Hitachi ZAXIS 450LC-3 User manual

Serial No 020001 and up
ZX450LC-3 • 650LC-3 • 850LC-3 HYDRAULIC EXCAVATOR OPERATOR’S MANUAL
EM1J3-NA1-2
Hydraulic Excavator
PART NO. EM1J3-NA1-2
URL:http://www.hitachi-c-m.com
This book is printed on recycled paper.
450LC-3
650LC-3
850LC-3
PRINTED IN JAPAN (E) 2011, 12

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CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

INDEX
MACHINE NUMBERS
SAFETY
SAFETY SIGNS
COMPONENTS NAME
GETTING ON/OFF THE MACHINE
OPERATOR’S STATION
BREAK-IN
OPERATING THE ENGINE
DRIVING THE MACHINE
OPERATING THE MACHINE
ASSEMBLING
MAINTENANCE
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
TROUBLESHOOTING
SPECIFICATIONS
OPTIONAL ATTACHMENTS AND DEVICES
INDEX

MACHINE NUMBERS
The manufacturing Nos. explained in this group is the
individual number (serial No.) given to each machine and
hydraulic components. These numbers are requested when
inquiring any information on the machine and/or components.
Fill these serial Nos. in the blank spaces in this group to
immediately make them available upon request.
MACHINE
MODEL/TYPE:
PRODUCT
IDENTIFICATION
NUMBER:
PRODUCT IDENTIFICATION NUMBER
PRODUCT
IDENTIFICATION
NUMBER:
fNOTE:
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
*HCM1J300P00020001*
PRODUCT IDENTIFICATION
NUMBER (PIN)
Marks to indicate the
start and end of the
PIN
M111-12-007
ZX450LC-3

MACHINE NUMBERS
M17P-01-001
SWING MOTOR TYPE AND SERIAL NUMBER
TYPE:
MFG. NO.:
M17V-00-002
ZX650LC-3
ZX850LC-3
M16J-07-007
M1J7-07-005
ZX650LC-3
ZX450LC-3

MACHINE NUMBERS
M1JB-00-001
HYDRAULIC PUMP TYPE AND SERIAL NUMBER
TYPE:
MFG. NO.:
ZX850LC-3
M1J1-001
ZX450LC-3
M1J7-07-003
ZX650LC-3, 850LC-3

MACHINE NUMBERS
BOOM TYPE AND SERIAL NUMBER
TYPE:
MFG. NO.:
ARM TYPE AND SERIAL NUMBER
TYPE:
MFG. NO.:
BUCKET TYPE AND SERIAL NUMBER
TYPE:
MFG. NO.:
M111-12-005
M17V-00-005
M116-12-004

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-4
Never Ride Attachment.................................................................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 OPG.......................................................................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 and Silicon Dust and
Other Contamination...........................................................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
Visibility from Operator’s Seat .................................................S-31
SAFETY SIGNS..............................................................................S-32
COMPONENTS NAME ................................................................. 1-1
GETTING ON / OFF THE MACHINE
Getting On / Off the Machine.................................................... 1-2
OPERATOR’S STATION
Cab Features..................................................................................... 1-4
Multi Function Monitor................................................................ 1-6
Outline................................................................................................ 1-7
Menu Screen (23)...................................................................1-10
Hour Meter...............................................................................1-11
Fuel Gauge...............................................................................1-11
Clock...........................................................................................1-11
Back Monitor Selector..........................................................1-11
Menu Key..................................................................................1-12
Optional Function Key.........................................................1-12
Return to Basic Screen Key ................................................1-12
Alarm Light ..............................................................................1-12
Optional Function Display ................................................1-12
Coolant Temperature Gauge.............................................1-13
Operating Status Icon Display ..........................................1-13
Password Input (Optional) ........................................................1-14
In Case of Inputting an Incorrect Password.................1-15
Extending Password Duration Time ..............................1-17
Alarm Occurrence Screen..........................................................1-18
Contents of Alarms ......................................................................1-20
Clock Setting..................................................................................1-22
Attachment Selection
(Only Machines Equipped with Optional Parts).........1-23
Pump 2 Flow Rate Adjustment
(Only Machines Equipped with Optional Parts).........1-28
Displaying Operating Conditions...........................................1-29
Fuel Rate Display/No Display...................................................1-30
Password Change (Optional)....................................................1-34
Back Monitor Settings ................................................................1-37
Maintenance Settings.................................................................1-39
Mail (Optional)...............................................................................1-44
Language Settings.......................................................................1-46

CONTENTS
Switch Panel...................................................................................1-48
Engine Control Dial......................................................................1-49
Auto-idle Switch ...........................................................................1-49
Power Mode Switch ....................................................................1-50
Travel Mode Switch .....................................................................1-50
Work Light Switch ........................................................................1-51
Wiper/Washer Switch..................................................................1-52
Switch Panel (Optional Included)...........................................1-53
Fan Rotation Direction Control System (Optional)...........1-57
Key Switch.......................................................................................1-59
Power Boost Switch.....................................................................1-59
Horn Switch....................................................................................1-59
Cigar Lighter...................................................................................1-60
Cab Light .........................................................................................1-61
Installing Fire Extinguisher (Optional)..................................1-61
Pilot Control Shut-off Lever ......................................................1-62
Engine Stop Switch......................................................................1-62
Fuse Box...........................................................................................1-63
Air Conditioner Operation ........................................................1-64
Auto Air Conditioner...................................................................1-65
Cab Heater Operation.................................................................1-70
Cooling Operation .......................................................................1-70
Defroster Operation ....................................................................1-71
Tips for Optimal Air Conditioner Usage ...............................1-72
AM/FM Radio Operation ...........................................................1-73
Digital Clock Setting Procedure..............................................1-74
Cab Door Release Lever .............................................................1-75
Opening Upper Front Window................................................1-75
Closing Upper Front Window...................................................1-76
Removing and Storing Lower Front Window.....................1-77
Opening Side Windows..............................................................1-77
Opening/Closing Overhead Window....................................1-78
Emergency Exit .............................................................................1-79
Adjusting the Seat .......................................................................1-80
Adjusting the Seat (Heater Seat Optional)..........................1-82
Adjusting the Air-suspension Seat (Optional) ...................1-84
Adjusting Console Height .........................................................1-86
Seat Belt...........................................................................................1-87
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.............................................................. 3-6
Check Instruments After Starting............................................. 3-8
Using Booster Batteries................................................................ 3-9
Stopping the Engine...................................................................3-11
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
Attachment Pedal (Hydraulic Breaker) (Optional).............. 5-4
Attachment Pedal (Hydraulic Crusher) (Optional).............. 5-6
Pilot Control Shut-off Lever ........................................................ 5-7
Warming-up Operation................................................................ 5-8
Engine Speed Control................................................................... 5-9
Auto-idle .........................................................................................5-10
Work Mode .....................................................................................5-11
Work Mode Select........................................................................5-12
Power Boost ...................................................................................5-13
Power Mode ..................................................................................5-14
Operating Backhoe......................................................................5-15
Grading Operation.......................................................................5-15
Precaution for Arm Roll-in/ Bucket Roll-in Combined
Operation ................................................................................5-16
Avoid Abusive Operation ..........................................................5-16
Operating Tips...............................................................................5-17
Select Correct Track Shoes........................................................5-17
Object Handling --- If Equipped..............................................5-18
Hydraulic Breaker And Hydraulic Crusher...........................5-19
Stop Valve Operation ..................................................................5-20
Three-Way-Valve Operation
(Machines Equipped with the Piping Common
to Hydraulic Breaker and Crusher Operation).............5-21
Flow Combining Valve Operation ..........................................5-21
Precautions for Breaker Operation.........................................5-22
Breaker Maintenance..................................................................5-26
Replace Breaker Circuit Return Oil Filter..............................5-28
Precautions for Crusher Operation ........................................5-29
Attachment.....................................................................................5-31
Overnight Storage Instructions...............................................5-34
ASSEMBLING
Precautions for Assembling........................................................ 6-1
Precautions for Slinging Work.................................................... 6-3
Precautions for Operating Machine......................................... 6-4
Machine Lifting Procedure (ZX450LC-3)................................. 6-5
Installing Counterweight............................................................. 6-6
Installing Boom Cylinder ............................................................. 6-7

CONTENTS
Installing Boom............................................................................... 6-9
Connecting Hoses Between Boom Cylinder and
Machine ....................................................................................6-10
Installing Boom Cylinder Rod ..................................................6-11
Installing Arm ................................................................................6-12
Connecting Arm Cylinder Rod.................................................6-13
Connecting Bucket Cylinder Hoses........................................6-14
Installing Bucket ...........................................................................6-15
Installing and Adjusting Mirror ...............................................6-16
Machine Lifting Procedure (ZX650LC-3)...............................6-17
Installing Counterweight...........................................................6-18
Installing Boom Cylinder ...........................................................6-19
Installing Boom.............................................................................6-21
Connecting Hoses Between Boom Cylinder and
Machine ....................................................................................6-22
Installing Boom Cylinder Rod ..................................................6-23
Installing Arm ................................................................................6-24
Connecting Arm Cylinder Rod.................................................6-25
Connecting Bucket Cylinder Hoses........................................6-26
Installing Bucket ...........................................................................6-27
Installing and Adjusting Mirror ...............................................6-28
Machine Lifting Procedure (ZX850LC-3)...............................6-29
Installing Counterweight...........................................................6-30
Installing Boom Cylinder ...........................................................6-31
Installing Boom.............................................................................6-33
Connecting Hoses Between Boom Cylinder and
Machine ....................................................................................6-34
Installing Boom Cylinder Rod ..................................................6-35
Installing Arm ................................................................................6-36
Connecting Arm Cylinder Rod.................................................6-37
Connecting Bucket Cylinder Hoses........................................6-38
Installing Bucket ...........................................................................6-39
Installing and Adjusting Mirror ...............................................6-40
Final Inspection.............................................................................6-41
Transporting by Road .................................................................6-42
Transporting the Machine by Trailer .....................................6-42
Loading/Unloading on a Trailer ..............................................6-42
Retracting or Extending the Side Frame..............................6-46
Retracting the Side Frame.........................................................6-47
Extending the Side Frame.........................................................6-49
ZX450LC-3 (BACKHOE)................................................................6-52
ZX650LC-3 (BACKHOE)................................................................6-60
ZX850LC-3 (BACKHOE)................................................................6-69
MAINTENANCE
Correct Maintenance and Inspection Procedures.............. 7-1
Check the Hour Meter Regularly............................................... 7-2
Use Correct Fuels and Lubricants............................................. 7-2
Layout................................................................................................. 7-3
Prepare Machine for Maintenance........................................... 7-6
Hood and Access Covers.............................................................. 7-7
Periodic Replacement of Parts.................................................7-10
Maintenance Guide .....................................................................7-11
A. Greasing .....................................................................................7-17
Automatic Lubrication --- If Equipped ...........................7-17
Automatic/manual Lubrication--- If Equipped ...........7-19
Electric Grease Gun...............................................................7-23
Electric Grease Gun --- If Equipped .................................7-31
Lubricator --- If Equipped ...................................................7-33
Front Joint Pins (Backhoe)..................................................7-37
Swing Bearing.........................................................................7-39
Swing Internal Gear..............................................................7-40
B. Engine..........................................................................................7-41
Engine Oil Level......................................................................7-41
Change Engine Oil ...............................................................7-42
Replace Engine Oil Filter .....................................................7-42
C. Transmission..............................................................................7-44
Pump Transmission...............................................................7-44
Swing Reduction Gear.........................................................7-45
Travel Reduction Gear..........................................................7-47
D. Hydraulic System ....................................................................7-49
Inspection and Maintenance of Hydraulic
Equipment................................................................................7-49
Check Hydraulic Oil Level...................................................7-51
Drain Hydraulic Oil Tank Sump.........................................7-52
Change Hydraulic Oil ...........................................................7-53
Suction Filter Cleaning .......................................................7-53
Replace Hydraulic Oil Tank Filter......................................7-56
Replace Pump Drain Filter..................................................7-57
Replace Pilot Oil Filter..........................................................7-58
Replace Air Breather Element ...........................................7-59
Check Hoses and Lines........................................................7-60
Service Recommendations for Hydraulic Fittings .....7-63
E. Fuel System ...............................................................................7-65
Drain Fuel Tank Sump ..........................................................7-66
Drain Fuel Filter......................................................................7-67
Replace Fuel Main Filter Element.....................................7-70
Replace Fuel Pre-filter Element ........................................7-72
Check Fuel Hoses...................................................................7-74
F. Air Cleaner...................................................................................7-75
Clean the Air Cleaner Outer Element .............................7-75
Replace the Air Cleaner Outer and Inner Elements...7-75
G. Cooling System ........................................................................7-78
Check Coolant Level.............................................................7-80
Change Coolant .....................................................................7-81
Clean Radiator/ Oil Cooler/ Inter Cooler/
Fuel Cooler Core.....................................................................7-83
Clean Oil Cooler Front Screen...........................................7-84
H. Air Conditioner ........................................................................7-85
Clean and Replace Air Conditioner Filter .....................7-85
Check Refrigerant (Gas) Quantity....................................7-87
Check Compressor Belt Tension.......................................7-88
Clean Condenser Core.........................................................7-88
Check Looseness at Each of Fastened Areas................7-89
Check In-season and Off-season......................................7-90
I. Electrical System........................................................................7-91
Batteries....................................................................................7-92
Replacing Fuses......................................................................7-96
J. Miscellaneous ............................................................................7-98
Check Bucket Teeth...............................................................7-98
Change Bucket .....................................................................7-101

CONTENTS
Adjust the Bucket Linkage (Backhoe) ..........................7-102
Remove the Travel Levers.................................................7-103
Check and Replace Seat Belt ...........................................7-103
Check Windshield Washer Fluid Level..........................7-104
Check Track Sag ...................................................................7-105
Clean Cab Floor....................................................................7-107
Retighten Cylinder Head Bolt..........................................7-108
Inspect and Adjust Valve Clearance..............................7-108
Check Fuel Injection Timing ............................................7-108
Measure Engine Compression Pressure......................7-108
Check Starter and Alternator...........................................7-108
Check Water Pump..............................................................7-108
Check and Replace EGR Device......................................7-108
Check Tightening Torque of Bolts and Nuts ..............7-109
Check O-rings in Bucket Joints.......................................7-137
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 (Backhoe)............................................................12-1
Working Ranges (Backhoe).......................................................12-2
Shoe Types and Applications...................................................12-3
Bucket Types and Applications (Backhoe)...........................12-4
Specifications.................................................................................12-5
Working Ranges............................................................................12-6
Shoe Types and Applications...................................................12-7
Bucket Types and Applications ...............................................12-8
Specifications (Backhoe)............................................................12-9
Working Ranges (Backhoe).....................................................12-10
Shoe Types and Applications.................................................12-11
Bucket Types and Applications (Backhoe).........................12-12
Sound Level Results (2000/14/EC) .......................................12-13
Vibration Level.............................................................................12-13
OPTIONAL ATTACHMENTS AND DEVICES
Counterweight Removal............................................................13-1
Counterweight Installation.......................................................13-7
Counterweight Removal/Install Device Alarm
(Optional) ...............................................................................13-11
ZX450LC-3 (BACKHOE)..............................................................13-12
ZX650LC-3......................................................................................13-16
ZX650LC-3 (BACKHOE)..............................................................13-17
ZX850LC-3 (BACKHOE)..............................................................13-25
ZX850LC-3......................................................................................13-26
INDEX...............................................................................................14-1

SAFETY
S-1
SA-688
SA-1223
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
specific 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
machine.
• fNOTE indicates an additional explanation for an element
of information.
002-E01A-1223

SAFETY
S-2
SA-003
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
unauthorized modifications will void Hitachi Warranty
Policy.
• Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
•The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/or
your authorized dealer before operating or performing
maintenance work on the machine.
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

SAFETY
S-3
SA-438
SA-434
SA-435
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the job.
Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
• Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
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
earmuffs 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 “INSPECT MACHINE DAILY BEFORE
STARTING”section in the operator’s manual.
007-E01A-0435

SAFETY
S-4
SA-439
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 accident.
• 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 windowpanes as they may focus sunlight, possibly
starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
• Keep all flammable objects and/or explosives away from
the machine.
• After using the ashtray, always cover it to extinguish the
match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may explode.
524-E01A-0000
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
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
008-E01A-0439

SAFETY
S-5
SA-378
NEVER RIDE ATTACHMENT
•Never allow anyone to ride attachments or the load. This is
an extremely dangerous practice.
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
operator for the machine.
• The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462
ENSURE SAFETY BEFORE RISING FROM OR
LEAVING OPERATOR’S SEAT
• Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the 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.

SAFETY
S-6
SA-426
SA-293
SA-237
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
• Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every 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
operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
• Use appropriate illumination. Check that all lights are
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
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
pressurized container, keep the cap on the container, and
store it in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
036-E01A-0293-3

SAFETY
S-7
SA-444
SA-032
SA-379
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”
chapter in the operator’s manual.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
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

SAFETY
S-8
M104-05-015
PRECAUTIONS FOR OPERATIONS
• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety
equipment 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.