Hitachi ZW 180-6 User manual

TTPD850-EN-00
ZW180-6 WHEEL LOADER TECHNICAL MANUAL TROUBLESHOOTING
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle) : Vol. No.TOPD850-EN
Technical Manual (Troubleshooting) : Vol. No.TTPD850-EN
Workshop Manual : Vol. No.WPD850-EN
TTPD850-EN-00
PART NO.
Wheel Loader
Technical Manual
Troubleshooting
180-6
ZW
PRINTED IN JAPAN (K) 2016, 09
URL:http://www.hitachi-c-m.com

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Group 1 Introduction
Operational Performance Tests...................................... T4-1-1
Preparation for Performance Tests ............................... T4-1-2
Group 2 Standard
Operational Performance Standard Table ................. T4-2-1
Main Pump P-Q Diagram ...............................................T4-2-10
Sensor Activating Range................................................T4-2-12
Group 3 Engine Test
Engine Speed ....................................................................... T4-3-1
Lubricant Consumption ................................................... T4-3-3
Group 4 Machine Performance Test
Travel Speed ......................................................................... T4-4-1
Service Brake Function Check ........................................ T4-4-4
Service Brake Wear Amount............................................ T4-4-6
Parking Brake Function Check ....................................... T4-4-7
Bucket Stopper and Bell Crank Stopper
Clearance.......................................................................... T4-4-8
Hydraulic Cylinder Cycle Time......................................T4-4-10
Dig Function Drift Check................................................T4-4-12
Bucket Levelness...............................................................T4-4-13
Control Lever Operating Force.....................................T4-4-14
Control Lever Stroke ........................................................T4-4-16
Group 5 Component Test
Primary Pilot Pressure (Including Brake Circuit) ...... T4-5-1
Secondary Pilot Pressure.................................................. T4-5-4
Main Pump Delivery Pressure......................................... T4-5-6
Main Relief Set Pressure ................................................... T4-5-8
Steering Relief Pressure ..................................................T4-5-12
Overload Relief Valve Set Pressure .............................T4-5-14
Main Pump Flow Rate Measurement.........................T4-5-16
Service Brake Pressure (Front and Rear) ..................T4-5-24
Parking Brake Release Pressure ...................................T4-5-26
Brake Accumulator Pressure ........................................T4-5-28
Brake Warning Pressure (Pressure-Decreasing) .....T4-5-30
Brake Warning Pressure (Pressure-Increasing).......T4-5-32
Transmission Clutch Pressure.......................................T4-5-34
Torque Converter Pressure (Inlet) ...............................T4-5-36
Group 6 Adjustment
Rewrite of Aftertreatment Device Serial NO. ............ T4-6-1
Clean DEF Tank..................................................................... T4-6-2
Transmission Learning ...................................................... T4-6-3
Lift Arm Angle Sensor Learning..................................... T4-6-7
Digging Position Adjustment......................................... T4-6-9
SECTION 4
OPERATIONAL PERFORMANCE TEST
CONTENTS
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(Blank)
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Group 1 Diagnosing Procedure
Introduction.......................................................................... T5-1-1
Diagnosis Procedure.......................................................... T5-1-2
Electrical System Inspection ........................................... T5-1-5
Precautions for Inspection and Maintenance .......... T5-1-6
Instructions for Disconnecting Connectors .............. T5-1-8
Fuse Inspection..................................................................T5-1-10
Fusible Link Inspection ...................................................T5-1-13
Battery Voltage Check.....................................................T5-1-14
Alternator Check ...............................................................T5-1-15
Continuity Check...............................................................T5-1-16
Voltage and Current Measurement............................T5-1-18
Check by False Signal ......................................................T5-1-25
Test Wire Harness ..............................................................T5-1-26
Group 2 Monitor
Outline .................................................................................... T5-2-1
Operating Procedures of Service Menu...................... T5-2-2
Engine Tachometer ..........................................................T5-2-37
Transmission Oil Temperature Gauge and
DEF / AdBlue Level Gauge........................................T5-2-38
Coolant Temperature Gauge ........................................T5-2-39
Group 3 e-Service
Outline .................................................................................... T5-3-1
List of Operation Data....................................................... T5-3-2
Snapshot Data...................................................................... T5-3-6
Communication System................................................... T5-3-7
Group 4 Component Layout
Main Component (Overview)......................................... T5-4-1
Main Component................................................................ T5-4-3
Electrical System (Overview) .......................................... T5-4-5
Air Cleaner and Radiator Assembly.............................. T5-4-6
Battery Box............................................................................ T5-4-8
Hydraulic Oil Tank ............................................................... T5-4-9
Fuel Tank ..............................................................................T5-4-10
Drive Unit.............................................................................T5-4-11
Front Axle.............................................................................T5-4-12
Cab .........................................................................................T5-4-13
Engine...................................................................................T5-4-19
Aftertreatment Device ....................................................T5-4-20
Fan Valve (Optional).........................................................T5-4-21
Priority Valve.......................................................................T5-4-21
Pump Device ......................................................................T5-4-22
Control Valve.......................................................................T5-4-22
Manifold Valve....................................................................T5-4-23
Parking Brake Solenoid Valve Block ...........................T5-4-23
Brake Charge Valve...........................................................T5-4-23
Ride Control Valve (Optional) .......................................T5-4-24
Emergency Steering Block (Optional) .......................T5-4-25
Emergency Steering Pump (Optional)......................T5-4-25
Flow Regulator Valve .......................................................T5-4-25
DEF Tank...............................................................................T5-4-26
DEF Supply Module..........................................................T5-4-26
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis
By Using Fault MC Fault Code List ........................... T5-5-1
MC Fault Code List.............................................................. T5-5-3
Monitor Controller (Monitor) Fault Code List .........T5-5-15
Monitor Controller (Information)
Fault Code List ..............................................................T5-5-16
Column Display Controller Fault Code List..............T5-5-19
Air Conditioner Controller Fault Code List...............T5-5-21
ECM Fault Code List..........................................................T5-5-23
TCU Fault Code List ..........................................................T5-5-53
MC Fault Codes 111000 to 111002.............................T5-5-73
MC Fault Code 111003....................................................T5-5-74
MC Fault Codes 111006, 111007,
111009, 111011............................................................T5-5-77
Monitor Controller (Monitor) Fault Codes
113002, 113003, 113005, 113012..........................T5-5-77
CAN1 Harness Check .......................................................T5-5-78
CAN3 (Engine) Harness Check ....................................T5-5-82
MC Fault Codes 111008, 111010,
111014, 111025............................................................T5-5-85
Monitor Controller (Monitor) Fault Codes
113004, 113006, 113007...........................................T5-5-85
CAN2 Harness Check ......................................................T5-5-86
MC Fault Code 111100....................................................T5-5-89
MC Fault Code 111103....................................................T5-5-90
MC Fault Codes 111205, 111207 .................................T5-5-91
MC Fault Codes 111200..................................................T5-5-92
MC Fault Codes 111217, 111312 .................................T5-5-93
MC Fault Codes 111204, 111206 .................................T5-5-94
MC Fault Code 111208....................................................T5-5-95
MC Fault Codes 111311, 111313 .................................T5-5-96
MC Fault Code 111411....................................................T5-5-99
MC Fault Code 111412................................................. T5-5-100
MC Fault Code 111413................................................. T5-5-101
MC Fault Code 111422................................................. T5-5-102
MC Fault Codes 111901, 111902 .............................. T5-5-103
SECTION 5
TROUBLESHOOTING
CONTENTS
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MC Fault Codes 120000, 120002 to 120005......... T5-5-104
MC Fault Code 120014................................................. T5-5-105
Monitor Controller Fault Code 115001 .................. T5-5-107
Monitor Controller (Information)
Fault Code 113311 ................................................... T5-5-108
Monitor Controller (Information)
Fault Code 120300 ................................................... T5-5-109
Monitor Controller (Monitor) Fault Codes
120400, 120401......................................................... T5-5-110
Column Display Controller Fault Codes
120500 to 120505..................................................... T5-5-111
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by
Using Trouble Symptom) Procedure ...................... T5-6-1
Relationship between Machine Trouble
Symptoms and Related Parts.................................... T5-6-3
Correlation between Trouble Symptoms and
Part Failures ...................................................................T5-6-26
Engine System Troubleshooting .................................T5-6-46
All Actuator System Troubleshooting........................T5-6-52
Front Attachment System Troubleshooting............T5-6-57
Steering System Troubleshooting ..............................T5-6-66
Travel System Troubleshooting ...................................T5-6-70
Brake System Troubleshooting ....................................T5-6-79
Other System Troubleshooting....................................T5-6-82
Exchange Inspection .......................................................T5-6-96
Air Bleeding Procedures for Brake (Axle)..................T5-6-98
Group 7 Air Conditioner
Outline .................................................................................... T5-7-1
Functions of Main Parts .................................................... T5-7-4
Troubleshooting.................................................................. T5-7-9
Air Conditioner Controller Fault Code List...............T5-7-10
Air Conditioner Controller Fault Codes 11 to 22....T5-7-11
Air Conditioner Controller Fault Codes 43 to 92....T5-7-12
Work after Replacing Components ............................T5-7-34
Refill Compressor Oil .......................................................T5-7-35
Charge Air Conditioner with Refrigerant .................T5-7-36
Hose and Pipe Tightening Torque...............................T5-7-44
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INTRODUCTION
IN-1
To The Reader
Additional References
Manual Composition
Page Number
Trademark
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.
Be sure to thoroughly read this manual for correct
product information and service procedures.
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
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.
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 Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
AdBlue® is a registered trademark of the Verband der
Automobilindustrie e.V. (VDA).
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: [phone]
FAX: [phone]
E-mail: HCM-TIC-[email protected]
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.
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.
Workshop Manual: W 1-3-2-5
W Workshop Manual
1 Section Number
3 Group Number
2 Sub Group Number
5 Consecutive Page Number for Each Group
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INTRODUCTION
IN-2
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.
dThis is the safety alert symbol. When you see this
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.
dCAUTION:
Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
fNOTE:
Indicates supplementary technical information or know-
how.
Units Used
Quantity To Convert From Into Multiply By
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3yd31.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm210.197
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-1 rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
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.
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SYMBOL AND ABBREVIATION
SY-1
Symbol /
Abbreviation
Name Explanation
TO Technical manual (Operational principle) Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
VGS 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.
GSM Global System for Mobile communications
controller
Communication controller. GSM is a type of wireless
communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
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SYMBOL AND ABBREVIATION
SY-2
Symbol /
Abbreviation
Name Explanation
DPF Diesel Particulate Filter 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 Diesel Particulate Diffuser 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.
DOC Diesel Oxidation Catalyst Oxidation catalyst for the diesel engine. Diesel oxidation
catalyst oxidizes unburnt fuel and raises exhaust
temperature.
CSF Catalyzed Soot Filter 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.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation 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.
HRV Hose Rupture Valve Hose rupture valve.
LLC Long Life Coolant Long life coolant.
SCR Selective Catalytic Reduction The urea SCR system injects diesel exhaust fluid to nitrogen
oxide (NOx) exhausted from the engine and purifies NOx.
DCU Dosing Control Unit Urea SCR system controller. DCU controls the diesel exhaust
fluid injection amount according to the machine operating
condition.
S/M Supply Module 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.
D/M Dosing Module Dosing module. The dosing module (D/M) injects diesel
exhaust fluid into the exhaust piping according to the signal
from DCU.
NOx Nitrogen Oxide Nitrogen oxide.
DEF Diesel Exhaust Fluid Diesel exhaust fluid. The diesel exhaust fluid concentration is
32.5 %, which is specified in ISO22241.
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SA-1
SAFETY
Recognize Safety Information
These are the SAFETY ALERT SYMBOLS.
When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating
practices.
Understand Signal Words
On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
DANGER or WARNING safety signs signs are located
near specific hazards. General precautions are listed on
CAUTION safety signs.
Some safety signs are occasionally used on this machine
that do not use any of the designated signal words
mentioned above after the safety alert symbol.
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.
fNOTE Indicates an additional explanation for an a piece
of information.
SA-688
SA-1223

SAFETY
SA-2
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.
SA-003

SAFETY
SA-3
Prepare for Emergencies
Be prepared for a fire or an accident.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
Establish emergency procedure guidelines to cope with
fires and accidents.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone.
Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
SA-438
SA-437

SAFETY
SA-4
Protect Against Noise
Prolonged exposure to loud noise can cause impairment or
loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
Inspect Machine
Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
In the walk-around inspection, be sure to cover all points
described in the “Inspect Machine Daily Before Starting”
section in the operator’s manual.
SA-435
SA-434

SAFETY
SA-5
General Precautions for the Cab
Before entering the cab, thoroughly remove all dirt and/
or oil such as mud, grease, soil or stones from the soles
of your work boots. If any controls such as a pedal is
operated while with dirt and/or oil on the soles of the
operator’s work boots, the operator’s foot may slip off the
pedal, possibly resulting in a personal accident.
Do not make a mess around the operator's seat with
parts, tools, soil, stones or other, obstacles that may fold
up or turn over such as cans or lunch box. The levers or
pedals become inoperable if an obstacle jams during the
operation stroke of the accelerator pedal, brake pedals,
control lever lock switch or control levers, which may
result in serious injury or death.
Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
Keep all flammable objects and/or explosives away from
the machine.
After using the ashtray, always cover it to extinguish the
match and/or tobacco.
Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
Correctly lay the floor mat specific to the machine. If
another floor mat is used, it may be displaced and contact
with the accelerator or brake pedals during operation,
resulting in serious injury or death.

SAFETY
SA-6
Use Handrails and Steps
Falling is one of the major causes of personal injury.
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
Do not use any controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
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.
Never Ride Attachment
Never allow anyone to ride on attachment or the load. This
is an extremely dangerous practice.
Adjust Operator’s Seat
A seat which is poorly adjusted for the individual operator,
or the work to be undertaken, may quickly fatigue the
operator leading to misoperation.
The seat should be adjusted whenever the operator of
the machine changes.
The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
If not, move the seat forward or backward, and check
again.
Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
SA-439
SA-462

SAFETY
SA-7
Ensure Safety Before Rising from or Leaving
Operator’s Seat
Before rising from the operator’s seat to open / close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the control lever lock switch to the lock ( ) position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.
Before leaving the machine, be sure to first lower the front
attachment to the ground and then move the control
lever lock switch to the lock ( ) position. Turn the 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.
SA-237

SAFETY
SA-8
Move and Operate Machine Safely
Bystanders can be run over.
Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, or operating the
machine.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
Use a signal person when moving, or operating the
machine in congested areas. Coordinate hand signals
before starting the machine.
Use appropriate illumination. Check that all lights are
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
Ensure the cab door, windows, doors and covers are
securely locked.
Check the mirrors and the monitor in the cab for
problems.
If there is any problem, replace the problem part(s) or
clean the mirror, camera and the monitor.
Refer to Rear View Monitor section for information on
cleaning the camera lens and the monitor display.
Handle Starting Aids Safely
Starting fluid:
Starting fluid is highly flammable.
Keep all sparks and flame away when using it.
Keep starting fluid well away from batteries and cables.
Remove container from machine if engine does not need
starting fluid.
To prevent accidental discharge when storing a
pressurized container, keep the cap on the container, and
store it in a cool, well-protected location.
Do not incinerate or puncture a starting fluid container.
SA-293
SA-398

SAFETY
SA-9
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.
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. SA-032
SA-431

SAFETY
SA-10
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.
SA-447