Hitachi EX 3600-6 Operator's Manual
PRINTED IN JAPAN (E) 2006, 08
This book is printed on recycled paper.
Serial No 001001 and up
Hydraulic Excavator
PART NO.
EM18M-1-1T
3600
-6
URL:http://www.hitachi-c-m.com
EX3600-6 HYDRAULIC EXCAVATOR OPERATOR’S MANUAL EM18M-1-1T
INTRODUCTION
COPYRIGHT © 2006
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved.
Read this manual carefully to learn how to operate
and service your machine correctly. Failure to do so
could result in personal injury and/or machine damage.
This manual should be considered a permanent
part of your machine and should remain with the machine when you sell it.
This machine is of metric design. Measurements in
this manual are metric. Use only metric hardware and
tools as specified.
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.
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 when defects occur 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.
Moreover, when replacement parts are required, be
sure to use genuine Hitachi parts. Failure to do so may
result in voiding the warranty and/or denial of field improvements.
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/service the machine.
The Yellow Pages in this operator’s manual contain IMPORTANT SAFETY INFORMATION.
Read these pages thoroughly and familiarize yourself with the safety standards and recommendations set forth in these yellow pages of the manual.
Follow all safety instructions prior to and while
operating the excavator.
Prior to operating this machine, 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.
MACHINE NUMBERS
MACHINE TYPE AND SERIAL NUMBER
MODEL/TYPE:
PRODUCT
IDENTIFICATION
NUMBER:
PRODUCT IDENTIFICATION NUMBER
PRODUCT
IDENTIFICATION
NUMBER:
NOTE:
∗HCM18M00P00001001∗
PRODUCT IDENTIFICATION
NUMBER (PIN)
ENGINE TYPE AND SERIAL NUMBER
TYPE:
MFG. NO.
TRAVEL MOTOR TYPE AND SERIAL NUMBER
TYPE:
MFG. NO.(LEFT FRONT) :
MFG. NO.(LEFT REAR) :
MFG. NO.(RIGHT FRONT) :
MFG. NO.(RIGHT REAR) :
M18M-00-001
M146-07-018
M18M-00-002
M145-07-079
Marks to indicate the
start and end of the
PIN
MACHINE NUMBERS
SWING MOTOR TYPE AND SERIAL NUMBER
TYPE:
MFG. NO.(FRONT LEFT) :
MFG. NO.(FRONT RIGHT):
MFG. NO.(REAR LEFT):
MFG. NO.(REAR RIGHT):
HYDRAULIC PUMP TYPE AND SERIAL
NUMBER
TYPE:
MFG. NO.(1, 2):
MFG. NO.(3, 4):
MFG. NO.(5, 6):
MFG. NO.(7, 8):
FRONT TYPE AND SERIAL NUMBER
(LOADING SHOVEL)
TYPE:
MFG. NO.:
BUCKET TYPE AND SERIAL NUMBER
(LOADING SHOVEL)
TYPE:
MFG. NO.:
M146-07-028
M146-07-059
M146-07-060
M117-12-003
MACHINE NUMBERS
FRONT TYPE AND SERIAL NUMBER
(BACKHOE BOOM)
TYPE:
MFG. NO.:
FRONT TYPE AND SERIAL NUMBER
(BACKHOE ARM)
TYPE:
MFG. NO.:
BUCKET TYPE AND SERIAL NUMBER
(BACKHOE)
TYPE:
MFG. NO.:
CONTROL VALVE TYPE AND SERIAL
NUMBER
TYPE:
MFG. NO.(UPPER LEFT):
MFG. NO.(UPPER RIGHT):
MFG. NO.(LOWER LEFT):
MFG. NO.(LOWER RIGHT):
M146-07-060
M146-07-061
M146-01-020
M18M-00-003
Upper Right Upper Left
Lower Right Lower Left
CONTENTS
MACHINE NUMBERS
SAFETY
Recognize Safety Information..............................S-1
Understand Signal Words....................................S-1
Follow Safety Instructions....................................S-2
Prepare for Emergencies.....................................S-2
Wear Protective Clothing .....................................S-3
Protect Against Noise ..........................................S-3
Inspect Machine...................................................S-3
General Precautions for Cab ...............................S-4
Use Handholds and Steps ...................................S-5
Adjust the Operator’s Seat ..................................S-5
Fasten Your Seat Belt..........................................S-6
Move and Operate Machine Safely .....................S-6
Handle Starting Aids Safely .................................S-6
Operate Only from Operator’s Seat .....................S-7
Jump Starting ......................................................S-7
Keep Riders Off Machine ....................................S-7
Investigate Job Site Beforehand..........................S-8
Protect Against Falling Stones and Debris ..........S-8
Provide Signals for Jobs Involving Multiple
Numbers of Machines ...................................S-9
Confirm Direction of Machine to be Driven ..........S-9
Drive Machine Safely.........................................S-10
Avoid Injury from Rollaway Accidents................S-11
Avoid Injury from Back-Over
and Swing Accidents ...................................S-12
Keep Person Clear from W orking Area.............S-13
Never Position Bucket Over Anyone .................S-13
Avoid Undercutting ............................................S-13
Avoid Tipping .....................................................S-14
Never Undercut a High Bank .............................S-14
Dig with Caution.................................................S-15
Operate with Caution .........................................S-15
Avoid Power Lines .............................................S-15
Object Handling .................................................S-16
Protect Against Flying Debris ............................S-16
Park Machine Safely..........................................S-17
Handle Fluids Safely − Avoid Fires....................S-17
Practice Safe Maintenance................................S-18
Warn Others of Service Work ...........................S-19
Support Machine Properly .................................S-19
Stay Clear of Moving Parts ................................S-19
Prevent Parts from Flying ................................S-20
Store Attachments Safely ..................................S-20
Prevent Burns ....................................................S-21
Replace Rubber Hoses Periodically ..................S-21
Avoid High-Pressure Fluids ...............................S-22
Prevent Fires .....................................................S-23
Evacuating in Case of Fire.................................S-24
Beware of Exhaust Fumes ................................S-24
Precautions for Welding and Grinding...............S-25
Avoid Heating Near Pressurized Fluid Lines .....S-25
Avoid Applying Heat to Lines Containing
Flammable Fluids ........................................S-25
Remove Paint Before Welding or Heating ........ S-26
Beware of Asbestos Dust.................................. S-26
Prevent Battery Explosions ............................... S-27
Service Air Conditioning System Safely ............ S-27
Handle Chemical Products Safely..................... S-28
Dispose of Waste Properly ............................... S-28
SAFETY SIGNS .................................. S-29
COMPONENTS NAME ......................... 1-1
HANDLING STAIRWAY/EMERGENCY ROPE
Using Stairway .................................................... 1-2
Operating Stairway.............................................. 1-2
Emergency Escape ............................................. 1-5
Emergency Exit ................................................... 1-6
Evacuating in Case of Fire .................................. 1-6
OPERATOR’S STATION
Cab Features .......................................................1-8
Monitor Display.....................................................1-9
Starting Check Screen .........................................1-9
Meter Check Screen ..........................................1-10
Tachometer..................................................1-11
Coolant Temperature Gauge .......................1-11
Hydraulic Oil Temperature Gauge ...............1-11
Fuel Gauge ..................................................1-11
Engine Oil Pressure Gauge .........................1-12
Engine Oil Temperature Gauge ...................1-12
Hour Meter...................................................1-12
Warning Indicators.......................................1-12
Alternator Indicator.......................................1-12
Pump Transmission Oil Level Indicator .......1-13
Engine Stop Indicator...................................1-13
Engine Oil Pressure Indicator ......................1-13
Coolant Overheat Indicator ..........................1-13
Coolant Level Indicator ................................1-14
Engine Over Run Indicator...........................1-14
Fuel Temperature Indicator .........................1-14
Hydraulic Oil Level Indicator ........................1-14
Stop Valve Indicator.....................................1-15
Auto-Lubrication Indicator ............................1-15
Fast-Filling Indicator.....................................1-16
Emergency Engine Stop Indicator ...............1-16
Tension Indicator .........................................1-16
Electric Lever Indicator ................................1-16
Caution Indicators........................................1-17
Exhaust Temperature Indicator ...................1-17
Engine Warning Indicator ............................1-17
Hydraulic Oil Overheat Indicator ..................1-17
Pump Contamination Indicator.....................1-17
Stairway Position Indicator...........................1-18
Air Cleaner Restriction Indicator ..................1-18
Electrical Equipment Box Indicator ..............1-18
Status Indicators ..........................................1-18
Auto-Idle Indicator........................................1-18
CONTENTS
Travel Mode Indicator.................................. 1-19
Prelub Indicator ........................................... 1-19
Left Console....................................................... 1-20
Warning Lamp ............................................. 1-20
Caution Lamp .............................................. 1-20
Key Pad .......................................................1-20
Monitor Contrast Switch ..............................1-20
Wiper Switch ............................................... 1-21
Washer Switch ............................................ 1-21
Wiper Delay Selector Switch ....................... 1-21
Air Conditioners ................................................. 1-22
Designations And Functions Of Controls........... 1-23
Cooling ........................................................ 1-25
Heating ........................................................ 1-25
Dehumidifying And Heating .........................1-25
Defrosting .................................................... 1-26
Blower Operation Without Cooling
or Heating.............................................. 1-26
Ventilation The Cab .....................................1-26
AM/FM Radio Operation .................................... 1-27
Digital Clock Setting Procedure .........................1-28
Right Console ....................................................1-29
Key Switch................................................... 1-29
Emergency Engine Stop Switch ..................1-30
Engine Start Switch ..................................... 1-30
Engine Stop Switch ..................................... 1-30
Engine Speed Control Dial ..........................1-31
Work Light Switch........................................ 1-32
Dome Light Switch....................................... 1-33
Maintenance Light Switch............................ 1-34
Entrance Light Switch.................................. 1-35
Travel Mode Switch ..................................... 1-36
Auto-Idle Switch........................................... 1-36
Buzzer Stop Switch......................................1-37
Fast-Filling System ...................................... 1-38
Rear Console..................................................... 1-39
Horn Switch .......................................................1-40
Adjusting The Seat ............................................1-41
Seat Belt ............................................................ 1-44
Cab Door Release Button.................................. 1-45
Opening Cab Left Window................................. 1-45
BREAK-IN
Observe Machine Closely.................................... 2-1
Every 10 Hours or Each Shift ..............................2-1
After the First 50 Hours ....................................... 2-2
OPERATING THE ENGINE
Inspect Machine Daily Before Starting................. 3-1
Before Turning Power ON ...................................3-2
Turning Power ON ............................................... 3-3
Starting the Engine .............................................. 3-8
Starting in Cold Weather ..................................... 3-9
Check Instruments after Starting....................... 3-10
Using Booster Batteries ..................................... 3-11
Stopping the Engine ..........................................3-13
Stopping the Engine in Emergency
(In The Cab).................................................3-14
Stopping the Engine in Emergency
(Except In The Cab).....................................3-15
DRIVING THE MACHINE
Drive the Machine Carefully .................................4-1
Steering the Machine Using Pedals .....................4-2
Steering the Machine Using Levers .....................4-3
Travel Mode Switch..............................................4-4
Travel Alarm.........................................................4-5
Traveling ..............................................................4-6
Operating on Soft Ground ....................................4-7
Raise One Track Using Boom and Arm...............4-7
Towing Machine a Short Distance .......................4-8
Operating Ground Condition ................................4-9
Precautions for Traveling on Slopes ..................4-10
Parking the Machine on Slopes .........................4-11
Parking the Machine ..........................................4-11
OPERATING THE MACHINE
Control Lever (ISO Pattern Backhoe) ................5-1
Control Lever (HITACHI Pattern Backhoe) ........5-2
Control Lever (ISO Pattern Loading Shovel) ......5-3
Control Lever (HITACHI Pattern
Loading Shovel) ...........................................5-4
Bucket Open-Close Pedals (Loading Shovel) ......5-5
Pilot Control Shut-Off Lever .................................5-6
Engine Speed Control ..........................................5-7
Auto-Idle...............................................................5-8
Warming-Up Operation........................................5-9
Warming-Up the Cylinders and Motors..............5-10
Precautions for Operations ................................5-11
Operate the Machine Safely...............................5-12
Operating Backhoe ............................................5-13
Grading Operation..............................................5-13
Avoid Abusive Operation....................................5-14
Operating Tips....................................................5-15
Avoid Swinging Bucket to Move Objects............5-15
Loading Shovel Operation..................................5-16
Prohibited Operation ..........................................5-16
Object Handling..................................................5-18
Overnight Storage Instructions...........................5-19
MAINTENANCE
Correct Maintenance and Inspection Procedures ....7-1
Check the Hour Meter Regularly..........................7-2
Use Correct Fuels and Lubricants .......................7-2
Prepare Machine for Maintenance .......................7-3
Open Access Doors for Service...........................7-5
Inspection/Maintenance Lights.............................7-6
Use a Chain to Prevent Falling Accidents ............7-7
Electric Pump (Optional) ......................................7-8
Construction Outline...........................................7-10
Hydraulic System ...............................................7-11
Periodic Replacement of Parts ..........................7-14
CONTENTS
Periodic Replacement of Rubber Hoses ........... 7-15
Maintenance Interval Guide............................... 7-20
A. Greasing .................................................... 7-24
Loading Shovel Front Joint Pins.................. 7-25
Backhoe Front Joint Pins ............................ 7-28
Swing Bearing .............................................7-31
Swing Internal Gear..................................... 7-32
Center Joint ................................................. 7-33
Operating the Lubricator.............................. 7-34
B. Engine ......................................................... 7-36
Engine Oil Level in Engine Oil Pan.............. 7-37
Check LED Monitor Signal
(on Reserve Tank) ................................ 7-38
Change Engine Oil in Engine Oil Pan.......... 7-39
Replace Engine Oil Filters ...........................7-39
C. Transmission ............................................. 7-43
Pump Transmission Gear ........................... 7-44
Pump Transmission Oil Level...................... 7-44
Change Oil................................................... 7-45
Replace Filter ..............................................7-46
Clean Breather ............................................7-46
Swing Reduction Gear................................. 7-47
Check Oil Level ...........................................7-47
Change Gear Oil.......................................... 7-48
Clean Breather ............................................7-48
Travel Reduction Gear ................................7-49
Check Oil Level ...........................................7-49
Change Gear Oil.......................................... 7-50
D. Hydraulic System......................................... 7-51
Inspection and Maintenance
of Hydraulic Equipment .........................7-52
Check Hydraulic Oil Level ...........................7-54
Drain Hydraulic Oil Tank Sump ................... 7-55
Change Hydraulic Oil................................... 7-56
Replace Full-Flow Filter and Drain Filter .....7-59
Replace Bypass Filter.................................. 7-61
Replace Pilot Oil Filter .................................7-63
Suction Filter .............................................. 7-65
Replace Suction Filter .................................7-66
Replace High-Pressure Strainer.................. 7-67
Clean Oil Cooler Core .................................7-68
Check Hoses and Lines .............................. 7-69
Service Recommendations for
Hydraulic Fittings ................................... 7-72
E. Fuel System................................................. 7-74
Drain Fuel Tank Sump ................................ 7-76
Drain Fuel Filter Sediment........................... 7-76
Replace Fuel Element ................................. 7-77
Replace Fuel Filter ......................................7-78
Check Fuel Hoses .......................................7-79
F. Air Cleaner................................................... 7-81
Clean Air Cleaner Outer Element ................7-81
Replace Air Cleaner Outer
and Inner Elements ............................... 7-81
G. Cooling System ........................................... 7-83
Check Coolant Level ...................................7-84
Check DCA4 Concentration in Coolant........7-85
Replace Coolant Filter .................................7-93
Change Coolant ...........................................7-94
Clean Radiator Interior.................................7-94
Clean Radiator Core ....................................7-96
H. Air Conditioner .............................................7-97
Recirculation Air Filter..................................7-97
Ventilation Air Filter ......................................7-98
Check Refrigerant Quantity..........................7-99
Check Compressor Belt Tension ...............7-100
Clean Condenser Core ..............................7-101
Check Tightening Torque ..........................7-102
Seasonal Maintenance ..............................7-103
I. Electrical System ......................................7-104
Batteries.....................................................7-104
Replace Batteries.......................................7-108
Replacing Fuses ........................................7-109
Power Source Terminal .............................7-112
High Current Fuse......................................7-113
Check Electrical Cables and
Wire Harnesses for Short Circuits .......7-115
Check Emergency Engine Stop Switch .....7-117
J. Miscellaneous ..........................................7-118
Check Bucket Teeth ..................................7-119
Inspect Emergency Evacuation
Equipment and Hanger........................7-121
Auto-Lubrication System ............................7-122
Check and Replace Seat Belt ....................7-126
Check Windshield Washer Fluid Lever......7-126
Clean Air Horn Compressor Filter..............7-127
Check and Adjust Track Sag .....................7-128
Check Accumulator and Track
Adjuster Cylinder Circuit ......................7-130
Check Side Frame Area ............................7-130
Check Tightening Torque of Bolts
and Nuts...............................................7-131
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special
Environmental Conditions ..............................9-1
STORAGE
Storing the Machine ...........................................10-1
Removing the Machine from Storage ................10-2
Transporting the Machine ..................................10-2
TROUBLESHOOTING
Cummins Fault Code Lamps and
Diagnostic Switches .....................................11-1
Engine ................................................................11-2
Electrical System................................................11-6
Mode Selection ..................................................11-9
Hydraulic System ...............................................11-9
Auto-Idle...........................................................11-12
CONTENTS
SPECIFICATIONS
Specifications ................................................... 12-1
Working Range (Loading Shovel)...................... 12-2
Working Range (Backhoe) ................................12-3
INDEX .............................................................14-1
SAFETY
S-1
RECOGNIZE SAFETY INFORMATION
• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or in
this manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.
001-E01A-0001
SA-688
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.
• DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
• Some safety signs don’t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.
• CAUTION also calls attention to safety messages in this
manual.
• 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.
002-E01A-1223
SA-1223
SAFETY
S-2
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
• Safety signs should be installed, maintained and re-
placed 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 cor-
rectly and safely.
• Allow only trained, qualified, authorized personnel to op-
erate 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.
• The safety messages in this SAFETY chapter are in-
tended to illustrate basic safety procedures of machines.
However it is impossible for these safety messages to
cover every hazardous situation you may encounter. If
you have any questions, you should first consult your
supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.
003-E01B-0003
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.
004-E01A-0437
SA-437
SAFETY
S-3
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment appro-
priate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for
the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items
that can catch on control levers or other parts of the
machine.
• Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating the machine.
005-E01A-0438
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.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by walk-
ing around it before you start it to avoid personal injury.
• In the walk-around inspection, be sure to cover all
points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.
007-E01A-0435
SA-435
SAFETY
S-4
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt
and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the operator’s work boots the
operator’s foot may slip off the pedal, possibly result-
ing in a personal accident.
• Do not leave parts and/or tools lying around the op-
erator’s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
• Keep all flammable objects and/or explosives away
from the machine.
• After using the ashtray, always cover it to extinguish
the match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may ex-
plode.
524-E01A-0000
SAFETY
S-5
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps,
and handrails when leaving the machine.
008-E01A-0439
SA-439
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 ped-
als 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.
009-E01A-0378
SA-378
SAFETY
S-6
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may be-
come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.
• Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation
to minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every
three years regardless of its apparent condition.
010-E01A-0237
SA-237
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 con-
dition (if equipped). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or oper-
ating the machine in congested areas. Coordinate
hand signals before starting the machine.
011-E01A-0426
SA-426
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 ca-
bles.
• Remove container from machine if engine does not
need starting fluid.
• To prevent accidental discharge when storing a pres-
surized container, keep the cap on the container, and
store it in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
036-E01A-0293-3
SA-293
SAFETY
S-7
OPERATE ONLY FROM OPERATOR’S SEAT
• Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury
or death.
• Start the engine only from the operator’s seat.
• NEVER start the engine while standing on the track or
on ground.
• Do not start engine by shorting across starter termi-
nals.
• Before starting the engine, confirm that all control lev-
ers are in neutral.
012-E01B-0444
SA-444
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE EN-
GINE” chapter.
• 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 ma-
chine.
S013-E01A-0032
SA-032
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as being
struck by foreign objects and being thrown off the machine.
• Only allow the operator on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in
the machine being operated in an unsafe manner.
014-E01B-0379
SA-379
SAFETY
S-8
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 nec-
essary. 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 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 ma-
chine near flammable objects such as dry grass.
015-E01A-0380
SA-380
PROTECT AGAINST FALLING STONES AND
DEBRIS
• Confirm that your machine is FOPS cab equipped
before working in areas where the possibility of falling
stones or debris exist.
015-E01A-0380
SA-490
SAFETY
S-9
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines, pro-
vide signals commonly known by all personnel involved.
Also, appoint a signal person to coordinate the job site.
Make sure that all personnel obey the signal person’s
directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO BE
DRIVEN
• Incorrect travel pedal/lever operation may result in seri-
ous injury death.
• Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If
the travel motors are located in front of the cab, the
machine will move in reverse when travel ped-
als/levers are operated to the front.
017-E01A-0491
SA-491
SAFETY
S-10
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the direction you wish to drive.
• Be sure to detour around any obstructions.
• Avoid traveling over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Don’t allow personnel to stay around the
machine while traveling.
• Driving on a slope may cause the machine to slip or
overturn, possibly resulting in serious injury or death.
• When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 0.5 to 1.0
m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
• Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure
sage operation.
019-E01C-0492
SA-387
SA-388
SA-441
SA-589
SAFETY
S-11
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch and the H/P mode switch off.
• Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must
park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E02A-0493
SA-391
SA-392
SAFETY
S-12
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when backing
or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
• Always look around BEFORE YOU BACK UP AND
SWING THE MACHINE. BE SURE THAT ALL BY-
STANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local regula-
tions, when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
• Learn the meanings of all flags, signs, and markings
used on the job and confirm who has the responsibility
for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.
021-E01A-0494
SA-383
SA-384
SAFETY
S-13
KEEP PERSON CLEAR FROM WORKING
AREA
• A person may be hit severely by the swinging front at-
tachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
• Keep all persons clear from the area of operation and
machine movement.
• Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to pre-
vent anyone from entering the work area.
022-E01A-0386
SA-386
NEVER POSITION BUCKET OVER ANYONE
• Never lift, move, or swing bucket above anyone or a
truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.
023-E01A-0487
SA-487
AVOID UNDERCUTTING
• In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with
the travel motors at the rear.
• If the footing starts to collapse and if retreat is not
possible, do not panic. Often, the machine can be se-
cured by lowering the front attachment, in such cases.
024-E01A-0488
SA-488
SAFETY
S-14
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN
JUMP FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when operating
on a grade, possibly resulting in serious injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable.
• Reduce swing speed as necessary when swinging
loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to be-
come soft and make ground travel unstable.
025-E01B-0495
SA-012
SA-440
NEVER UNDERCUT A HIGH BANK
• The edges could collapse or a land slide could occur
causing serious injury or death.
026-E01A-0489
SA-489
SAFETY
S-15
DIG WITH CAUTION
• Accidental severing of underground cables or gas lines
may cause an explosion and/or fire, possibly resulting in
serious injury or death.
• Before digging check the location of cables, gas lines,
and water lines.
• Keep the minimum distance required, by law, from ca-
bles, gas lines, and water lines.
• If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in seri-
ous eye injury.
• Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382
SA-382
OPERATE WITH CAUTION
• If the front attachment or any other part of the machine
hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.
• Take care to avoid hitting overhead obstacles with the
boom or arm.
028-E01A-0389
SA-389
AVOID POWER LINES
• Serious injury or death can result if the machine or front
attachments are not kept a safe distance from electric
lines.
• When operating near an electric line, NEVER move
any part of the machine or load closer than 3 m plus
twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
029-E01A-0381
SA-381
SAFETY
S-16
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath
it, resulting in serious injury or death.
• When using the machine for craning operations, be
sure to comply with all local regulations.
• Do not use damaged chains or frayed cables, sables,
slings, or ropes.
• Before craning, position the upperstructure with the
travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons will away from the load.
• Never move a load over a person’s head.
• Do not allow anyone to approach the load until it is
safely and securely situated on supporting blocks or
on the ground.
• Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
030-E01A-0014
SA-014
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body, se-
rious injury may result.
• Guard against injury from flying pieces of metal or de-
bris; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
031-E01A-0432
SA-432
SAFETY
S-17
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a level surface.
• Lower bucket to the ground.
• Turn auto-idle switch and H/P mode switch off.
• Run engine at slow idle speed without load for 5 min-
utes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK posi-
tion.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E08B-0390
SA-390
HANDLE FLUIDS SAFELY－AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel ig-
nites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when
near open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are flam-
mable.
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spon-
taneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-018
SA-019
SAFETY
S-18
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.
Before servicing the machine:
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5
minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by mov-
ing the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK posi-
tion.
10. Allow the engine to cool.
• If a maintenance procedure must be performed with
the engine running, do not leave machine unattended.
• If the machine must be raised, maintain a 90 to 110°
angle between the boom and arm. Securely support
any machine elements that must be raised for service
work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or replace
as necessary. Refer to the section discussing that part
in the “MAINTENANCE” chapter of this manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable de-
tergent oil. Never use highly flammable oil such as
fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (–) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02B-0497
SA-028
SA-527
SAFETY
S-19
• Sufficiently illuminate the work site. Use a mainte-
nance work light when working under or inside the
machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, anti-
freeze fluid, or window washer fluid may catch fire.
SA-037
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious in-
jury.
• Before performing any work on the machine, attach a
“Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
SA-287
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without securing
the machine first.
• Always lower the attachment to the ground before you
work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a
jack.
519-E01A-0527
SA-527
STAY CLEAR OF MOVING PARTS
• Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure
that hands, feet, clothing, jewelry and hair do not be-
come entangled when working around rotating parts.
502-E01A-0026
SA-026
SAFETY
S-20
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or
VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and face
away from valve.
• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face
away from AIR RELEASE PLUG to avoid injury. GEAR
OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen AIR
RELEASE PLUG to release pressure.
503-E01B-0344
SA-344
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
• Securely store attachments and implements to pre-
vent falling. Keep children and bystanders away from
storage areas.
504-E01A-0034
SA-034
SAFETY
S-21
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under pres-
sure. Hot water or steam is contained in the engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water. DO
NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow
all pressure to be released before removing the cap.
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
• Wait for the oil and components to cool before starting
any maintenance or inspection work.
505-E01B-0498
SA-039
SA-225
REPLACE RUBBER HOSES PERIODICALLY
• Rubber hoses that contain flammable fluids under pres-
sure may break due to aging, fatigue, and abrasion. It is
very difficult to gauge the extent of deterioration due to
aging, fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the page
of “Periodic replacement of parts” in the operator’s
manual).
• Failure to periodically replace rubber hoses may cause a
fire, fluid injection into skin, or the front attachment to fall
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.
S506-E01A-0019
SA-019
Loading...