Hitachi Zaxis 450-3 User manual

Serial No 20001 and up

PRINTED IN JAPAN (E) 2006, 01

This book is printed on recycled paper.

ZAXIS450-3 •470H-3 •450LC-3 •470LCH-3 •500LC-3 •520LCH-3 HYDRAULIC EXCAVATOR OPERATOR’S MANUAL EM1J1-1-1

Hydraulic Excavator

PART NO. EM1J1-1-1

450-3

470H-3

450LC-3

470LCH-3

500LC-3

520LCH-3

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

0511D48ZX4504705001 2006.1.27,20:14:48

Hitachi Zaxis 450 470h 450lc 470lch 500lc 520lch 3 Series Operatior S Manual

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INTRODUCTION

Read this manual carefully to learn how to operate and

service your machine correctly. Failure to do so could re-

sult 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 deal-

er 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 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 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.

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.

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 TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

TRAVEL MOTOR TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

M157-00-001

M111-07-010

M1J1-00-001

*HCM1J100P00020001*

PRODUCT IDENTIFICATION

NUMBER (PIN)

Marks to indicate the

start and end of the

M111-12-007

MACHINE NUMBERS

M16J-07-007

M1J1-001

SWING MOTOR TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

HYDRAULIC PUMP TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

BOOM TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

ARM TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

M111-12-005

M17V-00-005

MACHINE NUMBERS

M116-12-004

BUCKET TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

MACHINE NUMBERS

MEMO

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

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 Lightening .......................................................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

SSAFETY SIGNS/Europe/Asia/Middle and

Near East Model Only ........................................................S-31

SAFETY SIGNS/North America and Oceania

Model Only .............................................................................S-38

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

OPERATOR’S STATION

Getting On / Off the Machine ....................................................1-2

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

Multi Function Monitor ................................................................1-5

Outline ................................................................................................ 1-6

Menu Screen (23) ..................................................................... 1-9

Hour Meter ...............................................................................1-10

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

Clock ...........................................................................................1-10

Back Monitor Selector ..........................................................1-10

Menu Key ..................................................................................1-11

Optional Function Key .........................................................1-11

Return to Basic Screen Key ................................................1-11

Alarm Light ..............................................................................1-11

Optional Function Display ................................................1-11

Coolant Temperature Gauge .............................................1-12

Operating Status Icon Display ..........................................1-12

Alarm Occurrence Screen ..........................................................1-17

Contents of Alarms ......................................................................1-19

Clock Setting ..................................................................................1-21

Attachment Selection

(Only Machines Equipped with Optional Parts) .........1-22

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 .................................................................1-42

Mail (Optional) ...............................................................................1-47

Language Settings .......................................................................1-49

Switch Panel ...................................................................................1-51

Engine Control Dial ......................................................................1-52

Auto-idle Switch ...........................................................................1-52

Power Mode Switch ....................................................................1-53

Travel Mode Switch .....................................................................1-53

CONTENTS

Work Light Switch ........................................................................1-54

Wiper/Washer Switch ..................................................................1-55

Switch Panel (Optional Included) ...........................................1-56

Fan Rotating Direction Device(Optional) ............................1-60

Key Switch .......................................................................................1-61

Power Boost Switch .....................................................................1-61

Horn Switch ....................................................................................1-61

Cigar Lighter ...................................................................................1-62

Cab Light .........................................................................................1-63

Installing Fire Extinguisher (Optional) ..................................1-63

Pilot Control Shut-off Lever ......................................................1-64

Engine Stop Switch ......................................................................1-64

Fuse Box ...........................................................................................1-65

Additional Fuse Box .....................................................................1-65

Air Conditioner Operation ........................................................1-66

Auto Air Conditioner ...................................................................1-67

Cab Heater Operation .................................................................1-72

Cooling Operation .......................................................................1-72

Defroster Operation ....................................................................1-73

Tips for Optimal Air Conditioner Usage ...............................1-74

AM/FM Radio Operation ...........................................................1-75

Digital Clock Setting Procedure ..............................................1-76

Cab Door Release Lever .............................................................1-77

Opening Upper Front Window

(ZAXIS450-3, 450LC-3, 500LC-3) .........................................1-77

Closing Upper Front Window ...................................................1-78

Removing and Storing Lower Front Window

(ZAXIS450-3, 450LC-3, 500LC-3) .........................................1-79

Opening Side Windows ..............................................................1-79

Opening/closing Overhead Window

(ZAXIS450-3, 450LC-3, 500LC-3) .........................................1-80

Opening/closing Overhead Window ....................................1-80

Emergency Exit(ZAXIS450-3, 450LC-3, 500LC-3) .................1-81

Emergency Exit(ZAXIS470H-3, 470LCH-3, 520LCH-3) ........1-82

Adjusting the Seat .......................................................................1-83

Adjusting the Seat (Heater Seat Optional) ..........................1-85

Seat With a Built-in Heater ........................................................1-86

Adjusting the Air-suspension Seat (Optional) ...................1-87

Seat With a Built-in Heater ........................................................1-88

Adjusting Console Height .........................................................1-89

Seat Belt ...........................................................................................1-90

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

Level Check ....................................................................................... 3-3

Starting the Engine in Ordinary Temperature ...................... 3-4

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

Pilot Control Shut-off Lever ........................................................ 5-3

Engine Speed Control ................................................................... 5-6

Auto-idle ........................................................................................... 5-7

Work Mode ....................................................................................... 5-8

Work Mode Select .......................................................................... 5-9

Power Boost ...................................................................................5-10

Power Mode ..................................................................................5-11

Operating Backhoe ......................................................................5-12

Grading Operation .......................................................................5-12

Precaution for Arm Roll-in/ Bucket Roll-in Combined

Operation ................................................................................5-13

Avoid Abusive Operation ..........................................................5-13

Operating Tips ...............................................................................5-14

Select Correct Track Shoes ........................................................5-14

Object Handling --- If Equipped ..............................................5-15

Overnight Storage Instructions ...............................................5-17

ASSEMBLING

Precautions for Assembling ........................................................ 6-1

Precautions for Slinging Work ................................................... 6-3

Precautions for Operating Machine ........................................ 6-4

Installing Counterweight ............................................................. 6-5

Installing Boom Cylinder ............................................................. 6-6

Installing Boom ............................................................................... 6-8

Connecting Hoses Between Boom Cylinder and

Machine ...................................................................................... 6-9

Installing Boom Cylinder Rod ..................................................6-10

Installing Arm ................................................................................6-11

Connecting Arm Cylinder Rod .................................................6-12

Connecting Bucket Cylinder Hoses .......................................6-13

Installing Bucket ...........................................................................6-14

Final Inspection .............................................................................6-15

Transporting by Road .................................................................6-16

Transporting the Machine by Trailer .....................................6-16

Loading/Unloading on a Trailer ..............................................6-16

ZAXIS450-3 (Backhoe) .................................................................6-20

CONTENTS

ZAXIS470H-3 (Backhoe) ..............................................................6-24

ZAXIS450LC-3 (Backhoe) ............................................................6-28

ZAXIS470LCH-3 (Backhoe) .........................................................6-32

ZAXIS500LCH-3 (Backhoe) .........................................................6-36

ZAXIS520LCH-3 (Backhoe) .........................................................6-40

Retracting or Extending the Side Frame ..............................6-44

Retracting the Side Frame .........................................................6-45

Extending the Side Frame .........................................................6-46

MAINTENANCE

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

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

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

Prepare Machine for Maintenance ........................................... 7-3

Hood and Access Covers .............................................................. 7-4

Periodic Replacement Of Parts .................................................. 7-5

Maintenance Guide ....................................................................... 7-6

A. Greasing ....................................................................................... 7-9

Automatic Lubrication --- If Equipped ...........................7-10

Front Joint Pins (Backhoe) ..................................................7-12

Swing Bearing .........................................................................7-14

Electric Grease Gun --- If Equipped .................................7-15

Swing Internal Gear ..............................................................7-19

B. Engine Oil ...................................................................................7-20

Engine Oil Level ......................................................................7-21

Change Engine Oil ...............................................................7-22

Replace Engine Oil Filter .....................................................7-22

C. Transmission Oil .......................................................................7-24

Swing Reduction Gear .........................................................7-25

Travel Reduction Gear ..........................................................7-26

D. Hydraulic System ....................................................................7-28

Inspection and Maintenance of Hydraulic

Equipment ................................................................................7-29

Check Hydraulic Oil Level ...................................................7-31

Drain Hydraulic Oil Tank Sump .........................................7-32

Change Hydraulic Oil ...........................................................7-33

Suction Filter Cleaning .......................................................7-33

Replace Hydraulic Oil Tank Filter ......................................7-36

Replace Pump Drain Filter ..................................................7-37

Replace Pilot Oil Filter ..........................................................7-38

Replace Air Breather Element ...........................................7-39

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

Service Recommendations for Hydraulic Fittings ............7-43

E. Fuel System ...............................................................................7-45

Drain Fuel Tank Sump ..........................................................7-46

Check Water Separator ........................................................7-47

Replace Fuel Main Filter Element .....................................7-50

Replace Fuel Pre-filter Element ........................................7-51

Clean Feed Pump Strainer .................................................7-52

Check Fuel Hoses ...................................................................7-53

F. Air Cleaner ...................................................................................7-54

Clean the Air Cleaner Outer Element .............................7-54

Replace the Air Cleaner Outer and Inner Elements ...7-54

G. Cooling System ........................................................................7-56

Check Coolant Level .............................................................7-58

Change Coolant .....................................................................7-59

Clean Radiator/ Oil Cooler/ Inter Cooler/

Fuel Cooler Core .....................................................................7-60

Clean Oil Cooler Front Screen ...........................................7-60

H. Air Conditioner ........................................................................7-61

Clean and Replace Air Conditioner

Filter Clean Filter ....................................................................7-62

Check Refrigerant (Gas) Quantity ....................................7-64

Check Compressor Belt Tension .......................................7-64

Clean Condenser Core .........................................................7-65

Check Looseness at Each of Fastened Areas ................7-65

Check in-season and Off-season ......................................7-66

I. Electrical System ........................................................................7-67

Batteries ....................................................................................7-68

Replace Batteries ...................................................................7-71

Replacing Fuses ......................................................................7-72

Fuse Box ....................................................................................7-72

Additional Fuse Box ..............................................................7-72

J. Miscellaneous ............................................................................7-74

Check Bucket Teeth ...............................................................7-75

Change Bucket .......................................................................7-78

Adjust the Bucket Linkage (Backhoe) ............................7-79

Remove the Travel Levers ...................................................7-80

Check and Replace Seat Beltcheck .................................7-80

Check Windshield Washer Fluid Level ............................7-80

Check Track Sag .....................................................................7-81

Clean Cab Floor --- As Necessary .....................................7-83

Check Tightening Torque of Bolts and Nuts ................7-84

Check O-rings in Bucket Joints .........................................7-97

Retighten Cylinder Head Bolt ...........................................7-98

Inspect and Adjust Valve Clearance ................................7-98

Check Fuel Injection Timing ..............................................7-98

Measure Engine Compression Pressure ........................7-98

Check Starter and Alternator ............................................7-98

Check Water Pump ................................................................7-98

HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT

Hydraulic System ............................................................................ 8-1

Main Circuit ...................................................................................... 8-2

Electrical Circuit .............................................................................. 8-4

Electrical Diagram .......................................................................... 8-5

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

Engine ...............................................................................................11-1

Electrical System ...........................................................................11-5

Control Levers ................................................................................11-9

Hydraulic System ..........................................................................11-9

CONTENTS

SPECIFICATIONS

Specifications (Backhoe)

ZAXIS450-3, ZAXIS450LC-3, ZAXIS500LC-3 ....................12-1

Working Ranges (Backhoe)

ZAXIS450-3, ZAXIS450LC-3 ..................................................12-2

ZAXIS500LC-3 ..........................................................................12-3

Shoe Types and Applications ...................................................12-4

ZAXIS450-3 ...............................................................................12-4

ZAXIS450LC-3 ..........................................................................12-4

ZAXIS500LC-3 ..........................................................................12-5

Bucket Types and Applications (Backhoe) ..........................12-6

ZAXIS450-3, ZAXIS450LC-3 ..................................................12-6

ZAXIS500LC-3 ..........................................................................12-6

Specifications (Backhoe) ............................................................12-7

ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3 ...........12-7

Working Ranges (Backhoe) .......................................................12-8

ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3 ...........12-8

Shoe Types and Applications ...................................................12-9

ZAXIS470H-3 ............................................................................12-9

ZAXIS470LCH-3 .......................................................................12-9

ZAXIS520LCH-3 .................................................................... 12-10

Bucket Types and Applications (Backhoe) ....................... 12-11

ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3 ........ 12-11

Lifting Capacities ....................................................................... 12-12

Sound Level Results (2000/14/EC) ...................................... 12-16

Vibration Level ............................................................................ 12-16

OPTIONAL ATTACHMENTS and DEVICES

Hydraulic Breaker .........................................................................13-1

Work Mode .....................................................................................13-2

Breaker Operation ........................................................................13-3

Precautions for Breaker Operation .........................................13-5

Breaker Maintenance ..................................................................13-9

Replace Breaker Circuit Return Oil Filter ........................... 13-11

Hydraulic Crusher ...................................................................... 13-12

Stop Valve Operation ............................................................... 13-13

Three-way-valve Operation (Machines Equipped

with the Piping Common to Hydraulic Breaker

and Crusher Operation) ................................................... 13-14

Flow Combining Valve Operation ....................................... 13-14

Precautions for Crusher Operation ..................................... 13-15

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 in-

jury.

• 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

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-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

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 un-

comfortably 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 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

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 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

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-293

SA-237

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.

M104-05-015

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 a 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

SAFETY

S-10

EQUIPMENT OF HEAD GUARD, ROPS, FOPS

In case the machine is operated in areas where the possibility

of falling stones or debris exist, equip a head guard, ROPS, or

FOPS according to the potential hazardous conditions. (The

standard cab for this machine corresponds to ROPS and FOPS.)

ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure

PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

TIPLE NUMBERS OF MACHINES

• For jobs involving multiple numbers of machines, provide

signals commonly known by all personnel involved. Also,

appoint a signal person to coordinate the job site. Make

sure that all personnel obey the signal person’s directions.

018-E01A-0481

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN

• Incorrect travel pedal/lever operation may result in serious

injury death.

• Before driving the machine, confirm the position of the

undercarriage in relation to the operator’s position. If the

travel motors are located in front of the cab, the machine

will move in reverse when travel pedals/levers are oper-

ated to the front.

017-E01A-0491

SA-481

SA-490

SA-491

Hitachi Zaxis 450 470h 450lc 470lch 500lc 520lch 3 Series Operatior S Manual

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Hitachi ZAXIS 450-3 User manual

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