Hitachi ZW 550-6 User manual

550-6
ENMNHK-NA1-1ZW550-6 WHEEL LOADER OPERATOR'S MANUAL
PRINTED IN JAPAN (T) 2018, 03
URL:http://www.hitachi-c-m.com
ENMNHK-NA1-1
PART NO.
Wheel Loader
Operator's Manual
Serial No. 005201 and up
This book is printed on recycled paper.

©2018 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
INTRODUCTIONINTRODUCTION
Read this manual carefully to learn how to operate and
service your machine correctly. Failure to do so could
result in personal injury or machine damage.
This standard specification machine can be operated
under the following conditions without being modified.
Atmospheric Temperature: -20 °C to 45 °C (-4 °F to 113 °F)
Altitude: 0 m to 2000 m (0 ft to 6600 ft)
In case the machine is used under conditions other than
described above, consult your authorized dealer.
This manual should be considered a permanent part of
your machine and should remain with the machine when
you sell it.
This machine is of metric design. Measurements in this
manual are metric. Use only metric hardware and tools as
specified.
Right-hand and left-hand sides are determined by
facing in the direction of forward travel.
Write product identification numbers in the Machine
Numbers section. Accurately record all the numbers
to help in tracing the machine should it be stolen.
Your dealer also needs these numbers when you order
parts. If this manual is kept on the machine, also file the
identification numbers in a secure place off the machine.
Use only diesel fuel with quality specified in JIS K-2204,
EN-590 or ASTM D-975 which contents 15 ppm or lower
sulfur.
Also use fuel that complies with solid contamination level
of class 18/16/13 of ISO4406-1999 (solid contamination
includes dust). If the fuel specified above is not used,
exhaust gas that exceeds the regulation values may be
discharged, causing serious problem on the engine.
Consult your authorized dealer.
Warranty is provided as a part of Hitachi’s support
program for customers who operate and maintain their
equipment as described in this manual. The warranty is
explained on the warranty certificate which you should
have received from your dealer.
This warranty provides you with the assurance that
Hitachi will back its products where defects appear within
the warranty period. In some circumstances, Hitachi also
provides field improvements, often without charge to the
customer, even if the product is out of warranty.
Should the equipment be abused, or modified to
change its performance beyond the original factory
specifications, the warranty will become void and field
improvements may be denied.
Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
Only qualified, experienced operators officially licensed
(according to local law) should be allowed to operate
the machine. Moreover, only officially licensed personnel
should be allowed to inspect and service the machine.
PRIOR TO OPERATING THIS MACHINE, INCLUDING
COMMUNICATION SYSTEM, IN A COUNTRY OTHER
THAN A COUNTRY OF ITS INTENDED USE, IT MAY
BE NECESSARY TO MAKE MODIFICATIONS TO IT SO
THAT IT COMPLIES WITH THE LOCAL REGULATORY
STANDARDS (INCLUDING SAFETY STANDARDS)
AND LEGAL REQUIREMENTS OF THAT PARTICULAR
COUNTRY. PLEASE DO NOT EXPORT OR OPERATE
THIS MACHINE OUTSIDE OF THE COUNTRY OF ITS
INTENDED USE UNTIL SUCH COMPLIANCE HAS
BEEN CONFIRMED. PLEASE CONTACT HITACHI
CONSTRUCTION MACHINERY CO., LTD. OR ANY OF
OUR AUTHORIZED DISTRIBUTOR OR DEALER IF YOU
HAVE ANY QUESTIONS CONCERNING COMPLIANCE.
In this manual, urea water is indicated as DEF/AdBlue®.
“DEF” stands for the Diesel Exhaust Fluid. AdBlue®
is a registered trademark of the Verband der
Automobilindustrie e.V. (VDA).
All information, illustrations and specifications in this manual are based on the latest product information available at the
time of publication. The right is reserved to make changes at any time without notice.

T
MACHINE NUMBERS
SAFETY
SAFETY LABELS
COMPONENTS NAME
OPERATOR’S STATION
BREAK-IN
OPERATING THE ENGINE
MOVING THE MACHINE
OPERATING THE MACHINE
TRANSPORTING
MAINTENANCE
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
SPECIFICATIONS
INDEX
INDEX
ENMNHK-NA1-1
TROUBLESHOOTING

CONTENTS
MACHINE NUMBERS .........................................................1
SAFETY .......................................................................... S-1
Recognize Safety Information ....................................................S-1
Understand Signal Words.............................................................S-1
Follow Safety Instructions............................................................S-2
Prepare for Emergencies...............................................................S-3
Wear Protective Clothing..............................................................S-3
Protect Against Noise ....................................................................S-4
Inspect Machine ..............................................................................S-4
General Precautions for Cab........................................................S-5
Use Handrails and Steps ...............................................................S-6
Never Ride Attachment.................................................................S-6
Adjust Operator’s Seat...................................................................S-6
Ensure Safety Before Rising from or Leaving Operator’s
Seat .................................................................................................S-7
Fasten Your Seat Belt......................................................................S-7
Move and Operate Machine Safely...........................................S-8
Handle Starting Aids Safely .........................................................S-8
Operate Only from Operator’s Seat ..........................................S-9
Jump Starting ...................................................................................S-9
Investigate Job Site Beforehand ............................................. S-10
Equipment of Head Guard, ROPS, FOPS............................... S-11
Provide Signals for Jobs Involving Multiple Machines.... S-11
Keep Riders Off Machine ........................................................... S-12
Drive Safely..................................................................................... S-12
Drive Machine Safely (Work Site)............................................ S-13
Drive Safely with Bucket Loaded ............................................ S-14
Drive on Snow Safely .................................................................. S-14
Travel on Public Roads Safely................................................... S-15
Avoid Injury from Rollaway Accidents.................................. S-15
Avoid Accidents from Backing Up and Turning ................ S-16
Avoid Positioning Bucket or Attachment Over
Anyone........................................................................................ S-17
Avoid Tipping................................................................................. S-17
Never Undercut a High Bank.................................................... S-18
Dig with Caution........................................................................... S-18
Perform Truck Loading Safely .................................................. S-18
Avoid Power Lines........................................................................ S-19
Precautions for Operation......................................................... S-19
Precautions for Lightning.......................................................... S-19
Object Handling ........................................................................... S-20
Protect Against Flying Debris .................................................. S-20
Park Machine Safely..................................................................... S-21
Store Attachments Safely.......................................................... S-21
Transport Safely ............................................................................ S-22
Handle Fluids Safely−Avoid Fires............................................S-23
Practice Safe Maintenance ....................................................... S-24
Warn Others of Service Work ................................................... S-25
Support Machine Properly........................................................ S-25
Stay Clear of Moving Parts ........................................................ S-26
Support Maintenance Properly............................................... S-26
Prevent Parts from Flying .......................................................... S-27
Prevent Burns................................................................................. S-27
Replace Rubber Hoses Periodically........................................ S-28
Avoid High-Pressure Fluids....................................................... S-28
Prevent Fires................................................................................... S-29
Evacuating in Case of Fire.......................................................... S-30
Beware of Exhaust Fumes..........................................................S-31
Precautions for Welding and Grinding ................................. S-31
Avoid Heating Near Pressurized Fluid Lines....................... S-31
Avoid Applying Heat to Lines Containing Flammable
Fluids ........................................................................................... S-32
Precautions for Handling Accumulator and Gas
Damper....................................................................................... S-32
Precautions for Diesel Exhaust Fluid (DEF).......................... S-32
Remove Paint Before Welding or Heating........................... S-33
Beware of Asbestos and Silicon Dust and Other
Contamination......................................................................... S-33
Prevent Battery Explosions ....................................................... S-34
Service Air Conditioning System Safely ............................... S-34
Handle Chemical Products Safely........................................... S-35
Dispose of Waste Properly......................................................... S-35
Notes on Aftertreatment Device ............................................ S-36
Precautions for Communication Terminal........................... S-36
Precaution for Communication Terminal Equipment ..... S-37
Articulation Stopper (Lock Bar)............................................... S-38
Joystick Steering System ON/OFF .......................................... S-39
ROPS (Roll Over Protective Structure)................................... S-40
SAFETY LABELS........................................................... S-41
COMPONENTS NAME.................................................... 1-1
Components Name ........................................................................1-1
OPERATOR’S STATION .................................................. 1-3
Aftertreatment Device...................................................................1-3
Automatic Regeneration .............................................................1-5
Repeated Inhibiting of Exhaust Filter Cleaning ..............1-6
Cab Features......................................................................................1-7
Front Console....................................................................................1-8
Joystick Steering..............................................................................1-9
Right Console.................................................................................1-10
Fingertip Control Type ..........................................................1-10
Multi-Function Joystick Type .............................................. 1-11
Monitor Panel ................................................................................1-12
Parking Brake Indicator (Red)...................................................1-13
Brake Oil Low Pressure Indicator (Red)................................. 1-13
Hydraulic Oil Level Indicator (Red)......................................... 1-13
Low Steering Oil Pressure Indicator (Option) (Red) .........1-14
Transmission Warning Indicator (Red)..................................1-14
Communication Error Indicator (Yellow) ............................. 1-14
Discharge Warning Indicator (Red)........................................1-14
Engine Warning Indicator (Red)..............................................1-15
Overheat Indicator (Red) ...........................................................1-15
Engine Oil Low Pressure Indicator (Red) ..............................1-15
Air Filter Restriction Indicator (Red)....................................... 1-16
Preheat Indicator (Yellow)......................................................... 1-16
Coolant Temperature Gauge....................................................1-17
Fuel Gauge......................................................................................1-17
Turn Signal Indicator (Green) ...................................................1-18
High Beam Indicator (Blue)....................................................... 1-18
Work Light Indicator (Yellow)................................................... 1-18
Clearance Light Indicator (Green) .......................................... 1-18
Control Lever Lock Indicator (Red)......................................... 1-18

CONTENTS
Multi Function Monitor ..............................................................1-19
Feature........................................................................................1-19
Screen Configuration.............................................................1-19
Default Setting ..............................................................................1-20
Basic Screen....................................................................................1-21
How to Use Screens.....................................................................1-22
Displaying Basic Screen........................................................ 1-22
Monitor Operation ................................................................. 1-26
Alarm Occurrence Screen.......................................................... 1-27
Remedy....................................................................................... 1-29
DEF/SCR System Alarm...............................................................1-32
DEF/AdBlue® Level Alarm .................................................... 1-32
Urea SCR System Malfunction............................................ 1-33
Aftertreatment Device Regeneration ................................... 1-34
Aftertreatment Device Regeneration Status
Display...................................................................................1-34
Automatic regeneration (Auto-regeneration).............. 1-35
Manual Regeneration............................................................ 1-36
Main Menu......................................................................................1-37
Ride Control Drive Speed Setting (Option).........................1-38
Dual Lift Arm Auto-Leveler ....................................................... 1-39
Height Kickout ON/OFF, Stop Height Setting............... 1-40
Lower Kickout ON/OFF, Stop Height Setting ................ 1-41
Brightness Adjustment...............................................................1-42
Mail (Option) ..................................................................................1-44
Setting Menu .................................................................................1-46
Date and Time................................................................................1-47
Time Adjustment ....................................................................1-47
Date Adjustment.....................................................................1-49
Display Mode Setting............................................................ 1-51
Auto Idling Stop............................................................................1-53
Auto Idling Stop: ON/OFF .................................................... 1-53
Acting Time Setting................................................................ 1-54
Rear View Camera Monitor .......................................................1-55
Aftertreatment Device Regeneration Inhibited................ 1-57
Setting Procedure................................................................... 1-57
Transmission Setting................................................................... 1-59
Shift Change Delay Mode Setting ....................................1-59
Lockup Setting......................................................................... 1-61
Traction Control Setting ....................................................... 1-63
Parallel/Tandem Switching Height Setting.........................1-65
Warm Up Operation ....................................................................1-67
Display Item Selection................................................................ 1-69
Main Menu Display Order Change......................................... 1-71
Information Menu........................................................................ 1-73
Operation Condition...................................................................1-74
Fuel Consumption .................................................................. 1-74
Maintenance ..................................................................................1-76
Maintenance Notice............................................................... 1-76
Time Remains and Maintenance Interval....................... 1-78
Troubleshooting ...........................................................................1-80
Monitoring......................................................................................1-82
Front Console Switches, Pedals, and Joystick Steering... 1-85
Hazard Switch................................................................................ 1-86
Work Light Switch ........................................................................ 1-87
Parking Brake Switch...................................................................1-88
Key Switch.......................................................................................1-89
Accelerator Pedal..........................................................................1-90
Brake Pedal .....................................................................................1-90
Service Brake ............................................................................ 1-90
Declutch Brake......................................................................... 1-90
Joystick Steering........................................................................... 1-91
Joystick Steering Lever .........................................................1-91
Forward/Reverse Switch....................................................... 1-91
Joystick Steering System Switch .......................................1-91
Shift Switch ...............................................................................1-92
Light Switch.................................................................................... 1-93
Wiper Switch ..................................................................................1-94
Wiper Operation...................................................................... 1-94
Front/Rear Wiper Switch....................................................... 1-95
Right Console/Switches .............................................................1-96
Fingertip Control Type ..........................................................1-96
Loading Control Levers ..............................................................1-97
Lift Arm Control Lever........................................................... 1-97
Bucket Control Lever .............................................................1-97
Right Console/Switches .............................................................1-99
Multi-Function Joystick Type .............................................. 1-99
Loading Multi-Function Joystick Lever (Option).............1-100
Auxiliary Control Lever (Option) ...........................................1-101
Turn Signal Switch......................................................................1-101
Loading Control Lever Lock Switch .....................................1-102
Armrest Adjust Handle.............................................................1-102
Declutch Position Switch.........................................................1-103
Travel Mode Selector Switch..................................................1-104
Power Mode Selector Switch .................................................1-105
2nd/3rd Speed Limit Switch (Option).................................1-105
Fan Reverse Rotation Switch..................................................1-106
OFF.............................................................................................1-106
AUTO ........................................................................................1-106
Manual Operation ................................................................1-107
Hydraulic Coupler Switch (Option)......................................1-107
Secondary Steering Operation Check Switch
(Option) ....................................................................................1-108
Aftertreatment Device Regeneration Switch...................1-108
Ride Control Switch (Option) .................................................1-109
AUTO..........................................................................................1-109
OFF.............................................................................................1-109
Hold Switch ..................................................................................1-110
Quick Power Switch...................................................................1-111
Right Console Slide Lever........................................................1-111
DSS (Down Shift Switch)..........................................................1-112
Horn Switch .................................................................................1-113
Cigar Lighter (24 V DC Electrical Outlet) ............................1-114
Using Cigar Lighter...............................................................1-114
Ash Tray..........................................................................................1-114
Auto Air Conditioner.................................................................1-115
Feature......................................................................................1-115
Components Name..............................................................1-116
Controller Part Name and Function ...............................1-117
Mode/Temperature Control Switch ...............................1-117
Fan/AUTO Switch ..................................................................1-118
Air Conditioner ON/OFF Switch.......................................1-118

CONTENTS
Circulation/Fresh Air Switch..............................................1-118
Defroster Switch....................................................................1-118
Cab Heater Operation .........................................................1-119
Cooling Operation................................................................1-120
Defroster Operation.............................................................1-121
Cool Head/Warm Feet Operation....................................1-121
Tips for Optimal Air Conditioner Usage .............................1-122
For Rapid Cooling .................................................................1-122
When Windows Become Fogged ....................................1-122
Off-Season Air Conditioner Maintenance....................1-122
Adjusting Operator's Seat (Air Suspension Type
Seat)...........................................................................................1-123
Components Name..............................................................1-123
Rear Tray ........................................................................................1-124
Electric Power Output (Option).............................................1-124
Fuse Box.........................................................................................1-125
Fuse Box A ...............................................................................1-126
Fuse Box B................................................................................1-126
Hot/Cool Box................................................................................1-127
Tray and Drink Holder...............................................................1-127
Cab...................................................................................................1-128
Front Interior Light.....................................................................1-130
Rear Interior Light ......................................................................1-130
Sun Visor........................................................................................1-131
Emergency Exit Hammer.........................................................1-131
Coat/Hat Hook.............................................................................1-131
Upper Switch Panel (Option)..................................................1-132
Rotary Light Switch (Option)..................................................1-132
Outside Rear View Mirror.........................................................1-133
Inside Rear View Mirror ............................................................1-133
Cab Door........................................................................................1-133
Door Open/Close Lever............................................................1-134
Window Open/Close Levers ...................................................1-134
Battery Disconnect Switch .....................................................1-135
Switch Operation ..................................................................1-136
Articulation Stopper (Lock Bar).............................................1-137
Towing Pin ....................................................................................1-138
Inspection/Maintenance Access Covers ............................1-139
Rear Grille......................................................................................1-140
Steps................................................................................................1-141
Tool Box .........................................................................................1-141
Vandal-Resistant Devices.........................................................1-142
BREAK-IN ....................................................................... 2-1
Break-in Period for New Machine..............................................2-1
Work Mode for Break-in ................................................................2-1
OPERATING THE ENGINE .............................................. 3-1
Inspect Machine Daily Before Starting ....................................3-1
Check Before Starting....................................................................3-3
Starting Engine ................................................................................3-6
Starting in Cold Weather...............................................................3-8
Preheating ....................................................................................3-8
Check After Starting .......................................................................3-9
Check Monitor Operation.......................................................3-9
Check Engine Noise and Exhaust Gas Color.....................3-9
Using Booster Batteries..............................................................3-10
Warm Up.......................................................................................... 3-12
Cold Weather Warm Up.............................................................. 3-13
Stopping Engine...........................................................................3-15
MOVING THE MACHINE ................................................ 4-1
Driving the Machine.......................................................................4-1
Precautions for Starting to Move .........................................4-1
Starting to Move..............................................................................4-2
Shift Range of Auto Transmission ........................................4-5
Power Mode Selector ...............................................................4-6
Shift Change Delay Mode .......................................................4-6
Parking Brake Switch......................................................................4-7
Drive Speed Change (Manual Shift) .........................................4-8
Changing Forward/Reverse Drive Direction..........................4-8
Steering...............................................................................................4-9
Secondary Steering (Option) ...................................................4-10
Emergency Stop and Restart of Operation......................... 4-11
Precautions for Traveling ...........................................................4-12
Operating in Water or on Soft Ground............................ 4-13
Precautions for Driving on Slopes.......................................... 4-14
Precautions to be Taken if Machine Failure Occurs..........4-15
Stop ................................................................................................... 4-16
Parking .............................................................................................4-18
Emergency Stopping ..................................................................4-19
When the Engine has Stalled During Operation ......... 4-19
Auto Brake.......................................................................................4-20
OPERATING THE MACHINE........................................... 5-1
Loading Control Levers .................................................................5-1
Fingertip Control Type .............................................................5-1
Loading Multi-Function Joystick Lever (Option) ............5-3
Control Lever Lock ..........................................................................5-4
Control Lever Lock Operation ...............................................5-4
Declutch Position Switch..............................................................5-5
Adjustment of Bucket Auto Leveler..........................................5-6
Adjustment of Bucket Angle Switch.........................................5-8
Adjustment of Dual Lift Arm Auto Leveler.......................... 5-10
Auto Idling Stop............................................................................5-11
Auto Idling Stop Operating Condition............................ 5-12
Aftertreatment Device Manual Regeneration ...................5-13
Manual Regeneration Procedure ...................................... 5-13
Before Operation .......................................................................... 5-16
Precautions for Operation.........................................................5-16
Ensure Safety When Operating on Road Shoulders ........ 5-16
Avoid Overloading.......................................................................5-17
Avoid Rapid Steering Changes and/or Sudden
Braking........................................................................................ 5-17
Avoid Operation with Loads on Only One Side................. 5-17
Excavation.......................................................................................5-18
Loading Accumulated Soil...................................................5-18
Digging and Loading Level Ground................................. 5-19
Grading ............................................................................................5-20
Loading ............................................................................................5-21
Load and Carrying Method ................................................. 5-21
Loader and Dump Truck Combination Method...........5-22
V-Shape Loading..................................................................... 5-22
I-Shape Loading ...................................................................... 5-22

CONTENTS
Dumping into Truck or Hopper..........................................5-23
Dozing.............................................................................................. 5-24
Stock Piling .....................................................................................5-24
Removing Snow............................................................................5-25
Lifting Wheel Loader................................................................... 5-25
Precautions for After Operation..............................................5-26
TRANSPORTING ............................................................ 6-1
Transporting by Road ....................................................................6-1
Selecting a Trailer ............................................................................6-1
Loading/Unloading on Trailer.....................................................6-2
Ramp/Loading Dock.................................................................6-2
Loading/Unloading on Trailer ...............................................6-3
Loading..........................................................................................6-3
Fastening Machine for Transporting ........................................6-4
Transporting Wheel Loader (Urgent Situation) ....................6-5
Precautions for Driving On Roads........................................6-5
Precautions for Towing ............................................................6-6
Releasing Parking Brake ..........................................................6-7
Towing Method................................................................................6-9
Lifting Machine .............................................................................6-10
MAINTENANCE.............................................................. 7-1
Correct Maintenance and Inspection Procedures...............7-1
Check the Hour Meter Regularly................................................7-3
Layout..................................................................................................7-4
Lubrication Guide............................................................................7-5
Preparations for Inspection and Maintenance .....................7-6
Articulation Lock..............................................................................7-8
Inspection/Maintenance Access Covers .................................7-9
Rear Grille........................................................................................ 7-10
Inspection and Maintenance Table........................................7-11
Kind of Oils...................................................................................... 7-15
Grease .........................................................................................7-15
Engine Oil .................................................................................. 7-15
Transmission Oil ...................................................................... 7-15
Axle Oil........................................................................................7-16
Hydraulic Oil ............................................................................. 7-16
Recommended Coolant ....................................................... 7-16
List of Consumable Parts ...........................................................7-17
A. Greasing......................................................................................7-19
B. Engine.......................................................................................... 7-25
Check Engine Oil Level ......................................................... 7-25
Change Engine Oil .................................................................7-26
Replace Engine Oil Filter.......................................................7-28
C. Power Train ................................................................................ 7-30
Check Transmission Oil Level..............................................7-30
Change Transmission Oil...................................................... 7-31
Clean Suction Strainer...........................................................7-31
Change Transmission Oil Filter........................................... 7-31
Clean Transmission and Torque Converter
Air Breathers........................................................................ 7-34
Check Axle Oil Level...............................................................7-35
Check Differential Gear Oil Level .................................7-35
Check Planetary Gear Oil Level.....................................7-36
Change Axle Oil....................................................................... 7-37
Change Differential Gear Oil .........................................7-37
Change Planetary Gear Oil.............................................7-38
Replace Axle Oil Cooler Line Filter (Option).................. 7-39
Clean Axle Oil Cooler Fins (Option) .................................. 7-40
D. Hydraulic System.....................................................................7-41
Inspection and Maintenance of Hydraulic
Equipment ...........................................................................7-41
Check Hydraulic Oil Level ....................................................7-43
Change Hydraulic Oil............................................................. 7-44
Bleed Air from the Hydraulic System..........................7-45
Clean Suction Filter ................................................................7-46
Clean Pilot Oil Filter................................................................7-47
Line Filter in Steering Circuit ......................................... 7-47
Line Filter in Brake Circuit............................................... 7-48
Replace Hydraulic Oil Return Filter................................... 7-49
Replace Air Breather Element............................................. 7-50
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage ..............................7-51
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage (Option) ............ 7-52
Check Gas Pressure in Ride Control Accumulator
(Option).................................................................................7-52
Check Gas Pressure in Steering Accumulator...............7-52
Check Hoses and Lines .........................................................7-53
Service Recommendations for Hydraulic
Fittings................................................................................... 7-56
Flat Face O-ring Seal Fitting (ORS Fitting)................. 7-56
Metal Face Seal Fittings................................................... 7-56
E. Fuel System................................................................................ 7-57
Check Fuel Level......................................................................7-57
Recommended Fuel ......................................................... 7-57
About Biodiesel Fuel ........................................................7-57
Refueling ..............................................................................7-58
Drain Water and Sediment from Fuel Tank .................... 7-58
Drain Fuel Filter........................................................................ 7-59
Draining Procedures (Pre-Filter)................................... 7-59
Bleed Air from the Fuel System .................................... 7-60
Air Bleeding Procedure ................................................... 7-60
If Air Mixed After Common Rail.................................... 7-61
Replace Fuel Main Filter Element......................................7-62
Replace Fuel Pre-Filter Element.........................................7-64
Clean Fuel Pump Strainer.....................................................7-66
Clean Fuel Priming Solenoid Pump Strainer.................7-67
Check Fuel Hoses .................................................................... 7-69
F. Air Cleaner...................................................................................7-71
Replace Air Cleaner Element...............................................7-71
G. Cooling System ........................................................................ 7-72
Coolant..................................................................................7-72
Check Coolant Level .............................................................. 7-73
Check Drive Belt ...................................................................... 7-74
Measurement of Deflection Amount and Vibration
Frequency ............................................................................ 7-74
Adjusting Drive Belt.......................................................... 7-74
Replacing Drive Belt ......................................................... 7-75
Change Coolant.......................................................................7-76
Clean Radiator/Oil Cooler Cores and Other Cooling
System ...................................................................................7-79

CONTENTS
H. Electrical System......................................................................7-80
Batteries .....................................................................................7-80
Electrolyte Level Check ................................................... 7-82
Check Electrolyte Specific Gravity...............................7-83
Replace Batteries ...............................................................7-84
Check Monitor Functions and All Other Instrument
Operation .............................................................................7-84
Check Work Lights ..................................................................7-85
Check Horn and Backup Alarm..........................................7-85
Check Electrical Harnesses and Fuses .............................7-86
Fuse Box A............................................................................7-87
Fuse Box B ............................................................................ 7-87
I. Brake System...............................................................................7-88
Check Right and Left Brake Interlocking
Performance........................................................................ 7-88
Check Brake Performance .............................................. 7-88
Check Play in Brake Pedal Stroke................................. 7-88
Check Parking Brake Force .................................................. 7-89
Check Parking Brake Gear Oil Level..................................7-90
Change Parking Brake Gear Oil..........................................7-91
Check Accumulator Function, Gas Leakage,
Looseness, and Damage................................................. 7-92
Check Brake Disks (Service and Parking)........................ 7-93
Check Gas Pressure in Accumulator................................. 7-93
J. Tire..................................................................................................7-94
Check and Replace Tire (Tire Pressure)............................7-94
Check Air Pressure.............................................................7-94
Check Tire for Damage..........................................................7-95
Check Wheel Bolt Torque .....................................................7-95
Replace Tire..........................................................................7-95
Tire Sizes to be Used.........................................................7-96
Driving on Public Roads: Standard Pressure............ 7-96
Tire Rotation........................................................................7-97
Rotation Procedure........................................................... 7-97
How to Check Wear Amount (Tread Design Groove
Depth)....................................................................................7-97
Removal and Installation of Tire...................................7-98
Tire Wheel.............................................................................7-98
K. Air Conditioner .........................................................................7-99
Clean/Replace Air Conditioner Circulation/
Fresh Air Filters................................................................... 7-99
Clean Fresh Air Filter......................................................... 7-99
Clean Circulation Air Filter............................................7-100
Check Air Conditioner.........................................................7-101
Check Air Conditioner Piping ...........................................7-101
Check Air Conditioner Condenser..................................7-102
Check Air Conditioner Compressor Belt.......................7-102
Compressor Belt Tension Adjustment
Procedure...........................................................................7-102
Check Refrigerant .................................................................7-103
Replace Air Conditioner Receiver Dryer .......................7-103
Check Compressor and Pulley..........................................7-103
Check Compressor..........................................................7-103
L. Aftertreatment Device .........................................................7-104
Check and Clean Aftertreatment Device......................7-104
M. Urea SCR System...................................................................7-105
Specified DEF/AdBlue® .......................................................7-105
Check DEF Level ....................................................................7-106
Refill DEF.............................................................................7-106
Clean DEF Strainer...........................................................7-107
DEF Exchange Procedure..............................................7-108
Replace DEF Supply Module Main Filter.......................7-109
Check Dosing Module.........................................................7-110
Replace DEF Tank Inlet Filter.............................................7-110
N. Miscellaneous.........................................................................7-111
Check Bucket Teeth..............................................................7-111
Check and Replace Seat Belt and Lower Tether.........7-112
Check ROPS, ROPS Mounting Bolts, and Cab .............7-112
Check Windshield Washer Fluid Level ...........................7-113
Check Play Amount in Joystick Steering
Movement..........................................................................7-113
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise .......................................................7-114
Exhaust Gas Color and Noise ......................................7-114
Check Rearview Mirror and Inside Rearview
Mirror ...................................................................................7-115
Check Steps and Handrails for Damage and
Looseness...........................................................................7-115
Clean Engine Compartment and Hood ........................7-116
Check Sound Absorbing Mat Around Engine ............7-116
Check and Adjust Valve Clearance..................................7-116
Check Engine Compression Pressure ............................7-116
Check and Clean Starter and Alternator.......................7-116
Check Fuel Injector...............................................................7-117
Check Turbocharger.............................................................7-117
Check and Adjust Engine Controller (ECM).................7-117
Check and Clean EGR Valve...............................................7-117
Check and Clean EGR Cooler ............................................7-117
Check Urea SCR System......................................................7-117
Cleaning of Rear View Camera Lens...............................7-118
Retighten Front Axle and Rear Axle Support
Mounting Bolts.................................................................7-118
Check Tightening Torque of Nuts and Bolts................7-119
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
Removing the Machine from Storage............................. 10-2
TROUBLESHOOTING................................................... 11-1
Troubleshooting ...........................................................................11-1
1. Engine.....................................................................................11-1
2. Engine Auxiliaries............................................................... 11-1
3. Engine does not Start. ...................................................... 11-2
4. Control Lever........................................................................ 11-3
5. Hydraulic System................................................................ 11-3
6. Drive Function ..................................................................... 11-4
7. Others..................................................................................... 11-5

CONTENTS
SPECIFICATIONS ......................................................... 12-1
Specifications.................................................................................12-1
Intended Use ............................................................................ 12-1
INDEX........................................................................... 14-1