPERATOR'S STATION Controller Part Name and Function  Power OFF Switch (6) Stops the blower. When the switch is pressed, all displays (vent mode, set- temperature, and blower speed) on the LCD (8) panel will disappear and the blower stops in both the auto and manual modes.
Page 152 OPERATOR'S STATION  Temperature Control Switch (9) Sets the air temperature in the range of 18 to 32.0 °C (65 to 90 °F) in the MANUAL and AUTO modes. Temperature can be set by 0.5 °C (0.9 °F) increments. The set-temperature is displayed on the LCD (8) center.
Page 153: Mode/Temperature Control Switch
OPERATOR'S STATION Mode/Temperature Control Switch  Mode Switch (10) Selects the air vent. The selected air vent is indicated on LCD (8). Front Vent Mode Front/Rear Vent Mode MNDB-01-011 Front/Rear/Foot Vent Mode Foot Vent Mode Foot/Defroster Vent Mode Defroster Vent Mode Each time mode switch (10) is pressed, the vent location can be changed in 6 stages as illustrated below.
Page 154 OPERATOR'S STATION  AUTO Switch (11) Selects the air conditioner operation mode in either AUTO or MANUAL.  AUTO Operation Mode 15 16 Press AUTO switch (11). When the indicator comes ON, the AUTO operation mode is selected. In response to the set temperature, the blower speed, vent mode, and ventilation mode are automatically controlled.
Page 155: Defroster Operation
OPERATOR'S STATION Defroster Operation 1. Press defroster switch (14) to change defroster vent mode; the fresh air mode and air conditioner will turn 2. Temperature in the cab can be adjusted by operating temperature control switch (9). 3. Operate blower switch (7) to adjust flow. 4.
Page 156: Tips For Optimal Air Conditioner Usage
OPERATOR'S STATION Tips for Optimal Air Conditioner Usage For Rapid Cooling Temperature in the cab may rise over 80°C (176°F) when the machine is exposed to sun light in the summer. For rapid cooling, ventilate air in the cab first. After starting the engine, set the temperature control to maximum cooling (18°C, 65°F) using temperature control switch (9).
Page 157: Adjusting Operator's Seat (Air Suspension Type Seat)
OPERATOR'S STATION Adjusting Operator's Seat (Air Suspension Type Seat) Adjust the seat for comfort and so that the pedals may be pushed fully down when the operator's back is fully against the seat back. Components Name 1- Armrest Angle Adjustment 2- Lumbar Support Adjustment 3- Reclining Angle Adjustment 4- Damper Adjustment...
Page 158: Rear Tray
OPERATOR'S STATION Rear Tray 1- Document Holder 2- Hot/Cool Box 3- Electric Power Output 4- Tray 5- Fuse Box 6- Cup Holder MNEC-01-046 Electric Power Output (12 VDC Electrical Outlet) 12 V DC electric power is available from electric power output (3).
Page 159: Fuse Box
OPERATOR'S STATION Fuse Box IMPORTANT: If a fuse blows, turn the key switch OFF. After checking and correcting the cause of the trouble, replace the fuse with a new one. Slow blow fuses (1 and 2) function as a safety valve to prevent excess current from flowing in the electrical system.
Page 160: Fuse Box A
OPERATOR'S STATION Fuse Box A 10- PARKING 20- OPTION 4 (ACC3) (10 A) 9- AC1 19- OPTION 3 (ACC2) 10 A (15 A) 8- STOP LAMP 18- DEF HEATER 15 A 7- BACK ALARM 17- DEF SUPPLY 15 A 6- HST 2 16- DEF SENSOR 15 A 5- HEAD LAMP LH...
Page 161: Hot/Cool Box
OPERATOR'S STATION Hot/Cool Box Cool or warm air from the air conditioner is routed to hot & cool box (1) so that food or a drink can be temporarily stored. Use a container with a tight cap in the hot/cool box. MNEC-01-048 Tray and Drink Holder IMPORTANT: Tray (2) is not a waterproof type.
Page 162: Rops Cab
OPERATOR'S STATION ROPS Cab ROPS cab (1) is standard equipment. 1- ROPS Cab 2- Speakers 3- Front Room Light 4- Sun Visor MNDF-07-029 M4GB-01-113 M4GB-01-114 MNEC-01-052 1-100...
Page 163 OPERATOR'S STATION 5- Radio 6- Cab Switch Panel (Optional) 7- Room Rear View Mirror 8- Rear Room Light 9- Emergency Evacuation Hammer 10- Coat Hook MNDF-01-051 M4GB-01-117 MNEC-01-536 1-101...
Page 164: Front Room Light
OPERATOR'S STATION Front Room Light Press ON side of switch (1) to turn the room light ON. The room light switch has three operation positions. : Light (2) comes and stays ON. Neutral : When the cab door is opened, light (2) comes ON. When closed, light (2) goes OFF.
Page 165: Sun Visor
OPERATOR'S STATION Sun Visor When sunlight is strong, use sun visor (4) by hanging its edge from the cab top down to a desired hook preset. MNEC-01-052 Coat Hook Use to hang your coat, hat, etc. MNEC-01-536 1-103...
Page 166: Upper Switch Panel
OPERATOR'S STATION Upper Switch Panel 1- Rotary Light Switch (Optional) 2- Rear View Mirror Heater Switch 3- Auxiliary 4- Auxiliary 5- Auxiliary MNDF-01-051 Rotary Light Switch (Optional) Press either upper part or lower part of the switch to turn the rotary light ON.
Page 167: Outside Rear View Mirror
OPERATOR'S STATION Outside Rear View Mirror WARNING: Do not travel the machine in reverse by relying on only the range of vision rear view mirror (1) provides. Use the rear view mirror only as an assistant during travel operation. Be sure to confirm the safety by using your own visibility when traveling the machine in reverse.
Page 168: Door Lock Knob
OPERATOR'S STATION Door Lock Knob CAUTION: After closing the door, always check that the door lock is securely engaged. Depress door lock knob (5) to engage the door lock. M4GB-01-128 Door Open/Close Lever When opening the door, while lifting door lock knob (5), pull lever (6) to disengage the door lock.
Page 169: When Fully Opening The Door
OPERATOR'S STATION When Fully Opening the Door WARNING: Before getting on or off the cab using the hand rails, check that the cab door is securely locked. If the hand rails are used without locking the door securely, the door lock may come off, possibly causing falling accident.
Page 170: Battery Disconnect Switch
OPERATOR'S STATION Battery Disconnect Switch IMPORTANT: Never turn the disconnect switch OFF while the engine is running or the key switch is in the position other than OFF. Failure to do so may damage the electrical system. The battery disconnect switch is different from the engine start key switch.
Page 171: Switch Operation
OPERATOR'S STATION Switch Operation 1. Open the cover of the battery box. When lever (1) is vertical to the ground, battery disconnect switch (2) turns ON. The lever can not be removed when lever (1) points downward. When operating the machine with battery disconnect switch (2) ON, close the cover.
Page 172: Articulation Lock Bar
OPERATOR'S STATION Articulation Lock Bar WARNING:  Before servicing or transporting the machine, be sure to engage lock bar (1).  Before driving the machine, be sure to disengage lock bar (1) from the rear frame and fasten lock bar (1) to the front frame with pin (2) and β-form lock pin (3).
Page 173: Towing Pin
Available towing force ZW140-6: 94.5 kN (9640 kgf) (21245 lbf) MPTC-01-007 ZW150-6, 150PL-6: 104 kN (10600 kgf) (23380 lbf) Towing pin (4) is located on the rear end of the base machine.
Page 174: Inspection/Maintenance Side Access Cover
OPERATOR'S STATION Inspection/Maintenance Side Access Cover CAUTION:  Always close side covers (1) during traveling and/or working operation.  Do not keep the side cover open on a slope or when a strong wind is blowing. Failure to do so may be dangerous because the side cover may unexpectedly close.
Page 175: Steps
OPERATOR'S STATION Steps WARNING: When getting on and off the machine, use steps and hand rails to support your body with at least three points. Getting on and off the machine with less than three support points may cause you to slip, possibly resulting in a falling accident.
Page 176: Vandal-Proof Devices
OPERATOR'S STATION Vandal-Proof Devices A lock key can be installed to transmission inlet cap (1), tool box (2), and battery cover (3). MNDF-01-033 MPTC-01-010 1-114...
Page 177 OPERATOR'S STATION Vandal-Proof Devices (continue from previous page) Fuel tank cap (4), side covers (5), and air conditioner fresh air filter (6) can be locked with the keys. MPTC-01-011 MPTC-01-010 MNEC-01-055 1-115...
Page 178: Seat Belt
OPERATOR'S STATION Seat Belt WARNING:  Be sure to use seat belt (1) when operating the machine.  Before operating the machine, be sure to examine seat belt (1) and attaching hardware for any failure. If any damage and/or wear are found, replace the part concerned.
Page 179: Rear View Camera Monitor
OPERATOR'S STATION Rear View Camera Monitor Components Name 1- Monitor 2- Setting and Adjustment Switches ( to ) 3- Camera Starting and Stopping the Rear View Camera Monitor (Optional) MNDB-13-001 WARNING: The image displayed on the rear view monitor is meant only as an aid. Actual position and distance of people and objects in the rear view monitor will be different.
Page 180: Monitor Setting And Adjustment (Optional)
OPERATOR'S STATION Monitor Setting and Adjustment (Optional) A switch panel is located on the underside of monitor (1), providing 8 switches (switch  to ).  Switch : Do not use  Switch : Auto Backlight Control, Day setting and Night setting Push this switch to adjust the Auto Backlight Control (ABC) mode, the LCD backlight day and the LCD backlight night...
Page 181 OPERATOR'S STATION  Switch : Contrast Adjustment Contrast is the difference in brightness between brightest and darkest part of the image. In high contrast, difference of highest and lowest brightness becomes significant, making the bright part and dark part Switches No. ...
Page 182 OPERATOR'S STATION  Push switches  and  simultaneously: Saturation Adjustment The saturation switch adjusts image colorfulness. When the saturation value is increased, image colorfulness increases, making the darker part of the image brighter. However, Switches No.    ...
Page 183: Break-In
BREAK-IN Break-in Period for New Machine Machine life and performance will be greatly affected by the treatment during operation and maintenance of the machine, but especially so during the initial operation. IMPORTANT: Always correctly warm the machine up to operating temperatures before running the machine ! This is always a requirement for good machine life.
Page 184 BREAK-IN MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 185: Operating Engine
OPERATING ENGINE Inspect Machine Daily Before Starting IMPORTANT: Make sure there are no oil and water leaks on the ground under the machine. If there is oil and water leakage, it may cause damage. Please check the cause immediately, and perform the maintenance. Perform the required daily check before starting the engine.
Page 186 OPERATING ENGINE Check Points Check Contents 9. Chassis 1. Oil level and leaks of the transmission and the axle. 2. Level, leaks and contamination of the fuel tank. Drain fuel tank sump. 3. Fuel leaks and damage of the fuel hoses and pipe lines. 4.
Page 187: Check Before Starting
OPERATING ENGINE Check Before Starting CAUTION: If your machine is equipped with forward/ reverse selector switch (11), be sure to turn the switch in the OFF position before starting the engine to ensure safety. 1. If your machine is equipped with the battery disconnect switch, check that the switch is in the ON position.
Page 188 OPERATING ENGINE 5. Check that control lever lock switch (7) is in the LOCK ( ) position. MNDB-01-005 6. Adjust the position of outside rear view mirror (8) and room rear view mirror (9) so that the best rear visibility can be obtained.
Page 189: Starting Engine
(11) is lit. If it is not lit, the secondary steering device has a malfunction. Contact your authorized Hitachi dealer for machine inspection. Low steering oil pressure indicator (11) goes off after the engine starts.
Page 190 OPERATING ENGINE IMPORTANT: Never operate the starter for more than 10 seconds at a time. If the engine fails to start, return key switch to OFF. Wait for more than 30 seconds, then try again. Failure to do so may damage the starter or discharge the batteries.
Page 191: Starting In Cold Weather
OPERATING ENGINE Starting in Cold Weather Preheating 1. Turn key switch (1) ON. The coolant temperature sensor is activated so that the engine is automatically preheated. 2. Preheat indicator (2) comes ON. As long as the preheat indicator stays ON, the engine is being heated. MNDB-01-053 NOTE: Preheating time varies depending on the coolant temperature.
Page 192: Check After Starting
OPERATING ENGINE Check After Starting IMPORTANT: If any abnormality is found in the monitor functions, immediately stop the engine and investigate the cause of the trouble. Check the monitor operation: 1. Check that discharge warning indicator (1) is OFF. In case the discharge warning indicator stays ON, immediately stop the engine.
Page 193: Using Booster Batteries
OPERATING ENGINE Using Booster Batteries IMPORTANT: The machine electrical system is a 24 volt negative (-) ground. Use only 24 volt booster batteries with sufficient capacity. WARNING:  An explosive gas is produced while batteries are in use or being charged. Keep open flames and sparks away from the battery area.
Page 194 OPERATING ENGINE 1. Connecting the booster batteries 1.1 Stop the engine on the booster battery mounted machine. 1.2 Turn the battery disconnect switch to the OFF position. 1.3 Connect one end of red booster cable (1) to the positive (+) terminal of the machine battery, and the other end to the positive (+) terminal of the booster battery.
Page 195: Warm Up
OPERATING ENGINE Warm Up IMPORTANT: Right after the engine starts, the engine speed will be kept to slow idle speed for maximum 35 seconds when the coolant, hydraulic oil or transmission oil temperature is low, or for 3 seconds at normal temperature even if accelerator pedal (3) is operated.
Page 196: Cold Weather Warm Up
OPERATING ENGINE Cold Weather Warm Up IMPORTANT: At starting the engine, the engine RPM (min ) is kept at low idle for maximum 35 seconds to warm up the coolant or hydraulic oil. After this period, the engine RPM will increase by applying the accelerator pedal (3).
Page 197 OPERATING ENGINE 2. Keep the engine running at low to medium speed for about 5 minutes more. NOTE: At this time, do not operate the engine in slow or fast speed. Use medium engine speeds for safe and quick warm 3.
Page 198: Stopping Engine
OPERATING ENGINE Stopping Engine Stop the engine in the following manner. IMPORTANT: Never stop the engine while traveling the machine. If the engine stops, the steering system may become inoperable, or it may cause other malfunctions or seizure of parking brake. 1.
Page 199: Driving Machine
A Driving Position (A) the machine. ZW140-6: 350~400 mm (13.8~15.7 in) ZW150-6/150PL-6: 420~470 mm (16.5~18.5 in) 2. After raising the lift arm, set the machine to the driving position, fully tilt the bucket backward.
Page 200: Starting To Move
2. Set the front attachment in the driving position by operating control lever (2). 3. Turn neutral lever lock (4) to the UNLOCK ( ) position. MNDB-01-005 MPD8-04-002 Driving Position (A) ZW140-6: 350~400 mm (13.8~15.7 in) ZW150-6/150PL-6: 420~470 mm (16.5~18.5 in) MNDB-01-002...
Page 201 DRIVING MACHINE 4. Step on brake pedal (6) and press parking brake switch (7) to the OFF position to release the parking brake. 10, 11 Check that at this time parking brake indicator (1) goes OFF. 5. After moving forward/reverse lever (10) to either forward (F) or reverse (R) position, move shift switch (11) to the desired position.
Page 202: Parking Brake Switch
DRIVING MACHINE Parking Brake Switch WARNING:  To prevent accidents due to running away of the machine, after parking the machine or before leaving the machine, be sure to apply the parking brake.  Never apply the parking brake by operating parking brake switch (1) while traveling the machine except in an emergency.
Page 203: Drive Speed Change
DRIVING MACHINE Drive Speed Change The transmission gear range can be selected by turning shift switch (1). 1st and 2nd speed : To be used for excavation and loading work 3rd and 4th speed : To be used for traveling operation.
Page 204: Steering Wheel
DRIVING MACHINE Steering Wheel WARNING:  Avoid quick steering while driving the machine at high speeds, while driving on a steep slope, or while raising the lift arms. Failure to do so may cause the machine to turn over.  Never attempt to stop the engine while steering the machine.
Page 205: Secondary Steering (Optional)
DRIVING MACHINE Secondary Steering (Optional) If the oil pressure in the steering system lowers, the secondary steering system is activated so that steering operation can be achieved. If the secondary steering system is activated, secondary steering indicator (2) lights and the buzzer sounds. The steering wheel will become hard to rotate but it is operable.
Page 206: Stop And Restart Of Driving
DRIVING MACHINE Stop and Restart of Driving Follow the tips described below when required to stop or restart driving. 1. Slowly release the accelerator pedal. Depress the brake pedal to stop the machine. 2. Slowly depress the accelerator pedal to move the machine again.
Page 207 DRIVING MACHINE Precautions for driving During drive operation, observe the general operating manners beside the precautions described below to ensure safe and correct operation. WARNING:  In case a tire is punctured while driving, securely hold the steering wheel and slowly reduce the drive speed.
Page 208 DRIVING MACHINE Driving in Water or on Soft Ground IMPORTANT: If the axles, transmission, etc. should become submerged, they must be reconditioned immediately, otherwise the inner gears may wear excessively, or the machine may become damaged. Contact your authorized dealer for inspection and maintenance.
Page 209: Precautions For Driving On Slopes
DRIVING MACHINE Precautions for Driving on Slopes WARNING:  Never allow the machine to descend a slope with the forward/reverse lever in neutral (N). Failure to do so will not only work the engine braking to malfunction but also create the causes of various machine troubles.
Page 210: Precautions For Driving Speeds
DRIVING MACHINE Precautions for Driving Speeds CAUTION: Descend the machine on a steep slope with the shift switch in the slow drive gear range while depressing the brake pedal (normal brake) if necessary as well as applying engine brake sufficiently. Traveling for a long time without reducing the speed will create the causes of various machine troubles.
Page 211: Precautions To Be Taken If Machine Failure Occurs
DRIVING MACHINE Precautions to be Taken if Machine Failure Occurs  Keep alert. While paying attention to the vehicles following you, slowly reduce the travel speed and park the machine on the road shoulder as closely to the shoulder edge as possible.
Page 212: Stop The Machine
DRIVING MACHINE Stop the Machine 1. Avoid sudden deceleration. Smoothly reduce the drive speed. Release accelerator pedal (1) and step on brake pedal (2) to stop the machine on level surface. 2. Return forward/reverse lever (3) and forward/reverse switch (10) to neutral (N). Place neutral lever lock (4) to the LOCK position.
Page 213 DRIVING MACHINE IMPORTANT: Do not leave the machine by turning key switch (9) in ACC position. Failure to do so may discharge the batteries. Be sure to turn key switch to OFF position before leaving the machine. 7. Turn key switch (9) to OFF position to stop the engine. Remove the key from the switch.
Page 214: Parking
DRIVING MACHINE Parking IMPORTANT: When parking the machine with cab door and windows open, cab electrical components may be damaged by bad weather. Always close windows, roof vent and cab door when parking the machine. 1. Stop and park the machine on level surface. Lower the bucket to the ground.
Page 215: Emergency Evacuation
DRIVING MACHINE Emergency Evacuation When the engine has stalled during driving: Pressurized oil in the accumulator acts on the brake when the brake pedal is depressed. Immediately park and stop the machine in a safe location. At this time, do not repeat to pat the brake pedal.
Page 216 DRIVING MACHINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4-18...
Page 217: Operating Machine
OPERATING MACHINE Control Lever Multi-Function Joystick Lever The multi-function joystick lever is used to operate the lift arm and/or bucket. Lever Lift Arm/Bucket Operation Position Float: The lift arm free falls and can be moved as loads are applied. Lift Arm Lower Hold: The lift arm is stopped and held in that position.
Page 218 OPERATING MACHINE Fingertip Control Type The fingertip control lever is used to operate the lift arm and/or bucket. Lift Arm Control Lever (1) Lever Lift Arm Operation Position Float: The lift arm free falls and can be moved as loads are applied. Lift Arm Lower Hold: The lift arm is stopped and held in that...
Page 219 OPERATING MACHINE NOTE: Further pull lift arm control lever (1) from "Raise" position (A), the lever is held in the position (F) until the lift arm moves to the position preset by the lift arm kickout. When the lift arm moves the preset position, lift arm control lever (1) automatically moves to the Hold (N) position.
Page 220: Control Lever Lock Switch
OPERATING MACHINE Control Lever Lock Switch WARNING:  Ensure that control lever lock indicator (2) on the monitor panel is ON when control lever lock switch (1) is in LOCK ( ) position, and indicator (2) is OFF when control lever lock switch (1) is in UNLOCK ( ) position.
Page 221: Ride Control Switch
OPERATING MACHINE Ride Control Switch WARNING:  To ensure safety, operate the ride control switch only after parking the machine with the bucket lowered to the ground.  When operating the machine with the front attachment in the float position (scooping, grading, or snow removal), always turn the ride control switch OFF.
Page 222 OPERATING MACHINE AUTO When ride control switch (1) is turned to AUTO, the drive speed sensor and the controller is activated. Then, when the drive speed becomes faster than the preset travel speed, the ride control system automatically operates. When the drive speed becomes slower than the preset travel speed, the ride control system becomes inoperable.
Page 223: Lift Arm Kick Out
OPERATING MACHINE Lift Arm Kick Out WARNING:  Take extra care to prevent personal injury and/or death when adjusting the lift arm kick out system.  Apply the parking brake to prevent the machine from moving unexpectedly. Wedge the wheels with blocks.
Page 224: Dual Lift Arm Auto Leveler
OPERATING MACHINE Dual Lift Arm Auto Leveler WARNING:  Take extra care to prevent personal injury and/or death when adjusting the lift arm auto leveler.  Apply the parking brake to prevent the machine from moving unexpectedly. Wedge the wheels with blocks.
Page 225: Bucket Auto Leveler
OPERATING MACHINE Bucket Auto Leveler WARNING:  Pay attention to safety to avoid personal injury and/ or death when adjusting the bucket auto leveler.  Stop the engine. Lower the loader front on the ground to release oil pressure.  Apply the parking brake to prevent the machine from moving unexpectedly.
Page 226 OPERATING MACHINE Adjustment Procedures IMPORTANT: Do not operate the machine with the bucket dumped more than 10°. Avoid applying great towing force to the bucket cutting edge. 1. After moving the bucket to the desired digging angle, stop the engine. 2.
Page 227: Auto Shut-Down (Idling Stop)
OPERATING MACHINE Auto Shut-Down (Idling Stop) WARNING: This function automatically stops the engine. Take extra care on the work and work environment when using this function. When pressing auto shut-down (idling stop) switch (1), the auto idling stop function is ON and auto shut-down (idling stop) indicator (2) lights.
Page 228 OPERATING MACHINE Auto Idling Stop Operating Condition  The engine is running.  The parking brake is applied.  The forward/reverse lever (switch) is in neutral (N).  The accelerator pedal is not depressed.  The brake pedal is not depressed. ...
Page 229: Before Operation
OPERATING MACHINE Before Operation WARNING:  Be sure to install only authorized buckets and other work tools on the front attachment.  Never modify or increase the capacity of the bucket or other work tools without first receiving authorization. Do not overload the machine by installing additional counterweights.
Page 230: Avoid Overloading
OPERATING MACHINE Avoid Overloading WARNING:  Do not penetrate the bucket into piles of soil and/ or gravel at fast travel speed to avoid personal accidents.  Avoid excavating or scooping loads when the machine is articulated, which could possibly cause the machine to turn over.
Page 231: Excavation
OPERATING MACHINE Excavation Loading Accumulated Soil IMPORTANT: Avoid operating the machine with the front wheels raised off the ground. Machine traction force is reduced and excessive loads are applied to the undercarriage. M4GB-05-003 Scoop load while driving the machine forward as described below.
Page 232 OPERATING MACHINE Digging and Loading Level Ground IMPORTANT: While excavating with the bucket or fork, never apply excessive traction force to the tooth tips with the bucket or fork tilted more than 10°. Failure to do so may result in cracks or damage to the front attachment.
Page 233: Grading
OPERATING MACHINE Grading WARNING: When operating the ride control system equipped machine with the front attachment control lever in the float position when performing such works as soil scooping, land grading, or snow removal, be sure to turn the ride control switch OFF. Failure to do so may allow the ride control system to operate so that M4GB-05-011 the front attachment may automatically move up and...
Page 234: Loading
OPERATING MACHINE Loading IMPORTANT:  Always maintain a clean surface for machine operation. Cleaning of materials such as soil spilled on the driving surface will reduce wear and/or damage on tires.  When carrying loads in the bucket, pay attention to the travel road surface conditions.
Page 235 OPERATING MACHINE Load and Carrying Method WARNING:  Be sure to provide tire stopper (1) in front of the dumping port.  Before raising the lift arm, slightly tilt the bucket back and forth to stabilize the load in the bucket to avoid personal injury or damage to the machine due to falling of the load.
Page 236 OPERATING MACHINE Loader and Dump Truck Combination Method WARNING:  Always maintain a flat work site surface. Avoid rapid turns and/or sudden braking while raising the lift arm with the bucket loaded to prevent the machine from tipping over.  Do not penetrate the bucket into a loading face at fast travel speeds, possibly resulting in personal accident.
Page 237: Dozing
OPERATING MACHINE Dozing IMPORTANT:  Never attempt to forcibly push piled material higher than the bucket capacity. Premature wear of the tires due to slipping and/or waste of fuel may result.  Do not perform dozing with the bucket dumped. Abnormal excessive stress will be applied on the front attachment.
Page 238: Removing Snow
OPERATING MACHINE Removing Snow WARNING: When operating the ride control system equipped machine with the front attachment control lever in the float position when performing such works as soil scooping, land grading, or snow removal, be sure to turn the ride control switch OFF. Failure to do so may allow the ride control system to operate so that the front attachment may automatically move up and down.
Page 239: Precautions For After Operations
OPERATING MACHINE Precautions for After Operations 1. After finishing the day's operation, drive the machine to a firm, level ground where no possibility of falling stones, ground collapse, or floods are present. (Park the machine referring to the "Parking" in the "DRIVING THE MACHINE"...
Page 240 OPERATING MACHINE 5. Maintenance for long term machine storage after engaging in snow removal. (Refer to STORAGE section.) Anti-freeze agents such as salt (sodium chloride or Ground Side (Black Vinyl Cap) calcium chloride) are scattered on snow roads. When the machine is stored for a long time after engaging in snow removal work, perform the following maintenance to protect the machine from being corroded and/or (Red Vinyl Cap)
Page 241: Transporting
TRANSPORTING Transporting by Road When transporting the machine on public roads, be sure to first understand and follow all local regulations. 1. For transporting using a trailer, check the width, height, length and weight of the trailer when the machine is loaded.
Page 242: Loading / Unloading On Trailer
TRANSPORTING Loading / Unloading on Trailer WARNING: Be sure to use a loading dock or a ramp for loading/unloading. Always load and unload the machine on a firm, level surface. Ramp/Loading Dock: 1. Before loading, thoroughly clean the ramps, loading dock and flatbed.
Page 243 TRANSPORTING Loading / Unloading on Trailer WARNING:  Never steer while driving up or down a ramp as it is extremely dangerous and may cause the machine to turnover. Never attempt to steer the machine on a ramp. If the travel direction must be changed on a slope, move back the machine to the flat ground.
Page 244: Fastening Machine For Transporting
TRANSPORTING Fastening Machine for Transporting WARNING: Fasten the machine frame to the deck securely with chains and cables. While traveling, loads may shake around, move forward or backward or to the sides. 1. Apply the parking brake. Slowly rest the bucket on the trailer deck or load-carrying platform.
Page 245: Transporting Wheel Loader (Urgent Situation)
TRANSPORTING Transporting Wheel Loader (Urgent Situation) The following procedures shall only be applied to cases when urgently moving the wheel loader a short distance is required. When required to transport the wheel loader long distance, use a trailer. Precautions for Self-Traveling Avoid driving the wheel loader long distances at high-speed as much as possible as it may overheat the tires, possibly resulting in premature tire damage and/or wear.
Page 246 TRANSPORTING Precautions for Towing WARNING: Never attempt to tow the machine if the brake system is in need of repair. Ask your authorized dealer to repair the machine. Operate the machine only after repair is completed. Avoid towing the machine as much as possible. If the machine is to be unavoidably towed, beware of the following points.
Page 247 TRANSPORTING Hydraulic Circuit Bypass The machine can be towed by loosening shuttle valve (1) in an emergency. CAUTION: When towing the machine at high speed, components may be damaged by insufficient lubrication due to heat generated from the components. Use this towing method only in an emergency when towing for short distance at vehicle speed less than 3 km/h (1.86 mph).
Page 248 TRANSPORTING Releasing Parking Brake WARNING:  Once the parking brake is released, the machine becomes impossible to stop with the brake system, possibly resulting in personal injury or death.  Before releasing the parking brake or connecting the brake system, be sure to lock tires with wheel stoppers.
Page 249 TRANSPORTING Procedures WARNING:  Once the parking brake is released, the machine becomes impossible to stop with the brake system.  Wedge wheel stoppers to all tires to prevent the machine from moving.  Before restarting to operate the machine, consult your authorized dealer to have the parking brake adjusted.
Page 250: Towing Method
TRANSPORTING Towing Method CAUTION:  Use wire rope with a towing strength of at least 150 % of the machine weight.  Towing from the front side of the machine When using wire ropes, be sure to attach wire ropes to the front axle.
Page 251: Lifting Machine
TRANSPORTING Lifting Machine WARNING:  The lifting tools are optional. Install specified lifting tools at your authorized dealer.  Use lifting wire ropes and other lifting tools being free from any damage and/or aging, and having sufficient strength.  Consult your authorized dealer for correct lifting procedures, and size and types of lifting wire ropes and tools.
Page 252 TRANSPORTING Lifting 1. Straighten the machine and position the front attachment horizontally as illustrated to the right. 2. Move the control lever lock switch in the LOCK ( ) position. 3. Rigidly secure the front and rear frames using the articulation lock bar.
Page 253: Maintenance
IMPORTANT:  Use only recommended fuel 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 fuel, lubricants, and genuine Hitachi parts will result in loss of Hitachi product warranty.
Page 254: Check The Hour Meter Regularly
MAINTENANCE  Body Information Controller This machine provides a body information controller that stores machine operation information for preventive maintenance. When maintaining the machine, our authorized service man may down load the stored information. Consult with your authorized dealer for detailed function of this device. ...
Page 255: Layout
MAINTENANCE Layout ZW140-6/ZW150-6 22 21 26 25 14 12 MPTC-07-002 1. Bolt on Cutting Edge 15. Rear Axle 2. Bucket 16. Engine 3. Bucket Cylinder Pin 17. Rear Propeller Shaft 4. Bucket Cylinder 18. Transmission 5. Front Combination Lamp 19. Transmission Oil Filter 6.
Page 256 MAINTENANCE Layout ZW150PL-6 MPTC-07-001 1. Bolt on Cutting Edge 16. Rear Propeller Shaft 2. Bucket 17. Transmission 3. Bucket Cylinder Pin 18. Center Propeller Shaft 4. Bucket Cylinder 19. Front Propeller Shaft 5. Front Combination Lamp 20. Lift Arm Cylinder 6.
Page 257 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. ...
Page 258 MAINTENANCE  Maintenance Guide Table 4, 6 Lubrication Interval 67Z7B_YA00052226 Item Page Item Page Grease (Front Joint Pins) 7-24, 25 Transmission Oil 7-38 Grease (Center Hinge Pins) 7-26 Engine Oil Filter 7-33 Transmission Oil Filter 7-40 Hydraulic Oil Filter (Pilot) 7-50 Hydraulic Oil Filter (Suction) 7-49...
Page 259: Preparations For Inspection And Maintenance
MAINTENANCE Preparations for Inspection and Maintenance WARNING: 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.
Page 260 MAINTENANCE WARNING: Never attempt to maintain the machine when the engine is running in order to prevent the 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.
Page 261: Lock Frames
MAINTENANCE Lock Frames WARNING: Before beginning to work near the frame center hinge, install articulation lock bar (2) to securely lock and prohibit movement between the front and rear frames. Avoid accidents due to unexpected movement of the machine. 1. Align the front and rear frame centers with each other. 2.
Page 262: Inspection/Maintenance Access Side Cover
MAINTENANCE Inspection/Maintenance Access Side Cover CAUTION:  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 covers (1) may unexpectedly close.
Page 263: Inspection And Maintenance Table
MAINTENANCE Inspection and Maintenance Table Check and/or carry out the maintenance at intervals of IMPORTANT the specified operating hours below or the calender date, Severe applications require more frequent whichever comes first. maintenance. Severe conditions include heavy dust, extremely abrasive material, caustic chemicals, extremely wet conditions or abnormally hot or cold ambient temperatures.
Page 264 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Check Transmission Oil Level 7-37  Replace Transmission Oil Filter Element 7-40  Clean Transmission Air Breather 7-43 Transmission ...
Page 265 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Check Steering Wheel Play 7-104  Steering Greasing (Steering Cylinder)   7-26  system Check Gas Pressure in Steering Accumulator 7-57 ...
Page 266 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Check Hydraulic Oil Level 7-46  Check Bucket Teeth and Cutting Edge 7-102  Check Hoses and Lines for Leaks 7-58 ...
Page 267 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Check Monitor Functions and 7-82  Instrument Operation Check Horn and Back Up Alarm 7-83  Electrical Check Lights 7-83 ...
Page 268: Periodic Replacement Of Parts
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.
Page 269 MAINTENANCE Periodic Replacement Parts Replacement Intervals 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 (HST high pressure circuit hose) Hydraulic hose (HST cooler line hose) Hydraulic Every 2 years or 4000 hours...
Page 270: Kind Of Oils
Please be noted that all engine failures caused by using engine oil other than specified are excluded from Hitachi Warranty Policy. Consult your nearest authorized dealer for the unclear points. Kind of Oil...
Page 271 Gear Oil Axle & Wet Disc Brake Application Air Temperature -20 to 45 °C (-4 to 113 °F) High Gear Oil Hitachi Recommended Product TKTT15150-4th TO-4 SAE50 Fluid, with 6% friction modifier Alternative Product NOTE:  When using TO-4 SAE50 Fluid other than the listed recommended products, add 6% friction modifier or "anti-chatter"...
Page 272 Hydraulic System (Hydraulic Oil Tank) Application Air Temperature -20 to 45 °C (-4 to 113 °F) Change Interval 2000 hours Hitachi Recommended Product Super EX 46HN Alternative Product JCMAS HK VG46W NOTE:  Never mix hydraulic oils containing zinc with zinc-free hydraulic oils as hydraulic system component damage could result.
Page 273 MAINTENANCE Service Refill Capacity Location Liters Gallons Fuel Tank (Diesel Fuel) Engine Lubricant (Engine Oil) Engine Coolant Transmission Axle (Front/Rear) 25/25 6.6/6.6 Hydraulic Oil DEF Tank 3.2* NOTE: *: 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.
Page 274: List Of Consumable Parts
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) 263E237011 Air Cleaner Element (inner) 263E237001 Suction Filter 263E752001 Hydraulic Tank Oil Filter 263E752011 Pilot Oil Filter 2655742471 Transmission Oil Filter...
Page 275 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...
Page 276 MAINTENANCE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7-24...
Page 277: Greasing
MAINTENANCE A. Greasing WARNING: Apply the parking brake and the articulation lock bar. NOTE:  Until break-in operation is performed for more than 50 hours, lubricate the machine every day to get initial operational concordance.  In case excavation is made in mud, water or snow, lubricate M4GB-07-004 ZW140/150-6 the machine after operation is complete.
Page 278 MAINTENANCE 6. One point each to right and left link pins (9 and 10) ZW150PL-6 --- every 500 hours (250 hours at first time only) M4GB-07-180 ZW150PL-6 7. One point each to right and left lift arm cylinder rod pins (11).
Page 279 MAINTENANCE 8. One point each to right and left lift arm pivot pins (13). --- every 500 hours (250 hours at first time only) M4FC-07-004 ZW140/150-6 M4GB-07-180 ZW150PL-6 9. One point each to front right and left steering cylinder pins (14 and 15). --- every 500 hours (250 hours at first time only) Cylinder left front (14) Cylinder right front (15)
Page 280 MAINTENANCE 11. One point each to upper and lower frame center hinge pins (18 and 19). --- every 1000 hours Upper (18) Lower (19) M4FC-07-007 MNDF-07-056 12. One point each to front and rear axle support pins (20 and 21). --- every 10 hours Front (20) Rear (21)
Page 281 MAINTENANCE 14. One point to propeller shaft center support (23). --- every 1000 hours M4FC-07-005 15. One point to center propeller shaft universal front (24). --- every 12000 hours One point to center propeller shaft universal rear (26). --- every 12000 hours 16.
Page 282 MAINTENANCE 18. Two points to brake pedal (28) --- every 1000 hours M4FC-07-014 19. One point to brake pedal linkage (29) --- every 1000 hours M4FC-07-015 7-30...
Page 283: Engine
MAINTENANCE B. Engine Check Engine Oil Level --- every 10 hours (before starting the engine) IMPORTANT: Incorrect engine oil level may cause engine trouble (The oil level should be between the upper and lower marks on oil level gauge (1)). If the engine oil level is too high, control the oil level to the proper quantity before starting the engine.
Page 284: Change Engine Oil
MAINTENANCE Change Engine Oil --- every 500 hours WARNING: Immediately after the machine has been operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns. NOTE: Improper disposal of waste oil can threaten the earth's environment and ecology.
Page 285 MAINTENANCE 6. Allow oil to drain through a clean cloth to check if any foreign matters such as metal pieces are not included in the oil. 7. Install a new oil filter. (Refer to the descriptions for Replace Engine Oil Filter.) Clean cloth 8.
Page 286: Replace Engine Oil Filter
MAINTENANCE Replace Engine Oil Filter --- every 500 hours (each time when engine oil is changed) WARNING: Immediately after the machine has been operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns.
Page 287: Check Crankcase Breather Tube
MAINTENANCE Check Crankcase Breather Tube --- every 10 hours (daily) WARNING: Immediately after the machine has been operated, all engine parts are hot. Wait for the engine to cool down before starting any maintenance work. Failure to do so may cause severe burns. 1.
Page 288: Replace Crankcase Breather Filter Element
MAINTENANCE Replace Crankcase Breather Filter Element --- Every 2000 hours 1. Park the machine following the same procedure as described on page 7-7 for preparation of inspection/ maintenance work. 2. Disconnect open crankcase ventilation hose (1) from crankcase ventilation filter housing (2). 3.
Page 289: Check Oil Drain Tube
MAINTENANCE Check Oil Drain Tube --- Every 2000 hours WARNING: Be sure to wear safety glasses when using compressed air. 1. Remove oil drain tube (1) from crankcase ventilation filter housing (2) and cylinder block. NOTE: When oil drain tube (1) is removed, insert (3) may be left in the cylinder block.
Page 290: Power Train
MAINTENANCE C. Power Train Check Transmission Oil Level --- every 10 hours (daily) WARNING: 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. ...
Page 291: Change Transmission Oil
MAINTENANCE Change Transmission Oil --- every 1000 hours (500 hours at first change only) Clean Transmission Strainer ---every 1000 hours WARNING:  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.
Page 292 MAINTENANCE 5. Prepare a container of more than 50 L capacity to receive the drain oil. NOTE: Drain plug (5) is magnetized. If excessive amount of 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.
Page 293: Replace Transmission Oil Filter
MAINTENANCE Replace Transmission Oil Filter --- every 500 hours WARNING: 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 (4).
Page 294: Change Axle Oil
MAINTENANCE Change Axle Oil --- every 2000 hours WARNING: 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.
Page 295: Check Oil Level
MAINTENANCE Check Oil Level 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work. 2. Install articulation lock bar to the front and rear of the frame by following the procedures described on page 7-9.
Page 296: Check Surroundings Around Axle And Covers For Oil Leaks
MAINTENANCE Check Surroundings Around Axle and Covers for Oil Leaks --- every 1000 hours 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. MNDF-07-009 Clean Axle Housing Air Breather --- every 500 hours...
Page 297: Hydraulic System
MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment 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.
Page 298  When adding hydraulic oil, always use the same brand of oil; do not mix brands of oil. As the machine is filled with Hitachi Genuine Hydraulic Oil 5000 when it is shipped from the factory, use it as a general rule.
Page 299: Check Hydraulic Oil Level
MAINTENANCE Check Hydraulic Oil Level --- every 10 hours 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.
Page 300: Change Hydraulic Oil/Clean Hydraulic Oil Tank
MAINTENANCE Change Hydraulic Oil/Clean Hydraulic Oil Tank --- every 2000 hours Changing and cleaning procedure WARNING: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if the skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
Page 301: Bleed Air From The Hydraulic System
MAINTENANCE 6. Supply hydraulic oil through cover (3) hole on the hydraulic oil tank while checking the oil level at level gauge (10). Capacity of hydraulic oil tank : 80 liters (21 gallons) Total capacity in the hydraulic system : 150 liters (40 gallons) 7.
Page 302: Clean Suction Filter
MAINTENANCE Clean Suction Filter --- each time the hydraulic oil is changed. Two suction filters are located on the bottom of the hydraulic oil tank. Clean the suction filters when changing hydraulic oil. 1. After draining hydraulic oil, remove covers (2). Pull down to take out suction filters (3).
Page 303: Replace Pilot Oil Filter
MAINTENANCE Replace Pilot Oil Filter --- every 2000 hours Replace WARNING: 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.
Page 304 MAINTENANCE 9. Take care never to allow water and/or dust to enter the filter case. 10. Install case (2) into head cover (3) while rotating case (2) clockwise. Tightening torque: 20 to 30 N·m (2 to 3 kgf·m) (14.7 to 22 lbf·ft) 11.
Page 305: Replace Hydraulic Tank Oil Filter
MAINTENANCE Replace Hydraulic Tank Oil Filter --- every 1000 hours Replace WARNING: 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.
Page 306 MAINTENANCE 11. 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.
Page 307: Replace Hst Charge Filter
MAINTENANCE Replace HST Charge Filter --- every 500 hours Replace WARNING: 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.
Page 308: Replace Air Breather Element
MAINTENANCE Replace Air Breather Element --- every 2000 hours WARNING: 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.
Page 309: Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, And Damage
MAINTENANCE Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage --- every 2000 hours WARNING:  Allow only qualified personnel to handle the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator. Caution is required to prevent fires from occurring.
Page 310: Replace Pilot Circuit Accumulator
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 --- every 500 hours WARNING:  Allow only qualified personnel to handle the MNDF-07-015 accumulator.
Page 311: Check Hoses And Lines
MAINTENANCE Check Hoses and Lines --- every 10 hours (daily) / every 250 hours WARNING: Escaping fluid under pressure can penetrate the skin causing serious injury. To avoid this hazard, search for leaks with a piece of cardboard. Take care to protect hands and body from high-pressure fluids.
Page 312 MAINTENANCE Hose Interval Check Points Abnormalities Remedies (hours) Hose covers Leak (1) Replace Hose ends Leak (2) Replace Every 10 hours Fittings Leak (3) Retighten or replace hose or O-ring M137-07-008 Hose covers Leak (4) Replace Hose ends Leak (5) Replace Hose covers Exposed reinforcement...
Page 313 MAINTENANCE Interval Check Points Abnormalities Remedies (hours) Contact surfaces of Leak (11) Replace flange joints 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)
Page 314 MAINTENANCE Service Recommendations for Hydraulic Fittings Two hydraulic fitting designs are used on this machine. Flat Face O-ring Seal Fitting (ORS Fitting) An O-ring is used on the sealing surfaces to prevent oil leakage. 1. Inspect fitting sealing surfaces (6). They must be free of M104-07-033 dirt or defects.
Page 315 MAINTENANCE Metal Face Seal Fittings 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.
Page 316: Fuel System
MAINTENANCE E. Fuel System Check Fuel Level --- every 10 hours (daily) DANGER: Beware of fire Fuel is flammable. Keep fuel away from fire hazards. IMPORTANT: Always fill the fuel tank with the specified diesel fuel. Failure to do so may cause engine trouble and also making it difficult for the engine to start.
Page 317 MAINTENANCE Refueling 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down. DANGER: Handle fuel carefully. Shut the engine off before fueling.
Page 318: Drain Water And Sediment From Fuel Tank
MAINTENANCE Drain Water and Sediment from Fuel Tank --- every 1000 hours 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 tank.
Page 319: Drain Fuel Filter
MAINTENANCE Drain Fuel Filter --- every 10 hours (daily) IMPORTANT: Drain fuel filter daily before starting operation. The engine may be damaged if you do not drain fuel filter daily. Fuel pre-filter (1) has water separator function, which drains water. Drain water when the engine trouble indicator flashes.
Page 320: Replace Fuel Main Filter Element
Replace Fuel Main Filter Element ---every 500 hours 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 deteriorate the engine performance and/or shorten the engine service life.
Page 321: Replace Fuel Pre-Filter Element
Replace Fuel Pre-Filter Element ---every 500 hours IMPORTANT:  Be sure to use only genuine Hitachi elements for the main fuel filter and the pre-filter. Failure to do so may deteriorate the engine performance and/or shorten the engine service life. Please note that all engine failures caused by using other manufacturers' elements are excluded from Hitachi Warranty Policy.
Page 322: Clean Fuel Solenoid Pump Strainer
MAINTENANCE Clean Fuel Solenoid Pump Strainer --- every 1000 hours Cleaning When the strainer is disassembled, be sure to replace the gasket. Install the cover and the magnet only after sufficiently cleaning them. After being assembled, closely check the air-tightness of the strainer. MPTC-07-004 Disassembling/ Assembling To remove cover (1), loosen it with a spanner.
Page 323: Check Fuel Hoses
MAINTENANCE Check Fuel Hoses --- every 10 hours (daily) / every 250 hours WARNING: Fuel leaks can lead to fires that may result in serious injury. 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.
Page 324: Air Cleaner
MAINTENANCE F. Air Cleaner Clean and Replace Air Cleaner Element Clean --- when the monitor indicator is lit. Replace --- after cleaning six times or after one year. Air cleaner (1) is comprised of double elements, the outer element and inner element. 1.
Page 325: Cooling System
Coolant Use soft water or demineralized water as a coolant. Do not use strongly acid or strongly alkaline water. Use the coolant with Hitachi genuine coolant mixed by 50 %. Precautions for handling antifreeze WARNING: Antifreeze is poisonous.  Antifreeze is poisonous; if ingested, it can cause serious injury or death.
Page 326: Check Coolant Level
MAINTENANCE Check Coolant Level --- every 10 hours (daily) (before starting the engine) WARNING: 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).
Page 327: Check Drive Belt
MAINTENANCE Check Drive Belt --- every 10 hours Check the drive belt for any abnormality. If any cracks are found, replace the belt with a new one. 7-75...
Page 328: Check Drive Belt Tensioner
MAINTENANCE Check Drive Belt Tensioner --- every 1000 hours or once a year 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work. 2. Install articulation lock bar to the front and rear of the frame by following the procedures described on page 7-9.
Page 329: Change Coolant
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. 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work.
Page 330: Clean Radiator/Oil Cooler And Other Cooling System
MAINTENANCE Clean Radiator/Oil Cooler and Other Cooling System --- every 500 hours or when the core is clogged. CAUTION: Wear goggles or safety glasses when using compressed air [less than 0.2 MPa (2 kgf/cm ) (30 psi)]. IMPORTANT: If compressed air with the pressure of more than 0.2 MPa (2 kgf/cm ) (30 psi) or tap water with high delivery pressure is used for cleaning, damage to the...
Page 331: Electrical System
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. Also, improper installation of electrical equipment may cause machine failure and/or a fire on the machine.
Page 332 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: 1.
Page 333 MAINTENANCE Electrolyte Level Check --- every 100 hours 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.
Page 334 MAINTENANCE Check Electrolyte Specific Gravity --- every 250 hours WARNING: If you spill acid on yourself, call 911, then:  Battery gas can explode. Keep sparks and flames 1. Flush your skin with water. away from batteries. 2. Apply baking soda or lime to help neutralize the acid.
Page 335: Check Monitor Functions And All Other Instrument Operation
MAINTENANCE Replace Batteries IMPORTANT: Before adjusting the electrical system or welding on the machine, disconnect the negative (-) wiring from the battery. If the machine is equipped with the battery disconnect switch, turn the disconnect switch OFF. Your machine has two 12-volt batteries with negative (-) ground.
Page 336: Check Lights
MAINTENANCE Check Lights --- every 10 hours (daily) CAUTION: If any burned-out light is found, immediately replace it with a new one. Visually check all lights that they normally light and/or flash from the front and rear sides of the machine. MNDF-07-029 MPTC-01-007 Check Horn and Reverse Buzzer...
Page 337: Check Electrical Harnesses And Fuses
MAINTENANCE Check Electrical Harnesses and Fuses --- every 50 hours CAUTION: 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).
Page 338 MAINTENANCE Fuse Box A 10- PARKING 20- OPTION 4 (ACC3) (10 A) 9- AC1 19- OPTION 3 (ACC2) 10 A (15 A) 8- STOP LAMP 18- DEF HEATER 15 A 7- BACK ALARM 17- DEF SUPPLY 15 A 6- HST 2 16- DEF SENSOR 15 A 5- HEAD LAMP LH...
Page 339: Brake System
MAINTENANCE I. Brake System Check Right and Left Brake Interlocking Performance --- every 10 hours (daily) WARNING:  Put up a no admission notice for the range of 100 m ahead in the forward machine travel direction. Arrange a safety monitor person. ...
Page 340: Check Parking Brake Force
MAINTENANCE Check Parking Brake Force --- every 10 hours (daily) WARNING: Check the machine in a place where no one is present or ahead in the traveling direction. Keep bystanders away from the machine. Park the machine with no load applied on a 20 % (11.3°) inclining dry surface slope.
Page 341: Check Accumulator Function, Gas Leakage, Looseness, And Damage
MAINTENANCE Check Accumulator Function, Gas Leakage, Looseness, and Damage --- every 500 hours WARNING:  Allow only qualified personnel to handle the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator. Caution is required to prevent fires from occurring. ...
Page 342: Check Gas Pressure In Accumulator
MAINTENANCE Check Gas Pressure in Accumulator --- every 2000 hours Check the gas pressure at a regular interval. If the machine is operated with the gas pressure lower than specified value, normal brake operation and/or loading operation may not be achieved, possibly creating very hazardous situations.
Page 343: Tire
MAINTENANCE J. Tire Check and Replace Tire (Tire Pressure) Check appearance --- every 10 hours (daily) Replace --- as necessary WARNING:  Secure the front and rear frames with the articulation lock bar and pins.  When inflating tires, stand behind the tread and use the self-attaching chuck.
Page 344: Check Wheel Bolt Torque
MAINTENANCE Check Wheel Bolt Torque --- every 500 hours (50 hours at first time only) (Right) (Wrong) Be sure to check the wheel bolt torque by turning the bolt in the tightening direction. Tightening torque: 890 N·m (91 kgf·m) (655 lbf·ft) Replace Tire WARNING: Secure the front and rear frames with the articulation lock bar and pins.
Page 345 MAINTENANCE Applicable Tire Size NOTE: Consult your authorized Hitachi dealer for tread pattern of optional tires. The machine may vibrate while driving depending on the tread pattern of tires. This is a sympathetic vibration due to tread pattern, not a malfunction.
Page 346 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 WARNING: Install a tire with no external damage such as score and abnormal wear.
Page 347: Removal And Installation Of Tire
MAINTENANCE Removal and Installation of Tire WARNING: Wheel with tire is a very heavy part so that removal and installation of a tire is hazardous and difficult work. In addition, a crane to lift a tire is required when removing or installing the tire to the wheel.
Page 348: Air Conditioner
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) NOTE: In case the machine is operated at a dusty job site, clean or replace the filter element earlier than the normal interval.
Page 349 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.
Page 350 MAINTENANCE Clean and Replace Double Filter (Optional) --- 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.
Page 351 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). CAUTION: When using compressed air pressure, wear safety glasses or goggles.
Page 352: Check Air Conditioner
MAINTENANCE Check Air Conditioner --- every 6 months Check the air conditioner switch panel, air conditioner unit, and condenser mounting areas for any abnormality, and check hoses for any damage. NOTE: When the season to use the air conditioner comes close, check the air conditioner to get it ready to use at all times.
Page 353: Check Air Conditioner Condenser
MAINTENANCE Check Air Conditioner Condenser --- every 6 months If condenser (1) is covered with dirt and/or insects, air conditioner cooling performance will be reduced. Remove dirt or stain from fins of condenser (1) using tap water. In case the condenser has been severely contaminated, use a soft brush.
Page 354: Check Refrigerant
MAINTENANCE Check Refrigerant --- every 6 months Start the engine and run at approximately 1500 min (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.
Page 355: Miscellaneous
MAINTENANCE L. Miscellaneous Check Bucket Teeth and Cutting Edge --- every 10 hours (daily) Check bucket teeth for wear and looseness. Replace WARNING: Guard against injury from flying pieces of metal. Wear goggles or safety glasses, hard hat and face shield.
Page 356: Check And Replace Seat And Seat Belt
MAINTENANCE Check and Replace Seat and Seat Belt Check appearance --- every 10 hours (daily) Replace --- every 3 years Examine buckle (1), attaching hardware (2) and seat belt web. Replace the seat belt web, buckle, or attaching hardware if they are damaged, or worn.
Page 357: Check Play Amount In Steering Wheel Stroke
MAINTENANCE Check Play Amount in Steering Wheel Stroke --- every 10 hours (daily) WARNING: When the steering wheel is turned, the clearance between the front and rear frames becomes narrower, possibly creating a hazardous situation such as entanglement of limbs. Keep any personnel away from the frame articulation point during inspection.
Page 358: Check Accelerator Pedal Operation, And Exhaust Gas Color And Noise
MAINTENANCE Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise --- every 10 hours (daily) WARNING: Move the forward/reverse lever to neutral. Apply the parking brake. After 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.
Page 359: Check Rearview Mirror And Inside Rearview Mirror
MAINTENANCE Check Rearview Mirror and Inside Rearview Mirror --- every 10 hours (daily) Check that the inside of rearview mirror (1) and rearview mirror (2) are facing a correct direction. Check inside rearview mirror (1) and rearview mirror (2) for contamination or damage.
Page 360: Clean Engine Compartment And Hood
MAINTENANCE Clean Engine Compartment and Hood --- every 10 hours (daily) CAUTION: 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.
Page 361: Check And Adjust Valve Clearance
MAINTENANCE Check and Adjust Valve Clearance --- every 5000 hours Consult your authorized dealer for check and repair. Retighten Front Axle and Rear Axle Support Mounting Bolts --- every 2000 hours (50 hours at first time only) Check front and rear axle support mounting bolts for looseness.
Page 362: Tightening And Retightening Torque Of Nuts And Bolts
13 Counterweight mounting bolt 1510 (154, 1115) 14 Top center pin upper flange lock *210 (21, 155) 15 Bottom center pin lock 210 (21, 155) ZW140-6 210 (21, 155) ZW150-6 90 (9, 66) 16 Loader front pin lock 90 (9, 66)
Page 363 MAINTENANCE Tightening Torque Chart Hexagon Wrench Socket Bolt Bolt Dia. Wrench Size Wrench Size Socket Bolt mm (in) N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft) 3.3 to 4.2 6 (0.24) (2.4 to 3.1) 8 (0.31) (22) (14.8) (7.4) (14.8) 10 (0.39) (48) (36.9)
Page 364 MAINTENANCE 1. Front axle mounting bolt & nut (Double) Bolt dia. mm (in) 24 (0.9) Quantity Nut dia. mm (in) 24 (0.9) Quantity MPTC-07-046 2. Rear axle support mounting bolt Front Rear Bolt dia. mm (in) 20 (0.8) 24 (0.9) Quantity Rear Front...
Page 365 MAINTENANCE 4. Propeller shaft mounting bolt Bolt dia. mm (in) 10 (0.4) Quantity NOTE: Apply LOCTITE#262 or equivalent. M4FC-07-066 5. Propeller shaft support bearing mounting bolt Bolt dia. mm (in) 16 (0.6) Quantity M4FC-07-011 6. Transmission mounting bolt: Bracket Bolt dia. mm (in) 16 (0.6) Quantity NOTE: Apply LOCTITE#262 or equivalent.
Page 366 MAINTENANCE 7. Transmission mounting bolt: Cushion rubber Bolt dia. mm (in) 18 (0.7) Quantity MNDF-07-040 8. HST motor mounting bolt Bolt dia. mm (in) 16 (0.6) Quantity MNDF-07-041 9. HST pump mounting bolt Bolt dia. mm (in) 16 (0.6) Quantity MPTC-07-043 7-114...
Page 367 MAINTENANCE 10. Engine mounting bolt: Bracket Front Rear Bolt dia. mm (in) 12 (0.5) 12 (0.5) Quantity NOTE: Apply LOCTITE#262 or equivalent. MPTC-07-028 MPTC-07-029 11. Engine mounting bolt: Cushion rubber Bolt dia. mm (in) 16 (0.6) Quantity MPTC-07-029 7-115...
Page 368 MAINTENANCE 12. Aftertreatment device mounting nut (Double) Nut dia. mm (in) 10 (0.4) Quantity MPTC-07-035 MPTC-07-036 13. Counterweight mounting bolt Bolt dia. mm (in) 30 (1.2) Quantity MPTC-01-007 14. Top center pin upper flange lock Bolt dia. mm (in) 16 (0.6) Quantity NOTE: Apply LOCTITE#262 or equivalent.
Page 369 MAINTENANCE 15. Bottom center pin lock Bolt dia. mm (in) 16 (0.6) Quantity MNDF-07-046 16. Loader front pin lock ZW140/150-6 ZW150PL-6 Bolt dia. mm (in) 16 (0.6) 12 (0.5) 16 (0.6) 12 (0.5) Quantity ZW140/150-6 M4FC-07-075 M4GB-07-180 ZW150PL-6 17. Steering cylinder pin lock Bolt dia.
Page 370 MAINTENANCE 18. Radiator frame mounting bolt Bolt dia. mm (in) 16 (0.6) Quantity NOTE: Apply LOCTITE#262 or equivalent. MPTC-07-030 19. Radiator mounting bolt Bolt dia. mm (in) 8 (0.3) Quantity MPTC-07-031 20. Intercooler mounting bolt Bolt dia. mm (in) 8 (0.3) Quantity MPTC-07-032 7-118...
Page 371 MAINTENANCE 21. Oil cooler mounting bolt Bolt dia. mm (in) 10 (0.4) Quantity MPTC-07-031 MPTC-07-037 22. Air conditioner condenser mounting bolt Bolt dia. mm (in) 8 (0.3) Quantity MPTC-07-033 7-119...
Page 372 MAINTENANCE 23. Air conditioner compressor mounting bolt Bolt dia. mm (in) 8 (0.3) Quantity MPTC-07-034 24. Cab cushion rubber mounting bolt Bolt dia. mm (in) 16 (0.6) Quantity NOTE: Apply LOCTITE#262 or equivalent. MNDF-07-052 25. Bucket tooth mounting bolt (Optional) Bolt dia.
Page 373 MAINTENANCE 26. Cutting edge mounting bolt Bolt dia. in 1" Quantity M4GB-07-116 7-121...
Page 374: Aftertreatment Device
MAINTENANCE M. Aftertreatment Device Check and Clean Aftertreatment Device --- as required IMPORTANT:  Check and clean flammable materials on the area around the Aftertreatment device.  Condensation for dew may blow out from the exhaust outlet of the aftertreatment device and black deposition may be observed;...
Page 375: Urea Scr System
MAINTENANCE N. Urea SCR System WARNING: 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®...
Page 376 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®...
Page 377: Check Def/Adblue
MAINTENANCE Check DEF/AdBlue® --- every 10 hours (daily) Park the machine on a level surface. Lower the bucket to the ground. Check the DEF/AdBlue® level with DEF/AdBlue® gauge (1). If necessary, stop the engine and add DEF/AdBlue®. Refill DEF/AdBlue® CAUTION: ...
Page 378 MAINTENANCE 5. Install cap (3) after refilling DEF/AdBlue®. Close the DEF/ AdBlue® tank cover. IMPORTANT:  Do not get on top of DEF/AdBlue® tank (2) or sensors and piping on the tank. Failure to do so may damage the machine.  White deposits may be observed when DEF/AdBlue®...
Page 379 MAINTENANCE Change DEF ---As required CAUTION: Wear safety equipment such as safety glasses or goggles, rubber gloves appropriate to the job. Wash DEF with clean water when it contacts with the skin. If DEF is accidentally splashed into eyes, flush with water for 15 minutes or longer and get emergency medical attention.
Page 380: Replace Def/Adblue® Supply Module Main Filter
MAINTENANCE Replace DEF/AdBlue® Supply Module Main Filter DEF/AdBlue® Supply Module --- every 4500 hours A filter (2) is mounted in the DEF/AdBlue® supply module. Periodically replace filter (2). CAUTION: Use rubber glove for protection during operation. Wash DEF/AdBlue® with clean water when it contacts on the skin.
Page 381: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions WARNING:  Before operating the machine in a river, check the riverbed conditions in advance.  Avoid driving the machine into a river where the riverbed is steep and deep or the current is strong. Operating Conditions Precautions for Maintenance Muddy Soil, Rainy or...
Page 382: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Precautions for Maintenance During Cold Weather Season Before the atmospheric temperature becomes down below -0 °C, practice the following points.  Water and oil in the machine will freeze.  Road surfaces will freeze so that tires may slip. Keeping the above points in mind, follow the advices below: 1.
Page 383 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS DANGER: Sufficiently ventilate when carrying out warming up operation indoors. Failure to do so may cause intoxication by exhaust gas, possibly resulting in personal death accident. 7. After preheating the engine, start the engine. Sufficiently perform warm-up operation.
Page 384 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 385: Storage
STORAGE Storing the Machine WARNING: In case lubrication operation is unavoidably performed indoors, open windows and doors to maintain good air ventilation to prevent asphyxiation. Lubricant property will deteriorate even if the machine is kept stored. Check all lubricants before operating the machine after being stored. Apply the parking brake while storing.
Page 386 STORAGE Taking the Machine Out of Storage WARNING: If it is unavoidable to perform the lubrication operation indoors, open windows and doors to maintain good air ventilation to prevent asphyxiation. Lubricant property will deteriorate even if the machine is kept stored. Check all lubricants before operating the machine after being stored.
Page 387 STORAGE 1. Remove covers. 2. Remove grease from the cylinder rods if coated. 3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels. 4. Adjust alternator and fan belt tension. 5. Check the oil level. Add oil as needed. 6.
Page 388 STORAGE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................10-4...
Page 389: Troubleshooting
TROUBLESHOOTING Troubleshooting If any abnormality is found on the machine, immediately take action to solve it. Find out the cause of the abnormality to prevent the recurrence of malfunction. If the cause of malfunction is unknown or for inquiry on solution item with mark "*" on the list below, consult your authorized dealer.
Page 390 TROUBLESHOOTING Engine does not Start. Symptom Cause Solution The starter does not turn. Reduced battery voltage Charge the batteries. Replace. High resistance in the starter circuit * Clean and/or retighten the battery terminals and starter terminals Faulty key switch * Replace Damaged wire harness * Repair, Replace Faulty battery relay...
Page 391 TROUBLESHOOTING Hydraulic System After the machine has been kept stored for a long time, air in the oil may be separated and accumulate in the upper section in the cylinder, causing slow response time in operation or reducing cylinder power. In case these symptoms appear, repeatedly operate all actuators several times.
Page 392 TROUBLESHOOTING Drive Function Steering System Symptom Cause Solution Steering wheel is heavy to operate. Faulty hydraulic pump * Repair, Replace Faulty steering device * Repair, Replace Relief valve set pressure reduction *Adjust Faulty steering column * Repair, Replace Steering wheel turns in unexpected Faulty steering device * Repair, Replace direction.
Page 393 TROUBLESHOOTING Service Brake Symptom Cause Solution Service brake does not work properly Malfunction of brake valve * Repair, Replace Oil leak from brake line, Air mixing * Repair, Bleed air Brake is dragged Malfunction of brake valve * Repair, Replace Faulty brake pedal * Repair, Replace Lack of brake fluid (hydraulic oil)
Page 394 TROUBLESHOOTING MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................11-6...
Page 395: Specifications
SPECIFICATIONS SPECIFICATIONS Specifications 45 ° 50 ° 40 ° MPTC-12-001 Model ZW150-6 ZW140-6 Bucket Capacity: heaped *2.4 (3.1) *2.1 (2.7) Operating Weight kg (lbs) 12250 (27010) 11630 (25640) Tipping Load (full turn) kg (lbs) 9070 (20000) 7990 (17700) Engine CUMMINS QSB4.5 A: ...
Page 396 SPECIFICATIONS Specifications 45 ° 50 ° 40 ° MPTC-12-002 Model ZW150PL-6 Bucket Capacity: heaped *2.1 (2.7) Operating Weight kg (lbs) 13100 (28880) Tipping Load (full turn) kg (lbs) 7760 (17200) Engine CUMMINS QSB4.5 A: Overall Length mm (in) 7875 (310) B: Overall Width (Bucket) mm (in) 2535 (100)
Page 397: Optional Attachments
OPTIONAL ATTACHMENTS Hydraulic Type Quick Coupler Operation Hydraulic Type Quick Coupler Operation ZW140/150-6 A quick coupler is a system by which a front attachment work tool such as a bucket can be easily replaced with other type of a work tool. WARNING: During replacement work, keep personnel away from the machine.
Page 398 OPTIONAL ATTACHMENTS Hydraulic Type Quick Coupler Operation Installation WARNING: Complete installation work only after checking that both right and left coupler pins (1) have been correctly installed. WARNING: Before leaving the machine apply the parking brake. 1. After checking that coupler pin (1) is removed, slowly bring the machine close to bucket (attachment) hook (3) and install the quick coupler to the hook.
Page 399 OPTIONAL ATTACHMENTS Hydraulic Type Quick Coupler Operation Hydraulic Type Quick Coupler Operation ZW150PL-6 A quick coupler is a system by which a front attachment work tool such as a bucket can be easily replaced with other type of a work tool. WARNING: During replacement work, keep personnel away from the machine.
Page 400 OPTIONAL ATTACHMENTS Hydraulic Type Quick Coupler Operation Installation WARNING: Before leaving the machine apply the parking brake. 1. After checking that coupler pin (1) is removed, slowly bring the machine close to bucket (attachment) hook (3) and install the quick coupler to the hook. 2.
Page 401 OPTIONAL ATTACHMENTS Hydraulic Type Quick Coupler Operation Disconnecting/connecting hydraulic hose When activating an attachment with a hydraulic cylinder other than the lift arm cylinder or bucket cylinder using the machine hydraulic pressure oil, hydraulic hoses must be connected or disconnected. At this time, connect or disconnect the hydraulic hoses following the procedures below.
Page 402 OPTIONAL ATTACHMENTS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................13-6...
Page 403: Index
INDEX 1st Speed Select Switch ............. 1-63 Bleed Air from the Hydraulic System........7-49 Brake Oil Low Pressure Indicator (Red) ......... 1-13 Brake System .................. 7-87 About Aftertreatment Device .............1-4 Brake/Inching Pedal ..............1-61 Accelerator Pedal ................1-61 Break-in Period for New Machine ..........2-1 Adjust Operator’s Seat ..............S-6 Bucket Auto Leveler................5-9 Adjusting Operator’s Seat (Air Suspension Type Seat) ..
Page 404 INDEX Check Pilot Circuit Accumulator Function, Gas Leakage, Door Lock Knob ................1-106 Looseness, and Damage............7-57 Door Open/Close Lever ............1-106 Check Play Amount in Steering Wheel Stroke ....7-105 Dozing ....................5-21 Check Rearview Mirror and Inside Rearview Mirror ..7-107 Drain Fuel Filter ................7-67 Check Refrigerant ...............7-102 Drain Water and Sediment from Fuel Tank......
Page 405 INDEX General Precautions for the Cab ..........S-5 MAINTENANCE .................7-1 Getting ON/OFF the Machine .............1-3 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL Grading .................... 5-17 CONDITIONS ................9-1 Greasing ................... 7-25 Machine Information Display ........... 1-30 Maintenance Indicator (Yellow) ..........1-22 Maintenance Under Special Environmental Conditions ...9-1 Handle Chemical Products Safely ...........
Page 406 INDEX Precautions for Maintenance During Cold Weather Seat Belt Indicator (Red) ............1-18 Season ....................9-2 Seat Pocket ...................1-116 Precautions for Operation ..........S-19, 5-13 Secondary Steering (Optional) ...........4-7 Precautions for Welding and Grinding ......... S-32 Secondary Steering Indicator (Yellow) (Optional) .... 1-18 Precautions to be Taken if Machine Failure Occurs ..
Page 407 INDEX Understand Signal Words .............S-1 Upper Switch Panel ..............1-104 Urea SCR System .................7-123 Urea SCR System Malfunction ..........1-29 Urea Warning Indicator (Red) ........... 1-14 Use Handrails and Steps ...............S-6 Using Booster Batteries ..............3-9 Using Cigar Lighter ..............1-85 Vandal-Proof Devices ..............1-114 Warm Up ..................
Page 408 INDEX MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................14-6...

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Zw150-6 Zw150pl-6

Hitachi ZW140-6 Operator's Manual

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