Hitachi ZW 150-6 150PL-6 Wheel Loader Workshop Manual - PDF DOWNLOAD

PART NO.

WPTC50-EN-01

ZW150-6 • 150PL-6 WHEEL LOADER

Workshop Manual

WORKSHOP MANUAL

ZW

150-6 150PL-6 Wheel Loader

URL:http://www.hitachi-c-m.com

WPTC50-EN-01

PRINTED IN JAPAN (K) 2018, 07

Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TOPTC50-EN Technical Manual (Troubleshooting) : Vol. No.TTPTC50-EN Workshop Manual : Vol. No.WPTC50-EN

SECTION 1

GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling

Precautions for Disassembling and Assembling..................................................................W1-1-1-1

Group 2 Tightening

Tightening Bolts and Nuts...........................................W1-2-1-1 Piping Joint.......................................................................W1-2-1-4

Group 3 Painting

Painting..............................................................................W1-3-1-1 Painting (Parallel Link)...................................................W1-3-2-1

Group 4 Bleed Air from Circuit

Bleeding Air from Hydraulic System........................W1-4-1-1 Bleeding Air from Fuel System...................................W1-4-1-3 Bleeding Air from Brake (Axle)...................................W1-4-1-4

Group 5 Preparation

Preparation before Inspection and Maintenance...............................................................W1-5-1-1 Hydraulic Circuit Pressure Release Procedure......W1-5-1-6 Pressure Release from Ride Control Accumulator................................................................W1-5-1-7 Pressure Release from Hydraulic Oil Tank..............W1-5-1-8 Pressure Release from Expansion Tank...................W1-5-1-9

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SECTION 2

MAINTENANCE STANDARD CONTENTS Group 1 Body

Center Hinge....................................................................W2-1-1-1

Group 2 Front Attachment

Pin and Bushing...............................................................W2-2-1-1 Standard Dimensions for Lift Arm and Bucket.....W2-2-2-1 Cylinder..............................................................................W2-2-3-1

Group 3 Front Attachment (Parallel Link)

Pin and Bushing...............................................................W2-3-1-1 Standard Dimensions for Quick Coupler and Bucket............................................................................W2-3-2-1 Cylinder..............................................................................W2-3-3-1

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SECTION 3

VEHICLE CONTENTS Group 1 Cab

Removal and Installation of Cab...............................W3-1-1-1

Group 2 Counterweight

Removal and Installation of Counterweight.........W3-2-1-1 Removal and Installation of Counterweight (Parallel Link)...............................................................W3-2-2-1

Group 3 Center Hinge

Removal and Installation of Center Hinge.............W3-3-1-1 Removal and Installation of Center Hinge (Parallel Link)...............................................................W3-3-2-1

Group 4 Engine

Removal and Installation of Engine.........................W3-4-1-1 Removal and Installation of Cab...............................W3-4-1-2

Group 5 Radiator Assembly

Removal and Installation of Radiator Assembly......................................................................W3-5-1-1

Group 6 Hydraulic Oil Tank

Removal and Installation of Hydraulic Oil Tank................................................................................W3-6-1-1

Group 7 Fuel Tank

Removal and Installation of Fuel Tank.....................W3-7-1-1

Group 8 Pump Device

Removal and Installation of Pump Device.............W3-8-1-1 Removal and Installation of Cab...............................W3-8-1-2 Disassembly of HST Pump...........................................W3-8-2-1 Assembly of HST Pump.................................................W3-8-2-5 Disassembly of 3-Gear Pump.....................................W3-8-3-1 Assembly of 3-Gear Pump...........................................W3-8-3-6 Removal and Installation of Priority Valve.............W3-8-4-1 Structure of Priority Valve............................................W3-8-5-1

Group 9 Control Valve

Removal and Installation of Control Valve.............W3-9-1-1 Removal and Installation of Control Valve (Parallel Link)...............................................................W3-9-2-1 Disassembly of Control Valve (Parallel Link)..........W3-9-3-1 Assembly of Control Valve (Parallel Link)............ W3-9-3-10

Group 10 Pilot Valve

Removal and Installation of Pilot Valve................ W3-10-1-1 Disassembly of Pilot Valve........................................ W3-10-2-1 Assembly of Pilot Valve.............................................. W3-10-2-4

WPTC50-EN-01

Removal and Installation of Auxiliary Pilot Valve............................................................................ W3-10-3-1 Disassembly of Pilot Valve........................................ W3-10-4-1 Assembly of Pilot Valve.............................................. W3-10-4-4 Disassembly of Pilot Valve (Two Lever Type)...... W3-10-5-1 Assembly of Pilot Valve (Two Lever Type)........... W3-10-5-7 Disassembly of Auxiliary Pilot Valve...................... W3-10-6-1 Assembly of Auxiliary Pilot Valve........................... W3-10-6-4

Group 11 Brake Charge Valve

Removal and Installation of Brake Charge Valve............................................................................ W3-11-1-1 Structure of Brake Charge Valve............................. W3-11-2-1 Removal and Installation of Brake Accumulator............................................................. W3-11-3-1

Group 12 Manifold Valve

Removal and Installation of Manifold Valve....... W3-12-1-1 Disassembly of Manifold Valve............................... W3-12-2-1 Assembly of Manifold Valve..................................... W3-12-2-3

Group 13 Solenoid Valve

Removal and Installation of Front Attachment Load Reduction Control Solenoid Valve........ W3-13-1-1 Structure of Front Attachment Load Reduction Control Solenoid Valve................... W3-13-2-1 Removal and Installation of Coupler Cylinder Selector Solenoid Valve (Parallel Link)............ W3-13-3-1 Structure of Coupler Cylinder Selector Solenoid Valve......................................................... W3-13-4-1 Removal and Installation of Quick Coupler Pilot Solenoid Valve (Parallel Link)................... W3-13-5-1

Group 15 Cooling Fan System

Removal and Installation of Fan Valve.................. W3-15-1-1 Structure of Fan Valve................................................. W3-15-2-1 Removal and Installation of Fan Motor................ W3-15-3-1 Structure of Fan Motor............................................... W3-15-4-1 Removal and Installation of Fan Pump................ W3-15-5-1 Disassembly of Fan Pump......................................... W3-15-6-1 Assembly of Fan Pump.............................................. W3-15-6-3

Group 16 Ride Control Device

Removal and Installation of Ride Control Valve............................................................................ W3-16-1-1 Removal and Installation of Ride Control Valve (Parallel Link)................................................ W3-16-2-1 Disassembly of Ride Control Valve........................ W3-16-3-1

Assembly of Ride Control Valve.............................. W3-16-3-4 Removal and Installation of Ride Control Accumulator............................................................. W3-16-4-1

Group 17 Battery Disconnect Switch

Removal and Installation of Battery Disconnect Switch................................................. W3-17-1-1

Group 18 Aftertreatment Device

Removal and Installation of Aftertreatment Device......................................................................... W3-18-1-1

Group 19 DEF Tank

Removal and Installation of DEF Tank.................. W3-19-1-1

Group 20 Coolant Control Valve

Removal and Installation of Coolant Control Valve............................................................................ W3-20-1-1

Group 21 DEF Supply Module

Removal and Installation of DEF Supply Module....................................................................... W3-21-1-1

Group 22 Exterior Parts

Removal and Installation of Exterior Parts.......... W3-22-1-1

Group 23 Parallel Link (Special Parts)

Removal and Installation of Bucket Regenerative Valve ............................................... W3-23-1-1 Structure of Bucket Regenerative Valve.............. W3-23-2-1 Removal and Installation of Bucket Regenerative Selector Valve............................... W3-23-3-1 Structure of Bucket Regenerative Selector Valve............................................................................ W3-23-4-1

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SECTION 4

TRAVEL SYSTEM CONTENTS Group 1 Tire

Removal and Installation of Front Tire....................W4-1-1-1 Removal and Installation of Rear Tire......................W4-1-2-1

Group 2 Drive Unit

Removal and Installation of HST Motor..................W4-2-1-1 Disassembly of HST Motors 1, 2.................................W4-2-2-1 Assembly of HST Motors 1, 2......................................W4-2-2-3 Removal and Installation of Transmission.............W4-2-3-1 Disassembly of Transmission......................................W4-2-4-1 Assembly of Transmission......................................... W4-2-4-10 Disassembly of Clutch Assembly..............................W4-2-5-1 Assembly of Clutch Assembly....................................W4-2-5-3 Disassembly of Clutch Pressure Control Solenoid Valve............................................................W4-2-6-1 Assembly of Clutch Pressure Control Solenoid Valve...............................................................................W4-2-6-3

Group 3 Axle

Removal and Installation of Front Axle...................W4-3-1-1 Removal and Installation of Rear Axle.....................W4-3-2-1 Disassembly of Axle.......................................................W4-3-3-1 Assembly of Axle.......................................................... W4-3-3-17

Group 4 Propeller Shaft

Removal and Installation of Propeller Shaft..........W4-4-1-1

Group 5 Brake Valve

Removal and Installation of Brake Valve.................W4-5-1-1 Disassembly of Brake Valve.........................................W4-5-2-1 Assembly of Brake Valve...............................................W4-5-2-3

Group 6 Steering Device

Removal and Installation of Steering Valve...........W4-6-1-1 Disassembly of Steering Valve...................................W4-6-2-1 Assembly of Steering Valve.........................................W4-6-2-4 Removal and Installation of Steering Cylinder.....W4-6-3-1 Disassembly of Steering Cylinder.............................W4-6-4-1 Assembly of Steering Cylinder...................................W4-6-4-5 Removal and Installation of Steering Accumulator................................................................W4-6-5-1

Group 7 Emergency Steering Device

Removal and Installation of Emergency Steering Pump............................................................W4-7-1-1

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SECTION 5

FRONT ATTACHMENT CONTENTS Group 1 Front Attachment

Removal and Installation of Front Attachment....W5-1-1-1 Removal and Installation of Bell Crank...................W5-1-2-1 Removal and Installation of Bucket..........................W5-1-3-1 Removal and Installation of Bushing.......................W5-1-4-1

Group 2 Cylinder

Removal and Installation of Lift Arm Cylinder......W5-2-1-1 Removal and Installation of Bucket Cylinder........W5-2-2-1 Disassembly of Lift Arm Cylinder..............................W5-2-3-1 Assembly of Lift Arm Cylinder....................................W5-2-3-5 Disassembly of Bucket Cylinder................................W5-2-4-1 Assembly of Bucket Cylinder .....................................W5-2-4-5

Group 3 Front Attachment (Parallel Link)

Removal and Installation of Front Attachment....W5-3-1-1 Removal and Installation of Quick Coupler...........W5-3-2-1

Group 4 Cylinder (Parallel Link)

Removal and Installation of Lift Arm Cylinder......W5-4-1-1 Removal and Installation of Bucket Cylinder........W5-4-2-1 Removal and Installation of Quick Coupler Cylinder.........................................................................W5-4-3-1 Disassembly of Lift Arm Cylinder..............................W5-4-4-1 Assembly of Lift Arm Cylinder....................................W5-4-4-5 Disassembly of Bucket Cylinder................................W5-4-5-1 Assembly of Bucket Cylinder......................................W5-4-5-4 Disassembly of Quick Coupler Cylinder..................W5-4-6-1 Assembly of Quick Coupler Cylinder.......................W5-4-6-4

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INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

The machine specification and description according to destination may be explained on this manual.

 If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):  Technical Information Center Hitachi Construction Machinery Co., Ltd.  TEL: 81-29-832-7084  FAX: 81-29-831-1162  E-mail: HCM-TIC-GES@hitachi-kenki.com

 Be sure to thoroughly read this manual for correct product information and service procedures.

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

Manual Composition  Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.

This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.  Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T 1 3 5

 Workshop Manual: W 1-3-2-5 W 1 3 2 5

Technical Manual Section Number Group Number Consecutive Page Number for Each Group

Trademark AdBlue® is a registered trademark of the Verband der Automobilindustrie e.V. (VDA).

WPTC50-EN-01

IN-1

Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

d

CAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death.

d This is the safety alert symbol. When you see this

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed along with the safety alert symbol.

The safety alert symbol is also used to draw attention to component/part weights.

To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

fNOTE: Indicates supplementary technical information or knowhow.

Units Used SI Units (International System of Units) are used in this manual.

A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

mm

in

0.03937

mm

ft

0.003281

L

US gal

0.2642

L

US qt

1.057

m3

yd3

1.308

Weight

kg

lb

2.205

Force

N

kgf

0.10197

N

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

MPa

psi

145.0

Power

kW

PS

1.360

kW

HP

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Flow rate

WPTC50-EN-01

-1

IN-2

0.10197 2

10.197

SYMBOL AND ABBREVIATION Symbol / Abbreviation TO TT T/M W, W/M MC ECM VGS

GSM

GPS CAN

A/C OP, OPT MPDr. A/I WU Li ATT HI, Hi LO, Lo

WPTC50-EN-01

Name

Explanation

Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual

Technical manual (Operational Principle).

Technical manual (Troubleshooting).

Technical manual.

Workshop manual (Removal and Installation, Disassembly and Assembly).

Main Controller Main controller. MC controls the engine, pump, and valve according to the machine operating condition.

Engine Control Module Engine controller. ECM controls fuel injection amount according to the machine operating condition.

Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged system to supercharge the exhaust energy while running the engine at slow idle speed. VGS optimizes the turbine rotation, improves the performance at slow-speed torque and the acceleration, reduces fuel consumption, and reduces particulate matter (PM) by adjusting the nozzle opening of turbine housing.

Global System for Mobile communications Communication controller. GSM is a type of wireless controller communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone.

Global Positioning System Global positioning system.

Controller Area Network CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization).

Air Conditioner Air conditioner.

Option Optional component.

Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and adjustment.

Auto-Idle Auto-idle.

Warming-Up Warming-up.

Low (Slow) Idle Slow idle engine speed.

Attachment Attachment. Attachment is optional parts such as breaker, crusher, and pulverizer in this manual.

High Travel fast position.

Low Travel slow position.

SY-1

SYMBOL AND ABBREVIATION Symbol / Name Abbreviation DPF Diesel Particulate Filter

DPD

Diesel Particulate Diffuser

DOC

Diesel Oxidation Catalyst

CSF

Catalyzed Soot Filter

PM EGR

Particulate Matter Exhaust Gas Recirculation

HRV LLC SCR

Hose Rupture Valve Long Life Coolant Selective Catalytic Reduction

DCU

Dosing Control Unit

S/M

Supply Module

D/M

Dosing Module

NOx DEF

Nitrogen Oxide Diesel Exhaust Fluid

WPTC50-EN-01

Explanation DPF is a filter which removes particulate matter (PM) including the toxic substance of exhaust gas of the diesel engine. Exhaust particulate removal equipment.

DPD is an exhaust emission control system, a type of DPF, which cleans up particulate matter (PM) of diesel engine exhaust gas. DPD is a ceramic filter which traps and filters PM of exhaust gas. DPD burns up accumulated PM when PM increases and regenerates the filter.

Oxidation catalyst for the diesel engine. Diesel oxidation catalyst oxidizes unburnt fuel and raises exhaust temperature.

Filter. The filter traps, burns, and remove particulate matter (PM) by using high-temperature-exhaust gas with diesel oxidation catalyst. Catalyst is applied onto the filter. This advances PM burning.

Particulate matter.

The EGR control re-circulates a part of exhaust gas in the intake manifold and combines it with intake-air. Therefore, combustion temperature is lowered and generation of oxide of nitrogen (NOx) is controlled.

Hose rupture valve.

Long life coolant.

The urea SCR system injects diesel exhaust fluid to nitrogen oxide (NOx) exhausted from the engine and purifies NOx. Urea SCR system controller. DCU controls the diesel exhaust fluid injection amount according to the machine operating condition.

Diesel exhaust fluid supply module. The diesel exhaust fluid supply module pumps diesel exhaust fluid to the dosing module (D/M). Then, it returns diesel exhaust fluid in the diesel exhaust fluid circuit when the key switch is turned OFF. Dosing module. The dosing module (D/M) injects diesel exhaust fluid into the exhaust piping according to the signal from DCU. Nitrogen oxide.

Diesel exhaust fluid. The diesel exhaust fluid concentration is 32.5 %, which is specified in ISO22241.

SY-2

SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices.

SA-688

Understand Signal Words  On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.  DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.  WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.  CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.  DANGER or WARNING safety signs signs are located near specific hazards. General precautions are listed on CAUTION safety signs.  Some safety signs are occasionally used on this machine that do not use any of the designated signal words mentioned above after the safety alert symbol.  CAUTION also calls attention to safety messages in this manual.  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. 

f NOTE Indicates an additional explanation for an a piece of information.

WPTC50-EN-01

SA-1

SA-1223

SAFETY Follow Safety Instructions  Carefully read and follow all safety signs on the machine and all safety messages in operator's manual.  Safety signs should be installed, maintained and replaced when necessary.  If a safety sign or operator's 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.

WPTC50-EN-01

SA-2

SA-003

SAFETY Prepare for Emergencies  Be prepared for a fire or an accident.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly.  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.

SA-437

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.

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SA-3

SA-438

SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

Inspect Machine  Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.  In the walk-around inspection, be sure to cover all points described in the “Inspect Machine Daily Before Starting” section in the operator’s manual.

SA-435

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SA-4

SAFETY General Precautions for the Cab  Before entering the cab, thoroughly remove all dirt and/ or oil such as mud, grease, soil or stones from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.  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.

WPTC50-EN-01

SA-5

SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as handholds.  Never jump on or off the machine. Never mount or dismount a moving machine.  Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.  Never get on and off the machine with tools in your hands.

SA-439

Never Ride Attachment  Never allow anyone to ride 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.

WPTC50-EN-01

SA-6

SA-462

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

WPTC50-EN-01

SA-7

SA-237

SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.  Use a signal person when moving, or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Use appropriate illumination. Check that all lights are 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.

SA-398

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

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SA-8

SAFETY Operate Only from Operator’s Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  Never start the engine while standing on the tire or on ground.  Do not start engine by shorting across starter terminals.  Before starting the engine, confirm that all control levers are in neutral.  Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-431

Jump Starting  Battery gas can explode, resulting in serious injury.  If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING ENGINE” chapter in the operator’s manual.  The operator must be in the operator’s seat so that the machine will be under control when the engine starts.

Jump starting is a two-person operation.  Never use a frozen battery.  Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

WPTC50-EN-01

SA-9

SA-032

SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.  Make a work plan. Use machines appropriate to the work and job site.  Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.  When working on an incline or on a road shoulder, employ a signal person as required.  Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist.  When the ground footing is weak, reinforce the ground before starting work.  When working on frozen ground, be extremely alert. As ambient temperatures rise, the ground footing becomes loose and slippery.  Beware of the possibility of fire when operating the machine near flammable objects such as dry grass.

WPTC50-EN-01

SA-10

SA-447

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

ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

SA-521

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

SA-481

WPTC50-EN-01

SA-11

SAFETY Keep Riders Off Machine  Riders on the machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

SA-427

Drive Safely  Beware of the possibility of the machine slipping and/or turning over when driving on a slope.  When driving on level ground, hold the bucket at mark (A) 300 mm (12 in) above the ground as illustrated.  Avoid traveling over any obstacles.  Drive the machine slowly when driving on rough terrain.  Avoid quick direction changes. Failure to do so may cause the machine to turn over.  If the engine stops while driving, the steering function becomes inoperative. Immediately stop the machine by applying the brake to prevent personal accident.

SA-448

WPTC50-EN-01

SA-12

SAFETY Drive Machine Safely (Work Site)  Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

SA-449

 When driving up or down a slope, keep the bucket facing the direction of travel, approximately 200 to 300 mm (approximately 8 to 12 in) (A) above the ground.  If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.  Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-450

WRONG

SA-451

WPTC50-EN-01

SA-13

SAFETY Drive Safely with Bucket Loaded  If the machine is incorrectly operated while driving with the bucket loaded, turning over of the machine may result. Be sure to follow all the instructions indicated below.  When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.  Do not exceed the rated load capacity. Always operate the machine within the rated load capacity.  Avoid fast starts, stops, and quick turns. Failure to do so may result in personal injury and/or death.  Avoid rapid drive direction changes which could possibly cause personal injury and/or death.

SA-400

Drive on Snow Safely  Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces.  The machine may slip more easily than expected on frozen snow surfaces even if the inclination is small.

Reduce speed when driving. Avoid fast starts, stops and quick turns.  Road shoulder and/or set-up utilities covered with snow are difficult to locate. Make sure of their location before removing snow.  Be sure to use tire chains when driving on snow.  Avoid applying the brake for quick stops on snow. If a quick stop is required, lower the bucket to the ground.

WPTC50-EN-01

SA-14

SA-452

SAFETY Travel on Public Roads Safely  This machine is not allowed to drive on public roads with the bucket loaded.  Be sure to empty the bucket.  Hold the bucket at mark (A) 300 mm (12 in) above the road surface as illustrated.

SA-453

Avoid Injury from Rollaway Accidents  Death or serious injury may result if you attempt to mount or stop a moving machine.

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

SA-457

SA-458

WPTC50-EN-01

SA-15

SAFETY Avoid Accidents from Backing Up and Turning  Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine.  Keep all personnel away from the machine by sounding the horn and/or using hand signals. Use extra care to be sure no one is in the articulation area before turning the machine.  Keep windows, mirrors, and lights in good condition.  Reduce travel speed when dust, heavy rain, fog, etc., reduce the visibility.  If good visibility is not obtained, use a signal person to guide you.

SA-383

SA-312

WPTC50-EN-01

SA-16

SAFETY Avoid Positioning Bucket or Attachment Over Anyone  Never allow the bucket or attachment to pass over coworkers and/or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket or attachment may cause serious personal accidents and/or damage to the machine.  Avoid carrying the bucket or attachment over the coworkers to ensure safe operation.

SA-518

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

To avoid tipping:  Be extra careful before operating on a gradient.  Prepare machine operating area flat.  Keep the bucket low to the ground and close to the machine.  Reduce operating speeds to avoid tipping or slipping.  Avoid changing direction when traveling on gradients.  If crossing the gradient is unavoidable, never attempt to travel across a gradient steeper than 5 degrees.  Reduce swing speed as necessary when swinging loads.  Be careful when working on frozen ground.  Temperature increases will cause the ground to become soft and make ground travel unstable.

WPTC50-EN-01

SA-17

SA-463

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

SA-519

Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.  Before digging, check the location of cables, gas lines, and water lines.  Keep the minimum distance required by law, from cables, gas lines, and water lines.  If a fiber optic cable is accidentally severed, do not look into the end. Doing so may result in serious eye injury.  Contact your local “diggers hot line” if available in your area , and/or the utility companies directly.

Have them mark all underground utilities.

SA-396

Perform Truck Loading Safely  Do not operate the machine involuntarily. Unexpected machine movement may cause personal injury and/or death.  Do not lower the bucket with the lift arm control lever in the FLOAT position. The bucket may free fall, possibly causing personal injury and/or death.  Always select a level surface for truck loading.

SA-397

WPTC50-EN-01

SA-18

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

When operating near an electric line, never move any part of the machine or load to within 3 m (10 ft) plus twice the line insulator length of overhead wires.

SA-455

Precautions for Operation  If the front attachment or any part of the machine comes in contact with an overhead obstacle, both the machine and the overhead obstacle may become damaged, and personal injury may result.  Take care to avoid coming in contact with overhead obstacles with the bucket or arm during operation.

Precautions for Lightning  Lightning may strike the machine.

If lightning comes close, immediately stop the operation, and take the following action.  When you are around the machine or operating cabless machine, evacuate to a safe place far away from the machine.  When you are in the cab, stay in the cab until lightning has passed and safety is secured. Close the cab doors and windows. Lower the bucket to the ground, and stop the engine. Put your hands on your lap to avoid contact with any metal surfaces. Never go out of the cab.

If lightning strikes the machine or near the machine, check all of the machine safety devices for any failure after lightning has passed and safety is secured. If any trouble is found, operate the machine only after repairing it.

M4GB-0S-001

WPTC50-EN-01

SA-19

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

Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example). They may come off, causing the load to fall.

SA-132

Protect Against Flying Debris  If flying debris hit eyes or any other part of the body, serious injury may result.  Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.  Keep bystanders away from the working area before striking any object.

SA-432

WPTC50-EN-01

SA-20

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

SA-456

Store Attachments Safely  Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.  Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

SA-034

WPTC50-EN-01

SA-21

SAFETY Transport Safely  Be aware care that the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.  Observe the related regulations and rules for safe transportation.  Select an appropriate truck or trailer for the machine to be transported.  Be sure to use a signal person.  Always follow the following precautions for loading or unloading: 1. Select solid and level ground.

2. Always use a ramp or deck strong enough to support the machine weight.

3. Use the low speed gear.

4. Never steer the machine while on the ramp. If the traveling direction must be changed while on the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

5. After loading, install the lock bar to securely hold the articulation mechanism.

6. Wedge the front and rear of tires. Securely hold the machine to the truck or trailer deck with wire ropes.

Be sure to further follow the details described in the TRANSPORTING chapter of operator's manual.

WPTC50-EN-01

SA-22

Less than 15 ° SA-454

SAFETY Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.  Always stop the engine before refueling the machine.  Fill the fuel tank outdoors.  All fuels, most lubricants, and some coolants are flammable.  Store flammable fluids well away from fire hazards.  Do not incinerate or puncture pressurized containers.  Do not store oily rags; they can ignite and burn spontaneously.  Securely tighten the fuel and oil filler caps.

SA-018

SA-019

WPTC50-EN-01

SA-23

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

Before servicing the machine: 1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Run the engine at low idle speed without load for 5 minutes.

SA-028

4. Turn the key switch to OFF to stop engine.

5. Relieve the pressure in the hydraulic system by moving the control levers several times.

6. Remove the key from the key switch.

7. Attach a “Do Not Operate” tag on the control lever.

8. Turn the control lever lock switch to the lock ( ) position.

9. Lock bar connects the front and rear frames.

10. Allow the engine to cool.  If a maintenance procedure must be performed with the engine running, do not leave machine unattended.  Never work under a machine raised by the lift arm.  Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of operator's manual.  Keep all parts in good condition and properly installed.  Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.  When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.  Disconnect battery ground cable (-) before making adjustments to electrical systems or before performing welding on the machine.

SA-312

SA-134

SA-527

WPTC50-EN-01

SA-24

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

SA-037

Warn Others of Service Work  Unexpected machine movement can cause serious injury.  Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

SS2045102

Support Machine Properly  Never attempt to work on the machine without securing the machine first.  Always lower the attachment to the ground before you work on the machine.  If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

SA-527

WPTC50-EN-01

SA-25

SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

Support Maintenance Properly  Explosive separation of a tire and rim parts can cause serious injury or death.  Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

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

WPTC50-EN-01

SA-26

SA-249

SAFETY Prevent Parts from Flying  Travel reduction gears are under pressure.  As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.  GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

SA-344

Prevent Burns Hot spraying fluids:  After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.  Avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.  The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces:  Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.  Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

WPTC50-EN-01

SA-27

SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.  Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)  Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

Avoid High-Pressure Fluids  Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.  Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.  Tighten all connections before applying pressure.  Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.  If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours, or gangrene may result.

SA-031

SA-292

SA-044

WPTC50-EN-01

SA-28

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

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

WPTC50-EN-01

SA-29

SA-019

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

Check Key Switch:  If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check key switch function before operating the machine every day: 1. Start the engine and run it at low idle.

2. Turn the key switch to the OFF position to confirm that the engine stops.  If any abnormalities are found, be sure to repair them before operating the machine.

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

WPTC50-EN-01

SA-30

SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time.  Exit the machine.  In an emergency, if the cab door can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation pages on the Emergency Evacuation Method.

SA-393

SS-1510

Beware of Exhaust Fumes  Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.  If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.  PM (Particle Matter) combustion may generate white smoke during aftertreatment device regeneration. Do not attempt to perform aftertreatment device manual regeneration in a badly ventilated indoors.

SA-016

Precautions for Welding and Grinding  Welding may generate gas and/or small fires.  Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.  Only qualified personnel should perform welding.

Never allow an unqualified person to perform welding.  Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding.  After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

WPTC50-EN-01

SA-31

SA-818

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

Avoid Applying Heat to Lines Containing Flammable Fluids

SA-030

 Do not weld or flame cut pipes or tubes that contain flammable fluids.  Clean pipes and tubes thoroughly with non-flammable solvent before welding or flame cutting.

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

Strictly comply with the following items:  Do not disassemble the unit.  Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing of the unit, sealed gas must be released.

Consult your nearest Hitachi dealer.

WPTC50-EN-01

SA-32

SAFETY Remove Paint Before Welding or Heating  Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.  Avoid potentially toxic fumes and dust.  Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.  Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

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

SA-029

Beware of Asbestos and Silica Dust and Other Contamination  Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung cancer.

Inhalation of silica dust and other contamination may cause sickness.  Depending on the work site conditions, the risk of inhaling asbestos fiber, silica dust or other contamination may exist. Spray water to prevent asbestos fibers, silica dust or other contamination from becoming airborne. Do not use compressed air.  When operating the machine in a work site where asbestos fibers, silica dust or other contaminations might be present, be sure to operate the machine upwind, and wear a mask rated to prevent the inhalation of asbestos, silica dust or other contaminations.  Keep bystanders out of the work site during operation.  Asbestos might be present in non-genuine parts. Use only genuine Hitachi Parts.

WPTC50-EN-01

SA-33

SA-029

SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.  Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first.  Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.  Loose terminals may produce sparks. Securely tighten all terminals.  Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.

SA-032

 Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.  Be sure to wear eye protection when checking electrolyte specific gravity.

Service Air Conditioning System Safely  If spilled onto skin, refrigerant may cause a cold contact burn.  Refer to the instructions described on the container for proper use when handling the refrigerant.  Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.  Never touch the refrigerant.

SA-405

WPTC50-EN-01

SA-34

SAFETY Handle Chemical Products Safely  Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.  A Safety Data Sheet (SDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.  Check the SDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.  See your authorized dealer for SDS’s (available only in English) on chemical products used with your machine.

SA-2579

Dispose of Waste Properly  Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Hitachi equipment includes such items as oil, fuel, coolant, DEF/AdBlue®, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.  Do not pour waste onto the ground, down a drain, or into any water source.  Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.  Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

WPTC50-EN-01

SA-35

SA-226

SAFETY Notes on Aftertreatment Device About Aftertreatment Device The aftertreatment device removes particulate matter (PM) and NOx (Nitrogen Oxide) from the exhaust gas. Follow the instructions below to prevent the aftertreatment device from being damaged.

Exhaust gas from the aftertreatment dWARNING: device, muffler, exhaust piping and tail piping becomes hot during and right after engine running and regeneration of aftertreatment device. Keep away from the exhaust system or hot gas from the exhaust piping during regeneration. Be careful to avoid skin contact with exhaust gas. It may cause severe burns. ď‚– White smoke may be generated during aftertreatment device regeneration. Do not attempt to perform aftertreatment device manual regeneration in a badly ventilated area. ď‚– Do not touch water coming directly out of the aftertreatment device. The water is mildly-acidic by oxidation catalyst mounted in the aftertreatment device.

If filter water spills on your skin, immediately flush it out with clean water.

Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices.

Inquire to the device manufacturer for information on electrical wave disturbance when using an electronic device near the communication terminal.

WPTC50-EN-01

SA-36

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

Any person fitted with a medical device such as the above should not use this machine, unless the medical device and the rear tray are at least 22 centimeters (8.662 inches) apart at all times. If this condition cannot be met, please contact your authorized dealer and have the person in charge stop the communication terminal equipment from functioning completely and confirm that it is not emitting electrical waves.

This machine is equipped with a communication terminal type A or type B. Consult your nearest authorized dealer for the type of communication terminal.

Specific Absorption Rate ("SAR") (measured by 10 g per unit) of communication terminal equipments: Type A Type B E-GSM900 0.573 W/kg (914.8 MHz) 0.12 W/kg (897.6 MHz) DCS-1800 0.130 W/kg (1710.2 MHz) 0.06 W/kg (1748.0 MHz) 0.271 W/kg (1950.0 MHz) 0.05 W/kg (1950.0 MHz) WCDMA Band I 0.10 W/kg (892.6 MHz) WCDMA Band VIII * This data was measured by having each type of communication terminal equipment, such as the communication terminal equipment used with this machine, and a human body set apart by 3 cm (1.18 inches). * SAR is a measure of the amount of radio frequency energy absorbed by the body when using a wireless application such as a mobile phone.

In Japan: * Under the Japanese Radio Act and other relevant Japanese regulations, the maximum SAR value is 2 W/kg (as of March 2010).

In EU Member nation: * Under the "Council Recommendation 1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg (as of March 2010).

WPTC50-EN-01

SA-37

MNEC-01-046

SAFETY  Never attempt to disassemble, repair, modify or displace the communication terminal, antennas or cables. Failure to do so may result in damage and/or fire to the base machine or to the communication terminal. (When required to remove or install the communication terminal, consult your nearest Hitachi dealer.)  Do not pinch or forcibly pull cables, cords or connectors.

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

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

SA-435

WPTC50-EN-01

SA-38

SECTION AND GROUP SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and CONTENTS Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air Group 5 Preparation WORKSHOP MANUAL

SECTION 2 MAINTENANCE STANDARD Group 1 Body Group 2 Front Attachment Group 3 Front Attachment (Parallel Link)

SECTION 3 VEHICLE

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

COPYRIGHT(C)2018 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

WPTC50-EN-01

Group 1 Cab Group 2 Counterweight Group 3 Center Hinge Group 4 Engine Group 5 Radiator Assembly Group 6 Hydraulic Oil Tank Group 7 Fuel Tank Group 8 Pump Device Group 9 Control Valve Group 10 Pilot Valve Group 11 Brake Charge Valve Group 12 Manifold Valve Group 13 Solenoid Valve Group 14 Missing Number Group 15 Cooling Fan System Group 16 Ride Control Device Group 17 Battery Disconnect Switch Group 18 Aftertreatment Device Group 19 DEF Tank Group 20 Coolant Control Valve Group 21 DEF Supply Module Group 22 Exterior Components Group 23 Parallel Link (Special Parts)

(Blank)

WPTC50-EN-01

SECTION AND GROUP SECTION 4 TRAVEL SYSTEM Group 1 Tire CONTENTS

WORKSHOP MANUAL

Group 2 Drive Unit Group 3 Axle Group 4 Propeller Shaft Group 5 Brake Valve Group 6 Steering Device Group 7 Emergency Steering Device

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Front Attachment (Parallel Link) Group 4 Cylinder (Parallel Link)

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

COPYRIGHT(C)2018 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

WPTC50-EN-01

(Blank)

WPTC50-EN-01

SECTION 1

GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling

Precautions for Disassembling and Assembling..................................................................W1-1-1-1

Group 2 Tightening

Tightening Bolts and Nuts...........................................W1-2-1-1 Piping Joint.......................................................................W1-2-1-4

Group 3 Painting

Painting..............................................................................W1-3-1-1 Painting (Parallel Link)...................................................W1-3-2-1

Group 4 Bleed Air from Circuit

Bleeding Air from Hydraulic System........................W1-4-1-1 Bleeding Air from Fuel System...................................W1-4-1-3 Bleeding Air from Brake (Axle)...................................W1-4-1-4

Group 5 Preparation

Preparation before Inspection and Maintenance...............................................................W1-5-1-1 Hydraulic Circuit Pressure Release Procedure......W1-5-1-6 Pressure Release from Ride Control Accumulator................................................................W1-5-1-7 Pressure Release from Hydraulic Oil Tank..............W1-5-1-8 Pressure Release from Expansion Tank...................W1-5-1-9

WPTC50-EN-01

PTC50W-1-1

(Blank)

WPTC50-EN-01

PTC50W-1-2

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling Precautions for Disassembling  Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling / assembling, resulting in damage to machine components as well as decreased efficiency in service work.  Inspect the Machine Be sure to thoroughly understand all disassembling / assembling procedures beforehand to help avoid incorrect disassembling of components as well as personal injury.

Check and record the items listed below to prevent problems from occurring in the future.  The machine model, machine serial number, and hour meter reading.  Reason for disassembly (symptoms, failed parts, and causes).  Clogging of filters and oil, water, or air leaks, if any.

Capacities and condition of lubricants.  Loose or damaged parts.  Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.

Precautions for Disassembling and Assembling  Precautions for Disassembling  Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling.  Before disassembling, clean the exterior of the components and place on a workbench.  Drain hydraulic oil and gear oil from the hydraulic components and reduction gear.  Be sure to provide appropriate containers for draining fluids.  Use matching marks for easier reassembling if necessary.  Be sure to use the specified special tools when instructed.

WPTC50-EN-01

 If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause (s), and then take the appropriate measures to remove it.  Orderly arrange disassembled parts. Mark and tag them if necessary.  Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.  Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage.  Measure and record the degree of wear and clearances.  Precautions for Assembling  Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part.  Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces.  Apply appropriate lubricant oil to parts in order to prevent them from seizing.  Be sure to replace O-rings, backup rings, oil seals, and floating seals with new ones once they have been disassembled. Apply grease before installing.  Be sure that liquid-gasket-applied surfaces are clean and dry.  If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent.  Fit the matching marks made when disassembling and assemble them.  Be sure to use the designated tools to assemble bearings, bushings, and oil seals.  Keep a record of the number of tools used for disassembly / assembly. After assembling is completed, count the number of tools so as to make sure that no forgotten tools remain in the assembled machine.

W1-1-1-1

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Floating Seal

1

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

If the floating seal is required to be reused, follow these procedures:

 Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil to sliding surface (e) of seal ring (1).  Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear.

Check the step part of seal ring (1).  Check O-ring (2) for tears, breaks, deformation, or hardening.

W178-02-11-001

2

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble.  Clean the floating seal and seal mounting bores with cleaning solvent.

Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with compressed air.  Clean seal ring (1) and O-ring (2) mounting bores.

Check the bore surface for scuffing or scoring by touching the surface with finger.  After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1).  After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating surface (f ) by measuring the distances between (e) and (f ) at point (A) and (B), as illustrated.

If these distances differ, correct O-ring (2) seating.

a

c b d W178-02-11-002 a - Correct b - Incorrect

c - Twist of O-Ring d - Bend of O-Ring f a

b

A

A

e

2

B

A=B

B

A≠B W178-02-11-003

a - Correct b - Incorrect

WPTC50-EN-01

W1-1-1-2

e - Sliding Surface f - Seal Mating Surface

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Nylon Sling a

1. Follow the precautions below to use nylon slings safely.  Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping.  Lower the temperature of the lifted load to lower than 100 °C (212 °F). If the temperature of the lifted load is over 100 °C (212 °F), do not lift the load.  Do not lift acid or alkali chemicals.  Take care not to allow the sling to become wet. The load may slip.  When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced.  When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load.

(Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force.  Avoid using twisted, bound, connected, or hitched slings.  Do not place any object on twisted or bent slings.

(Refer to the right illustration.)  When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions.  Avoid dragging slings on the ground, throwing slings, or pushing slings with a metal object.  When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged.  Store the nylon slings indoors so that they won’t deteriorate with heat, sun light, or chemicals.

W102-04-02-016 a - Correct Eyehole Lifting Method b

W105-04-01-008 b - Incorrect Eyehole Lifting Method

c c - Bent of Sling

WPTC50-EN-01

W1-1-1-3

W162-01-01-009

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling If a load is lifted with a damaged dCAUTION: nylon sling, serious personal injury may result.

Be sure to visually check the nylon sling for any damage before using.

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to following examples. If any damage is found, cut and discard the sling.

Even if no damage is found, do not use slings older than 7 years.

Damaged Appearance

a a

W162-01-01-002 a - Broken Sewing Thread

W162-01-01-006

e a - Broken Sewing Thread

e - Separation of Belt

f

b

W162-01-01-003 b - Scuffing

b b - Scuffing

f -

W162-01-01-007

Scoring

c c

g

d

W162-01-01-004 c - Fuzz

W162-01-01-008

d - Broken Sewing Thread c - Fuzz a

W162-01-01-005 a - Broken Sewing Thread

WPTC50-EN-01

W1-1-1-4

g - Broken Warp

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated if necessary.

“Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit.

2. Repair or adjustment is difficult after exceeding this limit.

3. Repair or adjustment is impossible after exceeding this limit.

Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit”.

WPTC50-EN-01

W1-1-1-5

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling (Blank)

WPTC50-EN-01

W1-1-1-6

SECTION 1 GENERAL Group 2 Tightening Tightening Bolts and Nuts Use tools appropriate for the work dCAUTION: to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools.

Otherwise, tightening tools may slip, potentially causing personal injure.

Bolt Types Tighten the nuts or bolts correctly to the torque specifications.

As the different types and grades of bolt are used, use and tighten the correct bolts correctly when assembling the machine or components.

WDAA-01-02-001

Specified Tightening Torque Chart 2013/09 Bolt Dia. mm

Hexagon Head Bolt Wrench Size mm WDAA-01-02-002

N·m 6 8 10 12 14 16 18 20 22 24 27 30 33 36

30 65 110 180 270 400 550 750 950 1400 1950 2600 3200

WPTC50-EN-01

(lbf·ft) (22) (48) (81) (133) (200) (300) (410) (550) (700) (1030) (1440) (1920) (2360)

WDAA-01-02-003

N·m 20 50 90 140 210 300 400 550 700 1050 1450 1950 2450

(lbf·ft) (15) (37) (66) (103) (155) (220) (300) (410) (520) (770) (1070) (1440) (1810)

Socket Bolt Socket Bolt

Wrench Size mm

WDAA-01-02-004

N·m 3 to 4 10 20 35 55 80 120 170 220 280 400 550 750 950

(lbf·ft) (2.2 to 3) (7.4) (15) (26) (41) (59) (89) (125) (162) (205) (300) (410) (550) (700)

W1-2-1-1

N·m 10 13 17 19 22 24 27 30 32 36 41 46 50 55

20 50 90 140 210 300 400

(lbf·ft) (15) (37) (66) (103) (155) (220) (300)

5 6 8 10 12 14 14 17

SECTION 1 GENERAL Group 2 Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads.  Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it)  Torque tolerance is ±10 %.  Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of bolt hole.

Also the bolts that are too short cannot develop sufficient tightening force.  The torque given in the chart on the previous page are for general use only, however, a different torque is given for a specific application. Use the specified torque.  Clean the nut and bolt threads and remove dirt or corrosion before installing.

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

b

a

c

1 1, 4

12

9

4

1

6

7

14

13

8

5

2

3

10

11

3

6

5

4 2 2, 3

W105-01-01-003 a - Equally tighten upper and lower alternately

WPTC50-EN-01

b - Tighten diagonally

W1-2-1-2

c - Tighten from center diagonally

SECTION 1 GENERAL Group 2 Tightening Precautions for Spilt Flange IMPORTANT:  Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause oil leaks and damage to the O-ring.  Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces.

When installing O-ring into a groove, use grease in order to hold O-ring in place.  While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring.  Tighten the bolts up and down, right and left alternately, in order to ensure even tightening to the specified torque.  Do not use an impact wrench. It is difficult to evenly tighten the bolts by using an impact wrench. Using an impact wrench often causes uneven tightening of bolts or damage to O-rings.

WDAA-01-02-005

Incorrect

WDAA-01-02-006

Nut and Bolt Locking W105-01-01-008

 Lock Plate IMPORTANT: Do not reuse the lock plates. Do not try to bend the same point twice.

Incorrect

Correct

 Split Pin IMPORTANT: Do not turn in the loosening direction in order to align the grooves and holes on the nut.

Always turn in the tightening direction. Do not reuse the split pins.

a

b

Correct

Correct

Incorrect

 Wire IMPORTANT: Attach wires to bolts in the bolttightening direction. Do not reuse the wires. a a-

WDAA-01-02-007

Bend along edge sharply

Correct

b-

Do not bend it round

Correct

Correct

Incorrect

d

Incorrect

c

WDAA-01-02-008 c-

WPTC50-EN-01

W1-2-1-3

Tighten

d-

Loosen

SECTION 1 GENERAL Group 2 Tightening Piping Joint IMPORTANT:  The torque given in table below are for general use only, however, a different torque is given for a specific application. Use the specified torque.  Apply lubricant, such as the Grease Spray to the bolts and nuts in order to reduce friction coefficient of them.  Torque tolerance is ±10 %.  Slightly apply lubricant onto the threads first by using the Grease Spray.

WPTC50-EN-01

W1-2-1-4

SECTION 1 GENERAL Group 2 Tightening Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.

IMPORTANT:  Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking the adapter. Tighten union nut (3) to the specifications.  Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting / disconnecting.

2013/09 Description Wrench Size mm Tightening Torque Union Nut N·m (lbf·ft) 30 ° male 17 25 (18.5) 19 30 (22) 22 40 (29.5) 27 80 (59) 32 140 (103) 36 180 (133) 41 210 (155) 50 350 (260) 55 380 (280) 60 380 (280) 37 ° female 17 25 (18.5) 19 30 (22) 22 40 (29.5) 27 80 (59) 32 140 (103) 36 180 (133) 41 210 (155) 50 350 (260)

1

3

5

a - Joint Body

2

a

WDAA-01-02-009

37 ° 30 °

b b - Male Union Joint

fNOTE:

Tightening torque of 37 ° male coupling without union is similar to tightening torque of 37° female.

WPTC50-EN-01

4

W1-2-1-5

c c - Female Union Joint WDAA-01-02-010

SECTION 1 GENERAL Group 2 Tightening Pipe Joint Pipe connection (metal joint) (Union Nut Wrench Size: 17, 19, 22, 27) Metal (3) of adapter (1) and pipe (2) seals pressure oil.  Precautions for use Do not damage sealing surfaces (4) and (5) when disassembling and assembling.

1

4

5

3

2

Tightening Torque Use the specified tightening torque in the table below.

2013/09 Wrench Size (mm) 17 19 22 27 Tightening N·m 25 30 40 80 Torque (lbf·ft) (18.5) (22) (29.5) (59)

M1M7-07-005

O-Ring Face Seal Joint O-ring (6) is installed against the end surface of adapter (7) and seals pressure oil.

IMPORTANT:  Replace O-ring (6) with the new one when reinstalling.  Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.  Do not damage O-ring groove (8) of adapter (7) or sealing surface (10) on the hose side. Damage to O-ring (6) may cause oil leakage.  If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak.

Instead, replace O-ring (6) with the new one, and then tighten union nut (9) after confirming that O-ring (6) is securely seated in O-ring groove (8).

WPTC50-EN-01

7

6

8

9

10

a - Joint Body

2013/09 Wrench Size mm Tightening Torque Union Nut N·m (lbf·ft) 19 30 (22) 22 70 (52) 27 95 (70) 32 140 (103) 36 180 (133) 41 210 (155) 50 350 (260)

W1-2-1-6

a

WDAA-01-02-011

SECTION 1 GENERAL Group 2 Tightening Quick Coupling

3

1. Coupling procedure  Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you.  Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked completely by ball (2). At this time, check if socket ring (1) is returned to the original position (to the rightmost direction).

2. Separating procedure  Remove the hose by rotating socket ring (1) fully counterclockwise and then pulling it. Because no check function is attached inside, be careful that oil flows out.  Cap the removed hoses using special plug.

CAUTION:

d

 When disconnecting, do not damage joint surface.  When disconnecting, clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign material from entering.  Complete the joint disconnecting / connecting procedure. Check enough if oil leaks especially after installation.  After installation, check if socket ring (1) is returned to the original position (to the rightmost direction).

WPTC50-EN-01

W1-2-1-7

1

2

M1M7-07-006

SECTION 1 GENERAL Group 2 Tightening Screw-In Connection

R

G

Depending on types of screw and sealing, different types of screw-in connection are used.

IMPORTANT: Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

a

b

a - Male Tapered Thread

b - Male Straight Thread W105-01-01-018

Wrench Size mm Joint Body Seal Tape Application Seal tape is used in order to seal clearances between male (d) and female (c) threads so that any leaks between threads may be prevented. Therefore, apply just enough seal tape to fill up thread clearances (e). Do not overwrap.  Application Procedure Check that the thread surface is clean and, free of dirt or damage. Apply the seal tape around threads in order to leave one to two pitch threads uncovered. Wrap the seal tape in the same direction as the threads.

19 22 27 36 41 50 60

fNOTE:

2013/09 Tightening Torque Cast iron Structural rolled steel 15 (11) 35 (26) 30 (22) 50 (37) 50 (37) 95 (70) 70 (52) 160 (118) 110 (81) 200 (148) 160 (118) 330 (245) 200 (148)

Unit: N·m (lbf·ft) c

e

d

Low-Pressure-Hose Clamp Tightening Low-pressure-hose clamp tightening torque differs depending on the type of clamp. Tighten them according to each step.

c - Internal Thread d - External Thread

W105-01-01-019

e - Clearance f

 T-Bolt Type Band Clamp (g)  Worm Gear Type Band Clamp (h)

f -

Leave one to two pitch threads uncovered g

h

WDAA-01-02-012 g - T-Bolt Type Band Clamp

WPTC50-EN-01

W1-2-1-8

M114-07-041

M114-07-043 h - Worm Gear Type Band Clamp

SECTION 1 GENERAL Group 2 Tightening Connecting Hose When replacing the hoses, use only dCAUTION: genuine Hitachi service parts. Using hoses other

Correct

Incorrect

than genuine Hitachi hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install kinked hoses. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize the print marks on hoses when installing in order to prevent hose from being kinked. Take necessary measures to protect hoses from rubbing against each other. If the hoses rub against each other, wear to the hoses may result and lead to hose rupture. Take care so that the hoses do not come into contact with the moving parts or sharp objects.

W105-01-01-011

Incorrect

a

Correct

W105-01-01-012 a - Rubbing Against Each Other

b

Incorrect

Correct

b

a

W105-01-01-013 a - Rubbing Against Each Other

b - Clamp

Correct

Incorrect

a b W105-01-01-014 a - Rubbing Against Each Other

WPTC50-EN-01

W1-2-1-9

b - Clamp

SECTION 1 GENERAL Group 2 Tightening (Blank)

WPTC50-EN-01

W1-2-1-10

SECTION 1 GENERAL Group 3 Painting Painting 7

8

9

6 5 11

4 3

12

2

13 14

1

15 16 10

17

18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Surfaces to Be Painted Lift Arm Bell Crank Pipe Bracket (Control Valve) Bracket (Bucket Auto-Leveler) Bucket Cylinder Lift Arm Auto Leveler Pipe Pin (Lift Arm) Pipe (Lift Arm Cylinder) Pin (Lift Arm Cylinder) Lift Arm Cylinder Pin (Bucket Cylinder) Pin (Bell Crank) Pin (Bucket Link) Bucket Link Bucket Teeth

WPTC50-EN-01

WPTC50-01-03-101

Painting Colour YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow]

W1-3-1-1

SECTION 1 GENERAL Group 3 Painting

1

2

9 3

4 8

5

7

WNDB-01-03-001

6

1 2 3 4 5 6 7 8 9

Surfaces to Be Painted Cab (Outside) Plate Handrail Rear Console (Inner) Seat Bracket Cab Under Cover Cockpit Side Console (Inner) Cab (Inside)

WPTC50-EN-01

Painting Colour P1-01 [High Grade Black] Y1-03 [Shining Silver] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black]

W1-3-1-2

SECTION 1 GENERAL Group 3 Painting

8 1

2

3

9

4

5 6

20

10 19

11 18

17

16 15

14

13

WPTC50-01-03-102

12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Surfaces to Be Painted Light Bracket Pipe (Steering Cylinder) Support Cover Engine cover Pipe (Rain Cap) Cover Hydraulic Oil Tank Filter Cover Rear Cover Rear Grill Plate Handle Side Cover Lower Cover Filter Bracket Pipe Articulation Lock Bar Steering Cylinder Pin (Steering Cylinder)

WPTC50-EN-01

7

Painting Colour P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] Refer to W1-3-1-4.

P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] TCM Red YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow]

W1-3-1-3

SECTION 1 GENERAL Group 3 Painting

1

2

1 2

Surfaces to Be Painted Side Cover (Top) Side Cover (Bottom)

WPTC50-EN-01

WPTC50-01-03-103

Painting Colour YR1-01 [TAXI Yellow] P1-01 [High Grade Black]

W1-3-1-4

SECTION 1 GENERAL Group 3 Painting

11 2

12

3 1

13 4 5

6 10

1 2 3 4 5 6 7 8 9 10 11 12 13

7 9

Surfaces to Be Painted Rear Fender (Front) Battery Box Rear Fender (Front) (Cover) Step (Rear) Deck Step (Cab) Cover (Step) Front Fender (Cover) Front Fender Front Cover Rear Fender (Rear) Bracket (Rear Fender (Rear)) Bracket (Mud Guard)

WPTC50-EN-01

8

WPTC50-01-03-104

Painting Colour P1-01 [High Grade Black] YR1-01 [TAXI Yellow] Do not paint it.

P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] Do not paint it.

YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] Do not paint it.

P1-01 [High Grade Black] P1-01 [High Grade Black]

W1-3-1-5

SECTION 1 GENERAL Group 3 Painting

3

4

5

2

11 1

6

12 7 8 9 WPTC50-01-03-105

10

1 2 3 4 5 6 7 8 9 10 11 12

Surfaces to Be Painted Front Frame Plate Support (Real Axle) Pin Counterweight Fuel Tank Rear Axle Inspection Cover Rear Frame Front Axle Plate (Rear Combination Lamp) Under Guard

WPTC50-EN-01

Painting Colour YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] Refer to W1-3-1-8.

YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] Refer to W1-3-1-9.

YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow]

W1-3-1-6

SECTION 1 GENERAL Group 3 Painting

2

1

WPTC50-01-03-106

1 2

Surfaces to Be Painted Rim (17.5) Rim (20.5) Bracket (Under Mirror)

WPTC50-EN-01

Painting Colour YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black]

W1-3-1-7

SECTION 1 GENERAL Group 3 Painting B

3 4

A

1

2 2

5

WMDF-01-03-105

6 View A

View B

7

WMDF-01-03-106

8

1 2 3 4 5 6 7 8

Surfaces to Be Painted Rear Axle Rim (Wheel) Mounting Part (Shaded Area) Axle End Boss Part (Shaded Area) Boss Part (Shaded Area) Flange Part (Shaded Area) Name Plate End of Boss Part (Shaded Area)

WPTC50-EN-01

WMDF-01-03-107

Painting Colour P1-01 [High Grade Black] Do not paint it.

YR1-01 [TAXI Yellow] Do not paint it.

Do not paint it.

Do not paint it.

Do not paint it.

Do not paint it.

W1-3-1-8

SECTION 1 GENERAL Group 3 Painting 1

3

2

4

1

6 7

5

WMDF-01-03-108

A

View A

7

WNEC-01-03-012

1 2 3 4 5 6 7

Surfaces to Be Painted Rim (Wheel) Mounting Part (Shaded Area) Axle End Front Axle Axle Mounting Part (Shaded Area) Flange Part (Shaded Area) Name Plate Nut Surface (Shaded Area)

WPTC50-EN-01

Painting Colour Do not paint it.

YR1-01 [TAXI Yellow] P1-01 [High Grade Black] Do not paint it.

Do not paint it.

Do not paint it.

Do not paint it.

W1-3-1-9

SECTION 1 GENERAL Group 3 Painting (Blank)

WPTC50-EN-01

W1-3-1-10

SECTION 1 GENERAL Group 3 Painting Painting (Parallel Link)

9

10

11

12 13

8

14

7 6 5

15

4 3

16

2 17

1 18 19

20

WNDF-01-03-121

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Surfaces to Be Painted Guide Pin (Guide) Bucket Link Pin (Bucket Cylinder) Pipe Bracket (Bucket Auto-Leveler) Bucket Cylinder Bracket (Control Valve) Pipe Pipe Pin (Bell Crank) Bell Crank Pin (Lift Arm) Pin (Link) Pin (Lift Arm Cylinder) Link Lift Arm Cylinder Lift Arm Pin (Coupler) Quick Coupler

WPTC50-EN-01

Painting Colour P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black]

W1-3-2-1

SECTION 1 GENERAL Group 3 Painting

View A A

3

WNDF-01-03-122 View B

4

C B

WNDF-01-03-123

2

1

Detail C

WNDF-01-03-121

5 WPTC50-01-03-001

1 2 3 4 5

Surfaces to Be Painted Teeth Bucket Lift Arm Auto Leveler Quick Coupler Indicator Pipe (Lift Arm Cylinder)

WPTC50-EN-01

Painting Color P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] Red P1-01 [High Grade Black]

W1-3-2-2

SECTION 1 GENERAL Group 3 Painting

1

2

9 3

4 8

5

7

WNDB-01-03-001

6

1 2 3 4 5 6 7 8 9

Surfaces to Be Painted Cab (Outside) Plate Handrail Rear Console (Inner) Seat Bracket Cab Under Cover Cockpit Side Console (Inner) Cab (Inside)

WPTC50-EN-01

Painting Colour P1-01 [High Grade Black] Y1-03 [Shining Silver] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black]

W1-3-2-3

SECTION 1 GENERAL Group 3 Painting

8 1

2

3

9

4

5 6

20

10 19

11 18

17

16 15

14

13

WPTC50-01-03-102

12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Surfaces to Be Painted Light Bracket Pipe (Steering Cylinder) Support Cover Engine cover Pipe (Rain Cap) Cover Hydraulic Oil Tank Filter Cover Rear Cover Rear Grill Plate Handle Side Cover Lower Cover Filter Bracket Pipe Articulation Lock Bar Steering Cylinder Pin (Steering Cylinder)

WPTC50-EN-01

7

Painting Colour P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] Refer to W1-3-2-5.

P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] Red YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow]

W1-3-2-4

SECTION 1 GENERAL Group 3 Painting

1

2

1 2

Surfaces to Be Painted Side Cover (Top) Side Cover (Bottom)

WPTC50-EN-01

WPTC50-01-03-103

Painting Colour YR1-01 [TAXI Yellow] P1-01 [High Grade Black]

W1-3-2-5

SECTION 1 GENERAL Group 3 Painting

11 2

12

3 1

13 4 5

6 10

1 2 3 4 5 6 7 8 9 10 11 12 13

7 9

Surfaces to Be Painted Rear Fender (Front) Battery Box Rear Fender (Front) (Cover) Step (Rear) Deck Step (Cab) Cover (Step) Front Fender (Cover) Front Fender Front Cover Rear Fender (Rear) Bracket (Rear Fender (Rear)) Bracket (Mud Guard)

WPTC50-EN-01

8

WPTC50-01-03-104

Painting Colour P1-01 [High Grade Black] YR1-01 [TAXI Yellow] Do not paint it.

P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] Do not paint it.

YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] Do not paint it.

P1-01 [High Grade Black] P1-01 [High Grade Black]

W1-3-2-6

SECTION 1 GENERAL Group 3 Painting

3

4

5

2

11 1

6

12 7 8 9 WPTC50-01-03-105

10

1 2 3 4 5 6 7 8 9 10 11 12

Surfaces to Be Painted Front Frame Plate Support (Real Axle) Pin Counterweight Fuel Tank Rear Axle Inspection Cover Rear Frame Front Axle Plate (Rear Combination Lamp) Under Guard

WPTC50-EN-01

Painting Colour YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] Refer to W1-3-2-9.

YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] Refer to W1-3-2-10.

YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow]

W1-3-2-7

SECTION 1 GENERAL Group 3 Painting

2

1

WPTC50-01-03-106

1 2

Surfaces to Be Painted Rim (17.5) Rim (20.5) Bracket (Under Mirror)

WPTC50-EN-01

Painting Colour YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black]

W1-3-2-8

SECTION 1 GENERAL Group 3 Painting B

3 4

A

1

2 2

5

WMDF-01-03-105

6 View A

View B

7

WMDF-01-03-106

8

1 2 3 4 5 6 7 8

Surfaces to Be Painted Rear Axle Rim (Wheel) Mounting Part (Shaded Area) Axle End Boss Part (Shaded Area) Boss Part (Shaded Area) Flange Part (Shaded Area) Name Plate End of Boss Part (Shaded Area)

WPTC50-EN-01

WMDF-01-03-107

Painting Colour P1-01 [High Grade Black] Do not paint it.

YR1-01 [TAXI Yellow] Do not paint it.

Do not paint it.

Do not paint it.

Do not paint it.

Do not paint it.

W1-3-2-9

SECTION 1 GENERAL Group 3 Painting 1

3

2

4

1

6 7

5

WMDF-01-03-108

A

View A

7

WNEC-01-03-012

1 2 3 4 5 6 7

Surfaces to Be Painted Rim (Wheel) Mounting Part (Shaded Area) Axle End Front Axle Axle Mounting Part (Shaded Area) Flange Part (Shaded Area) Name Plate Nut Surface (Shaded Area)

WPTC50-EN-01

Painting Colour Do not paint it.

YR1-01 [TAXI Yellow] P1-01 [High Grade Black] Do not paint it.

Do not paint it.

Do not paint it.

Do not paint it.

W1-3-2-10

SECTION 1 GENERAL Group 4 Bleed Air from Circuit Bleeding Air from Hydraulic System

IMPORTANT: If air accumulates inside the hydraulic piping of the transmission charge pump, and if the engine starts without sufficient transmission oil, the transmission charge pump and the HST motor may be damaged and it may make the vehicle impossible to run.  Bleeding Air from Transmission Charge Pump

Bleed air from the hydraulic system as follows when hydraulic oil has been drawn, the suction filter and suction pipe have been replaced, or the HST pump, transmission charge pump, and cylinders have been removed and installed.

IMPORTANT: If air accumulates inside the HST pump and if the engine starts without sufficient hydraulic oil, the HST pump may be damaged.  Bleeding Air from HST Pump 1. Remove air bleed plug (1) on top of the HST pump.

Add hydraulic oil to the HST pump. l : 6 mm

fNOTE:

WPTC50-01-04-001 ab-

Amount of oil: 2.5 L

3-Gear Pump Transmission Charge Pump

1. Open cover (4) at the left side step (2) section. Place a container under transmission oil filter (3). Check that the engine has not started and remove case (5) of transmission oil filter (3). j : 27 mm

WPTC50-01-04-004

4

2. After the HST pump is filled with hydraulic oil, temporarily tighten air bleed plug (1) on the HST pump. Then, start the engine and run it at slow idle speed.

2

3. Slightly loosen air bleed plug (1) and bleed air from the HST pump until hydraulic oil comes out from the gap.

3

4. After bleeding all air, securely tighten air bleed plug (1).

MNDF-07-007

l : 6 mm m : 30 N·m

5 WPTC50-01-04-005

WPTC50-EN-01

W1-4-1-1

SECTION 1 GENERAL Group 4 Bleed Air from Circuit 2. Start the engine and, when transmission oil gushes from the transmission oil filter, immediately stop the engine.

fNOTE: Standard Engine Start Time 5 to 7 seconds 3. Install case (5) of the transmission oil filter. j : 27 mm m : 78.6±4 N·m

IMPORTANT: If air accumulates inside the cylinder and if the cylinder operates suddenly without sufficient hydraulic oil, the seal may be damaged or the cylinder may seize.  Bleeding Air from Hydraulic Circuit 1. After refilling hydraulic oil, start the engine. While operating each cylinder several times evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation at first.

2. As the pilot circuit has an air bleed device, air in the pilot circuit will be bled while performing the above operation for approx. 5 minutes.

3. Return the position to check hydraulic oil level.

4. Stop the engine. Check the hydraulic oil level. Add hydraulic oil if necessary.

5 WPTC50-01-04-005

4. After completion of the work, check the transmission oil level and add transmission oil again if necessary.

WPTC50-EN-01

W1-4-1-2

SECTION 1 GENERAL Group 4 Bleed Air from Circuit Bleeding Air from Fuel System IMPORTANT: Air in the fuel system may make the engine hard to start or make it run irregularly.

When the engine has run out of fuel, when draining water from the fuel filter or fuel prefilter (a), or when replacing the fuel prefilter element, be sure to bleed air from the fuel system.

1. Loosen air bleed plug (1). Press feed pump (2) until fuel without bubbles flows out of the air bleed plug.

2. When air is bled, tighten air bleed plug (1) and press in feed pump (2) until it is secured.

3. After feed pump (2) is secured, press in the feed pump (2) disk part to the original position.

WPTC50-01-04-002

4. Start the engine. Check the fuel system for any fuel leaks.

a-

Prefilter

b-

Main Filter

WPTC50-01-04-003 a-

WPTC50-EN-01

W1-4-1-3

Prefilter

SECTION 1 GENERAL Group 4 Bleed Air from Circuit Bleeding Air from Brake (Axle) If air is mixed in the service brake dCAUTION: system, the brake function is reduced and a hazard may occur. Bleed air from the service brake system after removing and installing the service brake pipelines and replacing hydraulic oil.

1, 2 1, 2

fNOTE: Perform this work on all wheels (4 places) by two or more persons. Air bleeder (1) is located around the top surface center on front and rear axles.

T4GB-05-04-004

1. Set the parking brake switch of front console to the ON position, start the engine, and increase service brake oil pressure.

2. Remove cap (2) of air bleeder (1). Insert clear vinyl tube (3) into the ends of air bleeder (1). Insert the other ends of clear vinyl tube (3) into container (4) to prevent hydraulic oil from flying off.

3 1

3. Depress brake pedal (5) several times. While depressing brake pedal (5), loosen air bleeder (1) one-half to one turn to drain hydraulic oil.

4

j : 10 mm 4. After hydraulic oil is drained, tighten air bleeder (1) and return brake pedal (5) to the original position.

T4GB-05-04-005

5. Repeat step 3 to step 4 until clean hydraulic oil flows through vinyl tube (3) and bubbles disappear to a satisfactory extent.

6. After bubbles in vinyl tube (3) disappear, tighten air bleeder (1) while depressing brake pedal (5). j : 10 mm m : 10 N¡m 7. Bleed air from three other places in the same way as step 2 to step 6.

After air bleeding is completed in four dCAUTION: places, bleed air from the four places again and check that no air remains inside.

WPTC50-EN-01

W1-4-1-4

5

T4GB-05-04-006

SECTION 1 GENERAL Group 5 Preparation Preparation before Inspection and Maintenance

1

2

Components, hydraulic oil, lubricant, dCAUTION: and coolant just after operation are too hot. Allow oil to cool before starting any work.

Turn ride control switch (2) OFF. If the dCAUTION: switch is in the AUTO position, the lift arm may move up.

8. When the vehicle is stopped, dCAUTION: apply the parking brake. An unexpected vehicle movement may cause a serious accident.

Secure Work Place and Co-Workers Before starting the work, select wide and solid footing and keep bystanders away from the vehicle operating area. Slowly operate the front attachment. Secure coworkers according to the work. When working with coworkers, thoroughly check hand signals and sufficiently pay attention.

MNEC-07-001

3

4

5

Machine Position for Inspection and Maintenance Before performing the inspection and maintenance procedures given in the following items, park the machine as described below, unless otherwise specified.

1. Park the vehicle on a flat, solid surface.

2. Lock the frame. (Refer to W1-5-1-3.)

MNDB-01-001

3. Lower the bucket to the ground.

4. Cool down the engine for 5 minutes.

5. Set the front control lever lock switch (1) to the LOCK position.

4

6. Turn ride control switch (2) OFF. 7. Set forward/reverse lever (3) to the neutral N position and neutral lever lock (5) to the Lock position.

8. Apply the parking brake. (Parking Brake Switch (4): ON Position) 9. Turn key switch (6) OFF to stop the engine. Take out the key.

10. Secure the wheels with wedges.

WPTC50-EN-01

W1-5-1-1

MNEC-01-058

SECTION 1 GENERAL Group 5 Preparation 11. Before performing any work on the machine, attach the "Under Inspection/Maintenance" sign in a highly visible place of the door or the front control lever.

WPTC50-EN-01

W1-5-1-2

SECTION 1 GENERAL Group 5 Preparation Frame Lock Before starting work around frame dCAUTION: axis (1), install articulation lock bar (4) to secure the front and rear frames.

1. Set the front and rear frames of the vehicle to the forward position.

2. Remove β (beta) pin (3) and pull set pin (5) out of the front frame hole.

3. Turn articulation lock bar (4) until it is aligned with rear frame hole (2).

4. Install set pin (5) in rear frame hole (2) and the articulation lock bar (4) end hole. Install β (beta) pin (3) and secure articulation lock bar (4) in place.

WPTC50-EN-01

a-

Machine Front Side

a-

Machine Front Side

W1-5-1-3

WPTC50-01-05-001

WPTC50-01-05-002

SECTION 1 GENERAL Group 5 Preparation Never attempt to maintain the dCAUTION: machine when the engine is running in order to prevent accidents. If maintenance work with the engine running is unavoidable, strictly comply with the following items.  One person should take the operator's seat to be ready to stop the engine any time while communicating with other workers.  When working around moving parts such as the fan or the belt is unavoidable, do not approach with the hands, feet, and clothes, which can easily become entangled.

SA-2294

 If parts or tools are dropped or inserted into the fan or the belt, they may fly off or be cut off. Do not drop or insert parts and tools into moving parts.  Set the front control lever lock switch (1) to the LOCK position to prevent the front attachment from moving.  Never touch the control levers and pedals.

If operating the control levers or pedals is unavoidable, give hand signals to co-workers and evacuate them to a safer place.

SA-026

1

MNEC-07-001

WPTC50-EN-01

W1-5-1-4

SECTION 1 GENERAL Group 5 Preparation Machine Position for Inspection and Maintenance (Lift Arm Raise)

2

3

When performing inspection and dCAUTION: maintenance work with the lift arm raised, securely support the lift arm by using a solid support.

1

Set the machine for inspection and maintenance in the previous section in cases other than the following. (Refer to W1-5-1-1.)

WPTC50-01-05-005

1. Raise lift arm (3) and roll out bucket (2).

2. Securely support lift arm (3) (both sides) by using solid support (1).

3. Set the front control lever lock switch (4) to LOCK Position.

4

4. Turn the key switch OFF to stop the engine. Take out the key.

MNEC-07-001

WPTC50-EN-01

W1-5-1-5

SECTION 1 GENERAL Group 5 Preparation Hydraulic Circuit Pressure Release Procedure Release any remaining pressure as follows before removing/installing the front attachment.

1

1. Cool down the engine for 5 minutes.

2. Turn the key switch OFF to stop the engine.

fNOTE: The front attachment operation control circuit of this machine is equipped with an accumulator.

3. Turn the key switch ON and set the front control lever lock switch (1) to UNLOCK position (b).

4. With the key switch in the ON position, operate the front control lever in order to release any pressure in the hydraulic circuit 4 to 5 times.

5. Return the front control lever lock switch (1) to the LOCK position (a).

MNEC-07-001

6. Turn the key switch OFF.

a

b

MNEC-01-015 a-

WPTC50-EN-01

W1-5-1-6

LOCK Position

b-

UNLOCK Position

SECTION 1 GENERAL Group 5 Preparation Pressure Release from Ride Control Accumulator Release any remaining pressure as follows before removing/installing the ride control valve or the ride control accumulator.

1. Set the machine position for inspection and maintenance (Lift Arm Raise). (Refer to W1-5-1-5.)

1

2. Release any pressure from the hydraulic circuit.

(Refer to W1-5-1-6.)

3. Release any pressure in the hydraulic oil tank. (Refer to W1-5-1-8.)

4. Remove front cover (1). (Refer to W3-22-1.) j : 17 mm

WMDF-03-09-005

IMPORTANT: Before loosening nut (4), secure drain plug (3) by using a hexagonal wrench to prevent drain plug (3) from turning together.

5. Loosen nut (4) of ride control valve (2). j : 13 mm

2

l : 4 mm IMPORTANT: Do not loosen drain plug (3) more than one turn. It may be dropped off because of residual pressure.

6. Loosen drain plug (3) about one turn to release residual pressure. Tighten drain plug (3). l : 4 mm

A

m : 7 to 9 N¡m IMPORTANT: Before tightening nut (4), secure drain plug (3) by using a hexagonal wrench to prevent drain plug (3) from turning together.

7. Secure drain plug (3) with nut (4).

WMDF-03-16-001

j : 13 mm Detail A

m : 10 to 12 N¡m l : 4 mm 3

4

WNDB-01-05-001

WPTC50-EN-01

W1-5-1-7

SECTION 1 GENERAL Group 5 Preparation Pressure Release from Hydraulic Oil Tank 1

Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes and cause serious injury. Release pressure before disconnecting the hydraulic piping. Hot hydraulic oil just after operation may spout out and cause severe burns.

Allow oil to cool before starting any work.

Preparation 1. Park the vehicle on a flat, solid surface. Set the vehicle position for checking the hydraulic oil level.

(Refer to W1-5-1-1.)

2

2. Stop the engine. Push pressure release button (1) of hydraulic oil tank (3) and release any pressure from hydraulic oil tank (3).

W4FC-01-04-001

fNOTE: The pressure in hydraulic oil tank (3) becomes negative by installing vacuum pump (a) to the position where cap (2) is removed while operating vacuum pump (a). This operation prevents hydraulic oil from draining when disconnecting the hoses. Operate vacuum pump (a) continuously while working.

3 MNDF-07-010

a

b c

W1R7-01-04-002 a- b- c-

WPTC50-EN-01

W1-5-1-8

Vacuum Pump Hose Adapter

SECTION 1 GENERAL Group 5 Preparation Pressure Release from Expansion Tank Do not loosen cap (1) when the dCAUTION: coolant temperature of radiator is too high. Hot steam may spout out and cause severe burns. Wait until coolant cools and loosen cap slowly. Release all pressure and remove the cap.

Preparation 1. Park the vehicle on a flat, solid surface. Set the vehicle position for checking the hydraulic oil level.

(Refer to W1-5-1-1.)

2. Remove cap (1).

3. After stopping the engine, remove cap (2) of expansion tank (3).

WPTC50-01-05-003

WPTC50-01-05-004

WPTC50-EN-01

W1-5-1-9

SECTION 1 GENERAL Group 5 Preparation (Blank)

WPTC50-EN-01

W1-5-1-10

MEMO

WPTC50-EN-01

MEMO

WPTC50-EN-01

SECTION 2

MAINTENANCE STANDARD CONTENTS Group 1 Body

Center Hinge....................................................................W2-1-1-1

Group 2 Front Attachment

Pin and Bushing...............................................................W2-2-1-1 Standard Dimensions for Lift Arm and Bucket.....W2-2-2-1 Cylinder..............................................................................W2-2-3-1

Group 3 Front Attachment (Parallel Link)

Pin and Bushing...............................................................W2-3-1-1 Standard Dimensions for Quick Coupler and Bucket............................................................................W2-3-2-1 Cylinder..............................................................................W2-3-3-1

WPTC50-EN-01

PTC50W-2-1

(Blank)

WPTC50-EN-01

PTC50W-2-2

SECTION 2 MAINTENANCE STANDARD Group 1 Body Center Hinge  Upper Hinge Part (A)

 Lower Hinge Part (B)

1

2

4 6

5

a

a

3

WMDF-02-01-002

WMDF-02-01-001

A B

Part Name Pin (1) Bushings (2), (3) Pin (4) Bushings (5), (6)

WPTC50-EN-01

Standard (a) 75 (2.95) 75 (2.95) 70 (2.76) 70 (2.76)

W2-1-1-1

Allowable Limit (a) 74.0 (2.91) 76.5 (3.01) 69.0 (2.72) 71.5 (2.82)

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 1 Body (Blank)

WPTC50-EN-01

W2-1-1-2

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment Pin and Bushing 1 E

D

F a

C G H

B

1-

I

WNEC-02-03-001

Pin

2 A

W4GB-04-01-008

a

2-

A B C D E F G H I

Part Name Pin Bushing (Lift Arm) Pin Bushing (Bucket Link) Pin Bushing (Bell Crank) Pin Bushing (Bucket Cylinder) Pin Bushing (Bucket Cylinder) Pin Bushing (Lift Arm) Pin Bushing (Lift Arm Cylinder) Pin Bushing (Lift Arm Cylinder) Pin Bushing (Bucket Link)

WPTC50-EN-01

Standard (a) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 100 (3.94) 100 (3.94) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 85 (3.35) 85 (3.35) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95)

W2-2-1-1

Bushing

Allowable Limit (a) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 99.0 (3.40) 101.5 (4.00) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 84.0 (3.31) 86.5 (3.41) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01)

WNEC-02-03-002

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment (Blank)

WPTC50-EN-01

W2-2-1-2

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment Standard Dimensions for Lift Arm and Bucket 1

2

b i

d

h g

a

e f

c WMDF-02-03-001

1-

a b c d e f g h i

Bucket

2-

Lift Arm

Unit: mm (in) Dimensions 75 (2.95) 75 (2.95) 844 (9.23) 94 (3.70) 96 (3.78) 96 (3.78) 230 (9.06) 356 (2.02) 55 (2.17)

WPTC50-EN-01

W2-2-2-1

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment (Blank)

WPTC50-EN-01

W2-2-2-2

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment Cylinder Rod

Rod Bend and Run Out b a A

W166-04-02-022 c W105-04-02-094

Cylinder Name Lift Arm Bucket Steering

WPTC50-EN-01

Unit: mm (in) Recommended Size After Remanufacturing (A) 65-0.01-0.023 (2.56-0.0004-0.0009) 85-0.012-0.027 (3.35-0.0005-0.0010) 40-0.009-0.020 (1.58-0.0004-0.0008)

a- b-

Cylinder Rod Dial Gauge

Bend 1.0 mm/1 m (0.039 in/39.4 in)

d c- d-

V Block 1 m (39.4 in)

Run Out 2.0 mm/1 m (0.079 in/39.4 in)

Remedy Replace

IMPORTANT: When measuring the items, bend and run out of the cylinder rod, the distance (d) may not be able to keep 1 m (39.4 in). In this case, the distance (d) of measurement is the full length of the rod.

W2-2-3-1

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment (Blank)

WPTC50-EN-01

W2-2-3-2

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Parallel Link) Pin and Bushing 1 F G

E D

a H

C B

I

1-

WNEC-02-03-001

Pin

A

2

J K

a

L

WNDF-02-04-001

A B C D E F

Part Name Pin Bushing (Bucket Link) Pin Bushing (Bucket Link) Pin Bushing (Bucket Link) Pin Bushing (Link) Pin Bushing (Lift Arm) Pin Bushing (Bucket Cylinder)

WPTC50-EN-01

Standard (a) 60 60 60 60 60 60 75 75 75 75 60 60

W2-3-1-1

2-

Bushing

Allowable Limit (a) 59.0 (2.32) 61.5 (2.42) 59.0 (2.32) 61.5 (2.42) 59.0 (2.32) 61.5 (2.42) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 59.0 (2.32) 61.5 (2.42)

WNEC-02-03-002

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Parallel Link)

1 F G

E D

a H

C B

I

1-

WNEC-02-03-001

Pin

A

2

J K

a

L

WNDF-02-04-001

G H I J K L

Part Name Pin Bushing (Lift Arm) Pin Bushing (Link) Pin Bushing (Lift Arm Cylinder) Pin Bushing (Lift Arm) Pin Bushing (Lift Arm) Pin Bushing (Lift Arm)

WPTC50-EN-01

Standard (a) 85 85 75 75 75 75 75 75 60 60 75 75

W2-3-1-2

2-

Bushing

Allowable Limit (a) 84.0 (3.31) 86.5 (3.41) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 59.0 (2.32) 61.5 (2.42) 74.0 (2.91) 76.5 (3.01)

WNEC-02-03-002

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Parallel Link) Standard Dimensions for Quick Coupler and Bucket Bucket

f a

b c g

h

d e WNDF-02-04-002

Quick Coupler i

j

l n k

a b c d e f g

m

Dimensions 30.75 mm (1.21 in) 13° 647 mm (25.5 in) 50.5 mm (1.99 in) 200 mm (7.87 in) 82 mm (3.23 in) 473 mm (18.6 in)

WPTC50-EN-01

W2-3-2-1

WNDF-02-04-003

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Parallel Link)

Bucket

f a

b c g

h

d e WNDF-02-04-002

Quick Coupler i

j

l n k

h i j k l m n

m

Dimensions 50 mm (1.97 in) 61.5 mm (2.42 in) 600 mm (23.6 in) 139 mm (5.47 in) 50 mm (1.97 in) 55 mm (2.16 in) 470 mm (18.5 in)

WPTC50-EN-01

W2-3-2-2

WNDF-02-04-003

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Parallel Link) Cylinder Rod

Rod Bend and Run Out b a A

W166-04-02-022 c W105-04-02-094

Cylinder Name Lift Arm Bucket Steering Quick Coupler

WPTC50-EN-01

Unit: mm (in) Recommended Size After ReManufacturing (A) 65-0.010-0.023 (2.56-0.0004-0.0009) 60-0.030-0.076 (2.36-0.0012-0.0030) 40-0.009-0.020 (1.58-0.0004-0.0008) 25-0.020-0.053 (0.98-0.0008-0.0021)

a- b-

Cylinder Rod Dial Gauge

Bend 0.5 mm/1 m (0.020 in/39.4 in)

d c- d-

V Block 1 m (39.4 in)

Run Out 1.0 mm/1 m (0.039 in/39.4 in)

Remedy Replace

IMPORTANT: When measuring the items, bend and run out of the cylinder rod, the distance (d) may not be able to keep 1 m (39.4 in). In this case, measure the full length of the rod.

W2-3-3-1

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Parallel Link) (Blank)

WPTC50-EN-01

W2-3-3-2

MEMO

WPTC50-EN-01

MEMO

WPTC50-EN-01