Hitachi Zw140-6 User manual

ENMPTC-NA1-3ZW140-6 • 150-6 • 150PL-6 WHEEL LOADER OPERATOR'S MANUAL

PRINTED IN JAPAN (E) 2022, 09

URL:https://www.hitachicm.com

ENMPTC-NA1-3

PART NO.

Operator's Manual

Serial No. 005201 and up

This book is printed on recycled paper.

140-6

150-6

150PL-6

Wheel Loader

INTRODUCTION

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.

INDEX

ENMPTC-NA1-3

SAFETY

SAFETY SIGNS

COMPONENTS NAME

GETTING ON/OFF THE MACHINE

OPERATOR’S STATION

BREAK-IN

OPERATING ENGINE

DRIVING MACHINE

OPERATING MACHINE

TRANSPORTING

MAINTENANCE

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

STORAGE

TROUBLESHOOTING

SPECIFICATIONSSPECIFICATIONS

OPTIONAL ATTACHMENTS

INDEXINDEX

MACHINE NUMBERS

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 the 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 and Falling Object............. S-21

Park Machine Safely..................................................................... S-22

Store Attachments Safely.......................................................... S-22

Transport Safely ............................................................................ S-23

Handle Fluids Safely−Avoid Fires............................................S-24

Practice Safe Maintenance ....................................................... S-25

Warn Others of Service Work ................................................... S-26

Support Machine Properly........................................................ S-26

Stay Clear of Moving Parts ........................................................ S-27

Support Maintenance Properly............................................... S-27

Prevent Parts from Flying .......................................................... S-28

Prevent Burns................................................................................. S-28

Replace Rubber Hoses Periodically........................................ S-29

Avoid High-Pressure Fluids....................................................... S-29

Prevent Fires................................................................................... S-30

Evacuating in Case of Fire.......................................................... S-32

Beware of Exhaust Fumes..........................................................S-32

Precautions for Welding and Grinding ................................. S-32

Avoid Heating Near Pressurized Fluid Lines....................... S-33

Avoid Applying Heat to Lines Containing Flammable

Fluids ........................................................................................... S-33

Precautions for Handling Accumulator and Gas

Damper....................................................................................... S-33

Remove Paint Before Welding or Heating........................... S-34

Beware of Asbestos and Silica Dust and Other

Contamination......................................................................... S-34

Prevent Battery Explosions ....................................................... S-35

Service Air Conditioning System Safely ............................... S-35

Handle Chemical Products Safely........................................... S-36

Dispose of Waste Properly......................................................... S-36

Notes on Aftertreatment Device ............................................ S-37

Precautions for Communication Terminal........................... S-37

Precaution for Communication Terminal Equipment ..... S-38

SAFETY SIGNS.............................................................................. S-40

COMPONENTS NAME ..................................................................1-1

Components Name ........................................................................1-1

GETTING ON/OFF THE MACHINE ...........................................1-3

Getting ON/OFF the Machine.....................................................1-3

OPERATOR'S STATION.................................................................1-4

About Aftertreatment Device.....................................................1-4

Cab Features......................................................................................1-7

Front Console....................................................................................1-8

Right Console....................................................................................1-9

Multi-Function Joystick Type .................................................1-9

Fingertip Control Type .......................................................... 1-10

Monitor Panel ................................................................................1-11

Service Indicator........................................................................... 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 (Red) (Optional)......1-14

HST Warning Indicator (Red).................................................... 1-14

Discharge Warning Indicator (Red)........................................ 1-14

Urea Warning Indicator (Red)................................................... 1-14

Engine Trouble Indicator (Red)................................................1-15

Overheat Indicator (Red) ...........................................................1-15

Engine Oil Low Pressure Indicator (Red) ..............................1-15

Aftertreatment Device Warning Indicator........................... 1-16

Aftertreatment Device Regeneration Request

(Blinking Yellow) ................................................................ 1-16

Aftertreatment Device Regeneration Inhibited Warning

Indicator..................................................................................... 1-16

Aftertreatment Device Regeneration Inhibited

Warning (Yellow) ...............................................................1-16

Aftertreatment Device Auto Regeneration Inhibited

Warning (Yellow) ...............................................................1-16

Air Filter Restriction Indicator (Red)....................................... 1-17

Preheat Indicator (Yellow).........................................................1-17

Fuel Filter Restriction Indicator (Red).................................... 1-17

CONTENTS

HST Oil Temperature Indicator (Red).....................................1-17

Secondary Steering Indicator (Yellow) (Optional)............1-18

Seat Belt Indicator (Red) ............................................................1-18

Water Separator Indicator (Red)..............................................1-18

Coolant Temperature Gauge....................................................1-19

Fuel Gauge...................................................................................... 1-19

HST Oil Temperature Gauge ..................................................... 1-19

Turn Signal Indicator (Green) ...................................................1-20

High Beam Indicator (Blue).......................................................1-20

Work Light Indicator (Yellow)................................................... 1-20

Aftertreatment Device Regeneration Inhibited

Indicator (Green) .....................................................................1-20

Clearance Light Indicator (Green) .......................................... 1-21

Control Lever Lock Indicator (Red).........................................1-21

Power Mode Indicator (Green) ................................................ 1-21

Maintenance Indicator (Yellow) .............................................. 1-22

Forward/Reverse Selector Switch Indicator (Green)........ 1-22

Fan Reverse Rotation Indicator (Green)................................1-22

Monitor Display............................................................................. 1-23

Forward/Reverse and Shift Position Indicator..............1-24

Speedometer............................................................................1-26

Ride Control Indicator...........................................................1-27

ECO Indicator............................................................................1-27

DEF/AdBlue® Level Gauge ................................................... 1-27

DEF/SCR System Alarm...............................................................1-28

DEF/AdBlue® Level Alarm .................................................... 1-28

Urea SCR System Malfunction............................................1-29

Machine Information Display...................................................1-30

Shifting Item to be Indicated on Machine

Information Display ......................................................... 1-31

Resetting of Oil Change and Filter Replacement

Intervals...................................................................................... 1-37

Hydraulic Oil Change Interval Hour Meter .................... 1-37

Hydraulic Oil Filter 1 Replacement Interval

Hour Meter........................................................................... 1-38

Hydraulic Oil Filter 2 Replacement Interval

Hour Meter........................................................................... 1-39

Hydraulic Oil Filter 3 Replacement Interval

Hour Meter........................................................................... 1-40

Transmission Oil Change Interval Hour Meter ............. 1-41

Transmission Oil Filter Replacement Interval

Hour Meter........................................................................... 1-42

Engine Oil Change Interval Hour Meter .........................1-43

Engine Oil Filter Replacement Interval Hour Meter ...1-44

Oil Separator Element Replacement Interval

Hour Meter........................................................................... 1-45

Fuel Filter Replacement Interval Hour Meter................ 1-46

DEF/AdBlue® Supply Module Main Filter

Replacement Interval Hour Meter............................... 1-47

Axle Oil Change Interval Hour Meter...............................1-48

Clock Setting Mode .....................................................................1-49

Clock (24H) Setting Procedures......................................... 1-49

Switches, Steering Wheel and Pedals....................................1-50

Forward/Reverse Lever/ Shift Switch .................................... 1-51

Forward/Reverse Lever .........................................................1-51

Shift Switch ...............................................................................1-51

Neutral Lever Lock (for the Forward/Reverse Lever) .......1-52

Steering............................................................................................ 1-52

Horn Switch.................................................................................... 1-52

Turn Signal Lever ..........................................................................1-53

Light Switch.................................................................................... 1-54

High-Low Beam Switch.............................................................. 1-55

Key Switch.......................................................................................1-55

Wiper Switch ..................................................................................1-56

Wiper Operation...................................................................... 1-56

Front/Rear Wiper Switch....................................................... 1-57

Hazard Switch................................................................................1-58

Work Light Switch ........................................................................ 1-59

Parking Brake Switch...................................................................1-60

Accelerator Pedal..........................................................................1-61

Brake/Inching Pedal ....................................................................1-61

Tilt, Telescopic Lever/Steering Column Tilt Pedal ............1-62

1st Speed Select Switch .............................................................1-63

Auto Shut-Down (Idling Stop) Switch...................................1-64

Right Console / Switches...........................................................1-65

Multi-Function Joystick Type .............................................. 1-65

Multi-Function Joystick Lever .................................................1-66

Right Console / Switches...........................................................1-67

Fingertip Control Type .......................................................... 1-67

Control Lever..................................................................................1-68

Control Lever Lock Switch.........................................................1-70

Armrest Adjust Handle............................................................... 1-71

Creep Mode Switch .....................................................................1-72

Traction Control Switch..............................................................1-73

Power Mode Switch.....................................................................1-74

Aftertreatment Device Regeneration Switch.....................1-75

Manual Regeneration Procedure ...................................... 1-76

Aftertreatment Device Regeneration Inhibited........... 1-78

Ride Control Switch ..................................................................... 1-79

AUTO............................................................................................1-79

OFF...............................................................................................1-79

Fan Reverse Rotation Switch....................................................1-80

Manual Operation ..................................................................1-80

AUTO ..........................................................................................1-81

Forward/Reverse Selector Switch...........................................1-82

Operational Procedure..........................................................1-82

Secondary Steering Operation Check Switch

(Optional)................................................................................... 1-83

Dual Lift Arm Auto Leveler........................................................1-84

Cigar Lighter (24 VDC Electrical Outlet) ...............................1-85

Using Cigar Lighter.................................................................1-85

Ash Tray............................................................................................ 1-86

Auto Air Conditioner................................................................... 1-87

Feature........................................................................................1-87

Components Name................................................................ 1-88

Controller Part Name and Function .................................1-89

Mode/Temperature Control Switch ................................. 1-91

Defroster Operation............................................................... 1-93

Cool Head/Warm Feet Operation......................................1-93

Tips for Optimal Air Conditioner Usage ............................... 1-94

For Rapid Cooling ...................................................................1-94

When Windows Become Clouded .................................... 1-94

CONTENTS

Off-Season Air Conditioner Maintenance...................... 1-94

Adjusting Operator's Seat (Air Suspension Type Seat) ...1-95

Components Name................................................................ 1-95

Rear Tray ..........................................................................................1-96

Electric Power Output (12 VDC Electrical Outlet) ............. 1-96

Fuse Box...........................................................................................1-97

Fuse Box A ................................................................................. 1-98

Fuse Box B.................................................................................. 1-98

Hot/Cool Box.................................................................................. 1-99

Tray and Drink Holder................................................................. 1-99

ROPS Cab.......................................................................................1-100

Front Room Light........................................................................1-102

Rear Room Light .........................................................................1-102

Emergency Evacuation Hammer..........................................1-102

Sun Visor........................................................................................1-103

Coat Hook .....................................................................................1-103

Upper Switch Panel ...................................................................1-104

Rotary Light Switch (Optional) ..............................................1-104

Rear View Mirror Heater Switch.............................................1-104

Outside Rear View Mirror.........................................................1-105

Room Rear View Mirror.............................................................1-105

Cab Door........................................................................................1-105

Door Lock Knob ..........................................................................1-106

Door Open/Close Lever............................................................1-106

Window Open/Close Levers ...................................................1-106

When Fully Opening the Door...............................................1-107

Cab Door Release Lever ...........................................................1-107

Battery Disconnect Switch......................................................1-108

Switch Operation ..................................................................1-109

Articulation Lock Bar.................................................................1-110

Towing Pin ....................................................................................1-111

Inspection/Maintenance Side Access Cover.....................1-112

Steps................................................................................................1-113

Tool Box..........................................................................................1-113

Vandal-Proof Devices................................................................1-114

Seat Belt.........................................................................................1-116

Seat Pocket ...................................................................................1-116

Rear View Camera Monitor .....................................................1-117

Components Name ...................................................................1-117

Starting and Stopping the Rear View Camera

Monitor (Optional)................................................................1-117

Monitor Setting and Adjustment (Optional)....................1-118

BREAK-IN...........................................................................................2-1

Break-in Period for New Machine..............................................2-1

Work Mode for Break-in ................................................................2-1

OPERATING ENGINE.....................................................................3-1

Inspect Machine Daily Before Starting ....................................3-1

Check Before Starting....................................................................3-3

Starting Engine ................................................................................3-5

Starting in Cold Weather...............................................................3-7

Check After Starting .......................................................................3-8

Using Booster Batteries.................................................................3-9

Warm Up..........................................................................................3-11

Cold Weather Warm Up.............................................................. 3-12

Stopping Engine...........................................................................3-14

DRIVING MACHINE .......................................................................4-1

Driving the Machine.......................................................................4-1

Starting to Move..............................................................................4-2

Parking Brake Switch......................................................................4-4

Drive Speed Change.......................................................................4-5

Changing Forward/Reverse Drive Direction..........................4-5

Steering Wheel.................................................................................4-6

Secondary Steering (Optional)...................................................4-7

Stop and Restart of Driving .........................................................4-8

Precautions for Driving on Slopes.......................................... 4-11

Precautions for Driving Speeds............................................... 4-12

Precautions to be Taken if Machine Failure Occurs.......... 4-13

Stop the Machine ......................................................................... 4-14

Parking .............................................................................................4-16

Emergency Evacuation............................................................... 4-17

OPERATING MACHINE.................................................................5-1

Control Lever.....................................................................................5-1

Control Lever Lock Switch............................................................5-4

Ride Control Switch ........................................................................5-5

Lift Arm Kick Out..............................................................................5-7

Dual Lift Arm Auto Leveler...........................................................5-8

Bucket Auto Leveler........................................................................5-9

Auto Shut-Down (Idling Stop) ................................................. 5-11

Before Operation .......................................................................... 5-13

Precautions for Operation.........................................................5-13

Ensure Safety When Operating on Road Shoulders ........ 5-13

Avoid Overloading....................................................................... 5-14

Avoid Rapid Steering Changes and/or Sudden

Braking........................................................................................ 5-14

Avoid Operation with Biased Loads ...................................... 5-14

Excavation....................................................................................... 5-15

Grading ............................................................................................5-17

Loading ............................................................................................5-18

Dozing.............................................................................................. 5-21

Scooping .........................................................................................5-21

Removing Snow............................................................................ 5-22

Lifting Wheel Loader................................................................... 5-22

Precautions for After Operations............................................ 5-23

TRANSPORTING .............................................................................6-1

Transporting by Road ....................................................................6-1

Transporting by Trailer ..................................................................6-1

Loading / Unloading on Trailer...................................................6-2

Fastening Machine for Transporting ........................................6-4

Transporting Wheel Loader (Urgent Situation) ....................6-5

Towing Method.............................................................................6-10

Lifting Machine .............................................................................6-11

MAINTENANCE...............................................................................7-1

Correct Maintenance and Inspection Procedures...............7-1

Check the Hour Meter Regularly................................................7-2

Layout..................................................................................................7-3

Preparations for Inspection and Maintenance .....................7-7

Lock Frames.......................................................................................7-9

Inspection/Maintenance Access Side Cover....................... 7-10

Inspection and Maintenance Table........................................ 7-11

CONTENTS

Periodic Replacement of Parts.................................................7-16

Kind of Oils...................................................................................... 7-18

List of Consumable Parts ...........................................................7-22

A. Greasing......................................................................................7-25

B. Engine.......................................................................................... 7-31

Check Engine Oil Level.......................................................... 7-31

Change Engine Oil..................................................................7-32

Replace Engine Oil Filter.......................................................7-34

Check Crankcase Breather Tube .......................................7-35

Replace Crankcase Breather Filter Element .................7-36

Check Oil Drain Tube .............................................................7-37

C. Power Train ................................................................................ 7-38

Check Transmission Oil Level.............................................. 7-38

Change Transmission Oil...................................................... 7-39

Clean Transmission Strainer................................................ 7-39

Replace Transmission Oil Filter........................................... 7-41

Change Axle Oil....................................................................... 7-42

Check Oil Level.........................................................................7-43

Check Surroundings Around Axle and Covers for Oil

Leaks ......................................................................................7-44

Clean Axle Housing Air Breather....................................... 7-44

D. Hydraulic System.....................................................................7-45

Inspection and Maintenance of Hydraulic Equipment...7-45

Check Hydraulic Oil Level ....................................................7-47

Change Hydraulic Oil/Clean Hydraulic Oil Tank........... 7-48

Bleed Air from the Hydraulic System...............................7-49

Bleed Air from the Hydraulic Circuit.................................7-49

Clean Suction Filter ................................................................7-50

Replace Pilot Oil Filter............................................................7-51

Replace Hydraulic Tank Oil Filter....................................... 7-53

Replace HST Charge Filter....................................................7-55

Replace Air Breather Element............................................. 7-56

Check Pilot Circuit Accumulator Function, Gas

Leakage, Looseness, and Damage ..............................7-57

Replace Pilot Circuit Accumulator .................................... 7-58

Check Ride Control Accumulator Function, Gas

Leakage, Looseness, and Damage ..............................7-58

Check Gas Pressure in Ride Control Accumulator....... 7-58

Check Gas Pressure in Steering Accumulator............... 7-58

Check Hoses and Lines .........................................................7-59

E. Fuel System................................................................................ 7-64

Check Fuel Level......................................................................7-64

Drain Water and Sediment from Fuel Tank .................... 7-66

Drain Fuel Filter........................................................................ 7-67

Bleed Air from the Fuel System.......................................... 7-67

Replace Fuel Main Filter Element......................................7-68

Replace Fuel Pre-Filter Element.........................................7-69

Clean Fuel Solenoid Pump Strainer.................................. 7-70

Check Fuel Hoses .................................................................... 7-71

F. Air Cleaner...................................................................................7-72

Clean and Replace Air Cleaner Element .........................7-72

G. Cooling System ........................................................................ 7-73

Coolant .......................................................................................7-73

Precautions for handling antifreeze.................................7-73

Check Coolant Level .............................................................. 7-74

Check Drive Belt ...................................................................... 7-75

Check Drive Belt Tensioner.................................................. 7-76

Change Coolant.......................................................................7-77

Clean Radiator/Oil Cooler and Other Cooling

System ...................................................................................7-78

H. Electrical System......................................................................7-79

Batteries .....................................................................................7-79

Check Monitor Functions and All Other Instrument

Operation .............................................................................7-83

Check Lights ............................................................................. 7-84

Check Horn and Reverse Buzzer........................................ 7-84

Check Electrical Harnesses and Fuses .............................7-85

I. Brake System...............................................................................7-87

Check Right and Left Brake Interlocking

Performance........................................................................ 7-87

Check Parking Brake Force .................................................. 7-88

Check Accumulator Function, Gas Leakage,

Looseness, and Damage................................................. 7-89

Check Gas Pressure in Accumulator................................. 7-90

Check Brake Disks (Service and Parking)........................ 7-90

J. Tire..................................................................................................7-91

Check and Replace Tire (Tire Pressure)............................7-91

Check Tire for Damage.......................................................... 7-91

Check Wheel Bolt Torque .....................................................7-92

Removal and Installation of Tire..............................................7-95

K. Air Conditioner .........................................................................7-96

Clean/Replace Air Conditioner Circulation/Fresh Air

Filters...................................................................................... 7-96

Check Air Conditioner.........................................................7-100

Check Air Conditioner Piping ...........................................7-100

Check Air Conditioner Condenser ..................................7-101

Check Air Conditioner Fan Belt ........................................7-101

Check Refrigerant .................................................................7-102

Check Compressor and Pulley..........................................7-102

L. Miscellaneous..........................................................................7-103

Check Bucket Teeth and Cutting Edge..........................7-103

Check and Replace Seat and Seat Belt..........................7-104

Check ROPS cab Mounting Bolts.....................................7-104

Check Windshield Washer Fluid Level ...........................7-104

Check Play Amount in Steering Wheel Stroke............7-105

Check Accelerator Pedal Operation, and Exhaust

Gas Color and Noise .......................................................7-106

Check Rearview Mirror and Inside Rearview

Mirror ...................................................................................7-107

Check Steps and Handrails for Damage and

Looseness...........................................................................7-107

Clean Engine Compartment and Hood ........................7-108

Check Sound Absorbing Mat Around Engine ............7-108

Check and Adjust Valve Clearance..................................7-109

Retighten Front Axle and Rear Axle Support

Mounting Bolts.................................................................7-109

Tightening and Retightening Torque of Nuts and

Bolts......................................................................................7-110

M. Aftertreatment Device........................................................7-122

Check and Clean Aftertreatment Device......................7-122

N. Urea SCR System....................................................................7-123

Check DEF/AdBlue®..............................................................7-125

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 ...........................................................................11-1

SPECIFICATIONS .........................................................................12-1

Specifications.................................................................................12-1

OPTIONAL ATTACHMENTS.....................................................13-1

Hydraulic Type Quick Coupler Operation............................13-1

INDEX............................................................................................... 14-1

CONTENTS

MEMO

..................................................................................................................................................................................................

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.

Machine

MODEL/TYPE :

PRODUCT

IDENTIFICATION

NUMBER :

Engine

TYPE :

MFG. NO. :

M4FC-00-05US

MPTC-00-001

1

MACHINE NUMBERS

Aftertreatment Device

1. SCR

TYPE :

MFG. NO. :

2. DOC

TYPE :

MFG. NO. :

MPTC-00-002

MPTC-00-003

MACHINE NUMBERS

2

S-1

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.

Understand Signal Words

On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or CAUTION

- are used with the safety alert symbol.

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious

injury.

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate

injury.

DANGER or WARNING safety signs signs are located

near specific hazards. General precautions are listed on

CAUTION safety signs.

Some safety signs are occasionally used on this machine

that do not use any of the designated signal words

mentioned above after the safety alert symbol.

To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates a

situation which, if not avoided, could result in damage to

the machine.

fNOTE Indicates an additional explanation for a piece of

information.

SA-1223

SA-2644

SAFETY

S-2

Follow Safety Instructions

Carefully read and follow all safety signs on the machine

and all safety messages in this manual.

Safety signs should be installed, maintained and replaced

when necessary.

If a safety sign or this manual is damaged or missing,

order a replacement from your authorized dealer in the

same way you order other replacement parts (be sure to

state machine model and serial number when ordering).

Learn how to operate the machine and its controls correctly

and safely.

Allow only trained, qualified, authorized personnel to

operate the machine.

Keep your machine in proper working condition.

Unauthorized modifications of the machine may impair

its function and/or safety and affect machine life.

Do not modify any machine parts without authorization.

Failure to do so may deteriorate the safety, function, and/

or service life of the part. In addition, personal accident,

machine trouble, and/or damage to material caused by

unauthorized modifications will void Hitachi Warranty

Policy.

Never attempt to modify or disassemble the inlet/exhaust

parts and the aftertreatment device. Avoid shocks to the

element of the aftertreatment device, such as striking

or dropping objects onto the elements. Failure to do so

may affect the exhaust gas purifying device, possibly

damaging it or lowering its performance.

Do not use attachments and/or optional parts or

equipment not authorized by Hitachi. Failure to do so

may deteriorate the safety, function, and/or service life

of the machine. In addition, personal accident, machine

trouble, and/or damage to material caused by using

unauthorized attachments and/or optional parts or

equipment will void Hitachi Warranty Policy.

The safety messages in this SAFETY chapter are intended

to illustrate basic safety procedures of machines. However

it is impossible for these safety messages to cover every

hazardous situation you may encounter. If you have any

questions, you should first consult your supervisor and/

or your authorized dealer before operating or performing

maintenance work on the machine.

SA-003

SAFETY

S-3

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.

To ensure that a fire extinguisher can be always used

when necessary, check and service the fire extinguisher

at the recommended intervals as specified in the fire

extinguisher manual.

Establish emergency procedure guidelines to cope with

fires and accidents.

Keep emergency numbers for doctors, ambulance

service, hospital, and fire department posted near your

telephone.

Wear Protective Clothing

Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

A hard hat

Safety shoes

Safety glasses, goggles, or face shield

Heavy gloves

Hearing protection

Reflective clothing

Wet weather gear

Respirator or filter mask.

Be sure to wear the correct equipment and clothing for the

job. Do not take any chances.

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

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

Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones while

operating the machine.

SA-438

SA-437

SAFETY

S-4

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.

Inspect Machine

Inspect your machine carefully each day or shift by walking

around it before you start it to avoid personal injury.

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

described in the “Inspect Machine Daily Before Starting”

section in the operator’s manual.

SA-435

SA-434

SAFETY

S-5

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.

Do not make a mess around the operator's seat with

parts, tools, soil, stones or other, obstacles that may fold

up or turn over such as cans or lunch box. The levers or

pedals become inoperable if an obstacle jams during the

operation stroke of the accelerator pedal, brake pedals,

control lever lock switch or control levers, which may

result in serious injury or death.

Avoid storing transparent bottles in the cab. Do not

attach any transparent type window decorations on

the windowpanes as they may focus sunlight, possibly

starting a fire.

Refrain from listening to the radio, or using music

headphones or mobile telephones in the cab while

operating the machine.

Keep all flammable objects and/or explosives away from

the machine.

After using the ashtray, always cover it to extinguish the

match and/or tobacco.

Do not leave cigarette lighters in the cab. When the

temperature in the cab increases, the lighter may

explode.

Correctly lay the floor mat specific to the machine. If

another floor mat is used, it may be displaced and contact

with the accelerator or brake pedals during operation,

resulting in serious injury or death.

SAFETY

S-6

Use Handrails and Steps

Falling is one of the major causes of personal injury.

When you get on and off the machine, always face the

machine and maintain a three-point contact with the

steps and handrails.

Do not use any controls as handholds.

Never jump on or off the machine. Never mount or

dismount a moving machine.

Before getting on or off the machine, check the condition

of the steps and handrails for sticking of slippery material

like grease or mud. Thoroughly remove such material if

stuck. In addition, repair the damage to the steps and/or

handrails. Retighten loose bolts.

Never get on and off the machine with tools in your

hands.

Never Ride Attachment

Never allow anyone to ride on attachment or the load. This

is an extremely dangerous practice.

Adjust Operator’s Seat

A seat which is poorly adjusted for the individual operator,

or the work to be undertaken, may quickly fatigue the

operator leading to misoperation.

The seat should be adjusted whenever the operator of

the machine changes.

The operator should be able to fully depress the pedals

and to correctly operate the control levers with his back

against the seat back.

If not, move the seat forward or backward, and check

again.

Adjust the rear view mirror position so that the best rear

visibility is obtained from the operator’s seat. If the mirror

is broken, immediately replace it with a new one.

SA-439

SA-462

SAFETY

S-7

Ensure Safety Before Rising from or Leaving

Operator’s Seat

Before rising from the operator’s seat to open / close either

side window or to adjust the seat position, be sure to first

lower the front attachment to the ground and then move

the control lever lock switch to the lock ( ) position. Failure

to do so may allow the machine to unexpectedly move

when a body part unintentionally comes in contact with a

control lever, possibly resulting in serious personal injury or

death.

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

attachment to the ground and then move the control

lever lock switch to the lock ( ) position. Turn the key

switch OFF to stop the engine.

Before leaving the machine, close all windows, doors, and

access covers and lock them.

Fasten Your Seat Belt

If the machine should overturn, the operator may become

injured and/or thrown from the cab. Additionally the

operator may be crushed by the overturning machine,

resulting in serious injury or death.

Prior to operating the machine, thoroughly examine

webbing, buckle and attaching hardware. If any item is

damaged or worn, replace the seat belt or component

before operating the machine.

Be sure to remain seated with the seat belt securely

fastened at all times when the machine is in operation to

minimize the chance of injury from an accident.

We recommend that the seat belt be replaced every three

years regardless of its apparent condition.

SA-237

SAFETY

S-8

Move and Operate Machine Safely

Bystanders can be run over.

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

location of bystanders before moving, or operating the

machine.

Always keep the travel alarm and horn in working

condition (if equipped). It warns people when the

machine starts to move.

Use a signal person when moving, or operating the

machine in congested areas. Coordinate hand signals

before starting the machine.

Use appropriate illumination. Check that all lights are

operable before operating the machine. If any faulty

illumination is present, immediately repair it.

Ensure the cab door, windows, doors and covers are

securely locked.

Check the mirrors and the monitor in the cab for

problems.

If there is any problem, replace the problem part(s) or

clean the mirror, camera and the monitor.

Refer to Rear View Monitor section for information on

cleaning the camera lens and the monitor display.

Handle Starting Aids Safely

Starting fluid:

Starting fluid is highly flammable.

Keep all sparks and flame away when using it.

Keep starting fluid well away from batteries and cables.

Remove container from machine if engine does not need

starting fluid.

To prevent accidental discharge when storing a

pressurized container, keep the cap on the container, and

store it in a cool, well-protected location.

Do not incinerate or puncture a starting fluid container.

SA-293

SA-398

Hitachi ZW140-6 User manual

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