MAINTENANCE

A. GREASING
Interval (hours)
Parts Quantity
5 10 100 250 500 1000 1500
1. Front Joint Pins Bucket 6 !
LD
Others 18
Bucket 11 !
BH
Others 11
2. Swing Bearing 4
3. Swing Internal Gear 1
4. Fan Pulley and Tension Pulley 2
NOTE: Apply grease every 5 hours when operating in water or mud.
Auto-lubrication is available. Greasing intervals shown in the above table are applied to manual
lubrication.

1
1

1
1
1 4
M113-07-009 M113-07-010

Brand Names of Recommended Grease Brand Names of Recommended Grease

Where to be Bucket, Arm and Boom, Swing Gear, Manufacturer Fan Pulley and Tension Pulley
applied Swing Bearing, etc.
Rykon Premium No.2
Manufacturer –20 to 50 °C (–4 to 122 °F) Amoco Oil
Rykon Premium No.2 EP
Nippon Koyu SEP 2 1 Chevron U.S.A SRI
Idemitsu Kosan Daphne Coronex Grease EP No 2
Exxon Company, U.S.A Unirex N2
Kyodo Oil Kyoseki Lithonic EP Grease 2
Daikyo Oil Dynamic Grease EP 2 Shell Oil Dolium
Nippon Oil Epinoc Grease AP 2 Texaco Inc Premium RB
Maruzen Oil Maruzen Grease EP 2
Mitsubishi Oil Diamond Multi-Purpose EP Grease 2
Caltex Oil Multifax EP 2
Esso Beacon EP 2
Kygnus Oil Kygunas EP Grease No. 2
Mobile Oil Mobilux EP 2
Shell Oil Shell Alvania EP Grease 2 2

NOTE: The machine is shipped from the factory is filled

with lubricants.
1 Swing Gear
2 Front Joint Pin and Swing Bearing

7-19
 MAINTENANCE

Front Joint Pins --- every 10 hours

Loading Shovel Front

Add grease to all fittings show below every 10 hours. 1
Most of the fittings are grouped, as shown, for quick and 1
safe lubrication.

NOTE: Auto-lubrication can be used for the fittings on

the loading shovel front.

Manually greasing places are as illustrated below.

M142-07-046

• Boom Cylinder Rod Pins (1)

• Grouped Grease Fittings (2) --- Boom 2
: Lubrication

M142-07-047

M142-07-103

7-20
 MAINTENANCE
• Grouped Grease Fittings (3) --- Arm
:Lubrication

3
M142-07-048

The end of the

hoses are
connected to
the bucket cyl-
inder bottom M142-07-104
pins.

• Bucket Pins

Dump Cylinder Rod Pin

Bucket Joint Pin
M113-07-012 Dump Cylinder Bottom Pin M142-07-042

7-21
 MAINTENANCE
Backhoe Front
Cap Head
• Bucket and Link Pins

Each grease fitting is provided with a protective cap.

Remove cap as shown below before greasing.

Removing/installing procedure: c

Insert a screw driver into the cap cavity along the ar-
row “a” direction, and scoop out the cap by applying
Grease Fitting
force in the arrow “b” direction. b
a
When installing, push the cap by hand in the arrow “c” Cap Pin
direction until it bottoms or tap using screw driver grip. M113-07-013

Cavity

Screw Driver

M113-07-014

M18J-07-003

M142-07-045

7-22
 MAINTENANCE
Add grease to all fittings show below every 10 hours.
Most of the fittings are grouped, as shown, for quick and
safe lubrication.

NOTE: Auto-lubrication can be used for the fittings on

the loading shovel front. 1
1
Manually greasing places are as illustrated below.

• Boom Cylinder Rod Pins (1)

M142-07-046

• Grouped Grease Fittings (2) --- Boom/Arm

M142-07-049

7-23
 MAINTENANCE

Swing Bearing --- every 250 hours

WARNING: Lubricating both the swing bearing

and gear and rotating the upperstructure must be
done by one person. Before you lubricate the
swing bearing, clear the area of all persons.

Each time you leave the cab

Lower the bucket to the ground.
Stop the engine.
Pull the pilot control shut-off lever to the
LOCK position.
Use handrails.
M142-07-046

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch OFF.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Turn the key switch OFF. Remove the key from the
key switch.
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
7. With the upperstructure stationary, apply grease via
the two grease fittings.
8. Start the engine. Raise the bucket several inches off
the ground and rotate the upperstructure 45° (1/8
turn).
9. Lower the bucket to the ground.
10. Repeat the procedure three times, beginning with
step 3.
11. Apply grease to the swing bearing until grease can be
seen escaping from the swing bearing seals.
12. Take care not to supply excessive grease.

7-24
 MAINTENANCE

LUBRICATOR
Lubricator Operation 8
1. Turn power switch (8) ON to activate pump (1). 2
Grease is sucked up and supplied to high-pressure
grease gun (3).
IMPORTANT: When pump (1) begins to suck grease,
any air inside pump (1) will be mixed in,
making grease turn whitish. Open check
valve cock (2) to bleed this air-mixed 1
grease. Securely close check valve cock
(2) when all air-mixed grease is bled out.
M111-07-011

2. Grab high-pressure grease gun (3) and pay out the

hose from hose reel (4) to the length required.
3. Press hydro-chuck (5) protruding from high-pressure
grease gun (3) into a grease nipple (7) and pull the
lever to discharge grease.
4. Release the lever when greasing is complete; grease
discharge will stop.
IMPORTANT: When detaching hydro-chuck (5) from
grease nipple (7), grease nipple (7) tip
may break unless a special care, is taken,
as follows:
• Tip nozzle (6) a little so as to release
the connecting pressure applied to
5
hydro-chuck (5).
6
• Slowly detach hydro-chuck (5) from
nipple (7). 3

5. When all greasing work is complete, turn power

switch (8) OFF, then pull grease gun (3) lever to re-
lease remaining pressure from grease gun (3), pump
(1), and the hose so as to ensure long life of the
components. A little grease will be discharged at this
time.
IMPORTANT: The hose has a limited service life. Pe- 4
riodically inspect the hose for cracks, M111-07-012
grease leakage, or any other damage. If
any damage is found, replace the hose.

M111-07-013

7-25
 MAINTENANCE
Grease Container Replacement
1
when the grease container becomes empty, follow the
procedure below to replace it:

IMPORTANT: When replacing the grease container, be

sure that no sand or debris sticks to
suction tube (5) or to follower plate (3). If 7
foreign matter, such as sand, gets into
grease, damage to the pump and to
parts being lubricated will result. If fol- 6
lower plate (3) is not correctly posi- 2
tioned inside the container, pump (1) 5
may not suck grease, even with grease
remaining in the container. Reposition
the plate correctly if this happens. 3

1. Loosen wing nuts (2) located on pail cover (7).

Remove the pump assembly (pump (1), pail cover (7), 4
and suction tube (5)) and follower plate (3) from the
empty grease container (4).
M111-07-014

2. Remove the cover from the new grease container.

3

3. Apply grease to the back of follower plate (3) to fill

concaved sections; this will prevent air from mixing
into the grease contents. 4

4. Place follower plate (3) flat on the grease contents in

the container. Using both hands, press follower plate
(3) down while moving both hands back and forth
along the periphery of the container inside, as illus-
trated, until grease comes out of seal packing (6)
hole. M111-07-087

IMPORTANT: Be careful not to damage seal packing

(6) by the end of suction tube (5) when 8
inserting it.

5. Slowly insert suction tube (5) (the pump assembly)

into the grease contents via the seal packing hole.

6. Be sure that pail cover (7) correctly settles on the

container. Equally tighten each wing nut (2) to pail
cover (7) to securely attach the pump assembly onto
the container (4). M166-07-103

7. After replacing the grease container, secure the lu- Grease Container
bricator unit with bracket (8).

7-26
 MAINTENANCE

Swing Internal Gear --- every 1000 hours

WARNING: Adding or changing swing internal

gear grease and rotating the upperstructure must
be done by one person. Before you start, clear
the area of all persons.

Each time you leave the cab

• Lower the bucket to the ground.
• Stop the engine.
• Pull the pilot control shut-off lever to the LOCK
position. 2
• Use handrails. M183-07-003

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
3. Turn the auto-idle switch OFF. 1
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Turn the key switch OFF. Remove the key from the
key switch.
M142-07-050
6. Pull the pilot control shut-off lever to the LOCK position.
7. Remove cover (2) on the under side of the swing
gear housing, located near the center joint and thor-
oughly remove old grease from the swing gear.
8. Install cover (2).
9. Remove cover (1) on the upperstructure.
10. In order to add new grease evenly to the swing gear,
swing the upperstructure twelve 30° intervals (one full
turn) and add grease at each interval using a putty
knife.
11. Install cover (1).
IMPORTANT: Excessive swing gear grease will con-
taminate the swing gear oil. Do not apply
excessive grease. Apply the same quan-
tity grease as removed.

7-27
 MAINTENANCE

Fan Pulley and Tension Pulley

--- every 1500 hours 2 1

WARNING: Before beginning to lubricate the fan

pulley and tension pulley, stop the engine.

1. Park machine on level ground.

2. Lower the bucket to the ground, turn the auto-idle
switch off, stop the engine and pull the pilot control
shut-off lever to the LOCK position.
3. Add grease to grease fitting (1) for the tension pulley
until the grease flow out from overflow valve (3).
4. Add grease to grease fitting (2) for the fan pulley until
the grease flow out from overflow valve (4).

IMPORTANT: Be sure to wipe off any old grease on

the fan belt when greasing to prevent
3
the fan belt from slipping and overheat-
ing.

M18E-07-009

7-28
 MAINTENANCE
B. ENGINE
Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
1. Engine Oil Check Oil Level 1
2. Engine Oil Change 70 L (18.5 US gal)
3. Replace Engine Oil Main Filter 2

Engine Oil Viscosity Requirements

API Service Class Type Viscosity Grade (SAE) Temperature Ranges

CH-4 All Season Multigrade 15W-40 −18° to 50°C (0° to 122°F)
CI-4 All Season Multigrade 15W-40 −18° to 50°C (0° to 122°F)
NOTE: (1) Oils with nominal ash content must be 1.0 to 1.5 percent mass. Oils with higher ash content, up to
1.85 percent ash, can be used in areas where the sulfur content of the fuel is normally 1 to 1.5
percent mass.
(2) Refer to the Cummins engine manual when you use oil other than CH-4 and CI-4 oils.
(3) The machine is shipped from the factory is filled with lubricants, Hitachi Super Wide DH-1 15W-40.

7-29
 MAINTENANCE

Engine Oil Level --- check daily

1

IMPORTANT: For most accurate readings, check the

oil level every day before starting the
machine. Be sure the machine is on a
level surface.

1. Remove dipstick (1). Wipe oil off with a clean cloth.

Reinsert dipstick (1).
2. Remove dipstick (1) again. Read level. Oil level must
be between the H and L mark.
3. If necessary, add oil via oil filler cap (2).
Be sure to use only recommended oil (see Recom-
mended Engine Oil Chart). 2

NOTE: Checking the oil level immediately after shut

down will result in inaccurate readings. M18E-07-004
Be sure to allow the oil to settle for at least 15
minutes before checking.

Change Engine Oil --- every 500 hours

Replace Engine Oil Filters

--- every 500 hours
1. Run the engine to warm oil.
DO NOT run the engine until oil is hot.
2. Park the machine on a level surface.
3. Lower the bucket to the ground.
4. Turn the auto-idle switch OFF.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

5. Run the engine at slow idle speed without load for

five minutes.
6. Turn the key switch OFF. Remove the key from the
key switch.
7. Pull the pilot control shut-off lever to the LOCK posi-
tion.

7-30
 MAINTENANCE

WARNING: Engine oil may be hot just after op- 1 2

eration. Take extra care to avoid burns.

8. Remove drain plug (2).

9. Loosen drain cock (1). Allow oil to drain through a
clean cloth into a container of 70 liter (18.5 US gal) or
more capacity container.
10. After all oil has drained, inspect cloth for any debris
such as small pieces of metal.
11. Install and tighten drain plug (2). Close drain cock (1).
12. Remove the filter cartridges of engine oil filters (5), by M142-07-110
turning them counterclockwise with filter wrench.
13. Clean the filter gasket contact area on the engine.
Oil Pan
14. Fill the new filters with lubricating oil to prevent
crankshaft or bearing damage. Apply a thin film of
clean oil to the gasket of the new filter. Clean Cloth

15. Install new filter. Turn the filter cartridge clockwise by Container
hand until the gasket touches the contact area. Be
sure not to damage the gasket when installing the fil-
ter.
M104-07-010
16. Tighten engine oil filters (5), 1/2 to 3/4 turn more us-
ing filter wrench.
Be careful not to overtighten.
17. Remove oil filler cap (3). Fill the engine with recom-
mended oil. Check that oil level is between the H and
L marks on the dipstick after 15 minutes.

Engine oil capacity: 70 L (18.5 US gal)

18. Install oil filler cap (3).

19. Start the engine. Run the engine at slow idle for 5
minutes.
20. Check that the engine oil pressure indicator on the
monitor panel goes out immediately. If not, stop the 3 5
4
engine immediately and find the cause.
21. Stop the engine. Remove the key from the key
switch.
M18E-07-004
22. Check for any leakage at the drain plug.
23. Check oil level on dipstick (4).

NOTE: Refer to the Operation and Maintenance Man-

ual for Cummins Engine for further details ex-
cept the filter replacement intervals, for which
this manual has priority.

7-31
 MAINTENANCE
C. TRANSMISSION

Interval (hours)
Parts Quantity
10 50 250 500 1000 1500 2000
Check Oil Level 1
1. Pump Transmission Change Oil 15 L (4.0 US gal)
Gear Replace Filter 1
Clean Breather 2
2. Swing Reduction Check Oil Level 2
Gear Change Oil 25 L (6.6 US gal)×2
3. Travel Reduction Check Oil Level 2
Gear Change Oil 43 L (11.4 US gal)×2
NOTE: First time only.
2

3 M18J-03-001

Brand Names of Recommended Oil

Application Swing and Travel Reduction Gear Pump Transmission
Kind of Oil Gear oil Engine Oil
Air Temp. –20 to 0°C –10 to 50°C 25 to 50°C
Manufacturer –20 to 50°C (–4 to 122°F)
(–4 to 32°F) (14 to 122°F) (77 to 122°F)
BP Vanellus C3
British Petroleum BP Gear oil SAE90EP
10W 30 40
RPM DELO 300 Oil
Caltex Oil Universal Thuban SAE 90
10W 30 40
Essolube D-3
Esso Esso Gear Oil 80W-90, 85W-90
10W 30 40
Apolloil diesel motive
Idemitsu Kosan Apollo Gear HE90
S-310 S-330 S-340
Mobil Delvac
Mobil Oil Mobilube GX90
1310 1330 1340
Hidiesel S3
Hypoid Gear Oil 90 (Swing and travel –10 to 40 °C –20 to 35 °C
Nippon Oil
reduction device) (14 to 104 °F) (–4 to 95 °F)
15W-40 10W-30
Shell Rymla D
Shell Oil Shell Spirax EP90
10W 30 40
Remarks API GL 4 Class API CD Class
NOTE: The machine shipped from the factory is filled with oil marked .

7-32
 MAINTENANCE

Pump Transmission
Check Oil Level --- every 50 hours
(first time after 10 hours)
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch OFF.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.
1
4. Run the engine at slow idle speed without load for
five minutes.
5. Stop the engine. Remove the key from the key M18J-07-004

switch.
1
6. Pull the pilot control shut-off lever to the LOCK posi-
tion.
7. Remove dipstick (1). Oil must be within the specified
range.
8. If necessary, remove dipstick (1) and add oil. (See
gear oil chart)
9. Recheck oil level.
M114-07-181

7-33
 MAINTENANCE
Change Oil --- every 500 hours
(first time after 50 hours)
Clean Air Breather Cap --- every 500 hours

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
Clean Cloth
3. Turn the auto-idle switch OFF. Container

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.
M104-07-010

4. Run the engine at slow idle speed without load for 2

five minutes.
5. Stop the engine. Remove the key from the key
switches.
6. Pull the pilot control shut-off lever to the LOCK
position. 3

WARNING: Oil may be hot just after operation.

Wait for oil to cool before starting work.

7. Prepare a container of 15 liter (4.0 US gal) or more

capacity for the drain oil.
M142-07-009

8. Remove under cover, located on the left of underside

of the upperstructure.
9. Remove drain plug (3), and loosen cock (2) to drain
the oil.
10. Check if foreign material like metal particles are
included in the drain oil by filtering it with a clean
cloth.

M183-07-005

M18J-07-004

7-34
 MAINTENANCE
11. Remove filter element (4) by turning it
counterclockwise with filter wrench.
12. Install new filter element (4) and new O-ring.
13. Remove breather cap (5) and clean the element.
After cleaning, apply LOCTITE to the threads of the
air breather cap. Then, tighten it.

M183-07-005

M18J-07-004

7-35
 MAINTENANCE

Swing Reduction Gear

2
Check Oil Level --- every 50 hours 1
(first time after 10 hours)
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch OFF.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Stop the engine. Remove the key from the key M142-07-051
switch.
6. Pull the pilot control shut-off lever to the LOCK
position.

WARNING: Gear oil may be hot just after

operation. Wait for gear oil to cool before starting
work. M104-07-017

7. Remove dipsticks (1). Oil must be between marks.

8. If necessary, add oil via filler tube (2). (See oil chart)
9. Recheck oil level.

7-36
 MAINTENANCE
Change Gear Oil --- every 1000 hours
(first time after 50 hours)
1. Park the machine on a level surface.
1
2. Lower the bucket to the ground. 2

3. Turn the auto-idle switch OFF.

IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

4. Run the engine at slow idle speed without load for

five minutes.
5. Stop the engine. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK
M142-07-051
position.

WARNING: Gear oil may be hot just after

operation. Wait for gear oil to cool before starting
work.

7. Prepare a container of 25 liter (6.6 US gal) or more

capacity for the drain oil. M104-07-017

8. Remove two swing gear box drain plugs (3), located 4

at boom foot and under the engine rear end and open
drain cocks (4) to drain oil.
9. Tighten drain cocks (4) and drain plugs (3).
Fill gear boxes with oil via filler tubes (2).
10. Confirm that the oil level is between the notches on
dipstick (1). Add oil if necessary.

3 M142-07-012
3
4

M142-07-013

7-37
 MAINTENANCE

Travel Reduction Gear 1

Check Oil Level --- every 250 hours

1. Park the machine on a level surface.
2
2. Rotate the travel motor until the imaginary line
through plug (1) and plug (3) is vertical.
3. Lower the bucket to the ground.
4. Turn the auto-idle switch OFF.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

5. Run the engine at slow idle speed without load for

five minutes.
6. Stop the engine. Remove the key from the key 3
switch. M142-07-052
1
7. Pull the pilot control shut-off lever to the LOCK posi-
tion.
2

WARNING: Keep body and face away from the air Oil Level
release plug. Gear oil may be hot just after opera-
tion. Wait for gear oil to cool and then gradually
loosen the air release plug to release pressure.
3
8. After gear oil has cooled, slowly loosen air release Vertical Line M113-07-040
plug (1) to release pressure.
9. Remove oil level check plug (2). Oil must be up to the
bottom of hole.
10. If necessary, after oil supply plug (1) have been re-
moved, add oil until oil flows out of the oil level check
plug (2) hole. (See gear oil chart)
11. Wrap the plug threads with sealing-type tape.
Tighten plugs (1) and (2) to 70 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
12. Check the gear oil level in the other travel reduction
gear.

7-38
 MAINTENANCE
1
Change Gear Oil --- every 2000 hours

1. Park the machine on a level surface.

2. Rotate the travel motor until the imaginary line
through plug (1) and plug (3) is vertical. 2
3. Lower the bucket to the ground.
4. Turn the auto-idle switch OFF.
IMPORTANT: The turbocharger may be damaged if the
engine is not properly shut down.

5. Run the engine at slow idle speed without load for

five minutes.
6. Stop the engine. Remove the key from the key
switch.
7. Pull the pilot control shut-off lever to the LOCK posi- 3
M142-07-052
tion.
1
WARNING: Keep body and face away from the air
release plug. Gear oil may be hot after operation. 2
Wait for gear oil to cool and then gradually Oil Level
loosen the air release plug to release pressure.

8. After gear oil has cooled, slowly loosen air release

plug (1) to release pressure, and temporarily re- 3
tighten plug (1). Vertical Line M113-07-040

9. Prepare a container of 50 liter (13.2 US gal) or more

capacity for the drain oil. Remove drain plug (3).
10. Clean drain plug (3). Wrap the threads of the drain
plug with sealing-type tape. Install the plug.
Tighten the plug to 70 N m (7 kgf m, 51 lbf⋅ft).
11. Remove oil level check plug (2) and oil supply plug
(1).
12. Add oil until oil flows out of the oil level check plug (2)
hole. (See gear oil chart)
13. Clean plugs (1) and (2). Wrap the threads of oil level
check plug (2) and air release plug (1) with seal-
ing-type tape. Reinstall the plugs.
Tighten the plugs to 70 N m (7 kgf m, 51 lbf⋅ft).
14. Repeat steps 8. to 13. for the other travel reduction
gear.

7-39
 MAINTENANCE
D. HYDRAULIC SYSTEM

Interval (hours)
Parts Quantity
10 50 250 500 1000 2000 2500 4000 12000
1. Check Hydraulic Oil Level 1
2. Drain Hydraulic Oil Tank Sump 1
1350 L
3. Change Hydraulic Oil
(357 US gal)
4. Suction Filter Cleaning 2 When changing hydraulic oil
5. Replace Drain Filter Element 1 !
6. Replace Full-Flow Filter Element 2
7. Replace Pilot Oil Filter Element 1
Check Hoses and Lines (for leak, loose) −
8.
Check Hoses and Lines (for crack, bend, etc.) −
9. Replace High-Pressure Filter 3
10. Clean Tank Breather 1

NOTE: Hydraulic oil changing intervals differ according to kind of hydraulic oil used. See recommended oil
chart.
! First time only.
1 2 3 4 5
6 8 9 10

7
M18J-03-001
Brand Names of Recommended Hydraulic Oil
Kind of Lubricant Hydraulic Oil
Where to be applied Hydraulic System
Change Interval 4000 hours 2500 hours 2000 hours
Environmental
–20 to 50°C –10 to 50°C –20 to 50°C –10 to 50°C –20 to 50°C –10 to 50°C
Temp.
(–4 to 122°F) (14 to 122°F) (–4 to 122°F) (14 to 122°F) (–4 to 122°F) (14 to 122°F)
Manufacturer
Hitachi Super EX 46HN
Idemitsu Kosan Super Hydro 46 WRHU
British Petroleum Bartran HV46
Rando Oil
Caltex Oil
HD46
Rando Oil
Texaco INC.
HD46
Chevron U.S.A INC. Chevron AW46
Esso NUTO H46
Mobil Oil DTE 25
Shell Oil Tellus Oil S46 Tellus Oil 46
Remarks Anti-wear type hydraulic oil

NOTE: Use proper hydraulic oil in accordance with the atmospheric temperature.
The machine shipped from the factory is filled with oil marked .

7-40