Hitachi ZAXIS 135US-3 class User manual

INTRODUCTION
©2008 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 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 fac-
ing 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 identifica-
tion 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 clean-
ness 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 pro-
gram 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 war-
ranty period. In some circumstances, Hitachi also provides
field improvements, often without charge to the custom-
er, 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.
PRIOR TO OPERATING THIS MACHINE, INCLUDING
SATELLITE COMMUNICATION SYSTEM, IN A COUNTRY
OTHER THAN A COUNTRY OF ITS INTENDED USE, IT
MAY BE NECESSARY TO MAKE MODIFICATIONS TO IT
SO THAT IT COMPLIES WITH THE LOCAL REGULATORY
STANDARDS (INCLUDING SAFETY STANDARDS) AND
LEGAL REQUIREMENTS OF THAT PARTICULAR COUN-
TRY. PLEASE DO NOT EXPORT OR OPERATE THIS MA-
CHINE OUTSIDE OF THE COUNTRY OF ITS INTENDED
USE UNTIL SUCH COMPLIANCE HAS BEEN CONFIRMED.
PLEASE CONTACT HITACHI CONSTRUCTION MACHIN-
ERY CO., LTD. OR ANY OF OUR AUTHORIZED DISTRIBU-
TOR OR DEALER IF YOU HAVE ANY QUESTIONS CON-
CERNING COMPLIANCE.
Hitachi machine models are classified into 3 classes and 3 models as shown in the table
below. When referring to the texts and/or illustrations indicated with the applicable
machine class names in this manual, check that the machine models concerned are
included using this table.
Class
ZX135US-3 Class ZX135US-3, 135USK-3, 135USL-3
ZX225US-3 Class ZX225US-3, 225USLC-3
ZX225USR-3 Class ZX225USR-3, 225USRLC-3, 225USRK-3, 225USRLCK-3
Model
Std. Model ZX135US-3,
ZX225US-3, 225USLC-3
ZX225USR-3, 225USRLC-3
K Model ZX135USK-3,
ZX225USRK-3, 225USRLCK-3
L Model ZX135USL-3
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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T
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 AND DEVICES
INDEX
INDEX
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MACHINE NUMBERS
The manufacturing Nos. explained in this group is the individ-
ual 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
MODEL/TYPE:
PRODUCT
IDENTIFICATION
NUMBER:
PRODUCT IDENTIFICATION NUMBER
PRODUCT
IDENTIFICATION
NUMBER:
NOTE:
ENGINE
(ZX135US-3 class)
TYPE:
MFG. NO.:
(ZX225US-3 • 225USR-3 class)
TYPE:
MFG. NO.:
M157-00-001
M157-12-008
M178-00-002
*HCM1U400L00100001*
PRODUCT IDENTIFICATION
NUMBER (PIN)
Marks to indicate the
start and end of the
PIN
M1V1-00-001
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MACHINE NUMBERS
M178-07-047
M178-07-086
TRAVEL MOTOR
TYPE:
MFG. NO.:
SWING MOTOR
TYPE:
MFG. NO.:
M157-00-004
HYDRAULIC PUMP
(ZX135US-3 class)
TYPE:
MFG. NO.:
(ZX225US-3 • 225USR-3 class)
TYPE:
MFG. NO.:
M1U4-00-001
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CONTENTS
MACHINE NUMBERS
SAFETY
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
Keep Riders Off Machine ..............................................................S-7
Precautions for Operations..........................................................S-8
Investigate Job Site Beforehand................................................S-9
Equipment of Head Guard, Rops, Fops ................................ S-10
Provide Signals for Jobs Involving Multiple
Numbers of Machines..........................................................S-10
Confirm Direction of Machine to Be Driven........................S-10
Drive Machine Safely...................................................................S-11
Avoid Injury From Rollaway Accidents.................................S-13
Avoid Injury From Back-over and Swing Accidents.........S-14
Keep Person Clear From Working Area................................. S-15
Never Position Bucket Over Anyone ..................................... S-15
Avoid Undercutting..................................................................... S-15
Avoid Tipping.................................................................................S-16
Never Undercut a High Bank....................................................S-16
Dig with Caution........................................................................... S-17
Operate with Caution .................................................................S-17
Avoid Power Lines........................................................................ S-18
Precautions for Lightning..........................................................S-18
Object Handling ...........................................................................S-18
Protect Against Flying Debris ..................................................S-19
Park Machine Safely.....................................................................S-19
Handle Fluids Safely−Avoid Fires............................................S-19
Transport Safely ............................................................................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
Prevent Parts From Flying ......................................................... S-23
Store Attachments Safely..........................................................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
SAFETY SIGNS/Oceania Model Only................................. S-31
SAFETY SIGNS/Asia/Middle and Near East
Model Only.............................................................................S-37
COMPONENTS NAME ................................................................. 1-1
OPERATOR’S STATION
Cab Features..................................................................................... 1-2
Multi Function Monitor................................................................ 1-4
Outline................................................................................................ 1-5
Menu Screen (23)..................................................................... 1-8
Hour Meter................................................................................. 1-9
Fuel Gauge................................................................................. 1-9
Clock............................................................................................. 1-9
Back Monitor Selector............................................................ 1-9
Menu Key..................................................................................1-10
Optional Function Key.........................................................1-10
Return to Basic Screen Key ................................................1-10
Alarm Light ..............................................................................1-10
Optional Function Display ................................................1-10
Coolant Temperature Gauge.............................................1-11
Operating Status Icon Display ..........................................1-11
Alarm Occurrence Screen..........................................................1-16
Contents of Alarms ......................................................................1-18
Clock Setting..................................................................................1-20
Attachment Selection
(Only Machines Equipped with Optional Parts) .........1-21
Selecting an Attachment from Main Menu ........................1-22
Attachment Specification Screen...........................................1-23
Pump 2 Flow Rate Adjustment
(Only Machines Equipped with Optional Parts) .........1-25
Displaying Operating Conditions...........................................1-26
Fuel Rate Display/No Display...................................................1-27
Back Monitor Settings ................................................................1-35
Maintenance Settings.................................................................1-37
Mail (Optional)...............................................................................1-42
Language Settings.......................................................................1-44
Switch Panel...................................................................................1-46
Engine Control Dial......................................................................1-47
Auto-idle Switch ...........................................................................1-47
Power Mode Switch.....................................................................1-48
Travel Mode Switch .....................................................................1-48
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CONTENTS
Work Light Switch ........................................................................1-49
Wiper/Washer Switch..................................................................1-50
Switch Panel (Optional)..............................................................1-52
Key Switch.......................................................................................1-54
Horn Switch....................................................................................1-54
Cigar Lighter...................................................................................1-55
Cab Light .........................................................................................1-56
Installing Fire Extinguisher (Optional) ..................................1-56
Pilot Control Shut-off Lever ......................................................1-57
Engine Stop Switch......................................................................1-57
Fuse Box...........................................................................................1-58
Auto Air Conditioner...................................................................1-59
Cab Heater Operation.................................................................1-62
Cooling Operation .......................................................................1-63
Defroster Operation ....................................................................1-63
Tips for Optimal Air Conditioner Usage ...............................1-65
Cab Heater (Optional).................................................................1-66
Cab Heater Operation.................................................................1-67
Defroster Operation ....................................................................1-68
AM/FM Radio Operation ...........................................................1-69
Digital Clock Setting Procedure..............................................1-70
Cab Door Release Lever .............................................................1-71
Opening Upper Front Window................................................1-71
Closing Upper Front Window...................................................1-72
Removing and Storing Lower Front Window.....................1-73
Opening Side Windows..............................................................1-73
Opening/Closing Overhead Window....................................1-74
Emergency Exit .............................................................................1-75
Adjusting the Seat .......................................................................1-76
Adjusting the Seat (Optional) ..................................................1-78
Adjusting Console Height.........................................................1-80
Seat Belt...........................................................................................1-81
BREAK-IN
Observe Engine Operation Closely.......................................... 2-1
Every 8 Hours or Daily................................................................... 2-1
After the First 50 Hours ................................................................ 2-1
After the First 100 Hours.............................................................. 2-1
OPERATING THE ENGINE
Inspect Machine Daily Before Starting................................... 3-1
Before Starting Engine ................................................................. 3-2
Starting the Engine in Ordinary Temperature...................... 3-3
Starting in Cold Weather.............................................................. 3-5
Check Instruments After Starting............................................. 3-6
Using Booster Batteries................................................................ 3-7
Stopping the Engine ..................................................................... 3-9
DRIVING THE MACHINE
Drive the Machine Carefully....................................................... 4-1
Steering the Machine Using Pedals......................................... 4-2
Steering the Machine Using Levers ......................................... 4-3
Travel Mode Switch ....................................................................... 4-4
Travel Alarm (Optional) ................................................................ 4-4
Operating on Soft Ground .......................................................... 4-5
Raise One Track Using Boom and Arm ................................... 4-5
Towing Machine a Short Distance............................................ 4-6
Operating in Water or Mud......................................................... 4-7
Parking the Machine on Slopes................................................. 4-8
Parking the Machine ..................................................................... 4-8
OPERATING THE MACHINE
Control Lever (ISO Pattern) ......................................................... 5-1
Control Lever (Hitachi Pattern).................................................. 5-2
Control Lever (4 Way Multi Valve) (Optional)........................ 5-3
Control Lever (2 Way Multi Valve) (Optional)........................ 5-4
Attachment Pedal (Hydraulic Breaker) (K Model)............... 5-5
Attachment Pedal (Hydraulic Crusher) (K Model)............... 5-6
Pilot Control Shut-off Lever ........................................................ 5-7
Engine Speed Control................................................................... 5-9
Auto-idle .........................................................................................5-10
Work Mode .....................................................................................5-11
Work Mode Select ........................................................................5-12
Power Mode ..................................................................................5-13
Precautions for Excavation (K Model) ...................................5-14
Operating Backhoe......................................................................5-15
Grading Operation.......................................................................5-15
Face Shovel Operation................................................................5-16
Avoid Abusive Operation ..........................................................5-16
Operating Tips...............................................................................5-17
Select Correct Track Shoes ........................................................5-17
Hydraulic Breaker and Hydraulic Crusher............................5-18
Pipings for Breaker and Crusher..............................................5-19
Secondary Relief Pressure Adjustment ................................5-21
Precautions for Breaker Operation.........................................5-23
Breaker Maintenance..................................................................5-26
Precautions for Crusher Operation ........................................5-27
Attachment.....................................................................................5-29
Attachment Connection Parts .................................................5-33
Precaution for Arm Roll-in/Bucket Roll-in
Combined Operation --- If Headguard-integrated
Cab or Rainguard is Equipped ..........................................5-34
When Installing an Attachment Longer
Than Standard Bucket..........................................................5-34
Shackle Hole Usage .....................................................................5-35
Overnight Storage Instructions...............................................5-35
Bucket Link Securing Method (L Model)..............................5-36
Emergency Boom Lowering Procedure
(Without Hose-rupture Safety Valve) .............................5-37
Object Handling --- If Equipped..............................................5-39
TRANSPORTING
Transporting by Road ................................................................... 6-1
Loading/Unloading on a Trailer ................................................ 6-1
Machine Lifting Procedure.......................................................... 6-5
MAINTENANCE
Correct Maintenance and Inspection Procedures.............. 7-1
Check the Hour Meter Regularly............................................... 7-2
Use Correct Fuels and Lubricants ............................................. 7-2
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CONTENTS
Layout................................................................................................. 7-3
Maintenance Guide Table............................................................ 7-4
Prepare Machine for Maintenance........................................... 7-6
Hood and Access Covers.............................................................. 7-7
Periodic Replacement of Parts................................................... 7-8
Maintenance Guide ....................................................................... 7-9
A. Greasing....................................................................................7-14
Front Joint Pins.......................................................................7-14
Swing Bearing.........................................................................7-16
Swing Internal Gear ..............................................................7-17
B. Engine........................................................................................7-18
Engine Oil Level......................................................................7-18
Change Engine Oil ................................................................7-19
Replace Engine Oil Filter.....................................................7-19
C. Transmission............................................................................7-21
Pump Transmission...............................................................7-21
Swing Reduction Gear.........................................................7-22
Travel Reduction Gear..........................................................7-23
D. Hydraulic System...................................................................7-25
Inspection and Maintenance of
Hydraulic Equipment ......................................................7-25
Breaker Maintenance ...........................................................7-27
Check Hydraulic Oil Level...................................................7-28
Change Hydraulic Oil ...........................................................7-29
Suction Filter Cleaning ........................................................7-29
Replace Hydraulic Tank Oil Filter......................................7-32
Replace Hydraulic Tank Oil Filter
(K Model, L Model)............................................................7-33
Replace Pilot Oil Filter ..........................................................7-34
Replace Air Breather Element ...........................................7-35
Check Hoses and Lines........................................................7-36
Service Recommendations for Hydraulic Fittings .....7-39
E. Fuel System..............................................................................7-41
Drain Fuel Tank Sump .........................................................7-43
Drain Fuel Filter ......................................................................7-44
Replace Fuel Main Filter Element.....................................7-48
Replace Fuel Pre-Filter Element .......................................7-49
Clean Fuel Solenoid Pump Strainer ................................7-50
Check Fuel Hoses...................................................................7-51
F. Air Cleaner................................................................................7-52
Clean Air Cleaner Outer Element.....................................7-52
Replace Air Cleaner Outer and Inner Elements ..........7-52
G. Cooling System ......................................................................7-54
Check Coolant Level.............................................................7-56
Check and Adjust Fan Belt Tension .................................7-57
Change Coolant .....................................................................7-59
Clean Radiator Interior.........................................................7-59
Clean Radiator, Oil Cooler Core
and Inter Cooler Outside................................................7-60
Clean Oil Cooler, Radiator and Inter
Cooler Front Screen .........................................................7-60
Clean Air Conditioner Condenser....................................7-60
Clean Fuel Oil Cooler ...........................................................7-60
Clean Air Conditioner Front Screen (Opt.)....................7-60
H. Electrical System....................................................................7-61
Replace Batteries ...................................................................7-64
Remove and Installing Battery .........................................7-65
Replacing Fuses......................................................................7-65
I. Miscellaneous ........................................................................7-67
Check Bucket Teeth...............................................................7-67
Change Bucket .......................................................................7-71
Convert Bucket Connection Into Face Shovel.............7-72
Adjust Bucket Linkage.........................................................7-73
Remove Travel Levers...........................................................7-74
Check and Replace Seat Belt .............................................7-74
Check Windshield Washer Fluid Level............................7-75
Check Track Sag......................................................................7-76
Clean and Replace Air Conditioner Filter .....................7-78
Check Air Conditioner..........................................................7-81
Clean Cab Floor......................................................................7-82
Retighten Cylinder Head Bolt............................................7-83
Inspect and Adjust Valve Clearance................................7-83
Measure Engine Compression Pressure ........................7-83
Check Starter and Alternator.............................................7-83
Check and Replace EGR Device........................................7-83
Check Tightening Torque of Bolts and Nuts ................7-84
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special Environmental
Conditions.................................................................................. 9-1
STORAGE
Storing the Machine....................................................................10-1
Removing the Machine from Storage...................................10-2
TROUBLESHOOTING
Impossible to Start the Engine................................................11-1
Engine...............................................................................................11-2
Electrical System...........................................................................11-6
Mode Selection .............................................................................11-8
Control Levers................................................................................11-9
Hydraulic System..........................................................................11-9
SPECIFICATIONS
Specifications (ZX135US-3).......................................................12-1
Working Ranges (ZX135US-3)..................................................12-2
Shoe Types and Applications (ZX135US-3).........................12-3
Bucket Types and Applications (ZX135US-3) .....................12-4
Specifications (ZX135USK-3)....................................................12-5
Working Ranges (ZX135USK-3) ...............................................12-6
Shoe Types and Applications (ZX135USK-3) ......................12-7
Bucket Types and Applications(ZX135USK-3)....................12-8
Specifications (ZX135USL-3).....................................................12-9
Working Ranges (ZX135USL-3)..............................................12-10
Shoe Types and Applications (ZX135USL-3).....................12-11
Bucket Types and Applications(ZX135USL-3) ..................12-12
Specifications (ZX225US-3, 225USLC-3).............................12-13
Working Ranges (ZX225US-3, 225USLC-3)........................12-14
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CONTENTS
Shoe Types and Applications
(ZX225US-3, 225USLC-3)...................................................12-15
Bucket Types and Applications
(ZX225US-3, 225USLC-3)...................................................12-16
Specifications
( ZX225USR-3, 225USRLC-3, 225USRK-3, 225USRLCK-3 ).....12-17
Working Ranges
( ZX225USR-3, 225USRLC-3, 225USRK-3, 225USRLCK-3 ).....12-18
Shoe Types and Applications
(ZX225USR-3, 225USRLC-3)..............................................12-19
(ZX225USRK-3, 225USRLCK-3).........................................12-20
Bucket Types and Applications
(ZX225USR-3, 225USRLC-3)..............................................12-21
(ZX225USRK-3, 225USRLCK-3).........................................12-22
OPTIONAL ATTACHMENTS AND DEVICES
Bucket Teeth (Transverse-Type-Pin-Used Type) ................13-1
Using Pad Crawler Shoe.............................................................13-2
Traveling and Other Cautions..................................................13-3
Transporting...................................................................................13-4
Precautions for Transporting Machines
with Pad Crawler Shoes.......................................................13-4
Long Arm Operation --- If Equipped......................................13-7
Blade Lever .....................................................................................13-8
Precautions for Blade Operation.............................................13-8
Avoid Hitting Blade with Front-end Attachment..............13-9
Avoid Hitting Blade with Bucket.............................................13-9
Avoid Striking The Blade Into a Rock.....................................13-9
Blade Maintenance....................................................................13-10
Specifications (ZX135US-3 with Blade) ..............................13-11
Working Ranges (ZX135US-3 with Blade) .........................13-12
Shoe Types and Applications
(ZX135US-3 with Blade) ....................................................13-13
Specifications (ZX135USL-3 with Blade) ............................13-14
Working Ranges (ZX135USL-3 with Blade) .......................13-15
Shoe Types and Applications
(ZX135USL-3 with Blade) ..................................................13-16
INDEX...............................................................................................14-1

SAFETY
S-1
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.
001-E01A-0001
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 are located near spe-
cific hazards. General precautions are listed on CAUTION
safety signs.
• Some safety signs don’t 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 ma-
chine.
•NOTE indicates an additional explanation for an element
of information.
002-E01A-1223
SA-688
SA-1223

SAFETY
S-2
SA-437
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 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
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.
004-E01A-0437
SA-003

SAFETY
S-3
WEAR PROTECTIVE CLOTHING
• 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
PROTECT AGAINST NOISE
• 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
uncomfortably loud noises.
006-E01A-0434
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 “PRE-START INSPECTION” chapter in the
operator’s manual.
007-E01A-0435
SA-438
SA-434
SA-435

SAFETY
S-4
GENERAL PRECAUTIONS FOR CAB
• 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 acci-
dent.
• 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

SAFETY
S-5
USE HANDHOLDS 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 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
ADJUST THE OPERATOR'S SEAT
• 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
ENSURE SAFETY BEFORE RISING FROM OR LEAV-
ING 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 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-378

SAFETY
S-6
FASTEN YOUR SEAT BELT
• 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
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 three
years regardless of its apparent condition.
010-E01A-0237
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 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
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 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-426
SA-237
SA-293

SAFETY
S-7
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 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
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 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
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
• Only the operator should be on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
014-E01B-0427
SA-444
SA-032
SA-379

SAFETY
S-8
PRECAUTIONS FOR OPERATIONS
•Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety equip-
ment appropriate for the job, such as a hard hat, etc.
when operating the machine.
• Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
• When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M178-05-007

SAFETY
S-9
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 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.
• Make sure the worksite has sufficient strength to firmly sup-
port the machine.
When working close to an excavation or at road shoulders,
operate the machine with the tracks positioned perpendicu-
lar to the cliff face with travel motors at the rear, so that the
machine can more easily evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
• Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
• Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent
machine tipping over from occurring. When operating on
rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with ma-
chine movements.
SA-380
M104-05-016