Hitachi ZW 120-6 User manual

120-6
ENMNSC-NA1-2ZW120-6 WHEEL LOADER OPERATOR'S MANUAL
PRINTED IN JAPAN (E) 2018, 07
URL:http://www.hitachi-c-m.com
ENMNSC-NA1-2
PART NO.
Wheel Loader
Operator's Manual
Serial No. 005201 and up
This book is printed on recycled paper.

©2018 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
INTRODUCTION
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.
Read this manual carefully to learn how to operate and
service your machine correctly. Failure to do so could
result in personal injury or machine damage.
This standard specification machine can be operated
under the following conditions without being modified.
Atmospheric Temperature: -20 °C to 40 °C (-4 °F to 104 °F)
Altitude: 0 m to 2000 m (0 ft to 6600 ft)
In case the machine is used under conditions other than
described above, consult your nearest Hitachi dealer.
This manual should be considered a permanent part of
your machine and should remain with the machine when
you sell it.
This machine is of metric design. Measurements in this
manual are metric. Use only metric hardware and tools as
specified.
Right-hand and left-hand sides are determined by
facing in the direction of forward travel.
Write product identification numbers in the Machine
Numbers section. Accurately record all the numbers
to help in tracing the machine should it be stolen.
Your dealer also needs these numbers when you order
parts. If this manual is kept on the machine, also file the
identification numbers in a secure place off the machine.
Use only diesel fuel with quality specified in JIS K-2204,
EN-590 or ASTM D-975 which contents 15 ppm or lower
sulfur.
Also use fuel that complies with solid contamination level
of class 18/16/13 of ISO4406-1999 (solid contamination
includes dust). If the fuel specified above is not used,
exhaust gas that exceeds the regulation values may be
discharged, causing serious problem on the engine.
Consult your nearest Hitachi dealer.
Warranty is provided as a part of Hitachi’s support
program for customers who operate and maintain their
equipment as described in this manual. The warranty is
explained on the warranty certificate which you should
have received from your dealer.
This warranty provides you with the assurance that
Hitachi will back its products where defects appear within
the warranty period. In some circumstances, Hitachi also
provides field improvements, often without charge to the
customer, even if the product is out of warranty.
Should the equipment be abused, or modified to
change its performance beyond the original factory
specifications, the warranty will become void and field
improvements may be denied.
Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
Only qualified, experienced operators officially licensed
(according to local law) should be allowed to operate
the machine. Moreover, only officially licensed personnel
should be allowed to inspect and service the machine.
PRIOR TO OPERATING THIS MACHINE, INCLUDING
COMMUNICATION SYSTEM, IN A COUNTRY OTHER
THAN A COUNTRY OF ITS INTENDED USE, IT MAY
BE NECESSARY TO MAKE MODIFICATIONS TO IT SO
THAT IT COMPLIES WITH THE LOCAL REGULATORY
STANDARDS (INCLUDING SAFETY STANDARDS)
AND LEGAL REQUIREMENTS OF THAT PARTICULAR
COUNTRY. PLEASE DO NOT EXPORT OR OPERATE
THIS MACHINE OUTSIDE OF THE COUNTRY OF ITS
INTENDED USE UNTIL SUCH COMPLIANCE HAS
BEEN CONFIRMED. PLEASE CONTACT HITACHI
CONSTRUCTION MACHINERY CO., LTD. OR ANY OF
OUR AUTHORIZED DISTRIBUTOR OR DEALER IF YOU
HAVE ANY QUESTIONS CONCERNING COMPLIANCE.
In this manual, urea water is indicated as DEF/
AdBlue®.
“DEF” stands for the Diesel Exhaust Fluid.
AdBlue® is a registered trademark of the Verband der
Automobilindustrie e.V. (VDA).
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.

T
SAFETY
SAFETY SIGNS
COMPONENTS NAME
GETTING ON/OFF THE MACHINE
OPERATOR’S STATION
BREAK-IN
OPERATING ENGINE
DRIVING MACHINE
OPERATING MACHINE
TRANSPORTING
MAINTENANCE
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
TROUBLESHOOTING
OPTIONAL ATTACHMENTS
SPECIFICATIONS
INDEX
INDEX
ENMNSC-NA1-2
MACHINE NUMBERS

CONTENTS
MACHINE NUMBERS ........................................................................1
SAFETY...............................................................................................S-1
Recognize Safety Information ....................................................S-1
Understand Signal Words.............................................................S-1
Follow Safety Instructions............................................................S-2
Prepare for Emergencies...............................................................S-3
Wear Protective Clothing..............................................................S-3
Protect Against Noise ....................................................................S-4
Inspect Machine ..............................................................................S-4
General Precautions for Cab........................................................S-5
Use Handrails and Steps ...............................................................S-6
Never Ride Attachment.................................................................S-6
Adjust Operator’s Seat...................................................................S-6
Ensure Safety Before Rising from or Leaving Operator’s
Seat .................................................................................................S-7
Fasten Your Seat Belt......................................................................S-7
Move and Operate Machine Safely...........................................S-8
Handle Starting Aids Safely .........................................................S-8
Operate Only from Operator’s Seat ..........................................S-9
Jump Starting ...................................................................................S-9
Investigate Job Site Beforehand ............................................. S-10
Equipment of Head Guard, ROPS, FOPS............................... S-11
Provide Signals for Jobs Involving Multiple Machines.... S-11
Keep Riders Off Machine ........................................................... S-12
Drive Safely..................................................................................... S-12
Drive Machine Safely (Work Site)............................................ S-13
Drive Safely with Bucket Loaded ............................................ S-14
Drive on Snow Safely .................................................................. S-14
Travel on Public Roads Safely................................................... S-15
Avoid Injury from Rollaway Accidents.................................. S-15
Avoid Accidents from Backing Up and Turning ................S-16
Avoid Positioning Bucket or Attachment Over
Anyone........................................................................................ S-17
Avoid Tipping................................................................................. S-17
Never Undercut a High Bank.................................................... S-18
Dig with Caution........................................................................... S-18
Perform Truck Loading Safely .................................................. S-18
Avoid Power Lines........................................................................ S-19
Precautions for Operation......................................................... S-19
Precautions for Lightning.......................................................... S-19
Object Handling ........................................................................... S-20
Protect Against Flying Debris ..................................................S-20
Park Machine Safely..................................................................... S-21
Store Attachments Safely.......................................................... S-21
Transport Safely ............................................................................ S-22
Handle Fluids Safely−Avoid Fires............................................ S-23
Practice Safe Maintenance........................................................ S-24
Warn Others of Service Work ................................................... S-25
Support Machine Properly........................................................ S-25
Stay Clear of Moving Parts ........................................................ S-26
Support Maintenance Properly............................................... S-26
Prevent Parts from Flying .......................................................... S-27
Prevent Burns................................................................................. S-27
Replace Rubber Hoses Periodically........................................ S-28
Avoid High-Pressure Fluids....................................................... S-28
Prevent Fires................................................................................... S-29
Evacuating in Case of Fire.......................................................... S-31
Beware of Exhaust Fumes..........................................................S-31
Precautions for Welding and Grinding ................................. S-31
Precautions for DEF/AdBlue® ................................................... S-32
Avoid Heating Near Pressurized Fluid Lines....................... S-33
Avoid Applying Heat to Lines Containing Flammable
Fluids ........................................................................................... S-33
Precautions for Handling Accumulator and Gas
Damper....................................................................................... S-33
Remove Paint Before Welding or Heating........................... S-34
Beware of Asbestos and Silicon Dust and Other
Contamination......................................................................... S-34
Prevent Battery Explosions ....................................................... S-35
Service Air Conditioning System Safely ............................... S-35
Handle Chemical Products Safely........................................... S-36
Dispose of Waste Properly.........................................................S-36
Notes on Aftertreatment Device ............................................S-37
Precautions for Communication Terminal........................... S-37
Precautions for Communication Terminal Equipment ... S-38
SAFETY SIGNS.............................................................................. S-40
COMPONENTS NAME ..................................................................1-1
Components Name ........................................................................1-1
GETTING ON/OFF THE MACHINE ...........................................1-2
Getting ON/OFF the Machine.....................................................1-2
OPERATOR’S STATION.................................................................1-3
About Aftertreatment Device.....................................................1-3
Cab Features......................................................................................1-6
Front Console....................................................................................1-7
Right Console....................................................................................1-8
Multi-Function Joystick Type .................................................1-8
Monitor Panel ...................................................................................1-9
Service Indicator........................................................................... 1-10
Parking Brake Indicator (Red)...................................................1-11
Brake Oil Level Indicator (Red)................................................. 1-11
HST Warning Indicator (Red).................................................... 1-12
Discharge Warning Indicator (Red)........................................1-12
Engine Trouble Indicator (Red)................................................ 1-12
Urea Warning Indicator (Red)................................................... 1-12
Overheat Indicator (Red) ........................................................... 1-13
Engine Oil Low Pressure Indicator (Red) .............................. 1-13
Aftertreatment Device Warning Indicator........................... 1-13
Aftertreatment Device Regeneration Request
(Blinking Yellow) ................................................................1-13
Preheat Indicator (Yellow).........................................................1-14
HST Oil Temperature Indicator (Red).....................................1-14
Seat Belt Indicator (Red) ............................................................1-14
Water Separator Indicator (Red)..............................................1-14
Coolant Temperature Gauge....................................................1-15
Fuel Gauge......................................................................................1-15
HST Oil Temperature Gauge..................................................... 1-15
Turn Signal Indicator (Green) ...................................................1-16
High Beam Indicator (Blue).......................................................1-16
Work Light Indicator (Yellow)................................................... 1-16
Clearance Light Indicator (Green) .......................................... 1-17

CONTENTS
Control Lever Lock Indicator (Red).........................................1-17
Power Mode Indicator (Green) ................................................1-17
Maintenance Indicator (Yellow) .............................................. 1-17
Monitor Display............................................................................. 1-18
Forward/Reverse and Shift Position Indicator..............1-19
Speedometer............................................................................1-21
Ride Control Indicator (Optional)......................................1-22
ECO Indicator............................................................................1-22
DEF/AdBlue® Level Gauge ................................................... 1-22
DEF/SCR System Alarm...............................................................1-23
DEF/AdBlue® Level Alarm .................................................... 1-23
Urea SCR System Malfunction............................................1-24
Machine Information Display...................................................1-25
Shifting Item to be Indicated on Machine
Information Display..........................................................1-26
Resetting of Oil Change and Filter Replacement
Intervals...................................................................................... 1-31
Hydraulic Oil Change Interval Hour Meter .................... 1-31
Hydraulic Oil Filter 1 Replacement Interval Hour
Meter......................................................................................1-32
Hydraulic Oil Filter 3 Replacement Interval Hour
Meter......................................................................................1-33
Transmission Oil Change Interval Hour Meter ............. 1-34
Transmission Oil Filter Replacement Interval Hour
Meter......................................................................................1-35
Engine Oil Change Interval Hour Meter .........................1-36
Engine Oil Filter Replacement Interval Hour Meter ...1-37
Fuel Filter Replacement Interval Hour Meter................ 1-38
Axle Oil Change Interval Hour Meter...............................1-39
Clock Setting Mode ..................................................................... 1-40
Clock (24H) Setting Procedures......................................... 1-40
Switches, Steering Wheel and Pedals....................................1-41
Forward/Reverse Lever/ Shift Switch ....................................1-42
Forward/Reverse Lever ......................................................... 1-42
Shift Switch/Quick Shift Switch (QSS)..............................1-42
Neutral Lever Lock (for the Forward/Reverse Lever) ....... 1-43
Steering............................................................................................ 1-43
Horn Button.................................................................................... 1-43
Turn Signal Lever ..........................................................................1-44
Light Switch.................................................................................... 1-45
High-Low Beam Switch.............................................................. 1-46
Key Switch.......................................................................................1-46
Wiper Switch ..................................................................................1-47
Wiper Operation...................................................................... 1-47
Front/Rear Wiper Switch....................................................... 1-48
Hazard Switch................................................................................1-49
Work Light Switch ........................................................................1-50
Parking Brake Switch...................................................................1-51
Accelerator Pedal..........................................................................1-52
Brake/Inching Pedal ....................................................................1-52
Tilt, Telescopic Lever/Steering Column Tilt Pedal............. 1-53
Slow Speed (L) Select Switch ...................................................1-54
Right Console.................................................................................1-55
Multi-Function Joystick Type ..............................................1-55
Control Lever..................................................................................1-56
Control Lever Lock Switch.........................................................1-57
Armrest Adjust Handle............................................................... 1-58
Traction Control Switch..............................................................1-59
Power Mode Switch.....................................................................1-60
Aftertreatment Device Regeneration Switch.....................1-61
Manual Regeneration Procedure ......................................1-62
Ride Control Switch .....................................................................1-64
AUTO............................................................................................1-64
OFF...............................................................................................1-64
Forward/Reverse Selector Switch...........................................1-65
Operational Procedure..........................................................1-65
Cigar Lighter................................................................................... 1-66
Using Cigar Lighter.................................................................1-66
Using Cigar Lighter Port as External Power Source.... 1-66
Ash Tray............................................................................................ 1-67
Auto Air Conditioner................................................................... 1-68
Feature........................................................................................1-68
Components Name................................................................1-69
Controller Part Name and Function ................................. 1-70
Mode/Temperature Control Switch ................................. 1-72
Defroster Operation............................................................... 1-74
Cool Head/Warm Feet Operation......................................1-74
Tips for Optimal Air Conditioner Usage ............................... 1-75
For Rapid Cooling ...................................................................1-75
When Windows Become Clouded ....................................1-75
Off-Season Air Conditioner Maintenance...................... 1-75
Adjusting Operator's Seat (Air Suspension Type Seat)
(Sears)..........................................................................................1-76
Components Name................................................................1-76
Rear Tray ..........................................................................................1-77
Electric Power Output.................................................................1-77
Fuse Box...........................................................................................1-78
Fuse Box A ................................................................................. 1-79
Fuse Box B.................................................................................. 1-79
Hot/Cool Box.................................................................................. 1-80
Tray and Drink Holder................................................................. 1-80
ROPS Cab......................................................................................... 1-81
Front Room Light..........................................................................1-83
Rear Room Light ........................................................................... 1-83
Sun Visor.......................................................................................... 1-84
Emergency Evacuation Hammer............................................ 1-84
Coat Hook .......................................................................................1-84
Upper Switch Panel (Optional)................................................1-85
Rear View Mirror Heater Switch...............................................1-85
Outside Rear View Mirror........................................................... 1-86
Room Rear View Mirror............................................................... 1-86
Cab Door..........................................................................................1-86
Door Lock Knob ............................................................................1-87
Door Open/Close Lever.............................................................. 1-87
Window Open/Close Levers ..................................................... 1-87
When Fully Opening the Left Door........................................ 1-88
Cab Door Release Lever .............................................................1-88
Battery Disconnect Switch........................................................ 1-89
Switch Operation ....................................................................1-90
Articulation Lock Bar................................................................... 1-91
Towing Pin ......................................................................................1-92
Inspection/Maintenance Side Access Cover....................... 1-93

CONTENTS
Steps..................................................................................................1-94
Rear Grille........................................................................................ 1-94
Opening the rear grille.......................................................... 1-94
Closing the rear grille ............................................................ 1-94
Grease Gun Box............................................................................. 1-94
Vandal-Proof Devices..................................................................1-95
Seat Belt...........................................................................................1-96
BREAK-IN...........................................................................................2-1
Break-in Operation for New Machine.......................................2-1
OPERATING ENGINE.....................................................................3-1
Inspect Machine Daily Before Starting ....................................3-1
Check Before Starting....................................................................3-3
Starting Engine ................................................................................3-5
Starting in Cold Weather...............................................................3-7
Check After Starting .......................................................................3-8
Using Booster Batteries.................................................................3-9
Warming Up Operation.............................................................. 3-11
Warming Up Operation in Cold Weather.............................3-12
Stopping Engine...........................................................................3-14
DRIVING MACHINE .......................................................................4-1
Driving the Machine.......................................................................4-1
Starting to Move..............................................................................4-2
Parking Brake Switch......................................................................4-4
Drive Speed Change.......................................................................4-5
Changing Forward/Reverse Drive Direction..........................4-5
Steering Wheel.................................................................................4-6
Stop and Restart of Driving .........................................................4-7
Precautions for Driving on Slopes.......................................... 4-10
Precautions for Driving Speeds............................................... 4-11
Precautions to be Taken if Machine Failure Occurs.......... 4-12
Stop the Machine ......................................................................... 4-13
Parking .............................................................................................4-15
Emergency Evacuation............................................................... 4-16
OPERATING MACHINE.................................................................5-1
Control Lever.....................................................................................5-1
Control Lever Lock Switch............................................................5-2
Ride Control Switch (Optional)...................................................5-3
Lift Arm Kick Out..............................................................................5-5
Bucket Auto Leveler........................................................................5-6
Before Operation .............................................................................5-8
Precautions for Operation............................................................5-8
Ensure Safety When Operating on Road Shoulders ...........5-8
Avoid Overloading..........................................................................5-9
Avoid Rapid Steering Changes and/or Sudden Braking ...5-9
Avoid Operation with Biased Loads .........................................5-9
Excavation.......................................................................................5-10
Grading ............................................................................................5-12
Loading ............................................................................................ 5-13
Dozing.............................................................................................. 5-16
Scooping .........................................................................................5-16
Removing Snow............................................................................ 5-17
Lifting Wheel Loader................................................................... 5-17
Precautions for After Operations............................................ 5-18
TRANSPORTING .............................................................................6-1
Transporting by Road ....................................................................6-1
Transporting by Trailer ..................................................................6-1
Loading / Unloading on Trailer...................................................6-2
Fastening Machine for Transporting ........................................6-4
Transporting Wheel Loader (Urgent Situation)....................6-5
Towing Method................................................................................6-9
Lifting Machine ............................................................................. 6-10
MAINTENANCE...............................................................................7-1
Correct Maintenance and Inspection Procedures...............7-1
Check the Hour Meter Regularly................................................7-3
Layout..................................................................................................7-4
Preparations for Inspection and Maintenance .....................7-7
Lock Frames.......................................................................................7-9
Inspection/Maintenance Access Side Cover....................... 7-10
Rear Grille........................................................................................ 7-11
Inspection and Maintenance Table........................................ 7-12
Kind of Oils...................................................................................... 7-16
List of Consumable Parts ........................................................... 7-19
A. Greasing......................................................................................7-21
B. Engine..........................................................................................7-27
Check Engine Oil Level.......................................................... 7-27
Change Engine Oil..................................................................7-28
Replace Engine Oil Filter.......................................................7-30
C. Power Train ................................................................................ 7-31
Check Transmission Oil Level.............................................. 7-31
Change Transmission Oil......................................................7-32
Clean Transmission Strainer................................................7-32
Replace Transmission Oil Filter...........................................7-34
Change Axle Oil....................................................................... 7-36
Check Surroundings Around Axle and Covers for Oil
Leaks ......................................................................................7-38
Clean Transmission Air Breather........................................ 7-38
D. Hydraulic System.....................................................................7-39
Inspection and Maintenance of Hydraulic Equipment...7-39
Check Hydraulic Oil Level ....................................................7-41
Change Hydraulic Oil/Clean Hydraulic Oil Tank...........7-42
Clean Suction Filter ................................................................7-42
Replace Hydraulic Tank Oil Filter....................................... 7-44
Replace HST Charge Filter....................................................7-46
Replace Air Breather Element............................................. 7-48
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage ..............................7-49
Replace Pilot Circuit Accumulator .................................... 7-50
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage ..............................7-50
Check Gas Pressure in Ride Control Accumulator
(Optional) .............................................................................7-50
Check Hoses and Lines .........................................................7-51
E. Fuel System................................................................................ 7-56
Check Fuel Level......................................................................7-56
Drain Water and Sediment from Fuel Tank.................... 7-58
Drain Fuel Pre-Filter................................................................7-59
Replace Fuel Main Filter Element...................................... 7-61
Replace Fuel Pre-Filter Element.........................................7-62
Check Fuel Hoses .................................................................... 7-63
F. Air Cleaner...................................................................................7-64

CONTENTS
Inspect the Air Cleaner Element for Clogging..............7-64
Clean and Replace Air Cleaner Element ......................... 7-65
G. Cooling System ........................................................................7-66
Check Coolant Level .............................................................. 7-67
Check Drive Belt ...................................................................... 7-68
Replace Drive Belt................................................................... 7-68
Replace Automatic Tensioner.............................................7-68
Change Coolant.......................................................................7-69
Clean Radiator/Oil Cooler and Other Cooling
System................................................................................... 7-70
H. Electrical System......................................................................7-71
Batteries .....................................................................................7-71
Check Monitor Functions and All Other Instrument
Operation .............................................................................7-75
Check Lights ............................................................................. 7-76
Check Horn and Reverse Buzzer........................................ 7-76
Check Electrical Harnesses and Fuses ............................. 7-77
I. Brake System...............................................................................7-79
Check Brake Oil Level ............................................................ 7-79
Check Right and Left Brake Interlocking
Performance........................................................................ 7-80
Check Parking Brake Force .................................................. 7-81
Check Brake Disks (Service and Parking)........................ 7-82
Change Brake Oil..................................................................... 7-82
J. Tire..................................................................................................7-83
Check and Replace Tire (Tire Pressure)............................7-83
Check Tire for Damage..........................................................7-83
Check Wheel Bolt Torque .....................................................7-84
Removal and Installation of Tire..............................................7-87
K. Air Conditioner .........................................................................7-88
Clean/Replace Air Conditioner Circulation/Fresh Air
Filters...................................................................................... 7-88
Check Air Conditioner........................................................... 7-92
Check Air Conditioner Piping .............................................7-92
Check Air Conditioner Condenser.................................... 7-93
Check Air Conditioner Fan Belt .......................................... 7-93
Check Refrigerant ................................................................... 7-94
Check Compressor and Pulley............................................ 7-94
L. Miscellaneous............................................................................7-95
Check Cutting Edge ............................................................... 7-95
Check and Replace Seat and Seat Belt............................ 7-96
Check ROPS cab Mounting Bolts....................................... 7-96
Check Windshield Washer Fluid Level .............................7-96
Check Play Amount in Steering Wheel Stroke..............7-97
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise ......................................................... 7-98
Check Rearview Mirror and Inside Rearview Mirror... 7-99
Check Steps and Handrails for Damage and
Looseness............................................................................. 7-99
Clean Engine Compartment and Hood ........................7-100
Check Sound Absorbing Mat Around Engine ............7-100
Check Engine Cylinder Head Bolts .................................7-101
Check Engine Compression Pressure ............................7-101
Check and Clean Starter and Alternator.......................7-101
Retighten Front Axle and Rear Axle Support
Mounting Bolts.................................................................7-101
Check and Replace EGR Device .......................................7-102
Clean EGR Cooler ..................................................................7-102
Check Turbocharger.............................................................7-102
Check and Clean Injector Nozzle.....................................7-102
Tightening and Retightening Torque of Nuts and
Bolts......................................................................................7-103
M. Aftertreatment Device........................................................7-114
Check and Clean Aftertreatment Device......................7-114
N. Urea SCR System....................................................................7-115
Check DEF/AdBlue® Level ..................................................7-117
Replace DEF/AdBlue® Tank Water Supply Inlet
Filter......................................................................................7-121
Replace DEF/AdBlue® Supply Module Main Filter ....7-122
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS....................................................................................9-1
Maintenance Under Special Environmental Conditions...9-1
Precautions for Maintenance During Cold Weather
Season............................................................................................9-2
STORAGE ........................................................................................10-1
Storing the Machine.................................................................... 10-1
TROUBLESHOOTING................................................................. 11-1
Troubleshooting ...........................................................................11-1
SPECIFICATIONS .........................................................................12-1
Specifications.................................................................................12-1
OPTIONAL ATTACHMENTS.....................................................13-1
Hydraulic Type Quick Coupler Operation............................13-1
INDEX............................................................................................... 14-1

1
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
TYPE :
PRODUCT
IDENTIFICATION
NUMBER :
Engine
TYPE :
MFG. NO. :
SCR (Selective Catalytic Reduction) Catalyst
TYPE :
MFG. NO. :
DOC (Diesel Oxidation Catalyst)
TYPE :
MFG. NO. :
MNSC-00-001
MNSC-00-002
MNSC-00-003
MNSC-00-004

MACHINE NUMBERS
2
MEMO
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S-1
SAFETY
Recognize Safety Information
These are the SAFETY ALERT SYMBOLS.
When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating
practices.
Understand Signal Words
On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
DANGER or WARNING safety signs signs are located
near specific hazards. General precautions are listed on
CAUTION safety signs.
Some safety signs do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.
fNOTE indicates an additional explanation for an
element of information.
SA-1223
SA-2644

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
unauthorized modifications will void Hitachi Warranty
Policy.
Never attempt to modify or disassemble the inlet/exhaust
parts and the muffler filter. Avoid giving shocks on the
muffler filter by striking elements with other objects or
dropping the elements. Failure to do so may affect the
exhaust gas purifying device, possibly damaging it or
lowering its performance.
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.
SA-003

SAFETY
S-3
Prepare for Emergencies
Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
Establish emergency procedure guidelines to cope with
fires and accidents.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone.
Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
SA-438
SA-437

SAFETY
S-4
Protect Against Noise
Prolonged exposure to loud noise can cause impairment or
loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
Inspect Machine
Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
In the walk-around inspection, be sure to cover all points
described in the “Inspect Machine Daily Before Starting”
section in the operator’s manual.
SA-435
SA-434

SAFETY
S-5
General Precautions for Cab
Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
Do not mess up around the operator's seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
accelerator pedal, brake pedals, control lever lock switch
or control levers, which may result in serious injury or
death.
Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
Keep all flammable objects and/or explosives away from
the machine.
After using the ashtray, always cover it to extinguish the
match and/or tobacco.
Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact
with the accelerator or brake pedals during operation,
resulting in serious injury or death.

SAFETY
S-6
Use Handrails and Steps
Falling is one of the major causes of personal injury.
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
Do not use any controls as hand-holds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Before getting on or off the machine, check the condition
of the steps and handrails for sticking of slippery material
like grease or mud. Thoroughly remove such material if
stack. In addition, repair the damage to the steps and/or
handrails. Retighten loose bolts.
Never get on and off the machine with tools in your
hands.
Never Ride Attachment
Never allow anyone to ride attachment or the load. This is
an extremely dangerous practice.
Adjust Operator’s Seat
A poorly adjusted seat for either the operator or the work
at hand may quickly fatigue the operator leading to
misoperations.
The seat should be adjusted whenever changing the
operator for the machine.
The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
If not, move the seat forward or backward, and check
again.
Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
SA-439
SA-462

SAFETY
S-7
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 control lever lock switch 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 control
lever lock switch 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.
Fasten Your Seat Belt
If the machine should overturn, the operator may become
injured and / or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident.
We recommend that the seat belt be replaced every four
years regardless of its apparent condition.
SA-237

SAFETY
S-8
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, 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, 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.
Ensure the cab door, windows, doors and covers are
securely locked.
Check the mirrors and the monitor in the CAB for
problems.
If there is any problem, replace the problem part(s) or
clean the mirror, camera and the monitor.
Refer to Rear View Monitor section on the cleaning of the
camera and the monitor.
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.
SA-293
SA-398

SAFETY
S-9
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 tire 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.
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 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. SA-032
SA-431

SAFETY
S-10
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
falling 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
excavations and road shoulders.
When working on an incline or on a road shoulder,
employ a signal person as required.
Confirm that your machine is equipped with 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.
SA-447