ΜΑΙΝΤΕΝΑΝCΕ

Maintenance Guide
A. Greasing (See Page 7-28)

Interval (hours)
Parts Quantity Auto-Lube
10 50 250 500 1600 2000 3000
1. Front Axle, Trailing Arm Pivot 4 
2. Front Axle, Steering Cylinder 4 
3. Front Axle, King Pin Bushings 4 
4. Front Axle, Suspension Pivot 4 
5. Front Axle, Tie Rod 2 
6. Rear Axle, Pivot Bearing 2 
7. Rear Axle, Track Rod 2 
8. Rear Axle, Suspension Pivot 4 
9. Front Axle, Kingpin Thrust Bearing 4 
10. Pump, Drive Shaft 5 
11. Body, Hoist Cylinder Pivot 4 
12. Alternator (AC) 1 
13. Wheel Motor 4  2000 hours or 40000 km travel distance
14. Body, Hinge Pin 2 
15. Wheel Motor Cooling Blower Motor 2 

fNOTE:  Component must be greased manually at specified interval. Not incorporated in automated lubrication system.
 Auto-Lubrication System.

B. Engine (Cummins) (See Page 7-32)

Interval (hours)
Classification of Oil
Parts Quantity 250 to
(API Service Class) 10 50 1000 2000
500
1. Engine Oil Check Oil Level - 1
Premium Oil (CI-4) or 260L
2. Engine Oil Change 
Standard Oil (CH-4) (69 US gal)
3. Replace Engine Oil Filter - 4  

fNOTE:  First time only (Before factory departure, the machine is filled with genuine Hitachi Premium Orange 15W-40.)
 The engine oil filter should be replaced concurrently with the oil.

B. Engine (MTU) (See Page 7-36)

Interval (hours)
Parts Classification of Oil Quantity
10 50 500 1000 3000
1. Engine Oil Check Oil Level - 1
Min. API CG-4/CH-4 250L
2. Engine Oil Change 
and ACEA E2-96 (66 US gal)
3. Replace Engine Oil Filter - 4  
4. Clean/Replace Centrifugal Oil
- 1  
Filter

fNOTE:  First time only (Before factory departure, the machine is filled with genuine Hitachi Premium Orange 15W-40.)
 The engine oil filter should be replaced concurrently with the engine oil.

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C. Travel Reduction Gear (See Page 7-41)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Gear Oil Check Oil Level 2
180 L (47.6 US
2. Gear Oil Change 
gal)`×2
3. Gear Oil Filter Replacement 2 
Cleaning 2
4. Air Breather
Replacement 2 
5. Oil Cooler Core Cleaning 2

fNOTE:  First time only.

D. Hydraulic System (See page 7-45)

Interval (hours)
Parts Quantity
10 50 250 500 2000 2500 4000 12000
1. Check Hydraulic Oil Level 1
2. Drain Hydraulic Oil Tank Sump 1
3. Replace Full-Flow Filter Element 2 
4. Replace Line Filter Element 1
950 L (251
5. Change Hydraulic Oil
US gal)
6. Replace Suction Filter 1 When changing hydraulic oil
Check Hoses and Lines (for leak, loose) -
7.
Check Hoses and Lines (for crack, bend, etc.) -
8. Replace Hydraulic Oil Tank Breather 2

fNOTE:  First time only.

E. Fuel System (Cummins Engine) (See Page 7-63)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Drain Fuel Tank Sump 1
2. Drain Fuel Filter Stage 1 filter 1 Weekly or as required
3. Replace Fuel Filter Element Stage 1 filter 1
4. Replace Fuel Filter Stage 2 filter 3
Check Fuel Hoses (for leak, loose) -
5.
Check Fuel Hoses (for crack, bend, etc.) -
Clean Fuel Tank Breather 2
6.
Replace Fuel Tank Breather 2

fNOTE: The machine has 2 stage filtration system on the fuel suction line.
Stage 1 filters are equipped on the frame of the engine right side.
Stage 2 filters are equipped on the engine.

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E. Fuel System (MTU Engine) (See Page 7-70)
Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Drain Fuel Tank Sump 1
2. Drain Fuel Pre-Filter 1
3. Replace Fuel Pre-Filter 1
4. Replace Fuel Filter 2
Check Fuel Hoses (for leak, loose) -
5.
Check Fuel Hoses (for crack, bend, etc.) -
Clean Fuel Tank Breather 2
6.
Replace Fuel Tank Breather 2
7. Clean Fuel Cooler 1

fNOTE: The machine has fuel pre-filter and fuel priming pump on the fuel suction line.
Fuel pre-filter and fuel priming pump are equipped on the frame of the engine left side.
Fuel filters are equipped on the engine.

F. Air Cleaner (See Page 7-77)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
Cleaning 4 As required
1. Air Cleaner Outer Element
Replacement 4 Replace per 6 cleaning
2. Air Cleaner Inner Element Replacement 4 When outer element is replaced
3. Dust Cup Cleaning 6
4. Vacuator Valve Check 6

G. Cooling System (Cummins Engine) (See Page 7-81)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Check Coolant Level 1
2. Check DCA4 Concentration in Coolant 1
3. Replace Coolant Filter 2
4. Change Coolant 729 L (192 US gal) Twice a year, (in spring and autumn) 
5. Clean Radiator, After Cooler Interior 1+1 When changing coolant
6. Clean Radiator, After Cooler Core 1+1 As required
7. Check Fan Belt for Wear 1

fNOTE:  Before leaving the Hitachi factory, the cooling system is filled with a mixture of water and genuine Hitachi Long-
Life Coolant. As long as genuine Hitachi Long-Life Coolant is used, the service intervals between changing the
coolant is once every 2 years, or every 4000 hours, whichever comes first.

G. Cooling System (MTU Engine) (See Page 7-94)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Check Coolant Level 1
2. Change Coolant 670 L (177 US gal) Twice a year, (in spring and autumn) 
3. Clean Radiator, After Cooler Interior 1+1 When changing coolant
4. Clean Radiator, After Cooler Core 1+1 As required
5. Check Fan Belt for Wear 1

fNOTE:  Before leaving the Hitachi factory, the cooling system is filled with a mixture of water and genuine Hitachi Long-
Life Coolant. As long as genuine Hitachi Long-Life Coolant is used, the service intervals between changing the
coolant is once every 2 years, or every 4000 hours, whichever comes first.

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H. Air Conditioner (See Page 7-98)

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
Cleaning 2 As required
1. Recirculation Air Filter
Replacement 2 Replace per 4 cleaning
Cleaning 1 As required
2. Ventilation Air Filter
Replacement 1 Replace per 4 cleaning
3. Check Refrigerant Quantity 1
4. Check Compressor Belt Tension 1
5. Clean Condenser Core 1 
6. Check Tightening Torque -
7. Seasonal Maintenance - Preseason (once a year), Off-season (once a week)

fNOTE:  Shorten the interval when operating under dusty condition.

I. Electrical System (See Page 7-105)

Interval (hours)
Parts Quantity
8 50 100 250 500 1000 2000
Electrolyte Level Check 4 Every month
1. Batteries
Check Electrolyte Specific Gravity 4 Every month
2. Replace Fuse - As required
3. Check Fusible Link - As required
4. Check Electrical Cables and Wire Harnesses -
5. Check Emergency Engine Stop Switch -
6. Check Lights -
7. Check Horn and Backup Alarm Buzzer -
8. Check Suspension Pressure Sensor 4

J. Brakes & Steering System (See Page 7-121)

Interval (hours)
Parts Quantity
10 250 500 1000 1500 2000
1. Brake Operation Check -
2. Service Brake Check -
3. Parking Brake Check 2
4. Accumulator Check 4
5. Front Brake Lining Check 12 Every 6 months or as required
6. Front Brake Disk Check 2 Every 6 months or as required
7. Check Rear Brake Cooling Oil Level 1
8. Drain Rear Brake Cooling Oil Tank Sump 1
9. Change Rear Brake Cooling Oil 170 L (45 US gal)
10. Replace Suction Filter 1
11. Replace Line Filter Element 1
12. Clean Rear Brake Cooling Oil Cooler Core 1

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K. Suspension, Wheels & Tires (See Page 7-133)

Interval (hours)
Item Quantity
10 50 100 250 500 1000 1500 2000
1. Suspensions Check 4 
2. Wheels Check 6 
3. Front Axle Check 1
4. Front Wheel Lubricant Check 2
12 L (3.2 US gal)
5. Front Wheel Lubricant Change 
each wheel
6. Tire Inflation Check 6 As required
7. Tire Condition Check 6
8. Wheel Alignment Check 2 As required 

fNOTE:  After wheel installation, check torque of wheel lug nuts again at 5 and 10 hours of operation.
Wheel lug nut torque must stabilize and remain tight to function properly.
 Contact your authorized dealer for maintenance.
 First time only.

L. Miscellaneous (See Page 7-139)

Interval (hours)
Item Quantity
10 50 250 500 1000 1500 3000
Check/Cleaning 16
1. Alternator Carbon Brush
Replacement 16 As required 
2. Alternator Carbon Brush Check/Cleaning 2
directly contacted with Drive
Shaft Replacement 2 As required 
Check 1
3. Coolant in the Control Cabinet 59 L
Change Every 4 years
(15.6 US gal)
Cleaning 1 As required
4. Filter in Control Cabinet
Replacement 1 After cleaning 4 times 
5. Cleaning in Rear Axle 1 As required
Check 2
6. Seat Belt
Replacement 2 At least once every 3 years
7. Check Windshield Washer Tank 1 As required
8. Check Play Amount in Steering Wheel Stroke 1 As required
9. Check Auto-Lubrication System 1
10. Check Tightening Torque of Bolts and Nuts - 
11. Check Dump Body Prop Cable 1

fNOTE:
 First time only.
Contact your authorized dealer for change.
 Replace the carbon brush as required according to the check result.
 Replace the filter after cleaning 4 times or every 4000 operating hours, whichever comes first.

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