Hitachi Zaxis 48U-5A User manual

Serial No.

ZX33U

-5A

030002 and up

ZX38U

-5A

050002 and up

ZX48U

-5A

030002 and up

ZX55U

-5A

050002 and up

ZX65USB

-5A

020001 and up

PRINTED IN JAPAN (E) 2014, 12

ZX33U

-5A •

38U

-5A •

48U

-5A •

55U

-5A •

65USB

-5A

HYDRAULIC EXCAVATOR OPERATOR’S MANUAL ENMADC-1-3

Hydraulic Excavator

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

33U

-5A

38U

-5A

48U

-5A

55U

-5A

65USB

-5A

ENMADC-1-3

PART NO.

Operator’s Manual

This book is printed on recycled paper.

INTRODUCTION

Read this manual carefully to learn how to operate and

service your machine correctly. Failure to do so could

result in personal injury or equipment 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 1500 m (0 ft to 4900 ft)

In case the machine is used under conditions other than

described above, consult your authorized 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.

• SIUnits(InternationalSystemofUnits)areusedinthis

manual.

ForreferenceMKSsystemunitsandEnglishunitsare

alsoindicatedinparenthesesaftertheSIunits.

Example:24.5MPa(250kgf/cm²,3560psi)

Right-hand and left-hand sides are determined by

facing in the direction of forward travel.

Write product identification numbers in the Machine

Numbers section. Accurately record all the numbers

to help in tracing the machine should it be stolen.

Your dealer also needs these numbers when you order

parts.Ifthismanualiskeptonthemachine,alsofilethe

identification numbers in a secure place off the machine.

UseonlydieselfuelwithqualityspecifiedinJISK-2204,

EN-590,ASTMD-975,GOSTR52368orGB252.

Failure to use diesel fuel with quality as specified

abovemayallowtheenginetoemitexhaustgaswhich

cleanness can not conform to the requests in various

relevant regulations. In addition, serious damage to the

engine may result. Consult with your authorized dealer for

detailed information.

Warranty is provided as a part of Hitachi’s support

program for customers who operate and maintain their

equipment as described in this manual. The warranty is

explainedonthewarrantycertificatewhichyoushould

have received from your dealer.

This warranty provides you the assurance that Hitachi

willbackitsproductswheredefectsappearwithinthe

warranty period. In some circumstances, Hitachi also

provides field improvements, often without charge to

the customer, even if the product is out of warranty.

Should the equipment be abused, or modified to

change its performance beyond the original factory

specifications, the warranty will become void and field

improvements may be denied. Settingfueldelivery

above specifications or otherwise overpowering machines

will result in such action.

Onlyqualified,experiencedoperatorsofficiallylicensed

(according to local law) should be allowed to operate

the machine. Moreover, only officially licensed personnel

should be allowed to inspect and service the machine.

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.

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.

AllRightsReserved.

T

MACHINE NUMBERS

SAFETY

SAFETY SIGNS

COMPONENTS NAME

OPERATOR’S STATION

BREAK-IN

OPERATING THE ENGINE

DRIVING THE MACHINE

OPERATING THE MACHINE

TRANSPORTING

MAINTENANCE

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

STORAGE

TROUBLESHOOTING

SPECIFICATIONS

OPTIONAL ATTACHMENT

INDEX

ENMADC-1-3

GETTING ON/OFF THE MACHINE

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

Adjustthe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

OperateOnlyfromOperator'sSeat ..........................................S-8

JumpStarting ...................................................................................S-9

KeepRidersoffMachine ...............................................................S-9

PrecautionsforOperations ....................................................... S-10

InvestigateJobSiteBeforehand .............................................S-11

InstallOPGGuard .........................................................................S-12

RestrictionofAttachmentInstallation .................................S-13

ProvideSignalsforJobsInvolvingMultipleMachines....S-13

ConfirmDirectionofMachinetoBeDriven ........................S-13

DriveMachineSafely ................................................................... S-14

AvoidInjuryfromRollawayAccidents .................................. S-16

AvoidInjuryfromBack-OverandSwingAccidents .........S-17

KeepPersonClearfromWorkingArea..................................S-18

NeverPositionBucketOverAnyone .....................................S-18

Avoid Undercutting ..................................................................... S-19

Avoid Tipping ................................................................................. S-19

NeverUndercutaHighBank ....................................................S-20

DigwithCaution ........................................................................... S-20

OperatewithCaution ................................................................. S-20

AvoidPowerLines ........................................................................S-21

PrecautionsforLightning ..........................................................S-21

ObjectHandling ...........................................................................S-22

ProtectAgainstFlyingDebris ..................................................S-22

ParkMachineSafely .....................................................................S-23

HandleFluidsSafely−AvoidFires ............................................S-23

TransportSafely ............................................................................S-24

PracticeSafeMaintenance ........................................................ S-25

WarnOthersofServiceWork ...................................................S-26

SupportMachineProperly ........................................................S-27

StayClearofMovingParts ........................................................ S-27

PreventPartsfromFlying ..........................................................S-28

Avoid Injury from Attachment Falling Accident ...............S-28

PreventBurns .................................................................................S-29

ReplaceRubberHosesPeriodically ........................................ S-30

AvoidHigh-PressureFluids ....................................................... S-30

PreventFires ................................................................................... S-31

EvacuatinginCaseofFire ..........................................................S-33

BewareofExhaustFumes..........................................................S-33

PrecautionsforWeldingandGrinding .................................S-34

AvoidHeatingNearPressurizedFluidLines .......................S-35

Avoid Applying Heat to Lines Containing Flammable

Fluids ...........................................................................................S-35

PrecautionsforHandlingAccumulatorandGas

Damper .......................................................................................S-35

RemovePaintBeforeWeldingorHeating ...........................S-36

BewareofAsbestosandSiliconDustandOther

Contamination .........................................................................S-36

PreventBatteryExplosions ....................................................... S-37

ServiceAirConditioningSystemSafely ...............................S-37

HandleChemicalProductsSafely ...........................................S-38

DisposeofWasteProperly .........................................................S-38

NeverRideAttachment .............................................................. S-39

PrecautionsforCommunicationTerminal ...........................S-39

PrecautionforCommunicationTerminalEquipment ..... S-40

SAFETY SIGNS .............................................................................. S-42

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

Layout ..................................................................................................1-3

KeySwitch ....................................................................................1-5

SwitchPanel ................................................................................1-5

Monitor ...............................................................................................1-6

Feature ...........................................................................................1-6

ScreenConfiguration................................................................1-6

BasicScreen .......................................................................................1-7

Indicators ............................................................................................1-8

OverheatIndicator(1) ..............................................................1-8

EngineOilPressureIndicator(2) ..........................................1-8

AlternatorIndicator(3) ............................................................1-8

Fuel Level Indicator (4) .............................................................1-8

HowtoUseScreens ........................................................................1-9

DisplayingBasicScreen ...........................................................1-9

Hour Meter ................................................................................1-13

Clock ............................................................................................1-13

FuelGauge ................................................................................1-13

CoolantTemperatureGauge ..............................................1-13

OperatingStatusIconDisplay ............................................1-13

AlarmOccurrenceScreen .......................................................... 1-14

ErrorDisplayScreen ...............................................................1-14

WarningDisplayScreen ........................................................1-14

AlarmListDisplay ...................................................................1-15

Contents of Alarms ......................................................................1-16

ErrorCode ..................................................................................1-16

WarningCodes........................................................................1-16

DTCCodeList ................................................................................1-18

MainMenu(MENU) ....................................................................1-20

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

ClockAdjustment ................................................................... 1-21

DisplayModeSetting ............................................................1-23

Trip .....................................................................................................1-24

Functions of Trip Meter ........................................................1-24

DisplayingTripMeter(1) ....................................................1-25

CONTENTS

DisplayingTripMeter(2) ....................................................1-27

ChangeTripMeterSetTime ...............................................1-28

BrightnessAdjustment ...............................................................1-30

HeaterOperation(ZX33U-5A,38U-5A,48U-5A,

55U-5A) .......................................................................................1-32

NameandFunctionofEachPartofControlPanel ......1-32

HeatingOperation ................................................................1-33

DefrosterOperation ...............................................................1-33

TipsforOptimalHeaterUsage.................................................1-34

WhenWindowsBecomeClouded ....................................1-34

AirConditionerOperation(Optional) ...................................1-35

NameandFunctionofEachPartofControlPanel ......1-35

HeatingOperation ................................................................1-36

CoolingOperation ..................................................................1-36

DefrosterOperation ...............................................................1-36

TipsforOptimalAirConditionerUsage ...............................1-37

ForRapidCooling ...................................................................1-37

WhenWindowsBecomeClouded ....................................1-37

Off-SeasonAirConditionerMaintenance ......................1-37

Radio(Cabequippedmachine)(Optional) ......................... 1-38

AM/FMRadioOperation(Cabequippedmachine) .......1-39

PartNameandFunction .....................................................1-39

RadioOperation .....................................................................1-39

TuningProcedure ...................................................................1-40

StationPresettingProcedure ..............................................1-40

DeletionofPresetMemory ................................................1-40

SoundAdjustment .................................................................1-41

DigitalClockSettingProcedure ......................................... 1-41

DoorLockReleaseLever(Cabequippedmachine) .........1-42

OpeningUpperFrontWindow(Cabequipped

machine) ...................................................................................1-43

FrontWindow ..........................................................................1-43

RemovingandStoringLowerFrontWindow ...............1-43

AdjustingtheSeat ........................................................................1-44

SeatFore-aftAdjustment .....................................................1-44

ToolBox...........................................................................................1-44

SeatBackBox ................................................................................. 1-44

EmergencyExit(Cabequippedmachine) ..........................1-45

SeatBelt ........................................................................................... 1-46

RoomLamp(Cabequippedmachine) ..................................1-46

BREAK-IN ...........................................................................................2-1

BreakinginNewMachine ............................................................2-1

OPERATING THE ENGINE ............................................................3-1

InspectMachineDailyBeforeStarting ....................................3-1

BeforeStartingEngine ..................................................................3-2

StartingtheEngine .........................................................................3-3

CheckInstrumentsAfterStartingEngine ...............................3-5

UsingBoosterBattery ....................................................................3-6

StoppingtheEngine ......................................................................3-8

DRIVING THE MACHINE ..............................................................4-1

TravelLeversandPedals(Optional) ..........................................4-1

TravelModeSwitch ........................................................................4-3

Traveling .............................................................................................4-4

TravelingonSoftGround .............................................................4-5

RaiseOneTrackbyUsingBoomandArm ..............................4-6

Towing Machine ..............................................................................4-7

OperatinginWaterorMud ..........................................................4-8

PrecautionsforTravelingonSlopes..........................................4-9

ParkingtheMachineonSlopes ...............................................4-10

ParkingtheMachine ................................................................... 4-10

OPERATING THE MACHINE .......................................................5-1

ControlLever(ISOPattern) ..........................................................5-1

Boom-SwingPedal ..........................................................................5-2

BladeLever ........................................................................................5-3

PrecautionsforBladeOperation ................................................5-4

PilotControlShut-OffLever ........................................................5-5

WarmingUpOperation .................................................................5-7

EngineSpeedControl ....................................................................5-8

Auto-Idle .............................................................................................5-9

Auto-IdleON/OFF ...................................................................5-10

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

OverloadAlarmSelector(Optional) .....................................5-12

OperatingBackhoe ...................................................................... 5-13

GradingOperation .......................................................................5-14

AvoidAbusiveOperation ..........................................................5-15

AvoidExcavationUsingUpperstructureand/orBoom

SwingPower ............................................................................. 5-15

AvoidDrivingBucketTeethintoGround .............................5-16

AvoidStrikingWithBucket ....................................................... 5-16

BoomCylindermayHitBlade ..................................................5-17

AvoidHittingBladeWithBucket .............................................5-18

AvoidCollidingBladeAgainstRocks .....................................5-18

AvoidCollidingBoomCylinderWithTrack .......................... 5-18

PrecautionsforInstallingWideBucketorSpecialType

Bucket .........................................................................................5-18

UseCorrectTrackShoe ...............................................................5-19

UsingRubberCrawler .................................................................5-20

AvoidotherthanSpecifiedMachineOperations .............5-22

ShackleBracketUsage ................................................................ 5-23

EmergencyBoomLoweringProcedure ...............................5-24

ReleasingHoseRuptureValve(MachineEquipped

withHoseRuptureValve)(Optional) ..........................5-25

PrecautionsforAfterOperations ............................................5-27

TRANSPORTING .............................................................................6-1

TransportingbyRoad ....................................................................6-1

Loading/UnloadingonaTruck ...................................................6-2

Fastening Machine for Transporting ........................................6-5

Unloading ..........................................................................................6-6

Lifting Machine ................................................................................6-7

MAINTENANCE ...............................................................................7-1

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

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

Layout ..................................................................................................7-3

MaintenanceGuideTable .............................................................7-4

PreparationsforInspectionandMaintenance .....................7-7

Access Covers ....................................................................................7-8

MaintenanceGuide .....................................................................7-11

PeriodicReplacementofParts .................................................7-15

KindofOils ......................................................................................7-16

RecommendedEngineOil ...................................................7-16

CONTENTS

A.Greasing ......................................................................................7-19

FrontJointPins ........................................................................7-19

Bucket .........................................................................................7-19

SwingPostandOthers ..........................................................7-19

BladePins ...................................................................................7-21

SwingBearing ..........................................................................7-22

SwingInternalGear................................................................7-23

Control Lever Universal Joint ..............................................7-23

B.Engine ..........................................................................................7-24

EngineOilLevel .......................................................................7-24

ChangeEngineOil .................................................................7-25

ReplaceEngineOilFilter .......................................................7-25

C. Transmission ..............................................................................7-28

TravelReductionGear ...........................................................7-28

D.HydraulicSystem .....................................................................7-31

Inspection and Maintenance of Hydraulic

Equipment ...........................................................................7-31

CheckHydraulicOilLevel ....................................................7-35

DrainHydraulicOilTankSump ..........................................7-36

ChangeHydraulicOil ............................................................. 7-37

SuctionFilterCleaning .......................................................... 7-37

ReplaceFull-FlowFilter .........................................................7-41

ReplacePilotOilFilterElement ..........................................7-43

CheckHosesandLines .........................................................7-45

E.FuelSystem ................................................................................7-52

RecommendedFuel ...............................................................7-52

CheckFuelLevel ......................................................................7-53

CheckWaterSeparator ........................................................7-54

BleedAirfromFuelSystem .................................................7-54

DrainFuelTankSump ............................................................7-55

ReplaceFuelMainFilterElement ...................................... 7-56

ReplaceFuelPre-FilterElement(Optional) ....................7-57

CheckFuelHoses .................................................................... 7-59

F. Air Cleaner ...................................................................................7-60

CleanAirCleanerOuterElement ......................................7-60

ReplaceAirCleanerOuterandInnerElements ............ 7-60

ReplaceAirCleanerInnerElement(Optional) ..............7-60

G.CoolingSystem ........................................................................7-62

CheckCoolantLevel ..............................................................7-63

CheckandAdjustFanBeltTension .................................. 7-64

Change Coolant .......................................................................7-67

CleanRadiator/OilCoolerCore ..........................................7-69

Clean Air Conditioner Condenser .................................... 7-70

CleanAirConditionerCondenserFrontScreen ...........7-70

H.ElectricalSystem ......................................................................7-71

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

CheckElectrolyteSpecificGravity ....................................7-74

ReplacingFuses .......................................................................7-75

I. Miscellaneous .............................................................................7-76

CheckandReplaceBucketTeeth ......................................7-76

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

AdjustTrackSag(RubberCrawler)andCheckfor

Damage................................................................................7-79

CheckRubberTrackforDamage ....................................... 7-79

ReplaceRubberCrawler ...................................................... 7-81

RemovingRubberCrawler ..................................................7-81

InstallingRubberCrawler ....................................................7-82

CheckTrackSag(SteelCrawler)(Optional) ....................7-83

ConvertingtheTrack .............................................................7-85

CheckandReplaceSeatBelt ...............................................7-86

CheckAirConditioner(Cabequippedmachine) ........7-87

CleanandReplaceHeater/AirConditionerFilter ......7-90

Clean Circulating Air Filter ................................................... 7-90

ReplaceCirculatingAirFilter ...............................................7-90

Clean Fresh Air Filter ..............................................................7-92

ReplaceFreshAirFilter ..........................................................7-92

Clean Fresh Air Filter ..............................................................7-93

ReplaceFreshAirFilter ..........................................................7-93

Clean Cab Floor........................................................................7-94

Check,CleanandFunctionCheckofInjection

Nozzle ...................................................................................7-95

InspectandAdjustValveClearance ................................7-95

CheckandAdjustInjectionTiming .................................7-95

MeasureEngineCompressionPressure.........................7-95

CheckStarterandAlternator ..............................................7-95

CheckCrankcaseBreather ..................................................7-95

CheckRadiatorCap ...............................................................7-95

TighteningandRetighteningTorqueofBoltsand

Nuts ........................................................................................7-96

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL

CONDITIONS ....................................................................................9-1

MaintenanceUnderSpecialEnvironmentalConditions ...9-1

STORAGE ........................................................................................10-1

StoringtheMachine ....................................................................10-1

TROUBLESHOOTING .................................................................11-1

Troubleshooting ...........................................................................11-1

SPECIFICATIONS .........................................................................12-1

Std.Specification .......................................................................... 12-1

WorkingRanges ............................................................................12-2

ShoeTypesandApplications ...................................................12-3

BucketTypesandApplicationsZX33U-5A .......................... 12-4

Std.Specification .......................................................................... 12-5

WorkingRanges ............................................................................12-6

ShoeTypesandApplications ...................................................12-7

BucketTypesandApplicationsZX38U-5A .......................... 12-8

Std.Specification .......................................................................... 12-9

WorkingRanges ..........................................................................12-10

ShoeTypesandApplications .................................................12-11

BucketTypesandApplicationsZX48U-5A ........................12-12

Std.Specification ........................................................................12-13

WorkingRanges ..........................................................................12-14

ShoeTypesandApplications .................................................12-15

BucketTypesandApplicationsZX55U-5A ........................12-16

Std.Specification ........................................................................12-17

WorkingRanges ..........................................................................12-18

ShoeTypesandApplications .................................................12-19

BucketTypesandApplicationsZX65USB-5A ...................12-20

CONTENTS

OPTIONAL ATTACHMENT .......................................................13-1

HydraulicBreaker,HydraulicCrusherandQuick

Coupler .......................................................................................13-1

Attachment .....................................................................................13-2

PipingforBreakerandCrusher(Optional) ........................13-3

AttachmentPedal(HydraulicBreaker)(Optional) ............13-4

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

AttachmentPedal(HydraulicCrusher)(Optional) ............13-9

PrecautionsforCrusherOperation ......................................13-10

AUXFunctionLeverforExtraPiping(Optional) ..............13-13

AuxiliaryFlowRateControl(Optional) ...............................13-14

ControlLever(H-pattern:HITACHIExcavatorPattern) ..13-15

ControlLever(SAE-backhoePattern) ..................................13-16

FuelFeedDevice(Optional)(ZX48U-5A,55U-5A,

65USB-5A) ................................................................................13-17

NumericKeypadLock(Optional)........................................13-18

Additional Counterweight ....................................................13-25

Cab Tilting Mechanism .............................................................13-26

Maintenance ...........................................................................13-33

CheckTiltMechanismFulcrumBoltsandWorking

ScrewLockNut ...............................................................13-33

Greasing ...................................................................................13-34

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

MODEL/TYPE:

PRODUCTIDENTIFICATIONNUMBER:

Product Identification Number

PRODUCTIDENTIFICATIONNUMBER:

NOTE:

*HCMADC00X00050002*

PRODUCTIDENTIFICATION

NUMBER(PIN)

Markstoindicatethe

startandendofthePIN

MADB-00-002

MADB-00-003

MADB-00-002

ZX33U-5A,38U-5A

ZX48U-5A,55U-5A,65USB-5A

MACHINE NUMBERS

2

Engine

TYPE:

MFG.NO.:

Travel Motor

TYPE:

MFG.NO.:

MADB-00-020

MADC-00-010

M1M0-00-004

MACHINE NUMBERS

3

Swing Motor

TYPE:

MFG.NO.:

ZX65USB-5A

ZX33U-5A,38U-5A,48U-5A,55U-5A

MADB-00-005

MADC-00-001

MACHINE NUMBERS

4

Hydraulic Pump

TYPE:

MFG.NO.:

MADB-00-006

ZX48U-5A,55U-5A

ZX33U-5A,38U-5A

MADB-00-021

ZX65USB-5A

MADC-00-002

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 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.

 NOTE:indicatesanadditionalexplanationforan

element of information.

S-1

SAFETY

SA-688

SA-1223

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.

SAFETY

S-2

SA-003

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.

SAFETY

S-3

SA-437

SA-438

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-434

SAFETY

S-4

SA-435

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

travellevers/pedals,pilotcontrolshut-offlever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 travel pedals during operation, resulting in serious

injury or death.

SAFETY

S-5

Use Handrails and Steps

 Falling is one of the major causes of personal injury.

 Whenyougetonandoffthemachine,alwaysusethe

crawler instead of the step for safety. Also get on and off

from the position of the crawler that can secure your feet

space enough.

 Whenyougetonandoffthemachine,alwaysfacethe

machine.

 Maintainathree-pointcontactwiththestepsand

handrails.

 Donotuseanycontrolsashandholds.

 Never jump on or off the machine. Never mount or

dismount a moving machine.

 In case adhered slippery material such as oil, grease,

or mud is present on steps, handrails, or platforms,

thoroughly remove such material.

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.

SAFETY

S-6

SA-439

SA-378

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.

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.

SA-237

SAFETY

S-7

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.

 Ensurethecabdoor,windows,doorsandcoversare

securelylocked.

 Checkthemirrorsforproblems.

If there is, replace the problem part(s) or clean the mirror.

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.

SA-444

SAFETY

S-8

SA-1291

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