Hitachi ZW180 User manual

Serial No 005101 and up
PRINTED IN EUROPE (ACI) 2007, 06
ZW180 • 220 • 250 • 310 WHEEL LOADER OPERATOR’S MANUAL EM4GF-EN2-1
Wheel Loader
PART NO. EM4GF-EN2-1
180
220
250
310
URL:http://www.hitachi-c-m.com

INTRODUCTION
©2007 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
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 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.
• SI Units (International System of Units) are used in this
manual.
For reference MKS system units and English units are
also indicated in parentheses after the SI units.
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
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.
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 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 Hitachi Construction Machinery France S.A.S.
Refer to enclosed list for approved equipments. Hitachi
Construction Machinery France S.A.S. 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.

EM4GF-EN2-1
INDEX
ENGIN EMISSION CONTROL LABEL
MACHINE NUMBERS
SAFETY
SAFETY SIGNS
COMPONENTS NAME
OPERATOR'S STATION
BREAK-IN
OPERATING THE ENGINE
DRIVING THE MACHINE
OPERATING THE MACHINE
TRANSPORTING
MAINTENANCE
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
TROUBLESHOOTING
SPECIFICATIONS
OPTIONAL ATTACHMENTS
INDEX

ENGINE EMISSION CONTROL LABEL
ZW180
EMISSION CONTROL LABEL: ENGINE LABEL (FOR EPA)
Emission control label is attached on the cylinder head cover.
EC EMISSION CONTROL LABEL: ENGINE LABEL

ENGINE EMISSION CONTROL LABEL
ZW220, ZW250
EMISSION CONTROL LABEL: ENGINE LABEL (FOR EPA)
Emission control label is attached on the cylinder head cover.
The following is the sample of a label required for engin emission control information, along with location.
EC EMISSION CONTROL LABEL: ENGINE LABEL
Emission control label is attached on the cylinder head cover.
The following is the sample of a label required for engine emission control information, along with location.

ENGINE EMISSION CONTROL LABEL
ZW310
EC EMISSION CONTROL LABEL: ENGINE LABEL
EMISSION CONTROL LABEL: ENGINE LABEL (FOR EPA)
Emission control label is attached on the cylinder head cover.

MACHINE NUMBERS
M4GF-00-003
ZW180
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
1. MODEL/TYPE
2. Product Identification Number
3. Year of Manufacturing
4. Operating mass (standard version)
5. Engine power in kW according to ISO9249
PRODUCT INDENTIFICATION NUMBER
PRODUCT
IDENTIFICATION
NUMBER: ___________________________
NOTE:
ENGINE
TYPE: _______________________________
MFG. NO.: ___________________________
Marks to indicate
the start and end of
the PIN
PRODUCT IDENTIFICATION
NUMBER (PIN)
*RYU4GF00H00005101*
M4GB-00-001
M4GB-00-002
ZW220, ZW250
M4GB-00-003
ZW310
SAMPLE

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


Recognize Safety Information ................................................... S-1
Understand Signal Words ............................................................ S-1
Follow Safety Instructions ........................................................... S-2
Prepare for Emergencies .............................................................. S-2
Wear Protective Clothing ............................................................ S-3
Protect Against Noise ................................................................... S-3
Inspect Machine ............................................................................. S-3
General Precautions for Cab ....................................................... S-4
Use Handholds and Steps ........................................................... S-5
Adjust the Operator’s Seat .......................................................... S-5
Ensure Safety Before Rising from or
Leaving Operator’s Seat ........................................................ S-5
Fasten Your Seat Belt ..................................................................... S-6
Move and Operate Machine Safely .......................................... S-6
Handle Starting Aids Safely ........................................................ S-6
Operate Only from Operator’s Seat ......................................... S-7
Jump Starting .................................................................................. S-7
Investigate Job Site Beforehand ............................................... S-8
Equipment of Head Guard, Rops, Fops .................................. S-9
Provide Signals for Jobs Involving
Multiple Numbers of Machines .......................................... S-9
Keep Riders Off Machine ..........................................................S-10
Drive Safely ..................................................................................... S-10
Drive Machine Safely (Work Site) ............................................S-11
Drive Safely with Bucket Loaded ............................................S-11
Drive on Snow Safely .................................................................. S-12
Travel on Public Roads Safely ...................................................S-12
Avoid Injury From Rollaway Accidents .................................S-13
Avoid Accidents From Backing Up And Turning ...............S-14
Avoid Positioning Bucket Over Anyone ............................... S-15
Avoid Tipping .................................................................................S-15
Never Undercut A High Bank ...................................................S-16
Dig With Caution .......................................................................... S-16
Perform Truck Loading Safely .................................................. S-16
Avoid Power Lines ........................................................................ S-17
Precautions For Operation ........................................................ S-17
Precautions For Lightening ......................................................S-17
Object Handling ...........................................................................S-17
Protect Against Flying Debris ..................................................S-18
Park Machine Safely .....................................................................S-18
Store Attachments Safely .......................................................... S-19
Transport Safely ............................................................................ S-19
Handle Fluids Safely−avoid Fires ............................................ S-20
Practice Safe Maintenance ........................................................S-21
Warn Others Of Service Work ...................................................S-22
Support Machine Properly ........................................................ S-22
Stay Clear Of Moving Parts .......................................................S-22
Support Maintenance Properly ...............................................S-23
Prevent Parts From Flying .........................................................S-23
Prevent Burns ................................................................................. S-24
Replace Rubber Hoses Periodically ........................................ S-24
Avoid High-pressure Fluids .......................................................S-25
Prevent Fires ................................................................................... S-26
Evacuating In Case Of Fire .........................................................S-27
Beware Of Exhaust Fumes .........................................................S-27
Precautions For Welding And Grinding ................................S-27
Avoid Heating Near Pressurized Fluid Lines .......................S-28
Avoid Applying Heat To Lines Containing
Flammable Fluids .................................................................. S-28
Remove Paint Before Welding Or Heating .......................... S-28
Beware Of Asbestos Dust .......................................................... S-29
Prevent Battery Explosions .......................................................S-29
Service Air Conditioning System Safely ...............................S-29
Handle Chemical Products Safely ...........................................S-30
Dispose Of Waste Properly ........................................................ S-30
 ..............................................................................S-31
 ................................................................. 1-1

Cab Features ..................................................................................... 1-2
Front Console ................................................................................... 1-3
Right Console ................................................................................... 1-4
Monitor Panel .................................................................................. 1-5
Stop Indicator ........................................................................... 1-6
Service Indicator ...................................................................... 1-6
Parking Brake Indicator ......................................................... 1-7
Brake Oil Low Pressure Indicator ....................................... 1-7
Brake Oil Low Level Indicator .............................................. 1-7
Emergency Steering Indicator (Optional) ....................... 1-7
Low Steering Oil Pressure Indicator (Optional) ............ 1-8
Seat Belt Indicator ................................................................... 1-8
Discharge Warning Indicator .............................................. 1-8
Engine Warning Indicator ..................................................... 1-8
Overheat Indicator .................................................................. 1-9
Engine Oil Low Pressure Indicator ..................................... 1-9
Fuel Filter Restriction Indicator ........................................... 1-9
Air Filter Restriction Indicator ............................................. 1-9
Transmission Warning Indicator .......................................1-10
Transmission Oil Filter Restriction Indicator ................1-10
Hydraulic Oil Temperature Indicator ..............................1-10
Transmission Oil Temperature Indicator .......................1-10
Engine Coolant Temperature Gauge ..............................1-11
Transmission Oil Temperature Gauge ............................1-11
Fuel Gauge ..............................................................................1-11
Preheat Lamp ..........................................................................1-12
Turn Signal Indicator ............................................................1-12
High Beam Indicator ............................................................1-12
Work Light Indicator .............................................................1-12
Clealance Light Indicator ....................................................1-12
Lever Steering Indicator (Optional) ................................1-13
Maintenance Indicator ........................................................1-13
Forward/Reverse Selector Switch Indicator .................1-13
Monitor Display .............................................................................1-14

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Forward/Reverse and Selection Gear Indicator ..........1-15
FNR (Forward/Reverse) Position Indicator ...................1-15
Hold Indicator .........................................................................1-16
Shift Position Indicator ........................................................1-16
Speedometer ..........................................................................1-17
Automatic Mode Indicator .................................................1-18
Ride Control Indicator ..........................................................1-19
Clutch Cut Position Indicator ............................................1-19
Machine Information Display ...................................................1-20
Clock Setting Mode ....................................................................1-25
Switches, Steering Wheel and Pedals ....................................1-26
Forward/Reverse Lever/Shift Switch ..............................1-27
Neutral Lever Lock (Forward/Reverse Lever) ...............1-28
Horn Switch ..........................................................................1-28
Turn Signal Lever ...................................................................1-28
Light Switch .............................................................................1-29
High-Low Beam Switch .......................................................1-30
Key Switch ................................................................................1-30
Windshield Wiper Switch ....................................................1-31
Rear Window Wiper Switch ................................................1-31
Hazard Switch .........................................................................1-32
Work Light Switch .................................................................1-33
Driving Mode Switch (ZW180) ..........................................1-34
Driving Mode Switch (ZW220, ZW250, ZW310) .........1-35
Clutch Cut Position Switch .................................................1-36
Work Mode Switch ................................................................1-36
Parking Brake Switch ............................................................1-37
Accelerator Pedal ..........................................................................1-38
Brake Pedal .....................................................................................1-38
Steering Column Tilt & Telescopic Lever ..............................1-38
Air Conditioner Operation ........................................................1-39
Auto Air Conditioner ..................................................................1-40
Defroster Operation ....................................................................1-45
Tips for Optimal Air Conditioner Usage ...............................1-46
Right Console/Switches .............................................................1-47
Loader Control Lever ...................................................................1-48
Front Control Lever Lock ............................................................1-51
Armrest Adjust Handle ...............................................................1-51
Finger Type .....................................................................................1-52
Hold Switch ....................................................................................1-52
DSS/USS (Down Shift/ Up Shift) Switch ................................1-52
DSS (Down Shift) Switch ............................................................1-52
Multi-Function Type ....................................................................1-53
Hold Switch ....................................................................................1-53
DSS (Down Shift) Switch ............................................................1-53
USS (Up Shift) Switch ..................................................................1-53
Right Console Switch Panel ......................................................1-54
Quick Coupler Switch (Optional) .....................................1-54
Lift Arm Auto Lever Switch (Optional) ...........................1-55
Forward/Reverse Selector Switch ....................................1-56
Ride Control Switch (Optional) .........................................1-57
Fog Lamp Switch (Optional) ..............................................1-58
Fan Reversing Switch ...........................................................1-58
Emergency Steering Operation Check Switch ............1-58
Cigarette Lighter ...........................................................................1-59
Ashtray .............................................................................................1-59
Adjusting Operator’s Seat (Air Suspension Type Seat) ....1-60
Adjusting Operator’s Seat
(Mechanical Suspension Type Seat) ................................1-64
Seat Belt ...........................................................................................1-67
Rear Tray ..........................................................................................1-68
Fuse Box ...........................................................................................1-69
Hot&Cool Box ................................................................................1-71
Tray and Drink Holder .................................................................1-71
ROPS Cab .........................................................................................1-72
Front Room Light .........................................................................1-74
Rear Room Light ...........................................................................1-74
Sun Visor ..........................................................................................1-75
Emergency Evacuation Hammer ............................................1-75
Coat Hook .......................................................................................1-75
AM/FM Radio Operation ...........................................................1-76
Digital Clock Setting Procedure ..............................................1-77
Upper Switch Panel (Optional) ................................................1-78
Front Hot-wire Heater Switch (Optional) ......................1-78
Rear Hot-wire Heater Switch (Optional) ........................1-78
Rotary Light Switch (Optional) .........................................1-78
Rear View Mirror ............................................................................1-79
Room Mirror ...................................................................................1-79
Cab Door ..........................................................................................1-79
Door Lock Knob ............................................................................1-80
Door Open/Close Lever ..............................................................1-80
Window Open/Close Lever .......................................................1-80
When Fully Opening The Door ................................................1-81
Door Lock Disengage Lever .....................................................1-81
Articulate Lock Bar .......................................................................1-82
Towing Pin ......................................................................................1-83
Seat Pocket .....................................................................................1-83
Tool Box ............................................................................................1-83
Inspection/ Maintenance Side Access Cover .....................1-84
Rear Grille ........................................................................................1-85
Steps .................................................................................................1-85
Vandal-Proof Devices ..................................................................1-86

Observe Engine Operation Closely .......................................... 2-1

Check Before Starting .................................................................. 3-1
Starting Engine ............................................................................... 3-3
Check After Starting ..................................................................... 3-5
Using Booster Batteries ................................................................ 3-6
Warming Up Operation ................................................................ 3-8
Warning Up Operation in Cold Weather ................................ 3-8
Stopping Engine ............................................................................. 3-9
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Driving Machine ............................................................................. 4-1
Starting To Move ............................................................................. 4-2
Parking Brake Switch ..................................................................... 4-5
Drive Speed Change ..................................................................... 4-6
Changing Forward/Reverse Drive Direction ......................... 4-6


Finger Type ....................................................................................... 4-7
Multi-Function Type ...................................................................... 4-7
Steering .............................................................................................. 4-8
Provisional Stop and Restart of Driving .............................. 4-9
Precautions for Driving on Slopes ..........................................4-11
Precautions To Be Taken If The Machine Failure Occurs ....4-12
Stop/Parking ..................................................................................4-13
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Loader Control Lever ..................................................................... 5-1
Front Control Lever Lock .............................................................. 5-4
Clutch Cut Position Switch .......................................................... 5-5
Adjustment of Loader Front ....................................................... 5-6
Lift Arm Auto Lever Switch (Optional) .................................... 5-7
Adjustment of Bucket Auto Leveler ......................................... 5-8
Adjustment of Lift Arm Kick Out ............................................... 5-9
Adjustment of Lift Arm Auto Leveler (Optional) ................. 5-9
Before Operation ..........................................................................5-10
Precautions for Operation .........................................................5-10
Ensure Safety When Operating on Road Shoulders ........5-10
Avoid Overloading .......................................................................5-11
Avoid Rapid Steering Changes and/or Sudden Braking .....5-11
Excavation .......................................................................................5-12
Digging And Loading Level Ground ......................................5-13
Grading ............................................................................................5-14
Loading ............................................................................................5-15
Dozing ..............................................................................................5-17
Scooping .........................................................................................5-17
Removing Snow ...........................................................................5-18
Lifting Wheel Loader ...................................................................5-18
Precautions for After Operations ............................................5-19

Transporting by Road ................................................................... 6-1
Transporting by Trailer ................................................................. 6-1
Loading/Unloading on Trailer .................................................... 6-1
Transporting ..................................................................................... 6-3
Transporting Wheel Loader (Urgent Situation) ................... 6-4
Towing Method .............................................................................6-10
Lifting Machine .............................................................................6-11

Correct Maintenance and Inspection Procedures .............. 7-1
Check the Hour Meter Regularly ............................................... 7-2
Use Correct Fuels and Lubricants ............................................. 7-2
Layout ................................................................................................. 7-3
Maintenance Guide Table ............................................................ 7-6
Preparations for Inspection and Maintenance .................... 7-8
Lock Frames ...................................................................................... 7-9
Inspection/Maintenance Access Side Cover .......................7-10
Rear Grille ........................................................................................7-11
Periodic Replacement of Parts .................................................7-12
Maintenance Guide .....................................................................7-13
Kind of Oils ......................................................................................7-19
A. Greasing ......................................................................................7-22
B. Engine ..........................................................................................7-28
Check Engine Oil Level ........................................................7-28
Change Engine Oil ................................................................7-28
Replace Engine Oil Filter .....................................................7-30
C. Power Train ................................................................................7-33
Check Transmission Oil Level ............................................7-33
Change Transmission Oil and Transmission Oil Filter ...7-34
Clean Transmission Oil Strainer .......................................7-34
Change Axle Oil ......................................................................7-36
Clean Torque Converter Air Breather ..............................7-38
Clean Axle Housing Air Breather .....................................7-39
D. Hydraulic System .....................................................................7-40
Inspection and Maintenance of Hydraulic Equipment ....7-40
Check Hydraulic Oil Level ...................................................7-41
Change Hydraulic Oil ...........................................................7-42
Clean Suction Filter ...............................................................7-45
Replace Pilot Oil Filter ..........................................................7-46
Replace Hydraulic Tank Oil Filter ......................................7-47
Check Hoses and Lines ........................................................7-48
Service Recommendations for Hydraulic Fittings .....7-51
E. Fuel System ...............................................................................7-53
Check Fuel Level ....................................................................7-53
Drain Water and Sediment from Fuel Tank ...................7-54
Check and Drain Water Separator ...................................7-54
Replace Fuel Main Filter ......................................................7-58
Replace Fuel Pre-Filter .........................................................7-60
Clean Fuel Solenoid Pump Strainer ................................7-62
Check Fuel Hoses ...................................................................7-63
F. Air Cleaner ...................................................................................7-64
Clean and Replace Air Cleaner Element ........................7-64
G. Cooling System ........................................................................7-65
Check Coolant Level .............................................................7-66
Check Fan Belt ........................................................................7-68
Check Fan Belt Tension ........................................................7-68
Adjust Fan Belt Tension .......................................................7-68
Change Coolant .....................................................................7-69
Clean Radiator/Oil Cooler Cores
and Other Cooling System ................................................7-73
H. Electrical System ......................................................................7-74
Replace Batteries ...................................................................7-77
Check Monitor Functions
and All Other Instrument Operation ..............................7-78
Check Work Lights .................................................................7-79
Check Horn And Reverse Buzzer ......................................7-79
Check Electrical Harnesses And Fuses ...........................7-80
I. Brake System ...............................................................................7-82
Check Right And Left Brake
Interlocking Performance ...................................................7-82
Check Parking Brake Force .................................................7-82
Check Accumulator Function,
Gas Leakage, Looseness, And Damage .........................7-83
Check Gas Pressure In Accumulator ...............................7-83
Check Brake Disks (Service And Paring) ........................7-84
J. Tire ..................................................................................................7-85
Check And Replace Tire (Tire Pressure) check .............7-85
Check Tire For Damage ........................................................7-86


Check Wheel Bolt Torque ....................................................7-86
K. Air Conditioner .........................................................................7-90
Clean/Replace Air Conditioner Circulation/
Fresh Air Filters .......................................................................7-90
Check Air Conditioner ..........................................................7-92
Check Air Conditioner Piping ............................................7-92
Check Air Conditioner Condenser ...................................7-93
Check Air Conditioner Fan Belt .........................................7-93
Check Refrigerant ..................................................................7-94
Check Compressor and Pulley ..........................................7-94
Check Switch Operation .....................................................7-94
L. Miscellaneous ............................................................................7-95
Check Bucket Teeth and Cutting Edge ..........................7-96
Check and Replace Seat Belt .............................................7-96
Check ROPS Cab, Resin Cab Roof,
and Roof Mounting Bolts ....................................................7-96
Check Windshield Washer Fluid Level ............................7-96
Check Play Amount in Steering Wheel Stroke ............7-97
Check Accelerator Pedal Operation,
and Exhaust Gas Color and Noise ....................................7-98
Check Rearview Mirror and Inside Rearview Mirror ....7-99
Check Turbocharger Bearing ............................................7-99
Check Engine Cylinder Head and Manifold .................7-99
Check and Adjust Valve Clearance .................................7-99
Check Fuel Injection Timing ........................................... 7-100
Check Engine Compression Pressure .......................... 7-100
Check and Clean Starter and Generator .................... 7-100
Retighten Front Axle
and Rear Axle Support Mounting Bolts ...................... 7-100
Tightening and Retightening Torque of Nuts
and Bolts ................................................................................ 7-101


Maintenance Under Special Environmental Conditions .. 9-1

Storing the Machine ....................................................................10-1
Removing the Machine from Storage ...................................10-2

Troubleshooting ...........................................................................11-1

Specifications .................................................................................12-1
Sound Level Results (2000/14/ec) ..........................................12-2

Specifications .................................................................................13-1
 ...............................................................................................14-1


S-1

• These are the .
• 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.
001-E01A-0001

• On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
•  indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
•  indicates a potentially hazardous situation
which, if not avoided, could result in death or serious in-
jury.
•  indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
•    are located near spe-
cific hazards. General precautions are listed on 
.
• 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  indicates a situation
which, if not avoided, could result in damage to the ma-
chine.
• NOTE indicates an additional explanation for an element
of information.
002-E01A-1223
SA-688
SA-1223


S-2

• 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 unauthor-
ized modifications will void Hitachi Warranty Policy.
• Do not use attachments and/or optional parts or equip-
ment 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 hazard-
ous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your autho-
rized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003

• 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-extinguish-
er 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.
004-E01A-0437
SA-003
SA-437


S-3

• Wear close fitting clothing and safety equipment appropri-
ate 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.
005-E01A-0438

• Prolonged exposure to loud noise can cause impairment or
loss of hearing.
• Wear a suitable hearing protective device such as ear-
muffs or earplugs to protect against objectionable or un-
comfortably loud noises.
006-E01A-0434

• 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 “PRE-START INSPECTION” chapter in the
operator’s manual.
007-E01A-0435
SA-438
SA-434
SA-435


S-4

• Before entering the cab, thoroughly remove all dirt and/
or oil 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 ac-
cident.
• Do not leave parts and/or tools lying around the operator’s
seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not attach
any transparent type window decorations on the win-
dowpanes as they may focus sunlight, possibly starting a
fire.
• Refrain from listening to the radio, or using music head-
phones 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 tem-
perature in the cab increases, the lighter may explode.
524-E01A-0000


S-5

• 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 hand-holds.
• Never jump on or off the machine. Never mount or dis-
mount a moving machine.
• Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
008-E01A-0439

• A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
• The seat should be adjusted whenever changing the op-
erator 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.
009-E01A-0462


• 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 pilot control shut-off lever 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 pilot
control shut-off lever 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.
SA-439
SA-462


S-6

• If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the opera-
tor may be crushed by the overturning machine, resulting in
serious injury or death.
• Prior to operating the machine, thoroughly examine web-
bing, buckle and attaching hardware. If any item is dam-
aged or worn, replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt securely fas-
tened 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 three
years regardless of its apparent condition.
010-E01A-0237

• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or oper-
ating the machine.
• Always keep the travel alarm and horn in working condi-
tion (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 op-
erable before operating the machine. If any faulty illumi-
nation is present, immediately repair it.
011-E01A-0398

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 pressur-
ized 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.
036-E01A-0293-3
SA-398
SA-293
SA-237


S-7

• 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 track 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.
012-E01B-0431

• 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 THE ENGINE” chap-
ter 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.
S013-E01A-0032
SA-431
SA-032


S-8

• 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 fall-
ing 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 excava-
tions and road shoulders.
• When working on an incline or on a road shoulder, em-
ploy a signal person as required.
• Confirm that your machine is equipped a FOPS cab before
working in areas where the possibility of falling stones or
debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
• Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
015-E01B-0447
SA-447