Hitachi Zw 65 User manual

65

75

95

EM4L2-EN1-2ZW65 • ZW75 • ZW95 WHEEL LOADER OPERATOR’S MANUAL

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

EM4L2-EN1-2

PART NO.

Wheel Loader

Operator's Manual

PRINTED IN THE NETHERLANDS 2012, 10

Serial No.

ZW65 000101 and up

ZW75 000101 and up

ZW95 000101 and up

INTRODUCTION

Read this manual carefully to learn how to operate and

service your machine correctly. Failure to do so could

result in personal injury or machine damage.

This standard specification machine can be operated

under the following conditions without being modified.

Atmospheric Temperature: -20 °C to 40 °C (-4 °F to 104 °F)

Altitude: 0 m to 2000 m (0 ft to 6600 ft)

In case the machine is used under conditions other than

described above, consult your nearest Hitachi dealer.

This manual should be considered a permanent part of

your machine and should remain with the machine when

you sell it.

This machine is of metric design. Measurements in this

manual are metric. Use only metric hardware and tools as

specified.

Right-hand and left-hand sides are determined by

facing in the direction of forward travel.

Write product identification numbers in the Machine

Numbers section. Accurately record all the numbers

to help in tracing the machine should it be stolen.

Your dealer also needs these numbers when you order

parts. If this manual is kept on the machine, also file the

identification numbers in a secure place off the machine.

Use only diesel fuel with quality specified in JIS K-2204,

EN-590, ASTM D-975, GOST R52368 or GB252.

Failure to use diesel fuel with quality as specified

above may allow the engine to emit exhaust gas which

cleanness can not conform to the requests in various

relevant regulations. In addition, serious damage to the

engine may result. Consult with your nearest Hitachi

dealer for detailed information.

Warranty is provided as a part of Hitachi’s support

program for customers who operate and maintain their

equipment as described in this manual. The warranty is

explained on the warranty certificate which you should

have received from your dealer.

This warranty provides you with the assurance that

Hitachi will back its products where defects appear within

the warranty period. In some circumstances, Hitachi also

provides field improvements, often without charge to the

customer, even if the product is out of warranty.

Should the equipment be abused, or modified to

change its performance beyond the original factory

specifications, the warranty will become void and field

improvements may be denied.

Setting fuel delivery above specifications or otherwise

overpowering machines will result in such action.

Only qualified, experienced operators officially licensed

(according to local law) should be allowed to operate

the machine. Moreover, only officially licensed personnel

should be allowed to inspect and service the machine.

The EC Declaration of conformity includes the machine

without equipment unless fitted with equipments

approved by TCM Corporation. Refer to enclosed list for

approved equipments. TCM Corporation will not cover

conformity of machines fitted with OEM equipments.

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.

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INDEX

EM4L2-EN1-2

SAFETY SIGNS

COMPONENTS NAME

OPERATOR’S STATION

BREAK-IN

OPERATING ENGINE

DRIVING MACHINE

OPERATING MACHINE

TRANSPORTING

MAINTENANCE

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

STORAGE

TROUBLESHOOTING

SPECIFICATIONS

SAFETY

MACHINE NUMBERS

ENGINE EMISSION CONTROL LABEL

OPTIONAL ATTACHMENT

OTHERS

INDEX

GETTING ON/OFF THE MACHINE

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CONTENTS

ENGINE EMISSION CONTROL LABEL .......................................1

EC Emission Control Label: Engine Label....................................1

MACHINE NUMBERS .......................................................................3

SAFETY ..............................................................................................S-1

Recognize Safety Information ...................................................S-1

Understand Signal Words ............................................................S-1

Follow Safety Instructions ...........................................................S-2

Prepare for Emergencies ..............................................................S-3

Wear Protective Clothing .............................................................S-3

Protect Against Noise ...................................................................S-4

Inspect Machine .............................................................................S-4

General Precautions for Cab .......................................................S-5

Use Handrails and Steps ..............................................................S-6

Never Ride Attachment.................................................................S-6

Adjust Operator’s Seat ..................................................................S-6

Ensure Safety Before Rising from or

Leaving Operator’s Seat ..........................................................S-7

Fasten Your Seat Belt .....................................................................S-7

Move and Operate Machine Safely ..........................................S-8

Handle Starting Aids Safely ........................................................S-8

Operate Only from Operator’s Seat .........................................S-9

Jump Starting ..................................................................................S-9

Investigate Job Site Beforehand ............................................S-10

Equipment of Head Guard, ROPS, FOPS ..............................S-11

Provide Signals for Jobs Involving Multiple Machines ...S-11

Keep Riders Off Machine ..........................................................S-12

Drive Safely .................................................................................... S-12

Drive Machine Safely (Work Site) ........................................... S-13

Drive Safely with Bucket Loaded ........................................... S-14

Drive on Snow Safely .................................................................. S-14

Travel on Public Roads Safely .................................................. S-15

Avoid Injury from Rollaway Accidents .................................S-15

Avoid Accidents from Backing Up and Turning ...............S-16

Avoid Positioning Bucket or Attachment

Over Anyone ............................................................................ S-17

Avoid Tipping ................................................................................S-17

Never Undercut a High Bank ................................................... S-18

Dig with Caution .......................................................................... S-18

Perform Truck Loading Safely ................................................. S-18

Avoid Power Lines .......................................................................S-19

Precautions for Operation ........................................................S-19

Precautions for Lightning ......................................................... S-19

Object Handling .......................................................................... S-20

Protect Against Flying Debris .................................................S-20

Park Machine Safely .................................................................... S-21

Store Attachments Safely .........................................................S-21

Transport Safely ...........................................................................S-22

Handle Fluids Safely−Avoid Fires ...........................................S-23

Practice Safe Maintenance .......................................................S-24

Warn Others of Service Work .................................................. S-25

Support Machine Properly .......................................................S-25

Stay Clear of Moving Parts ....................................................... S-26

Support Maintenance Properly ..............................................S-26

Prevent Parts from Flying ......................................................... S-27

Prevent Burns ................................................................................ S-27

Replace Rubber Hoses Periodically ....................................... S-28

Avoid High-Pressure Fluids ...................................................... S-28

Prevent Fires ..................................................................................S-29

Evacuating in Case of Fire ......................................................... S-30

Beware of Exhaust Fumes .........................................................S-30

Precautions for Welding and Grinding ................................S-30

Avoid Heating Near Pressurized Fluid Lines ......................S-31

Avoid Applying Heat to Lines Containing

Flammable Fluids ................................................................... S-31

Remove Paint Before Welding or Heating ..........................S-31

Beware of Asbestos and Silicon Dust and Other

Contamination......................................................................... S-32

Prevent Battery Explosions ...................................................... S-32

Service Air Conditioning System Safely .............................. S-33

Handle Chemical Products Safely .......................................... S-33

Dispose of Waste Properly ........................................................S-34

SAFETY SIGNS ............................................................................. S-35

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

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

Cab Vehicle...................................................................................1-1

GETTING ON/OFF THE MACHINE ...........................................1-2

OPERATOR’S STATION ................................................................1-3

Cab Features......................................................................................1-3

Front Console....................................................................................1-4

Right Console....................................................................................1-5

Multi-function Type...................................................................1-5

Monitor Panel ...................................................................................1-6

STOP Indicator (Red) ......................................................................1-7

Service Indicator (Yellow).............................................................1-7

Parking Brake Indicator (Red)......................................................1-8

Brake Oil Low Level Indicator (Red)..........................................1-8

Seat Belt Indicator...........................................................................1-8

Discharge Warning Indicator (Red)...........................................1-8

Overheat Indicator (Red) ..............................................................1-9

Engine Oil Low Pressure Indicator (Red).................................1-9

Air Filter Restriction Indicator (Red)..........................................1-9

Engine Coolant Temperature Gauge.....................................1-10

Fuel Gauge......................................................................................1-10

Preheat Lamp (Yellow)................................................................1-11

Turn Signal Indicator (Green)...................................................1-11

High-beam Indicator (Blue) ......................................................1-11

Work Light Indicator (Yellow)...................................................1-11

Clearance Light Indicator (Green) ..........................................1-11

Monitor Display.............................................................................1-12

F-N-R and Shift Position Indicator..........................................1-13

F-N-R (Forward / Reverse) Position Indicator................1-13

Shift Position Indicator..........................................................1-13

Speedometer.................................................................................1-14

Ride Control Indicator.................................................................1-14

Information Display.....................................................................1-15

Shifting Item to be Indicated on

Machine Information Display.............................................1-16

Hour Meter................................................................................1-16

Odometer ..................................................................................1-16

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CONTENTS

Fault Code..................................................................................1-17

Switches, Steering Wheel and Pedals....................................1-18

Steering Wheel..............................................................................1-19

Horn Switch....................................................................................1-19

Turn Signal Switch........................................................................1-19

Light Switch....................................................................................1-20

High-low Beam Switch...............................................................1-21

Hazard Switch................................................................................ 1-22

Front Work Light Switch (Optional) .......................................1-23

Rear Work Light Switch ..............................................................1-24

Front Wiper Switch....................................................................... 1-25

Front Washer Switch....................................................................1-25

Rear Wiper / Washer Switch......................................................1-26

Heated Rear Window Switch....................................................1-27

Handling of Heater ......................................................................1-28

Blower Switch ................................................................................1-28

Heater Switch.................................................................................1-28

Front Window Defroster / Front and Foot Air Vent...........1-28

Accelerator Pedal..........................................................................1-29

Brake / Inching Pedal ..................................................................1-29

Steering Column Tilt Lever........................................................ 1-29

Parking Brake Lever.....................................................................1-30

Right Console / Switch Panel ...................................................1-31

Key Switch.......................................................................................1-32

External Power Source................................................................1-32

Ride Control Switch (Optional)................................................1-33

Ride Control Operation.........................................................1-33

Right Console (Front Attachment).........................................1-34

Multi-function Type................................................................1-34

Loader Control Lever (Multi-function Joystick Type).......1-35

F-N-R Switch...................................................................................1-36

Shift Switch.....................................................................................1-36

Loader Control Lever Lock ........................................................ 1-37

Armrest Adjust Handle...............................................................1-37

Adjusting Operator’s Seat (Suspension Type)....................1-38

Components Name................................................................1-38

Seat Belt...........................................................................................1-40

Seat Pocket .....................................................................................1-40

Fuse Box...........................................................................................1-41

Fuse Box A .................................................................................1-42

Fuse Box B..................................................................................1-42

Tray and Drink Holder.................................................................1-43

ROPS Cab.........................................................................................1-44

Room Light ..................................................................................... 1-45

Sun Visor..........................................................................................1-45

Coat Hook .......................................................................................1-45

Outside Rear View Mirror...........................................................1-45

Cab Door..........................................................................................1-46

Left Door Open / Close Lever................................................... 1-46

Right Door Open / Close Lever................................................ 1-46

When Fully Opening Door ........................................................1-47

Door Lock Disengage Lever......................................................1-47

Articulation Lock Bar...................................................................1-48

Towing Pin ......................................................................................1-48

Engine Hood ..................................................................................1-49

Step ...................................................................................................1-49

Tool Box............................................................................................1-50

Vandal-proof Devices..................................................................1-51

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

Observe Engine Operation Closely...........................................2-1

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

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

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

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

Check After Starting .......................................................................3-7

Using Booster Batteries.................................................................3-8

Warming Up Operation..............................................................3-10

Warming Up Operation in Cold Weather.............................3-11

Stopping Engine...........................................................................3-12

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

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

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

Parking Brake Lever........................................................................4-4

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

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

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

Provisional Stop and Restart of Driving ..................................4-7

Precautions for Driving on Slopes..........................................4-10

Precautions to be Taken If Machine

Failure Occurs...........................................................................4-11

Stop ...................................................................................................4-12

Parking ............................................................................................. 4-13

Emergency Evacuation...............................................................4-15

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

Loader Control Lever (Multi-function Type) ..........................5-1

Loader Control Lever Lock ...........................................................5-2

Hydraulic Quick Coupler Operation .........................................5-3

Before Operation.............................................................................5-6

Precautions for Operation............................................................5-6

Ensure Safety when Operating on Road Shoulders............5-6

Avoid Overloading..........................................................................5-7

Avoid Rapid Steering Changes

and / or Sudden Braking .........................................................5-7

Avoid Operation with Biased Loads .........................................5-7

Excavation..........................................................................................5-8

Grading ............................................................................................5-10

Loading............................................................................................ 5-11

Dozing..............................................................................................5-14

Scooping .........................................................................................5-14

Removing Snow............................................................................5-15

Lifting Wheel Loader...................................................................5-15

Precautions for After Operations............................................5-16

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

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

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

Loading / Unloading on Trailer...................................................6-1

Transporting......................................................................................6-3

Transporting (Urgent Situation).................................................6-4

Towing Method................................................................................6-7

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CONTENTS

Lifting Machine ................................................................................6-8

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

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

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

Use Correct Fuels and Lubricants .............................................7-2

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

Maintenance Guide Table ............................................................7-4

Preparations for Inspection and Maintenance ....................7-5

Lock Frames ......................................................................................7-6

Maintenance Side Cover ..............................................................7-7

Engine Hood ....................................................................................7-8

Periodic Replacement of Parts ...................................................7-9

Maintenance Guide ....................................................................7-10

Kind of Oils ..................................................................................... 7-16

A. Greasing ..................................................................................... 7-19

B. Engine .........................................................................................7-22

Check Engine Oil Level .........................................................7-22

Change Engine Oil .................................................................7-23

Replace Engine Oil Filter ......................................................7-25

C. Power Train ...............................................................................7-26

Change Transmission Oil .....................................................7-26

Change Axle Oil ......................................................................7-27

Clean Transmission Air Breather .......................................7-29

Check Surrounding Areas Around Axles and

Covers for Oil Leaks ..........................................................7-30

Clean Axle Housing Air Breather ......................................7-30

D. Hydraulic System ....................................................................7-31

Inspection and Maintenance of Hydraulic Equipment ..7-31

Check Hydraulic Oil Level ...................................................7-32

Change Hydraulic Oil / Clean Hydraulic Oil Tank ........7-33

Clean Suction Filter ...............................................................7-35

Replace HST Oil Filter Element ..........................................7-36

Replace Return Filter .............................................................7-38

Check Hoses and Lines ........................................................7-40

E. Fuel System ............................................................................... 7-43

Check Fuel Level .....................................................................7-43

Drain Water and Sediment from Fuel Tank ...................7-44

Check and Drain Water from Fuel Pre-Filter .................7-45

Clean Fuel Pre-Filter Element ............................................7-46

Replace Fuel Filter Element ................................................7-47

Check Fuel Hose .....................................................................7-48

F. Air Cleaner ..................................................................................7-49

Clean and Replace Air Cleaner Element ........................7-49

G. Cooling System .......................................................................7-50

Check Coolant Level ............................................................. 7-52

Check Fan Belt ......................................................................... 7-53

Check Fan Belt Tension ........................................................7-53

Adjust Fan Belt Tension ........................................................7-53

Change Coolant ......................................................................7-54

Clean Radiator and Oil Cooler ...........................................7-55

H. Electrical System ..................................................................... 7-56

Check Monitor Function and All Other Instrument

Operation ............................................................................7-56

Check Work Lights .................................................................7-57

Check Horn and Backup Buzzer.........................................7-57

Check Electrical Harnesses and Fuses ............................7-58

Check Electrolyte Level ........................................................7-64

Check Electrolyte Specific Gravity ................................... 7-65

I. Brake System ..............................................................................7-66

Check Brake Oil Level ...........................................................7-66

Check Right and Left Brake Interlocking

Performance .......................................................................7-67

Check Parking Brake Force .................................................7-68

Check Service Brake...............................................................7-68

Change Brake Oil ....................................................................7-68

J. Tire .................................................................................................7-69

Check and Adjust Tire Pressure .........................................7-69

Check Tire for Damage .........................................................7-70

Check Wheel Bolt Torque ....................................................7-70

Removal and Installation of Tire........................................7-73

Tire Wheel .................................................................................7-74

K. Heater .........................................................................................7-75

Check Heater for Any Damage ..........................................7-75

Check Heater Piping .............................................................7-75

L. Miscellaneous ...........................................................................7-76

Check Bucket Teeth for Tightness and / or Wear ........7-76

Check and Replace Seat Belt ..............................................7-77

Check Cab for Damage and Mounting Bolts

for Tightness .......................................................................7-77

Check Windshield Washer Fluid Level

(Cab Vehicle) .......................................................................7-77

Check Play in Steering Wheel Stroke ..............................7-78

Check Accelerator Pedal Operation, and

Exhaust Gas Color and Noise .......................................7-79

Check Rearview Mirror and Inside Rearview Mirror .. 7-80

Check Steps and Handrails for Damage

and Tightness .....................................................................7-80

Clean Engine Compartment and Hood ......................... 7-80

Check and Adjust Valve Clearance ...................................7-81

Check Sound Absorbing Mat Around Engine .............7-81

Check Fuel Injection Timing ...............................................7-81

Check Engine Compression Pressure ............................. 7-82

Check and Clean Starter and Alternator ........................7-82

Retighten Front Axle, Rear Axle and Transmission

Mounting Nuts .................................................................. 7-82

Tightening and Retightening Torque of Nuts

and Bolts ................................................................................... 7-83

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL

CONDITIONS ...................................................................................9-1

Maintenance Under Special Environmental

Conditions....................................................................................9-1

Precautions for Maintenance During

Cold Weather Season................................................................9-2

STORAGE .......................................................................................10-1

Storing the Machine....................................................................10-1

Removing the Machine from Storage...................................10-2

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

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

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

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

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CONTENTS

Sound Level Results (2000/14/EC) .........................................12-2

Vibration Level...............................................................................12-2

OPTIONAL ATTACHMENT ......................................................13-1

Specifications (With Fork Attachment).................................13-1

OTHERS ..........................................................................................14-1

Pallet Forks (ZW65, 75, 95) ........................................................14-1

INDEX ..............................................................................................15-1

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1

EC Emission Control Label: Engine Label

M4FG-00-003

ZW65/ZW75

ZW95

ENGINE EMISSION CONTROL LABEL

M4L2-00-002

M4L2-00-003

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ENGINE EMISSION CONTROL LABEL

2

MEMO

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

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3

1. MODEL/TYPE

2. Homologation Number

3. Product Identification Number

4. Total Permissible Mass (kg)

5. Permissible Front Axle Mass (kg)

6. Permissible Rear Axle Mass (kg)

7. Permissible Towable Mass (kg)

8. Year of Manufacturing

9. Rated Power (kW)

10. Permissible Towable Mass Offroad (kg)

Product Indentification Number

PRODUCT

IDENTIFICATION

NUMBER: ___________________________

fNOTE:

Engine

TYPE:

_______________________________

MFG. NO.:

___________________________

Marks to indicate

the start and end

of the PIN

PRODUCT IDENTIFICATION

NUMBER (PIN)

*RYU4L200E00000102*

M4L2-00-001

The manufacturing Nos. explained in this group is the

individual number (serial No.) given to each machine and

hydraulic components. These numbers are requested

when inquiring any information on the machine and/or

components. Fill these serial Nos. in the blank spaces in

this group to immediately make them available upon

request.

Machine

M4FG-00-003

Sample

M4L2-00-004_CE

MACHINE NUMBERS

4

MEMO

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

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 do not use any of the designated signal

words above after the safety alert symbol are occasionally

used on this machine.

•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

element of information.

S-1

SA-688

SA-1223

SAFETY

Follow Safety Instructions

•Carefully read and follow all safety signs on the machine

and all safety messages in this manual.

•Safety signs should be installed, maintained and replaced

when necessary.

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

order a replacement from your authorized dealer in the

same way you order other replacement parts (be sure to

state machine model and serial number when ordering).

•Learn how to operate the machine and its controls correctly

and safely.

•Allow only trained, qualified, authorized personnel to

operate the machine.

•Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair

its function and / or safety and affect machine life.

• Do not modify any machine parts without authorization.

Failure to do so may deteriorate the part safety, function,

and / or service life. In addition, personal accident,

machine trouble, and / or damage to material caused by

unauthorized modifications will void Hitachi Warranty

Policy.

• 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.

SAFETY

S-2

SA-003

Prepare for Emergencies

•Be prepared if a fire starts or if an accident occurs.

• 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.

SAFETY

S-3

SA-438

SA-437

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.

SAFETY

S-4

SA-435

SA-434

General Precautions for Cab

• Before entering the cab, thoroughly remove all dirt

and / or oil such as mud, grease, soil or stones that may

mess up the cab 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 mess up around the operator’s seat with parts,

tools, soil, stones, obstacles that may fold up or turn

over, cans or lunch box. The levers or pedals become

inoperable if obstacle jams in operation stroke of the

accelerator pedal, brake pedal, pilot control shut-off lever

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.

• Use proper floor mat dedicated to the machine. If another

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

the accelerator pedal or brake pedal during operation,

resulting in serious injury or death.

SAFETY

S-5

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 Ride Attachment

•Never allow anyone to ride attachment or the load. This is

an extremely dangerous practice.

Adjust Operator’s Seat

•A poorly adjusted seat for either the operator or the work

at hand may quickly fatigue the operator leading to

misoperations.

• The seat should be adjusted whenever changing the

operator for the machine.

• 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.

SAFETY

S-6

SA-439

SA-462

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 loader control lever lock 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 loader

control lever lock to the LOCK position. Turn the key

switch OFF to stop the engine.

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

access covers and lock them up.

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.

SAFETY

S-7

SA-237

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, swinging, 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, swinging, 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.

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.

SAFETY

S-8

SA-293

SA-398

Hitachi ZW 65 User manual

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