S01NE0310410

ZX220LC-M HYDRAULIC EXCAVATOR OPERATION MANUAL

Operation Manual

220 LC-M

PRINTED ON :
Serial No. DC0L0-000001 ONWARDS
Tata Hitachi Construction Machinery Company Limited
Website : www.tatahitachi.co.in Toll Free : 1800 121 6633

Serial No.

DC0L0-000001 ONWARDS
Printed on : Manual No. : ED-220LC-M(OM)
 INTRODUCTION

Read this manual carefully to learn how to operate Warranty is provided as a part of Tata Hitachi’s
and service your machine correctly. Failure to do so support program for customers who operate and
could result in personal injury or machine damage. maintain their equipment as described in this manual.
The warranty is explained on the warranty certificate
This standard specification machine can be which you should have received from your dealer.
operated under the following conditions without
being modified. Atmospheric Temperature: –20 °C to This warranty provides you the assurance that Tata
40 °C (–4 °F to 104 °F) Altitude: 0 m to 1500 m (0 ft to Hitachi will back its products where defects appear
4900 ft) within the warranty period. In some circumstances,
Tata Hitachi also provides field improvements, often
In case the machine is used under conditions other without charge to the customer, even if the product is
than described above, consult your nearest Tata out of warranty.
Hitachi dealer.
Should the equipment be abused, or modified to
This manual should be considered a permanent
change its performance beyond the original
part of your machine and should remain with the
factory specifications, the warranty will become
machine when you sell it.
void and field improvements may be denied.
This machine is of metric design. Measurements in
Setting fuel delivery above specifications or
this manual are metric. Use only metric hardware and
otherwise overpowering machines will result in such
tools as specified.
action.
Right-hand and left-hand sides are determined by Only qualified, experienced operators officially
facing in the direction of forward travel. licensed (according to local law) should be allowed to
Write product identification numbers in the operate the machine. Moreover, only officially
Machine Numbers section. Accurately record all the licensed personnel should be allowed to inspect and
numbers to help in tracing the machine should it be service the machine.
stolen. Your dealer also needs these numbers when PRIOR TO OPERATING THIS MACHINE, INCLUDING
you order parts. If this manual is kept on the machine,
SATELLITE COMMUNICATION SYSTEM, IN A
also file the identification numbers in a secure place
COUNTRY OTHER THAN A COUNTRY OF ITS
off the machine.
INTENDED USE, IT MAY BE NECESSARY TO MAKE
Be sure to use fuel that complies with your local MODIFICATIONS TO IT SO THAT IT COMPLIES WITH
standard. Also use of fuel that complies with solid T H E L O C A L R E G U L AT O R Y S TA N D A R D S
contamination level of class 18/16/13 of ISO4406- (INCLUDING SAFETY STANDARDS) AND LEGAL
1999 (solid contamination includes dust) is REQUIREMENTS OF THAT PARTICULAR COUNTRY.
recommended. If the fuel specified above is not used, PLEASE DO NOT EXPORT OR OPERATE THIS
a problem may arise on the engine. Consult your MACHINE OUTSIDE OF THE COUNTRY OF ITS
nearest Tata Hitachi dealer. INTENDED USE UNTIL SUCH COMPLIANCE HAS
BEEN CONFIRMED. PLEASE CONTACT TATA
HITACHI CONSTRUCTION MACHINERY CO., LTD. OR
ANY OF OUR AUTHORIZED DISTRIBUTOR OR

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.
INDEX MACHINE NUMBERS
SAFETY
SAFETY SIGNS
COMPONENTS NAME
GETTING ON/OFF THE MACHINE
OPERATOR’S STATION
BREAK-IN
OPERATING THE ENGINE
DRIVING THE MACHINE
OPERATING THE MACHINE
TRANSPORTING
MAINTENANCE T
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
TROUBLESHOOTING
SPECIFICATIONS
INDEX
 CONTENTS
MACHINE NUMBERS .........................................................1 Avoid Applying Heat to Lines Containing Flammable
Fluids ...........................................................................................S-34
SAFETY .......................................................................... S-1 Precautions for Handling Accumulator and
Recognize Safety Information ....................................................S-1 Gas Damper ..............................................................................S-34
Understand Signal Words .............................................................S-1 Remove Paint Before Welding or Heating ...........................S-35
Follow Safety Instructions ............................................................S-2 Beware of Asbestos and Silicon Dust and Other
Prepare for Emergencies ...............................................................S-3 Contamination .........................................................................S-35
Wear Protective Clothing..............................................................S-3 Prevent Battery Explosions .......................................................S-36
Protect Against Noise ....................................................................S-4 Service Air Conditioning System Safely ...............................S-36
Inspect Machine ..............................................................................S-4 Handle Chemical Products Safely ...........................................S-37
General Precautions for Cab ........................................................S-5 Dispose of Waste Properly .........................................................S-37
Use Handholds and Steps ............................................................S-6 Never Ride Attachment ..............................................................S-38
Adjust the Operator's Seat ...........................................................S-6 Precautions for Communication Terminal ...........................S-38
Ensure Safety Before Rising from or Precaution for Communication Terminal Equipment .....S-39
Leaving Operator’s Seat ...........................................................S-7
Fasten Your Seat Belt ......................................................................S-7 SAFETY SIGNS ............................................................. S-41
Move and Operate Machine Safely ...........................................S-8 COMPONENTS NAME ....................................................1-1
Operate Only from Operator's Seat ..........................................S-8
Components Name ........................................................................1-1
Jump Starting ...................................................................................S-9
Keep Riders off Machine ...............................................................S-9 GETTING ON/OFF THE MACHINE ................................. 1-2
Precautions for Operations .......................................................S-10
OPERATOR’S STATION .................................................. 1-3
Investigate Job Site Beforehand .............................................S-11
Install OPG Guard .........................................................................S-12 Cab Features ......................................................................................1-3
Provide Signals for Jobs Involving Multiple Machines.... S-13 Monitor Panel ...................................................................................1-4
Confirm Direction of Machine to Be Driven ........................S-13 Coolant Temperature Gauge .................................................1-5
Drive Machine Safely ...................................................................S-14 Fuel Gauge ...................................................................................1-5
Avoid Injury from Rollaway Accidents ..................................S-16 Auto-Idle Indicator ....................................................................1-5
Avoid Injury from Back-Over and Swing Accidents .........S-17 ECO Mode Indicator ..................................................................1-5
Keep Person Clear from Working Area.................................. S-18 PWR Mode Indicator .................................................................1-5
Never Position Bucket Over Anyone .....................................S-18 Digging Indicator .......................................................................1-6
Avoid Undercutting .....................................................................S-19 Attachment Indicator ...............................................................1-6
Avoid Tipping .................................................................................S-19 Remaining Fuel Indicator ........................................................1-6
Never Undercut a High Bank ....................................................S-20 Air Filter Restriction Indicator ................................................1-6
Dig with Caution ...........................................................................S-20 Overheat Indicator ....................................................................1-6
Operate with Caution .................................................................S-20 Low Engine Oil Pressure Indicator .......................................1-7
Avoid Power Lines ........................................................................S-21 Alternator Indicator ...................................................................1-7
Precautions for Lightning ..........................................................S-21 Preheat Indicator ........................................................................1-7
Object Handling ........................................................................... S-22 Hydraulic Filter Indicator (Optional) ...................................1-7
Protect Against Flying Debris .................................................. S-22 Engine Trouble Indicator .........................................................1-8
Park Machine Safely .....................................................................S-23 Pilot Control Shut-Off Lever Indicator ................................1-8
Handle Fluids Safely-Avoid Fires ............................................ S-23 LCD ..................................................................................................1-9
Transport Safely ............................................................................S-24 Display Selector ..........................................................................1-9
Practice Safe Maintenance ........................................................S-25 Hour Meter ...................................................................................1-9
Warn Others of Service Work ...................................................S-26 Switch Panel ...................................................................................1-10
Support Machine Properly ........................................................S-26 Auto-Idle Switch ......................................................................1-11
Stay Clear of Moving Parts ........................................................S-27 Power Mode Switch ...............................................................1-12
Prevent Parts from Flying ..........................................................S-27 Travel Mode Switch ................................................................1-12
Store Attachments Safely ..........................................................S-28 Work Mode Switch .................................................................1-13
Prevent Burns .................................................................................S-28 Work Light Switch ...................................................................1-14
Replace Rubber Hoses Periodically ........................................S-29 Wiper/Washer Switch ............................................................1-15
Avoid High-Pressure Fluids .......................................................S-29 Switch Panel (for Optional Equipments) ..............................1-16
Prevent Fires ...................................................................................S-30 Travel Alarm Deactivation Switch (Optional) ................1-16
Evacuating in Case of Fire ..........................................................S-32 Swing Alarm Deactivation Switch (Optional) ...............1-16
Beware of Exhaust Fumes.......................................................... S-32 Key Switch .......................................................................................1-17
Precautions for Welding and Grinding .................................S-33 Power Boost Switch .....................................................................1-17
Avoid Heating Near Pressurized Fluid Lines .......................S-34 Horn Switch ....................................................................................1-17
 CONTENTS
Cigar Lighter ...................................................................................1-18 OPERATING THE ENGINE .............................................. 3-1
Using Cigar Lighter .................................................................1-18 Inspect Machine Daily Before Starting ....................................3-1
Using Cigar Lighter Port as External Power Source ....1-18 Before Starting Engine ..................................................................3-2
Cab Light Switch ...........................................................................1-19 Starting the Engine .........................................................................3-3
Pilot Control Shut-Off Lever .....................................................1-20 Check Instruments After Starting ..............................................3-5
Engine Stop Switch ......................................................................1-21 Using Booster Batteries .................................................................3-6
Handle (Emergency engine stop) ...........................................1-21 Stopping the Engine ......................................................................3-8
Fuse Box ...........................................................................................1-22
Auto Air Conditioner ...................................................................1-23 DRIVING THE MACHINE ................................................ 4-1
Features: .....................................................................................1-23 Drive the Machine Carefully ........................................................4-1
Components Name ................................................................1-24 Steering the Machine Using Pedals ..........................................4-2
Controller Part Name and Function .................................1-25 Steering the Machine Using Levers ..........................................4-3
Cab Heater Operation ...........................................................1-27 Travel Mode Switch ........................................................................4-4
Cooling Operation ..................................................................1-28 Operating on Soft Ground ...........................................................4-5
Defroster Operation ...............................................................1-29 Raise One Track Using Boom and Arm ....................................4-5
Cool Head/Warm Feet Operation ......................................1-29 Towing Machine a Short Distance .............................................4-6
Tips for Optimal Air Conditioner Usage ...............................1-30 Operating in Water or Mud ..........................................................4-7
For Rapid Cooling ...................................................................1-30 Parking the Machine on Slopes ..................................................4-8
When Windows Become Clouded ....................................1-30 Parking the Machine ......................................................................4-8
Off-Season Air Conditioner Maintenance ......................1-30 OPERATING THE MACHINE ...........................................5-1
AM/FM Radio Operation ............................................................1-31 Control Lever (ISO Pattern) .........................................................5-1
Controls on the radio .............................................................1-31 Control Lever (HITACHI Pattern) (Optional) ............................5-2
Station Presetting Procedure ..............................................1-32 Attachment Pedal (Hydraulic Breaker) (Optional) ...............5-3
Digital Clock Setting Procedure .........................................1-33 Pilot Control Shut-Off Lever ........................................................5-4
Time Adjustment ....................................................................1-33 Warming Up Operation .................................................................5-5
Sound Adjustment .................................................................1-34 Engine Speed Control ....................................................................5-6
Cab Door Release Lever .............................................................1-35 Auto-Idle .............................................................................................5-7
Opening/Closing and Removing Cab Inside Window ....1-36 Auto-Idle ON/OFF ......................................................................5-8
Opening Upper Front Window ................................................1-37 Work Mode ........................................................................................5-9
Opening Upper Front Window ..........................................1-37 Power Boost Switch ........................................................................5-9
Removing and Storing Lower Front Window .....................1-38 Power Mode ...................................................................................5-10
Removing and Storing Lower Front Window ...............1-38 Operating Backhoe ......................................................................5-11
Opening Side Windows ..............................................................1-39 Shovel ...............................................................................................5-12
Opening/Closing Overhead Window ....................................1-40 Grading Operation .......................................................................5-13
Emergency Exit .............................................................................1-41 Do not strike the ground with bucket teeth ......................5-14
Adjusting the Seat ........................................................................1-43 Avoid Hammer Work ...................................................................5-14
Seat Height and Angle Adjustment .................................1-43 Avoid Abusive Operation ..........................................................5-15
Console and Seat Fore-aft Adjustment ...........................1-43 Avoid Side Load the Bucket ......................................................5-15
Seat Fore-Aft Adjustment ....................................................1-43 Do not use wide track shoes on rough ground. ................5-16
Backrest Adjustment .............................................................1-43 Hydraulic Breaker, Hydraulic Crusher and
Armrest Adjustment ..............................................................1-44 Quick Coupler........................................................................... 5-17
Adjusting Operator's Seat (Optional) ....................................1-45 Piping for Breaker and Crusher (Optional) ..........................5-18
Seat Height and Angle Adjustment .................................1-45 Operational procedures for stop valves and
Console and Seat Fore-aft Adjustment ...........................1-45 selection valve. ........................................................................5-18
Seat Fore-Aft Adjustment ....................................................1-45 Secondary Relief Pressure Adjustment ................................5-19
Suspension Adjustment .......................................................1-45 Precautions for Breaker Operation .........................................5-20
Backrest Adjustment .............................................................1-46 Change Hydraulic Oil and Replace Full-Flow Filter
Armrest Adjustment ..............................................................1-46 Element ......................................................................................5-24
Installation and Adjustment of Mirrors ................................1-47 Precautions for Crusher Operation ........................................5-25
Seat Belt ...........................................................................................1-48 Attachment .....................................................................................5-28
Seat Belt...................................................................................... 1-48 Allowable Weight Limits of Installed Attachment ......5-28
BREAK-IN ....................................................................... 2-1 Precaution For Arm Roll-In/Bucket Roll-In Combined
Observe Engine Operation Closely ...........................................2-1 Operation ...................................................................................5-30
Every 8 Hours or Daily ....................................................................2-1 Shackle Hole Usage .....................................................................5-30
After the First 50 Hours .................................................................2-1 How to Lower Boom In Case of Emergency and
After the First 100 Hours ...............................................................2-1 When Engine Stops ................................................................5-31
 CONTENTS
Precautions for After Operations ............................................5-32 Clean Oil Cooler, Radiator and Inter Cooler Front
Screen ....................................................................................7-61
TRANSPORTING ............................................................ 6-1
Clean Air Conditioner Condenser .....................................7-61
Transporting by Road ....................................................................6-1 H. Electrical System ......................................................................7-62
Loading/Unloading on a Trailer .................................................6-2 Battery .........................................................................................7-63
Fastening Machine for Transporting ........................................6-5 Replacing Fuses .......................................................................7-68
Unloading ..........................................................................................6-5 I. Miscellaneous .............................................................................7-70
Lifting Machine ................................................................................6-7 Check and Replace Bucket Teeth ......................................7-70
MAINTENANCE ..............................................................7-1 Change Bucket .........................................................................7-71
Correct Maintenance and Inspection Procedures ...............7-1 Convert Bucket Connection Into Face Shovel ..............7-72
Check the Hour Meter Regularly ................................................7-3 Adjust Bucket Linkage ..........................................................7-73
Layout ..................................................................................................7-4 Remove Travel Levers ............................................................7-74
Maintenance Guide Table .......................................................7-5 Check and Replace Seat Belt ...............................................7-74
Preparations for Inspection and Maintenance .....................7-7 Check Windshield Fluid Level .............................................7-75
Hood and Access Covers ...............................................................7-8 Check Track Sag .......................................................................7-76
Maintenance Guide ........................................................................7-9 Clean and Replace Air Conditioner Filter .......................7-78
Periodic Replacement of Parts .................................................7-13 Check Air Conditioner ...........................................................7-80
Kind of Oils ......................................................................................7-12 Clean Cab Floor........................................................................ 7-82
Brand Names of Recommended Engine Oil ..................7-12 Check Injection Nozzle .........................................................7-83
A. Greasing ......................................................................................7-15 Retighten Cylinder Head Bolt .............................................7-83
Front Joint Pins ........................................................................7-15 Inspect and Adjust Valve Clearance .................................7-83
Swing Bearing ..........................................................................7-17 Check Injection Timing .........................................................7-83
Swing Internal Gear................................................................ 7-18 Measure Engine Compression Pressure.......................... 7-83
B. Engine ..........................................................................................7-19 Check Starter and Alternator ..............................................7-83
Engine Oil Level .......................................................................7-19 Replace Water Pump Grease ...............................................7-83
Change Engine Oil, Replace Engine Oil Filter ...............7-20 Check Gas Damper .................................................................7-84
C. Transmission ..............................................................................7-22 Tightening and Retightening Torque of Nuts and
Pump Transmission ................................................................7-22 Bolts ........................................................................................7-84
Swing Device ............................................................................7-23 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
Travel Reduction Gear ...........................................................7-24 CONDITIONS ................................................................. 9-1
D. Hydraulic System .....................................................................7-26 Maintenance Under Special Environmental Conditions ...9-1
Inspection and Maintenance of Hydraulic
Equipment .................................................................................7-29 STORAGE ..................................................................... 10-1
Check Hydraulic Oil Level ....................................................7-30 Storing the Machine ....................................................................10-1
Change Hydraulic Oil .............................................................7-31
TROUBLESHOOTING ...................................................11-1
Suction Filter Cleaning ..........................................................7-33
Replacement of Full-Flow Filter .........................................7-34 Troubleshooting ...........................................................................11-1
Replace Pilot Oil Filter............................................................ 7-39 SPECIFICATIONS ......................................................... 12-1
Replace Air Breather Element .............................................7-40 Specifications .................................................................................12-1
Check Hoses and Lines .........................................................7-41 ZX220LC-GI................................................................................ 12-1
E. Fuel System ................................................................................7-45 Working Ranges (Grouser shoe).............................................. 12-2
Recommended Fuel ...............................................................7-45 ZX220LC-GI................................................................................ 12-2
Drain Fuel Tank Sump ............................................................7-47 Shoe Types and Applications ...................................................12-3
Check Water Separator .........................................................7-48 ZX220LC-GI................................................................................ 12-3
Replace Fuel Pre-Filter Cartridge .......................................7-50 Bucket Types and Applications ...............................................12-4
Replace Fuel Main Filter Cartridge ....................................7-51 ZX220LC-GI................................................................................ 12-4
Clean Feed Pump Strainer ...................................................7-52
Check Fuel Hoses ....................................................................7-53 INDEX ...........................................................................14-1
F. Air Cleaner ...................................................................................7-54
Clean and Replace Air Cleaner Element .........................7-54
G. Cooling System ........................................................................7-56
Check Coolant Level ..............................................................7-57
Check and Adjust Fan Belt Tension ...................................7-58
Change Coolant .......................................................................7-59
Clean Radiator/Oil Cooler/Inter Cooler Core .................7-60
 MACHINE NUMBERS
The manufacturing Nos. explained in this group is the
individual number (serial No.) given to each machine and
hydraulic components. These numbers are requested when
inquiring any information on the machine and/or components.
Fill these serial Nos. in the blank spaces in this group to
immediately make them available upon request.

Machine

TYPE :

PRODUCT
M157-00-001
IDENTIFICATION
NUMBER :

M157-12-008

Product Identification Number

NOTE:
Marks to indicate the
start and end of the PIN

PRODUCT IDENTIFICATION NUMBER (PIN)

Engine

TYPE :

M178-00-001
MFG. NO. :

1
 MACHINE NUMBERS
Travel Motor

TYPE :

MFG. NO. :

M178-07-047

Swing Motor

TYPE :

MFG. NO. :

M178-07-086

Hydraulic Pump

TYPE :

MFG. NO. :

M157-00-004

2
 SAFETY

Recognize Safety Information

These are the SAFETY ALERT SYMBOLS.
When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating
practices.

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 do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.

SA-1223
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

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. SA-003
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 Tata Hitachi Warranty
Policy.
Never attempt to modify or disassemble the inlet/exhaust
parts and the muffler filter. Avoid giving shocks on the
muffler filter by striking elements with other objects or
dropping the elements. Failure to do so may affect the
exhaust gas purifying device, possibly damaging it or
lowering its performance.
Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.

S-2
 SAFETY

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. SA-437

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 SA-438
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.

S-3
 SAFETY

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.

SA-434

Inspect Machine
Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.

SA-435

S-4
 SAFETY
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.

S-5
 SAFETY

Use Handholds and Steps

Falling is one of the major causes of personal injury.
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
Do not use any controls as hand-holds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
Never get on and off the machine with tools in your
hands.
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 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 SA-378
is broken, immediately replace it with a new one.

S-6
 SAFETY
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 and/or pedal, 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 SA-237
minimize the chance of injury from an accident.
We recommend that the seat belt be replaced every three
years regardless of its apparent condition.

S-7
 SAFETY

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 SA-426
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 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

S-8
 SAFETY

Jump Starting
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
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 the operator should be on the machine. Keep riders
off.
Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.

SA-379

S-9
 SAFETY

Precautions for Operations

Investigate the work site before starting operations.
Be sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.

M178-05-007

S-10
 SAFETY

Investigate Job Site Beforehand

When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles or banks
from collapsing.
Make a work plan. Use machines appropriate to the work
and job site.
Reinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
When the footing is weak, reinforce the ground before
starting work.
When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.

S-11
 SAFETY
Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent M104-05-016
machine tipping over from occurring. When operating on
rough terrain or on slopes:
Reduce the engine speed.
Select slow travel speed mode.
Operate the machine slowly and be cautious with
machine movements.

Install OPG Guard

In case the machine is operated in areas where the possibilities
of falling stones or debris exist, equip Hitachi OPG guard.
Consult your authorized dealer for installing the OPG guard.
The guard can be compliant with ROPS standards depending
on the machine specifications.
In order not to impair operator protective structure:
Replace damaged ROPS or OPG guard. Never attempt to repair
or modify the guard.

ROPS: Roll Over Protective Structure

OPG: Operator Protective Guard

SA-490

S-12
 SAFETY

Provide Signals for Jobs Involving Multiple

Machines
For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.

SA-481

Confirm Direction of Machine to Be Driven

Incorrect travel pedal/lever operation may result in serious
injury or death.
Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when travel pedals/levers are
operated to the front.

SA-491

S-13
 SAFETY

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. Do A
not allow personnel to stay around the machine while
traveling.

Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.
Never attempt to ascend or descend 35 degrees or
steeper slopes.
Be sure to fasten the seat belt.
When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 0.2 to 0.3 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 A SA-658
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.

SA-441

WRONG

SA-590

S-14
 SAFETY
Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
When crossing train tracks, use wood plates in order not
to damage them.
Do not make contact with electric wires or bridges.
When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
Avoid operations that may damage the track and
undercarriage components.
During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.

S-15
 SAFETY

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 the 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 OFF and the power mode switch
E or P.
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.
SA-391
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 at a reasonable distance from other machines.

SA-2273

S-16
 SAFETY

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 BYSTANDERS 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. SA-383
Use hand signals, which conform to your local regulations,
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 SA-384
operator’s manual.

S-17
 SAFETY

Keep Person Clear from Working Area

A person may be hit severely by the swinging front
attachment 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 prevent
anyone from entering the work area.

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.

SA-487

S-18
 SAFETY
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 secured
by lowering the front attachment, in such cases.

SA-488

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 SA-012
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 become
soft and make ground travel unstable.

SA-440

S-19
 SAFETY

Never Undercut a High Bank

The edges could collapse or a land slide could occur causing
serious injury or death.

SA-489

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 cables,
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 serious eye
injury.
Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
SA-382
Have them mark all underground utilities.

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.

SA-389

S-20
 SAFETY

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.

SA-381

Precautions for Lightning

Lightning may strike the machine.
If lightning comes close, immediately stop the operation,
and take the following action.
When you are around the machine or operating cab-
less machine, evacuate to a safe place far away from the
machine.
When you are in the cab, stay in the cab until lightning
has passed and safety is secured. Close the cab doors and
windows. Lower the bucket to the ground (Lower the
dump body to the frame rail), and stop the engine. Put
your hands on your lap to avoid contact with any metal
surfaces. Never go out of the cab.

If lightning strikes the machine or near the machine,

check all of the machine safety devices for any failure after
lightning has passed and safety is secured. If any trouble is
found, operate the machine only after repairing it.

SA-1088

S-21
 SAFETY

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 well 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.

SA-014

Protect Against Flying Debris

If flying debris hit eyes or any other part of the body, serious
injury may result.
Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
Keep bystanders away from the working area before
striking any object.
Always close the front windows, doors, door windows and
the overhead window when operating the machine.

SA-432

S-22
 SAFETY

Park Machine Safely

To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle switch OFF.
Run engine at slow idle speed without load for 5 minutes.
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 position.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.

SA-390

Handle Fluids Safely-Avoid Fires

Handle fuel with care; it is highly flammable. If fuel ignites,
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 flammable.

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 SA-018
spontaneously.
Securely tighten the fuel and oil filler cap.

SA-019

S-23
 SAFETY

Transport Safely
Take care the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
Observe the related regulations and rules for safe
transportation.
Select an appropriate truck or trailer for the machine to
be transported.
Be sure to use a signal person.
Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight. SA-395

3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the travel mode
switch.
5. Never load or unload the machine onto or off a truck
or trailer using the front attachment functions when
driving up or down the ramp.
6. Never steer the machine while on the ramp. If the
traveling direction must be changed while the ramp,
unload the machine from the ramp, reposition the
machine on the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a
sudden bump. Take care when traveling over it.
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.

Be sure to further follow the details described in the

TRANSPORTING section.

S-24
 SAFETY

Practice Safe Maintenance

To avoid accidents:
Understand service procedures before starting 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 moving
the control levers several times. SA-028

7. Remove the key from the key switch.

8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.

If a maintenance procedure must be performed with the

engine running, do not leave the 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.
Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter in the operator’s manual. SA-527
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
detergent 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.

S-25
 SAFETY
Sufficiently illuminate the work site. Use a maintenance
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, antifreeze fluid, or
window washer fluid may catch fire.

SA-037

Warn Others of Service Work

Unexpected machine movement can cause serious injury.
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.

SS3076175 SS2045102

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.
SA-527

S-26
 SAFETY

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 become
entangled when working around rotating parts.

SA-026

SA-2294

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.
Do not attempt to remove grease fitting securing cover.
As pieces may fly off, be sure to keep body and face away
from valve.
Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster may
cause the parts such as a spring to fly off, possibly SA-344
resulting in severe personal injury or death.

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.

S-27
 SAFETY

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 prevent
falling. Keep children and bystanders away from storage
areas.

SA-034

Prevent Burns
Hot spraying fluids:

After operation, engine coolant is hot and under pressure.

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 SA-039
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.

SA-225

S-28
 SAFETY

Replace Rubber Hoses Periodically

Rubber hoses that contain flammable fluids under pressure
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
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.

Avoid High-Pressure Fluids

Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044

S-29
 SAFETY

Prevent Fires
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to fires.
Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged lines, pipes, or hoses.
Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
SA-019
Check for Shorts:
Short circuits can cause fires.
Clean and tighten all electrical connections.
Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
Never attempt to modify electric wirings.

S-30
 SAFETY
Clean up Flammable Materials:
Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammable materials may cause fires.
Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammable materials immediately. Check and clean
high temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
Do not store oily cloths as they are vulnerable to catching
fire.
Keep flammable materials away from open flames.
Do not ignite or crush a pressurized or sealed container.
Wire screens may be provided on openings on the engine
compartment covers to prevent flammable materials
such as dead leaves from entering. However, flammable
materials which have passed through the wire screen
may cause fires. Check and clean the machine every
day and immediately remove accumulated flammable
materials.

Check Key Switch:

If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
If any abnormalities are found, be sure to repair them
before operating the machine.

Check Heat Shields:

Damaged or missing heat shields may lead to fires.

Damaged or missing heat shields must be repaired or

replaced before operating the machine.
If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as mufflers may cause fire. Always close the engine cover
while operating the machine.

S-31
 SAFETY

Evacuating in Case of Fire

If a fire breaks out, evacuate the machine in the following
way:
Stop the engine by turning the key switch to the OFF
position if there is time.
Use a fire extinguisher if there is time.
Exit the machine.
In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method in the operator’s manual.

SS-1510

Beware of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.

SA-016

S-32
 SAFETY
Precautions for Welding and Grinding
Welding may generate gas and/or small fires.
Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe place
before starting welding.
Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818

S-33
 SAFETY

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc..

SA-030

Avoid Applying Heat to Lines Containing

Flammable Fluids
Do not weld or flame cut pipes or tubes that contain
flammable fluids.
Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.

Precautions for Handling Accumulator and Gas

Damper
High-pressure nitrogen gas is sealed in the accumulator and
the gas damper. Inappropriate handling may cause explosion,
possibly resulting in serious injury or death.

Strictly comply with the following items:

Do not disassemble the unit.
Keep the units away from open flames and fire.
Do not bore a hole, do not cut by torch.
Avoid giving shocks by hitting or rolling the unit.
Before disposing the unit, sealed gas must be released.
Consult your nearest Tata Hitachi dealer.

S-34
 SAFETY

Remove Paint Before Welding or Heating

Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
Avoid potentially toxic fumes and dust.
Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.

Beware of Asbestos and Silicon Dust and Other

Contamination
Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silicon dust or other contamination
may cause sickness.
Depending on the work site conditions, the risk
of inhaling asbestos fiber, silicon dust or other
contamination may exist. Spray water to prevent asbestos
fibers, silicon dust or other contamination from becoming
airborne. Do not use compressed air.
When operating the machine in a work site where
asbestos fibers, silicon dust or other contamination SA-029
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contamination.
Keep bystanders out of the work site during operation.
Asbestos fibers might be present in imitation parts. Use
only genuine Tata Hitachi Parts.

S-35
 SAFETY

Prevent Battery Explosions

Battery gas can explode.
Keep sparks, lighted matches, and flame away from the
top of battery.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm the
battery to 16 °C ( 60 °F ) first.
Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the
battery may result.
Loose terminals may produce sparks. Securely tighten all
terminals. SA-032
Connect terminals to the correct electrical poles. Failure
to do so may cause damage to the electrical parts or fire.

Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into eyes,
possibly resulting in blindness.
Be sure to wear eye protection when checking electrolyte
specific gravity.

Service Air Conditioning System Safely

If spilled onto skin, refrigerant may cause a cold contact
burn.
Refer to the instructions described on the container for
proper use when handling the refrigerant.
Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
Never touch the refrigerant.

SA-405

S-36
 SAFETY

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and use recommended equipment. SA-309
See your authorized dealer for MSDS’s (available only in
English) on chemical products used with your machine.

Dispose of Waste Properly

Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with TATA HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Battery contains hazardous lead and acid; do not dispose
off after use. Please return the battery to Central Board of
Pollution Control authorised recycler / dealers for disposal.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into SA-226
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.

S-37
 SAFETY

Never Ride Attachment

Never allow anyone to ride attachments or load. This is an
extremely dangerous practice.

Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.

S-38
 SAFETY
Precaution for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which is
situated at the back of the driver's seat. There is a possibility
that a medical device, including an implantable device
such as a cardiac pacemaker, would be affected and would
malfunction by the electrical waves emitted from the
communication terminal equipment.

Any person affixed with a medical device such as the above SA-2302
should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.662 inches) apart at
all times. If such condition cannot be met, please contact our
company's nearest dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.

Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipments:
E-GSM900 0.573 W/Kg (914.80 MHz)
DCS-1800 0.130 W/Kg (1710.20 MHz)
WCDMA Band I 0.271 W/Kg (1950.00 MHz)

*This data was measured by having each type of

communication terminal equipment, such as the
communication terminal equipment used with this machine,
and a human body set apart by 3 cm (1.18 inches).
* SAR is a measure of the amount of radio frequency energy
absorbed by the body when using a wireless application such
as a mobile phone.

In Japan: *Under the Japanese Radio Act and other relevant

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).

In EU Member nation: *Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).

S-39
 SAFETY
Never attempt to disassemble, repair, modify or displace the
communication terminal, antennas or cables. Failure to do
so may result in damage and/or fire to the base machine or
to the communication terminal. ( When required to remove
or install the communication terminal, consult your nearest
Hitachi dealer.)

Do not pinch or forcibly pull cables, cords or connectors.

Failure to do so may cause short circuit or broke circuit that
may result in damage and/or fire to the base machine or to
the communication terminal.

S-40
 SAFETY SIGNS
All safety signs and their locations affixed on the machine are
illustrated in this group. Make sure of the contents described
in the safety signs through reading actual ones affixed on
the machine to ensure safe machine operation. Always keep
the safety signs clean. In case a safety sign is broken or lost,
immediately, obtain a new replacement and affix it again in
position on the machine. Use the part No. indicated under the
right corner of each safety sign illustration when placing an
order of it to the Tata Hitachi dealer.

4
1 RIGHT WINDOW
7

8
3
17
10

18
2 6
11

13
12

9 13

14 15 19

OPEN

16

SS-3424

S-41
 SAFETY SIGNS
1.
WARNING!
Prior to operation, maintenance, disassembling, and
transportation of the machine, be sure to read and
understand the Operator’s Manual.

SS4420332

2.
If the parked machine is unexpectedly moved, serious injury
or death due to crushing may result. Be sure to lower the
front attachment to the ground, lock the control levers,
and remove the engine key before leaving the machine
unattended.

SS4420333

3.
Sign indicates an electrocution hazard if machine is brought
too near electric power lines.
Keep a safe distance from electric power lines.

SS4420334

4.
Sign indicates a hazard from falling window.
After raising window, be sure to lock it in place with lock
pins.

SS4420335

S-42
 SAFETY SIGNS
5.
When moving the seat height/tilt lever downward, press the
lever grip with a palm from the top side. Do not grasp the
lever grip to operate the lever, possibly resulting in pinch of
your fingers into the seat stand.

SS4371371

6.
If the machine should overturn, the operator may become
injured and/or throw from the cab and/or crushed by the
overturning machine.

SS4654287

7.
Do not extend your hands or head from the window. Your
hands or head may come in contact with the boom.
Keep away from machine during operation.

SS4459990

8.
Sign indicates a hazard of being hit by the working device of
the machine.
Keep away from machine during operation.

SS3089581

S-43
 SAFETY SIGNS
9.
Sign indicates a hazard of a flying plug from track adjuster
that could cause injury.
Read manual before adjusting track for safe and proper
handling.

SS3086091

10.
A
Sign indicates a burn hazard from compressed air and
spurting hot oil if the oil inlet is uncapped during or right
after operation.
Read manual for safe and proper handling.

SS4459928

Sign indicates a burn hazard from spurting hot water or oil if B

radiator or hydraulic oil tank is uncapped while hot.
Allow radiator or hydraulic oil tank to cool before removing
cap.

SS4420336

11.
Sign indicates a hazard of falling.
Do not stand on this place.

SS3092126

S-44
 SAFETY SIGNS
12.
Sign indicates a hazard of falling off the fender or hood.
Never stand close to the edge.

SS3092125

13.
Sign indicates a crush hazard by rotation of upper structure
of the machine.
Keep away from swinging area of machine.

SS3086090

14.
Sign indicates a burn hazard from spurting hot water or oil if
radiator or hydraulic oil tank is uncapped while hot.
Allow radiator or hydraulic oil tank to cool before removing
cap.

SS4420336

S-45
 SAFETY SIGNS
15.
Sign indicates a hazard of rotating parts, such as belt.
Turn off before inspection and maintenance.

SS3092127

SSYA00008776

S-46
 SAFETY SIGNS
16. A
Sign indicates an electrical hazard from handling the cable.
Read manual for safe and proper handling.

SS4459714

Sign indicates an explosion hazard. B

Keep fire and open flames away from this area.

SS4460067

Skin contact with electrolyte will cause burns. Splashed C

electrolyte into eyes will cause blindness. Take care not to
touch electrolyte.

SS4460056

17.

SS4467093

S-47
 SAFETY SIGNS
18.

SSYA00000341

19.
WARNING
IT CONTAINS NITROGEN UNDER HIGH PRESSURE.
DON’T ALLOW FIRE OR HEAT NEAR IT. DON’T TRY TO
DISASSEMBLE IT.
SS-3212
WEAR EYE PROTECTION AND CAREFULLY DRILL A HOLE AT
THE POINT MARKED × TO RELEASE GAS PRESSURE BEFORE
DISPOSAL.

S-48
 सु

सु जानकारी को पहचान
ये सु चेतावनी के संकेत ह।
जब आपको अपनी मशीन या इस िनदिशका म ये िचहन िदखाई
द, तो संभािवत चोट के से सावधान हो जाय।
िनधािरत सावधािनयां व सु पिरचालन का पालन
कर।

SA-688

संकेत को समझ
मशीन पर जोिखम
व संकेत को सु
या को सिू चत करने वाले सु
चेतावनी संकेत के साथ-खतरा, चेतावनी,
िचहन
खतरा
या सावधान िकया जाता है ।
खतरा, िनकटतम खतरनाक के बारे म सिू चत करता ह

चेतावनी
ै
िजससे यिद नहीं बचा गया, तो मौत होगी या गंभीर चोट
लगेगी।
चेतावनी, संभािवत खतरनाक के बारे म सूिचत करता ह
ै

सावधान
िजससे यिद नहीं बचा गया, तो मौत हो सकती है या गंभीर
चोट लग सकती है ।
सावधान, संभािवत खतरनाक के बारे म सूिचत करता है
िजससे यिद नहीं बचा गया, तो मामल
ू ी या चोट लग

म ूण
सकती है ।
खतरा या चेतावनी के सु िचहन के िनकट
लगे होते ह। को सावधान सु संके
की सच
ू ी म रखा जाता है ।
कुछ सु
को
िचहन म उपयु िनधािरत िकसी भी संकेत
नहीं िकया जाता है लेिकन इस मशीन पर सु
नोट
चेतावनी संकेत का कभी-कभार िकया जाता है ।
सु संदेश और मशीन सु संदेश के बीच से
बचने के िलए एक संकेत ूण, ऐसी के बारे म
सूिचत करता है िजससे यिद नहीं बचा गया, तो मशीन को नुकसान
हो सकता है । SA-1223

नोटः सच
ू ना अंश के िलए के बारे म
सिू चत करता है ।

S-1
 सु

सु िनद का पालन कर
मशीन म त सभी सु संकेत और इस िनदिशका म विणत
सभी सु संदे को व
ू क पढ़कर पालन कर।
सु संकेत लगाय, रखरखाव कर और पड़ने पर इसे
बदलकर दस
ू रा लगा द।
यिद सु संकेत या यह िनदिशका खराब हो गयी है या गम
ु
हो गई है , तो आप िजस तरीके से ेसमट स का
ऑडर करते ह उसी तरीके से अपने अिधकृत डीलर से
ेसमट ऑडर कर (ऑडर करते समय मशीन का मॉडल व
ंक नं. िलख)।
मशीन व इसके कं को सही व सु तरीके से करना SA-003

सीख।
िसफ , , व ृ त कािमक को ही मशीन
करने द।
अपनी मशीन को उिचत से चालू म रख।
मशीन का अनािधकृत ंतरण करने से इसकी काय या
सु तं िबगड़ सकता है और मशीन के जीवनकाल को
कर सकता है ।
िबना िकसी अिधकार के िकसी भी मशीन स का ंतर न
कर। इस अिधकार का ंघन करने पर स की सु ,
काय , और सिवस लाइफ हो सकती है । इसके
, अनािधकृत ंतरण करने से दघ
ु टना,
मशीन म खराबी, और/या म नुकसान हो सकता है और
इससे टाटा-िहताची वारं टी पॉिलसी हो जायेगी।
इनलेट/ स और मफलर को ंतिरत या
अलग करने का कभी-भी न कर। एिलमट को
एिलमट से टकराते समय मफलर पर झटका न लगाय। इसका
ंघन करने पर गैस िू रफाइंग िडवास हो
सकती है , और यह भी हो सकती है या इसकी काय
कमजोर हो सकती है ।
िहताची के अिधकार के िबना कोई भी अटै चमट और/या
वै स या का न कर। इसके ंघन
करने पर मशीन सु , काय , और/या सिवस लाइफ
खराब हो सकती है । इसके , अनािधकृत अटै चमट
और/या वै स या का करने से
दघ
ु टना, मशीन म खराबी, और/या म
नुकसान हो सकता है और इससे टाटा-िहताची वारं टी पॉिलसी
हो जायेगी।

S-2
 सु

इस सु पाठ म िदये गये सु संदे का मशीन की

मूल सु को समझाना है । हालांिक इन सु संदे म
आपको होने वाली हरे क खतरनाक को शािमल कर पाना
असंभव है । यिद आपका कोई सवाल है , तो आप मशीन को
करने या इस पर कोई रखरखाव काय ं भ करने से पूव सबसे पहले
अपने सुपरवाइजर/या अपने ृ त डीलर से परामश कर।
आपातकालीन के िलए तैयारी
आग लगने या दघ
ु टना होने की म तैयार रहना।
उपचार िकट और यं को अपन
े म रख।
यं के उिचत के िलए इस पर लगे हुए
लेबल को परू ी तरह पढ़कर समझ।
यह सु कर िक यं को पड़ने पर
िकया जा सकता है , इसिलए -यं िनदिशका
म ेिखत िनधािरत अं पर इसकी जाँच व सिवस कर।
आग व दघ
ु टना का सामना करने के िलए
आपातकालीन िदशािनदश कर।
अपने टे िलफोन के पास , ल
ु स सेवा, , और
िवभाग के िचपकाकर रख।

SA-437

सु उपकरण पहन।
तंग-कसे हुए कपड़े व काय के अनु सु उपकरण पहन।
आपको पहनने की है ः
कठोर टोपी
से जत
ू े
से , , या मुख कवच
कठोर
की सु
े
परावतक कपड
वेट वेदर िगयर
ं या
काय के अनु उिचत उपकरण व कपड़े पहन। िकसी भी SA-438

तरह का जोिखम न उठाय।

ढ़ीले-ढ़ाले कपड़े, आभूषण, या चीज न पहन जो िक मशीन
के कं लीवर या स म फंस सकते ह।
ऑपरे टर सु से उपकरण करने के िलए परू ा
रखना होता है । मशीन करते समय रे िडयो या संगीत
हे डफोन धारण न कर।

S-3
 सु

-शोर से बचाव कर।

अिधकतम समय तक तेज -शोरगुल सुनने से म खराबी
या बहरे हो सकते ह।
या असिु वधाजनक तेज से बचने के िलए
या जैसे उिचत कण उपकरण पहन।

SA-434

मशीन का
चोट से बचने के िलए मशीन को चालू करने से पहले
या इसके तरफ घूमते हुए ूवक जाँच
कर।
तरफ मशीन म ऑपरे टर िनदिशका के "मशीन
पव
ू दै िनक " भाग म ेिखत सभी ओ
ु ं
को शािमल कर।
SA-435

S-4
 सु

कैब के िलए बरती जाने वाली सावधािनयां

कैब म ेश करने से पहले, अपने वक बूट के से सभी
तरह की धूल- और/तेल जैसे कीचड़, , या कंकड़,
जो केिबन म मैला कर सकता है पूरी तरह साफ कर द। यिद
ऑपरे टर वक बट
ू के म जमी हुई गंदगी या तेल के साथ
पेडल जैसे िकसी कं को करता है , तो उसका पैर
पेडल से िफसल सकता है , और इससे दघ
ु टना भी हो
सकती है ।
ऑपरे टर सीट के आसपास स, औजार, , , अवरोध
जैस कैन या लंच जमा करके न रख जो मुड़ या पलट
सकते ह। यिद अवरोधक, े वल िलवर/पेडल, पायलट कं शट
ऑफ लीवर या कं लीवर के म फंस जाते ह
तो लीवर या पेडल हो जाता है और इससे गंभीर चोट
या मौत हो सकती है ।
कैब म बोतल न रख। िवंडोपेन पर िकसी भी के
िवंडो सजावटी सामान न लगाय इससे धूप का
फोकस पड़ने पर आग लग सकती है ।
मशीन पिरचालन करते समय कैब म रे िडयो सुनने, या ूिजक
हे डफोन या मोबाइल टे िलफोन का न कर।
सभी ुओं और/या को मशीन
से दरू रख।
मािचस और/या ू बुझाने के िलए राखदानी का
करने के बाद ढ़ककर रख द।
िसगरे ट लाइटर को कैब म न छोङ। कैब म जब तापमान बढ़
जाता है , तो लाइटर म हो सकता है ।
मशीन के अनु उिचत कालीन का कर। यिद
कालीन का िकया जाता है, तो यह जगह से हट सकती है
और पिरचालन के दौरान े वल पेडल म फंस सकती है , िजससे
गंभीर चोट या मौत हो सकती है ।

S-5
 सु

े व का कर।
िगरना चोट लगने का मु कारण होता है ।
मशीन पर चढ़ते व उतरते समय, हमेशा मशीन के िदशा म मंह
ु
रख और व से -पॉइंट संपक बनाये रख।
े के म िकसी भी कं का न कर।
मशीन से या ऊपर कभी-भी न कूद। चलती हुई मशीन पर
कभी-भी न तो चढ़ और न ही उतर।
मशीन छोड़ते समय ेटफॉम, व से िफसलने की
से सावधान रह।
हाथ म औजार लेकर मशीन पर कभी-भी न चढ़ और न ही
उतर। SA-439

ऑपरे टर सीट को कर
ऑपरे टर या मौजद
ू काय के िलए गलत से की गई सीट
से ऑपरे टर को थकान हो सकती और इससे गलत हो
सकता है ।
जब भी मशीन के िलए ऑपरे टर बदल तो सीट को
कर।
ऑपरे टर अपनी पीठ को सीट के सहारे रखते हुए पेडल को पूरे
दबाने म हो और कं लीवर को सही ढं ग से संचािलत
कर सक।
यिद ऐसा नहीं होता है , तो सीट को आगे या पीछे की तरफ
िखसकाकर, दब
ु ारा जाँच कर। SA-378

िरयर ू िमरर की पॉजीशन को कर तािक ऑपरे टर

की सीट से पीछे का े साफ-साफ िदखाई द। यिद शीशा टूटा
हुआ है , तो इसे बदल कर, तुरंत नया शीशा लगा द।

S-6
 सु

ऑपरे टर सीट से उठते या छोड़ते समय सु का रख

साइड िखड़की को खोलने/बंद करने या सीट पॉिजशन को
करने के िलए ऑपरे टर की सीट से उठने से पहले, सव ंट
अटै चमट को नीचे कर और पायलट कं शट-ऑफ लीवर को लॉक
पॉिजशन की तरफ िखसकाय। ऐसा न करने पर शरीर का कोई अंग
अनजाने म कं लीवर/या पेडल म छूने पर मशीन अचानक चल
सकती है िजससे गंभीर चोट या मौत हो सकती है ।
मशीन छोड़ने से पहले, सव ं ट अटै चमट को नीचे की तरफ
कर और पायलट कं शट-ऑफ िलवर को लॉक पोिजशन म
िखसकाय। इंजन को बंद करने के िलए चाबी के को ऑफ कर।
मशीन छोड़ने से पहले, सभी , दरवाज और ेस कवर
को बंद कर और लॉक कर द।

सीट बे बांिधए
यिद मशीन पलट जाती है , तो ऑपरे टर घायल हो सकता है और/या
कैब से बाहर िनकलकर िगर सकता है । इसके पलटती हुई
मशीन से ऑपरे टर दबकर कुचल सकता है और इससे गंभीर चोट या
मौत हो सकती है ।
मशीन करने से पहले, , बकल और अटै िचंग
हाडवेयर की तरह जाँच कर ल। यिद कोई भी ु
खराब या कटी-फटी है , तो मशीन चालू करने से पहले सीट बे
या उस पुरजे को बदल द।
मशीन की चालू म हर सीट बे को बांधकर रख
तािक िकसी भी की दघ
ु टना की म चोट की
संभावना को कम िकया जा सक।
हम िसफािरश करते ह िक सीट बे हर तीन वष म बदल द
चाहे यह सही हालत म हो। SA-237

S-7
 सु

मशीन का सु संचालन व
आस-पास खड़े लोग(तमाशाई) टकरा सकते ह।
िवशेष रख िक आसपास खड़े लोग न टकराय। मशीन
आगे बढ़ाने, ंिगंग करने या करने से पहले आसपास
खड़े की का रख।
हमेशा े वल अलाम और होन (यिद लगे हो) को चालू म
रख। मशीन आगे बढ़ने लगती है तो यह अलाम को
चेतावनी दे ता है ।
भीड़-भाड़ वाले इलाके म मशीन चलाते, ंग, या
करते समय का उपयोग कर। मशीन चालू करने
पर हाथ से इशारा कर।
उपयु लाइट का कर। मशीन करने से पहले
यह दे ख ल िक सभी लाइट चालू हो। यिद म कोई
गड़बड़ी है तो इसकी तरु ं त कर।
यह दे ख ल िक कैब , िखड़िकयां, दरवाजे और कवर
सु से लॉक िकये हुए ह।
SA-426
कैब के सीसे व मोिनटर की ं की जाँच कर ल।
यिद कोई है , तो स को बदल द या
शीशे, कैमरा व मोिनटर को साफ कर द।
कैमरा व मोिनटर को साफ करने के िलए िरयर ू मोिनटर
से रे फर कर।

िसफ ऑपरे टर की सीट से ही कर

इंजन को गलत तरीके से करने पर मशीन िनयं से बाहर हो
सकती है , और इससे गंभीर चोट या मौत हो सकती है ।
ऑपरे टर की सीट पर बैठकर ही इंजन को कर।
े क या जमीन पर खड़ा रहकर इंजन को कभी-भी न कर।
र टिम से सीधे शॉटकट से इंजन को न कर।
इंजन को करने से पहले, यह दे ख ल िक सभी कं
लीवर ू पॉिजशन म हो।
इंजन करने से पहले, यह दे ख ल िक मशीन के आसपास
सु है और तमाशाबीन को चेतावनी दे ने के िलए हॉन
बजाय।
SA-444

S-8
 सु

दे कर करना
बै गैस हो सकती है और इससे गंभीर चोट लग सकती है ।
यिद इंजन को दे कर करना है , तो ऑपरे टर
िनदिशका के "इंजन " पाठ म त िनद का
पालन कर।
इंजन को करते समय ऑपरे टर सीट पर बैठना
होता है तािक मशीन को िनयं िकया जा सके।
कभी-भी जमी हुई बै का न कर।
उिचत से दे कर करने की िविध का पालन न
करने पर बै म हो सकता है या मशीन अिनयं हो
जायेगी।

SA-032

मशीन पर सवारी न बैठाय

मशीन पर बैठी हुई सवािरयां ुओं के टकराने से िगर सकते
ह और चोट लग सकती है .
मशीन पर िसफ ऑपरे टर ही बैठना चािहए। को न
बैठाय।
सवािरयां ऑपरे टर का नजर बािधत करती है , िजससे मशीन
असु तरीके से संचािलत हो सकती है ।

SA-379

S-9
 सु

पिरचालन हे तु सावधािनयां
पिरचालन ं भ करने से पव
ू काय को तरह दे ख ल।
मशीन को पिरचािलत करते समय िनयत काय के िलए उपयु
तंग-कसे हुए कपड़े व सु उपकरण जैसे कठोर टोपी
पहन।
पिरचालन व मशीन संचलन े से सभी व
को दरू रख।
के दौरान पिरवेशी े से सावधान रह। से
िघरी हुई छोटी सी जगह म काम करते समय, यह रख
िक से ऊपरी ढांचा टकरा न जाय।
म लोिडंग करते समय, पीछे की साइड से बेड के ऊपर
से बकट लाय। यह रख िक यह बकट कैब या िकसी भी
के ऊपर से झूलती हुई न जाय।

M178-05-007

S-10
 सु

काय ं भ करने से पहले काय की जाँच कर

खुदाई या सड़क िकनारे काम करते समय, मशीन पलट सकती
है , और इससे गंभीर चोट या मौत हो सकती है ।
काय चालू करने से पहले काय की आकृित व जमीन
को तरह दे ख ल तािक मशीन को िगरने से रोका
जा सक और जमीन ढ़हने से ं ड, या ब को
बचाया जा सक।
काय योजना बनाय। काय व काय के अनु मशीन का
कर।
पड़ने पर जमीन, खद
ु ाई व सड़क िकनारे को दबाकर
मजबूत बनाय। खुदाई व सड़क के िकनारे से पया से
SA-380
पीछे रह।
ढ़लान या सड़क िकनारे काम करते समय ुसार
संकेतक ( ) लगाय।
यह पु कर िक िगरने या मलबा होने की संभावना
वाले े म काय करने से पहले आपकी मशीन म एफओपीएस
कैब लगा हो।
फूिटंग (िटकने की जगह आधार) कमजोर हो, तो काम चालू
करने से पहले जमीन को दबाकर मजबूत कर।
े े म जमीन पर काम करते समय सावधानी
बरत। पिरवेशी तापमान बढ़ने से फूिटंग ढ़ीला और
िफसलाऊ हो जाता है ।
सावधान रह िक ुओं जैसे सूखी घास के पास
मशीन करते समय आग लगने की संभावना होती है ।

S-11
 सु

सु कर िक काय पया से मजबूत हो तािक मशीन

को सु सहारा िमल सक।
खदान या सड़क िकनारे काम करते समय, े वल मोटर को िरयर म
रख और े क पॉजीशन को ऊँची व ढ़ालू के रखकर
मशीन कर, तािक यह ऊँची ढ़ह जाने पर मशीन से
आसानी से िनकलकर बच सकते ह।
यिद खड़ी की सतह या ऊँचे िकनारे पर काम करना पड़, तो
पहल उस जगह को मआ
ु यना कर ल और यह सु कर ल िक
या िकनारा ढ़ह जाने पर कोई खतरा न हो। यिद या
िकनारा ढह जाने की संभावना है , तो उस जगह काम न कर।
मशीन को नरम जमीन पर करने पर जमीन ढह सकती है
और इससे मशीन पलट सकती है । जब नरम जमीन पर काम करना
पड़, तो सव के बड़े ेट के टुकड़े से जमीन को दबाकर
पया से मजबत
ू कर तािक मशीन को पया से मजबूत
सहारा िमल सक।
द िक ऊबड़-खाबड़ या ढ़लान जमीन पर काम करते समय
मशीन पलटने की संभावना रहती है । मशीन पलटने से बचाय। ऊबड़-
खाबड़ या ढ़लान जमीन पर काम करते समयः
इंजन की को कम कर।
M104-05-016

े वल मोड का चयन कर।

मशीन को धीरे -धीरे कर और मशीन की गित के साथ-
साथ सावधानी बरत।

OPG गाड लगाय

मशीन को िगरने या मलबा होने की संभावना वाली जगह म
करना हो, तो िहताची OPG गाड लगाय। OPG गाड लगाने के
िलए अपने अिधकृत डीलर से परामश कर। मशीन िविनद के आधार
पर आरओपीएस मानक के अनु गाड हो।
ऑपरे टर सु ढ़ांचा खराब न हो इसिलएः
खराब ROPS या OPG गाड को बदल द। गाड को कभी-भी या
ंतिरत करने की कोिशश न कर।
ROPS : रोल ओवर े
OPG : ऑपरे टर े गाड

SA-490

S-12
 सु

ऐसे काय िजसम कई मशीन शािमल हो उसके िलए

(संकेत) कर
ऐसे काय िजसम कई मशीन शािमल हो, उसके िलए सभी कािम
को शािमल कर से संकेत ( ) कर।
इसके अलावा, काय के संचालन के िलए
िनयु कर। सु कर िक सभी कािमक के
िनद का पालन कर।

SA-481

संचािलत की जाने वाली मशीन के िनद को जाँच करके

दे ख ल।
गलत े वल पेडल/लीवर से गंभीर चोट या मौत हो सकती
है ।
मशीन संचािलत करने से पहले, ऑपरे टर पॉिजशन के अनुसार
अंडरकैिरज पॉिजशन की पु कर। यिद कैब के सामने े वल
मोटर है , तो े वल पेडल/लीवर आगे की तरफ
करने से मशीन िवपरीत िदशा म चलेगी।

SA-491

S-13
 सु

मशीन को सु तरीके से संचािलत कर

मशीन को संचािलत करने से पहले, यह दे ख ल िक आप िजस िदशा
म चलाना चाहते ह, तो उस िदशा के अनुसार े वल लीवर/पेडल की
िदशा हो।
िकसी भी अवरोधक के लगाकर ही चल।
के ऊपर से होकर न चल। मशीन के आसपास ,
के , और/या धातु के टुकड़े िबखर सकते ह।
संचालन के दौरान िकसी भी कािमक को मशीन के आसपास न
आने द।
मशीन को ढलान पर संचािलत करने पर मशीन िफसल या पलट
SA-657
सकती है और इससे गंभीर चोट या मौत हो सकती है ।
35 या इससे अिधक खड़ी ढ़लान पर चढ़ने या उतरने का
न कर।
सीट बे बांध।
ढ़लान के ऊपर या नीचे की तरफ ग
ं करते समय, बकट
को की िदशा म जमीन से लगभग 0.2 से 0.3 m (A)
ऊपर रख।
यिद मशीन िफसलने लगे या हो जाय, तो बकट को
तुरंत जमीन पर िटकाकर बंद कर द। SA-658

सीधी ढ़लान की चढ़ाई पर चलाने या िदशा बदलने से मशीन

िफसल या पलट सकती है । यिद िदशा बदलनी पड़, तो मशीन
समतल जमीन पर लाय और सु पिरचालन हे तु िदशा
बदल।

SA-441

SA-590

S-14
 सु

ढ़लान पर र को झूलने से बचाय। को

ढलान की तरफ झूकाने का न कर। इससे मशीन पलट
सकती है । यिद ऊपर की तरफ झूलना है , तो
व बम
ू को सावधानीपूवक धीमी गित से कर।
यिद ढ़लान पर इंजन बंद हो जाता है , तो बकट को तुरंत जमीन
पर िटका द। कं लीवर को वापस ू लगाय। इसके बाद
इंजन को दब
ु ारा कर
मशीन को खड़ी ढ़लान पर चढ़ाने से पहले इसे तरह से गम
कर। यिद ऑयल पया से गम नहीं होता है , तो
M104-05-008
पया काय नहीं की जा सकती है ।
मशीन को भीड़-भाड़ वाले इलाके म चलाते, ंिगंग या
करते समय का ेमाल कर। मशीन चालू करने
से पहले हाथ का इशारा कर।
मशीन को आगे बढ़ाने से पहले, यह सु कर ल िक आप
िजस िदशा म जाना चाहते ह उसी े की तरफ े वल
पेडल/लीवर को िखसकाय। जब े वल मोटर पीछे की साइड हो, तो
े वल पेडल के ं ट को दबाय या मशीन को आगे की तरफ बढ़ाने
के िलए लीवर को आगे आइडलर की तरफ िखसकाय।
M178-03-001

मशीन की को सूिचत करने के िलए साइड े म की

आंतिरक सतह पर तीर के िनशान की मोहर लगी होती है ।
े वल को जहाँ तक संभव हो ैट (समतल) का चयन कर।
जहाँ तक संभव हो मशीन को सीधे चलाय, िदशा म कुछ धीरे -धीरे
पिरवतन कर।
पुिलया और सड़क िकनारे जाने से पहले इनकी मजबूती की जाँच
कर और पड़ने पर दबाकर मजबत
ू बनाय।
SA-011
सड़क की सतह खराब न हो इसिलए लकड़ी की े का
ेमाल कर। गिम के म डामर की सड़क पर मशीन
करते समय ग
ं को सावधानीपूवक संभाल।
रे लमाग पार करते समय लकड़ी की े का ेमाल कर तािक
वे खराब न हो।
िबजली के या पिु लया के संपक म न आय। नदी पार करते
समय, बकट से नदी की गहराई को नाप कर ही धीरे -धीरे पार
कर। यिद नदी अपर रोलर के ऊपरी िकनारे से अिधक गहरी है तो
उस नदी को पार न कर।
ऊबड़-खाबड़ जमीन पर चलते समय, इंजन की को कम कर।
े वल का चयन कर। धीमी से मशीन म खराबी
होने की संभावना कम होती है ।
ऐसे न कर िजससे
ै क व अंडरकैिरज परु ज खराब हो।
ठं ड के मौसम म मशीन को िफसलने से बचाने के िलए मशीन
लदान व उतराई से पहले े क नाल से बफ को साफ कर।

S-15
 सु

रोलअवे दघ
ु टनाओं से होने वाली चोट से बच।
यिद आप चलती हुई मशीन को रोकने या उस पर चढ़ने का
करते ह तो इससे मौत हो सकती है या गंभीर चोट लग सकती है ।
रोलअवे से बचने के िलएः
मशीन को समतल जमीन पर ही खड़ा कर।
मशीन को ढ़लान पर खड़ी न कर।
बकट को नीचे कर द और/या काय को भी जमीन
पर िटका द।
ऑटो-आइडल को ऑफ कर और पॉवर मोड ECO कर।
इंजन को 5 िमनट िबना लोड के धीमी गित पर चलाय
तािक इंजन ठं डा हो सक।
इंजन को बंद करके चाबी से चाबी िनकाल ल।
पायलट कं शट-ऑफ लीवर को लॉक पॉिजशन की तरफ SA-391

खींच।
े क को आड़ लगाकर कर द और बकट को जमीन
पर िटका द। यिद आपको ढ़लान पर खड़ा करना पड़ तो बकट
दांत को जमीन म घस
ु ा द।
मशीन को लुढ़कने से रोकने के िलए उपयु पर खड़ा
कर।
अपनी मशीन को मशीन से पया दरू ी पर खड़ा कर।

SA-2273

S-16
 सु

बैक-ओवर व ंग दघ
ु टनाओं से होने वाली से बच।
यिद को बैक या ंग करते समय मशीन के पास कोई
हो, तो मशीन उस से टकरा सकती है या उसे कुचल
सकती है , िजससे गंभीर चोट या मौत हो सकती है ।
बैक-ओवर व ंग दघ
ु टनाओं से बचने के िलएः
मशीन को बैक व ंग करने से पहले तरफ दे ख। यह
दे ख ल िक मशीन के आसपास कोई भी खड़ा न हो।
े वल अलाम (यिद लगी हो) को चालू म रख।
काय म घम
ू ने वाले तमाशाई को हमेशा सतक रख।
मशीन को संचािलत करने से पहले होन या संके का
ेमाल कर।
यिद आपको दे खने म परे शानी हो रही है तो मशीन को बैक
करते समय का ेमाल कर।
को हमेशा िदखता हुआ रख। SA-383

काय म की हो तो अपने
िनयम के अनु हाथ के इशारे का ेमाल कर।
व ऑपरे टर को संकेत साफ-साफ समझ म
न आय तो मशीन को संचािलत न कर।
िनयत काय पर ु सभी ,े संकेत और के
को समझ और यह सु कर िक संकेत दे ने के िलए
कौनसा ेदार है ।
, , और को साफ व बेहतर म रख।
ू , भारी बािरश, कोहर से िदखने म कमी आ सकती है । जैसे
धल
SA-384
ही कम िदखने लगे, तो को कम कर और उिचत लाइिटंग
का ेमाल कर।
ऑपरे टर िनदिशका म विणत सभी िनद को पढ़ व
समझ।

S-17
 सु

को काय े से दरू रख।

ंिगंग ं ट अटै चमट या काउं टरवेट से को गंभीर चोट लग
सकती है और/िकसी ु से कुचल सकते ह िजससे गंभीर
चोट या मौत हो सकती है ।
सभी को व मशीन संचालन े से दरू रख।
मशीन करने से पहले, काय े म के ेश को
रोकने के िलए बकट ंग दायरे की व पीछे के े म
बैिरयर लगाय।

SA-386

बकट को िकसी भी या ु पर न रख
बकट को िकसी भी या कैब के ऊपर से न उठाय, और
न ही झुलाय।
बकट भार िबखरने या बकट से टकराने के कारण गंभीर चोट लग
सकती है या मशीन खराब हो सकती है ।

SA-487

S-18
 सु

अंडरकिटंग (नीचे की तरफ काटना) न कर

यिद फूिटंग (आधार) ढ़ह जाय तो खुदाई के िकनारे से पीछे हटने के
िलए, हमेशा अंडरकैिरज को खुदाई िकनारे के और े वल
मोटर के पीछे की तरफ रख।
यिद फूिटंग (आधार) ढ़हने लगता है और पीछे हटना मु है ,
तो घबराय नहीं। , ऐसे मामले म ं ट अटै चमट को नीचे
करके भी मशीन को बचाया जा सकता है ।

SA-488

पलटने से बचाय
पलटती हुई मशीन से सीधे छलांग लगाने का न कर --- गंभीर या
चोट लगेगी।
आप छलांग लगाकर अलग होने की तुलना म मशीन अिधक तेज गित से
पलटने लगेगी।
अपना सीट बे बांिधए
ढ़लान पर करते समय लुढकने या पलटने का हमेशा डर
बना रहता है , और इससे गंभीर चोट या मौत हो सकती है ।
मशीन को पलटने से बचाने के िलएः
ढ़लान पर पिरचालन करने से पहले अिधक सावधानी बरत।
मशीन े को समतल बनाय।
बकट को जमीन के पास और मशीन के िनकट रख।
SA-012
मशीन पलटने या िफसलने की घटना से बचने के िलए
गित को कम कर।
ढ़लान पर चलते समय िदशा न बदल।
15 से अिधक खड़ी ढलान को पार करना है तो
उसके आर-पार चलने का न कर।
लोड ंिगंग (झल
ू ाते) समय स
ु ार ंग गित को
कम कर।
े े म जमीन पर सावधानीपव
ू क काम कर।
तापमान बढ़ने से जमीन नरम हो सकती है और जमीन पर
संचलन करना हो जायेगा।

SA-440

S-19
 सु

ऊँचे टीले के नीचे न काट

टीले का िकनारे ढ़ह सकता है या भू होने से गंभीर चोट या
मौत हो सकती है ।

SA-489

सावधानीपूवक खुदाई कर
भूिमगत कैबल या गैस लाइन कट जाने से
और/या आग लग सकती है और इससे गंभीर चोट या मौत हो
सकती है ।
खद
ु ाई करने से पहले केबल, गैस लाइन, और पानी लाइन की
जगह की जाँच कर ल।
केबल, गैस लाइन, और पानी लाइन से िनयमानुसार ूनतम
दरू ी बनाये रख।
यिद संयोगवश फाइबर केबल कट जाती है , तो अंितम
छोर को न दे ख। ऐसा करने पर आँ म गंभीर चोट लग
सकती है ।
SA-382

यिद आपके इलाके म "डीलर हॉटलाइन" है , तो

उससे संपक कर। और/या यूिटिलटी से सीधे संपक कर।
उनसे सभी भिू मगत यिू टिलटी को कराय।

सावधानीपूवक करना
यिद मशीन का ं ट अटै चमट या पाट ओवरहे ड (ऊपरी)
अवरोधक जैसे पल
ु से टकरा जाता है , तो मशीन व ओवरहे ड(ऊपरी)
अवरोधक को नुकसान होगा, और चोट भी आ
सकती है ।
बूम या आम से ओवरहे ड अवरोधक से टकराने से बचाय।

SA-389

S-20
 सु

त
ु लाइन से दरू रह
यिद मशीन या ं ट अटै चमट को ुत लाइन से पया दरू ी पर
नहीं रखते ह तो गंभीर चोट या मौत हो सकती है ।
ुत लाइन के पास करते समय, मशीन के िकसी
भी पाट या लोड को लाइन से 3 मीटर से अिधक िनकट व
लाइन ल
ु ेटर से दग
ु ुनी दरू ी से िनकट न लाय।
जाँच कर और िकसी भी लागू का पालन
कर।
गीली जमीन की जगह फैल सकती है िजससे इस पर मौजद
ू
िकसी भी को िबजली का झटका लग सकता है ।
काय से सभी तमाशाई या सहकिम को दरू रख।

SA-381

आकाशीय िबजली की म बरती जाने वाली

सावधािनयां
मशीन पर िबजली िगरने की अिधक संभावना होती है ।
आकाशीय िबजली कड़कने के साथ तूफान आने पर, को
तुरंत बंद कर द, और बकट को जमीन पर िटका द। मशीन को
छोड़कर दरू िकसी सु पर चले जाय।
आकाशीय िबजली का तूफान बंद होने पर, मशीन के सभी
सु म िकसी भी खराबी की जाँच कर ल। यिद
सु उपकरण खराब पाये जाते ह, तो उनकी कराने
के बाद ही मशीन को कर।

SA-1088

खतरनाक े
गोलाकार े , मशीन का ंग े होता है , इसिलए मशीन के
दौरान इस े म खड़े तमाशाई लोग और इस े म काम करने वाले
कािम के िलए खतरनाक होता है ।
कािम को मशीन के गोलाकार े म खड़े होने या मशीन के
पीछे काम न करने की भी चेतावनी दे नी होगी मशीन िकसी भी
समय िवपरीत िदशा म चल सकती है और इससे गंभीर चोट या मौत हो
सकती है ।
यहाँ त आकृित 6.4m बूम, 2.67m आम और 1.3 Cu.M.
बकट के िलए है ।
यह दरू ी ु अटै चमट के आधार पर अलग हो सकती है ।

S-21
 सु

ु संचालन
यिद उठाया गया लोड (भार) िगर जाता है , तो लोड(भार) िगरने से
पास म खड़े िकसी भी को टकरा सकता है या इसके नीचे
कुचल सकते ह और इससे गंभीर चोट या मौत हो सकती है ।
भार उठाने के के िलए मशीन का ेमाल करते समय,
सभी का पालन कर।
खराब चैन या उधड़ी हुई केबल, सेबल, ं या का
ेमाल न कर।
िकसी सामान को उठाने से पहले, को पीछे े वल
मोटर के साथ उपयु पर कर।
लोड(भार) को धीरे -धीरे व सावधानीपूवक संचािलत कर। इसे
अचानक न िखसकाय।
सभी को लोड(भार) से पया दरू ी पर रख।
लोड(भार) को िकसी भी के ऊपर से होकर न ले जाय।
जब तक भार सहायक या जमीन पर सु व मजबूती
के साथ न हो जाता है तब तक इसके पास िकसी भी
को पहुँचने न द।
बकट के दां से कभी-भी ग
ं या चैन न जोड़। ये िनकल
सकती है और इससे लोड(भार) िगर सकता है ।
SA-432

उछलते हुए मलबे या कचरे से बचाव कर

यिद उछलता हुआ मलबा आँ या शरीर िकसी अंग से टकरा
जाता है , तो गंभीर चोट लग सकती है ।
िकसी धातु के उछलते टुकड़े या कचरे से लगने वाली चोट से
बचाव कर; गोगल या से पहन।
िकसी भी ु पर चोट मारने से पहले तमाशाई को
काय े से दरू रख।
मशीन के समय ंट , दरवाजे, दरवाजे की
िवंडो और ओवरहे ड िवंडो को बंद कर। SA-014

S-22
 सु

मशीन को सु से खड़ा कर
दघ
ु टना से बचने के िलएः
मशीन को मजबत
ू समतल सतह पर खड़ा कर।
बकट को जमीन पर िटका द।
ऑटो-आइडल को ऑफ कर और पॉवर मोड को ईको मोड
म कर द।
इंजन को 5 िमनट तक िबना लोड के धीमी आइडल( )
गित पर चलाय।
चाबी के को ऑफ करके इंजन को बंद कर द।
चाबी के से चाबी को िनकाल ल।
पायलट कं शट-ऑफ लीवर को लॉक पॉजीशन की तरफ
खींच।
िवंडो, वट, और कैब दरवाजे को बंद कर।
SA-390
सभी ेस दरवाजे व म को लॉक कर द।

तरल-पदाथ का सु संचालन- आग से बचाव कर।

को ूवक संभाल; यह अित होता है ।
यिद जल जाता है , तो या आग लग सकती है और
इससे गंभीर चोट या मौत हो सकती है ।
धू करते समय या खल
ु े आग या के िनकट
मशीन म तेल न भर।
मशीन म तेल भरने से पहले हमेशा इंजन बंद कर।
तेल की टं की को खुली जगह म भर।
सभी , िचकने, और कुछ कूलंट होते ह।
तरल को आग के खतरे से पया दरू ी पर
रख। SA-018

दाबयु कंटे नर को न तो जलाये और न ही उसम छे द कर।

तेलीय िचथड़े-कपड़े को न रख; ये अनायास ही आग लगकर
जल सकते ह।
और ऑयल िफलर कैप को सु से कस द।

SA-019

S-23
 सु

सु पिरवहन
मशीन को या े लर म चढ़ाते या उतारते समय पलटने का
रख।
सु पिरवहन से संबंिधत िनयम व का पालन
कर।
पिरवहन की जाने वाली मशीन के िलए उपयु या े लर
का चयन कर।
का उपयोग कर।
लदान व उतराई के िलए का पालन
कर:
1. ठोस व समतल जमीन का चयन करन।
2. मशीन वजन म सहायक पया से मजबत
ू रै या डेक SA-395

का ेमाल कर।
3. ऑटो-आइडल को ऑफ कर और मोड को ईको
पॉजीशन म घूमाय।
4. हमेशा े वल मोड से धीमी गित मोड का चयन कर।
5. मशीन को रै पर ं ट अटै चमट का उपयोग करते हुए
े क या े लर से चढ़ाय या उतार नहीं।
6. रै पर ग
ं न घूमाय। यिद रै पर संचलन िदशा
बदलनी हो, तो रै से मशीन को उतार, मशीन पुनः जमीन पर
कर और िफर से लदान करने का कर।
7. रै का ऊपरी िसरा जहाँ ैटबेड से िमलता है , वहाँ अचानक
धमाका हो सकता है । इसिलए इस सावधानीपूवक संचालन कर।
8. के आगे व पीछे रख। मशीन को े क या े लर डेक
म की से कसकर बांध द।
सु कर िक पिरवहन भाग म ेिखत िववरण का पालन िकया
जाता है ।

S-24
 सु

सु रखरखाव का करना
दघ
ु टना से बचने के िलएः
काय ं भ करने से पहले सिवस को समझ।
काय े को साफ व सख
ू ा रख।
कैब के अंदर पानी का िछड़काव या न कर।
चलती हुई मशीन म या सिवस न कर।
ुत-चािलत स से अपने हाथ, पैर व को दरू रख।
मशीन की सिवस करने से पहलेः
1. मशीन को समतल जगह पर खड़ा कर।
2. बकट को जमीन पर िटका द।
3. ऑटो-आइडल को ऑफ कर द।
4. इंजन को 5 िमनट तक भाररिहत धीमी आइडल से
चलाय।
5. चाबी को ऑफ करके इंजन को बंद कर द।
6. कं लीवर बार-बार िनकालते हुए से दाब
को िनकाल द।
7. चाबी के से चाबी को िनकाल ल।
8. कं लीवर पर " न कर" टै ग लगा द।
SA-028
9. पायलट कं शट-ऑफ लीवर को लॉक पॉजीशन की तरफ
खींच।
10. इंजन को ठं डा होने द।
यिद रखरखाव को इंजन को चालू करके करनी पड़े, तो
मशीन को अकेला न छोड़।
यिद मशीन को ऊपर उठानी है , तो बूम व आम के बीच 90 से
110° कोण बनाये रख। सिवस काय के िलए उठाये जाने वाले
िकसी भी मशीन के एिलमट को सु ढं ग से सपोट कर।
िवशेष स को समय-समय पर दे ख और पड़ने पर
कर या बदल द। इस िनदिशका म "रखरखाव" पाठ म
इस पाट के िववरण भाग को दे ख।
सभी स को बेहतर हालत म रख और उिचत से लगाय।
खराबी को तरु ं त ठीक कर। िघसे या टूटे हुए स को बदल द। SA-527

, ऑयल, या मलबे के उभार को िनकाल द।

स को साफ करते समय, हमेशा िडटजट
ऑयल का म
े ाल कर। स या सतह को साफ करने के
िलए कभी-भी अित ऑयल जैसे तेल व गैस
का ेमाल न कर।
मशीन पर इले म कोई समायोजन या वे ग
ं
करने से पहले बै ं ड केबल (-) को हटा द।

S-25
 सु

काय म पया उजाला कर। मशीन के नीचे या अंदर काम

करते समय मेनटे नस वकलाइट का ेमाल कर।
हमेशा कवच वकलाइट का ेमाल कर। यिद लाइट
टूटा हुआ है , , तेल, एं ूड, या िवंडो वॉशर
ड
ू फ ै ला हु आ है तो आग लग सकती है ।

SA-037

सिवस काय की चेतावनी

अचानक मशीन चलने से गंभीर चोट लग सकती है ।
मशीन पर कोई भी काय करने से पहले, कं लीवर पर
" न कर" टै ग लगा द।
यह टै ग( ) अपने ृ त डीलर से कर।

SS3076175 SS2045102

मशीन को सही ढं ग से सपोट कर

मशीन को पहले सु िकये िबना इस पर कोई भी काय
करने का न कर।
मशीन पर काय करने से पहले अटै चमट को जमीन पर िटका
द।
यिद आपको उठी हुई मशीन या अटै चमट पर काम करना पड़,
तो मशीन या अटै चमट को मजबूत के साथ सपोट कर। मशीन
को राख के , खाली टायर या आड़ पर सपोट न कर
ये लगातार भार के नीचे टूट सकते ह। िसफ जैक से
SA-527
सपोट की गई मशीन पर काम न कर।

S-26
 सु

घूमते हुए स से दरू रह।

घूमते हुए स म फंसने से गंभीर चोट लग सकती है ।
दघु टना से बचने के िलए, इस बात की सावधानी बरत िक
घूमते हुए स के आसपास काम करते समय हाथ, पैर, कपड़े,
आभूषण और बाल न फंसे।

SA-026

SA-2294

स को उछलने से रोक
दाब के अंतगत ेक म कर।
का पालन न करने पर गंभीर चोट, अंधापन, या मौत हो
सकती है ।
िफिटंग या असे को िनकालने का न
कर।
सु से ढ़के हुए िफिटंग को िनकालने का न
कर।
SA-344
कोई टुकड़े उछल सकते ह, तो से शरीर व चेहरे को दरू
रख।
ेक को कभी-भी खोलकर अलग न कर। ेक
को लापरवाही से खोलकर अलग करने पर ंग जैसे
स उछल सकते ह और गंभीर चोट या मौत हो
सकती है ।
े वल िगयर ेशरयु होते ह।
कोई टुकड़ा उछल सकता है , इसिलए चोट से बचने के िलए
एयर िरिलज से शरीर व चेहरे को दरू रख।
िगयर ऑयल गम होता है । िगयर ऑयल को ठं डा होने तक
इंतजार कर, और िफर दाब को िनकालने के िलए धीरे -धीरे एयर
िरिलज को ढ़ीला कर।

S-27
 सु

अटै चमट को सु से रख।

रखे हुए अटै चमट जैसे बकट, है मर और ैड िगर सकती
है और इससे गंभीर चोट या मौत हो सकती है ।
अटै चमट व को सु तरीके से रख तािक ये िगर न
सक। े से व तमाशाई को दरू रख।

SA-039

जलने से बचाव
गम तरल-पदाथ के छींटेः
के बाद, इंजन कूलंट गम और दाबयु होता है । इंजन,
रे िडयटर और हीटर लाइन म गम पानी या भाप होती है ।
गम पानी या भाप के संपक से दरू रह इससे बुरी तरह
जल सकती है ।
गम पानी के िछं टे से होने वाली चोट से बचने के िलए। इंजन
को ठं डा होने तक रे िडयटर कैप को न हटाय। खोलते समय, कैप
को धीरे -धीरे े तक घूमाय। कैप को िनकालने से पहले
ूण दाब को िनकलने द।
ऑयल टक दाबयु होता है । दब
ु ारा, सु कर SA-225

िक कैप को िनकालने से पहले ूण ेशर(दाब) िनकल जाय।

गम ूड व सतहः
के दौरान इंजन ऑयल, िगयर ऑयल और ऑयल
भी गम हो जाता है ।
इंजन, पाइप, लाइन और स भी गम हो जाते ह।
कोई भी रखरखाव या काय करने से पहले ऑयल व
पु को ठं डा होने तक इंतजार कर।

SA-034

S-28
 सु

रबर के को समय-समय पर बदल

दाबयु ूड वाले रबर के पाइप अिधक , थकाऊ व
घषण के कारण टूट सकते ह। रबर की अिधक , थकाऊ व
घषण के कारण खराबी की सीमा को िसफ से नापना
मु होता है ।
रबर के को समय-समय पर बदल। (ऑपरे टर िनदिशका
म " स का आविधक " पेज दे ख)
रबर को समय-समय पर न बदलने पर आग लग सकती है ,
पर ूड ेश कर सकती है , या ं ट अटै चमट पास म खड़े
पर िगर सकती है , िजससे गंभीर से जलन, गगरीन, या
SA-019
गंभीर चोट या मौत हो सकती है ।

-दाबयु ूड से बचाव
ूड जैसे डीज़ल या ऑयल दाबयु होते ह जो
या आँ म घस
ु सकते ह िजससे गंभीर चोट, अँधापन या
मौत हो सकती है ।
इस जोिखम से बचने के िलए या को
खोलकर अलग करने से पहले ेशर को िनकाल द।
ेशर लगाने से पहले सभी कने को कस द।
े के टुकड़े से िरसाव दे ख; हाथ व शरीर को सावधानीपूवक
-दाबयु ड
ू से बचाय। आँ की सु के िलए फेस
या गोगल धारण कर।
SA-031

ु टना हो जाय, तो इस
यिद दघ की चोट को जानकार
को तुरंत िदखाय। म ेश िकये गये िकसी भी
तरह के ड
ू को - से तरु ं त िनकलवाय
गगरीन हो सकता है ।

SA-292

SA-044

S-29
 सु

आग से बचाव
तेल िरसाव की जाँच करनाः
, ऑयल व लू ट िरसाव से आग लग सकती है ।
गुम या ढ़ीले , बल खोये हुए पाइप. रगड़ती हुई पाइप या
नािलयाँ ु ऑयल कूलर और ऑयल कूलर के ढ़ीले
ज के कारण तेल िरसाव की जाँच कर।
िकसी भी गुम, ढ़ीले या खराब , लाइन, पाइप, ऑयल-
कूलर व ऑयल-कूलर ज को कस, कर या
बदल द।
-दाबयु को न तो मोड़ और न ही इन पर चोट
SA-019
मार।
कभी-भी मुड़े हुए या खराब लाइन, पाइप, को न लगाय।
समय-समय पर पाइप व पाइप को बदल द
चाहे इनके आवरण म कोई खराबी न हो।
स (लघ-ु पिरपथ) की जाँच कर:
शॉट सिकट से आग लग सकती है ।
सभी इले कने को साफ करके कस द।
ेक पारी से पहले या आठ (8) से दस(10) घंटे के
बाद ढ़ीले, बल खाये हुए, कठोर या उधड़े हुए इले केबल
व की जाँच कर।
ेक पारी से पहले या आठ (8) से दस(10) घंटे के
बाद गुम या खराब टिमनल कैप की जाँच कर।
यिद केबल या तार ढ़ीले व ऐंठे हुए हो तो मशीन को
न कर।
इले वायिरं को ंतिरत करने का न कर।

S-30
 सु

वलनशील की सफाईः
फैले हुए , ऑयल, कचरा, , मलबा, संिचत कोयले का चूरा,
और से आग लग सकती है ।
मशीन की रोजाना जाँच व सफाई तथा िचपके हुए तेल या
सं ुओं को तुरंत हटाकर आग लगने से
बचाय। इंटरवल के बजाय तापमान के स जैसे
आउटलेट व मफलस की तरु ं त जाँच कर सफाई कर।
तापमाप के स जैसे मफलर या पाइप को
ऑयल से न ढके।
तेलीय कपड़े को न रख इनम आग लगने की अिधक
संभावना होती है।
को खुली आग से दरू रख।
दाबयु या सीलबंद कंटे नर को जलाय या दबाय नहीं।
इंजन मट कवर के छे द म वायर लगायी जा
सकती है तािक पदाथ जैसे सूखी को ेश
करने से रोका जा सक। हालांिक, वायर से ेश की गई
सूखी से आग लग सकती है । मशीन की जाँच
व सफाई कर और सं को तुरंत िनकाल
द।
चाबी के (की ) की जाँचः
शॉट सिकट से आग लग सकती है ।
यिद आग फैल जाती है , इंजन बंद नहीं हो जाता है , तो आग बढ़
जायेगी और आग बुझाना मु हो जायेगा।
मशीन करने से पहले चाबी के (की
) काय की जाँच कर:
1. इंजन को कर और इसे धीमी आइडल( ) गित पर
चलाय।
2. चाबी के को ऑफ पॉजीशन म घम
ू ाकर दे ख िक इंजन बंद
होता है या नहीं।
यिद कोई खराबी पायी जाती है , तो मशीन करने से
पहले इनकी कराय।
हीट की जाँचः
खराब या गुम हीट से आग लग सकती है ।
मशीन करने से पहले खराब या गुम हीट की
कराय या बदल द।
यिद इंजन कवर खुला हुआ हो और पाइप टूट जाते
ह तो तापमान के स जैसे मफलर पर तेल फैलने से
आग लग सकती है । मशीन करते समय हमेशा इंजन
कवर को बंद करके रख।

S-31
 सु

आग लगने पर बचकर िनकलना

ऑयल िरसाव की जाँचः
यिद आग फैल जाये, तो तरीके से मशीन से िनकल:
यिद समय िमले तो चाबी के को ऑफ पॉजीशन म
घूमाकर इंजन को बंद कर।
यिद समय िमले तो -शमक यं का कर।
मशीन से िनकल।
आपातकालीन म, यिद कैब या ं ट िवंडो नहीं
खल
ु ती है , तो आपातकालीन िनकास हथोड़े से ं ट या िरयर िवंडो को
तोड़कर कैब से बचकर िनकल जाय। आपातकालीन िनकास िविध के
पेज पर दे ख।
SA-393

SS-1510

धुएं से सावधान
(सांस घुटना) बचाव कर। इंजन से िनकलने वाली गैस से
बीमारी या मौत हो सकती है ।
यिद आपको िकसी भवन म करना पड़, तो वहाँ पया
विटलेशन (हवादार) हो। गैस को िनकालने के िलए
पाइप शन का कर या बाहर से पया
हवा आने के िलए दरवाजे या को खोल द।

SA-016

S-32
 सु

वे ग
ं व ंिडंग के िलए सावधािनयां
वे ग
ं करने से गैस या कुछ आग हो सकती है ।
पया हवादार िनिमत े म ही वे गं काय कर। वे ग
ं
काय ं भ करने से पहले ओ
ु ं को सु
पर रख द।
िसफ कुशल कािमक ही वे ग
ं काय कर। िकसी भी अकुशल
को वे ग
ं काय न करने द।
मशीन पर ंिडंग करने पर आग होने का खतरा होता है ।
ंिडंग काय ं भ करने से पहले ुओं को सु
पर रख द।
वे ग
ं व ंिडंग काय पूरा होने के बाद, पुनः जाँच कर िक कोई
SA-818

तो नहीं है जैसे वे ग
ं की गई जगह के
आसपास आग सुलग रही हो।

S-33
 सु

दाबयु ड
ू के िनकट हीिटंग(तापन) काय न कर।
दाबयु ूड के पास तापन काय करने से
फौवार हो सकती है िजससे आप व आसपास खड़े लोग बुरी
तरह जल सकते ह।
दाबयु ूड लाइन या के पास
वे ग
ं , टांका, या मशाल जलाकर गरम न कर।
जब ताप े से िनकट पहुँच जाता है , तो दाबयु
लाइन म कट हो सकता है । वे गं , टांका
काय करने से पहले पाइप या को बचाने के
िलए -रोधक कवच लगाय।

ड
ू यु को गरम न कर। SA-030

ूडयु पाइप या ूब पर वे ग
ं या ैम कट
न कर।
इन पर वे ग
ं या म
ै किटंग करने से पहले
ट (घोल) से तरह साफ कर।

ूमूलेटर व गैस डै को संभालने के िलए बरती जाने

वाली सावधािनयां
ूमूलेटर व गैस डै म -दाबयु गैस को सीलबंद
िकया जाता है । गलत संचालन से हो सकता है और इससे गंभीर
चोट या मौत हो सकती है ।
का पालन कर:
यिू नट को खोलकर अलग न कर।
यूिनट को खलु ी लपट व आग से दरू रख।
छे द न कर, न ही टॉक से काट।
यूिनट पर चोट दे कर या इसे लुढ़काकर झटका न द।
यूिनट को करने से पहले सीलबंद गैस को िनकाल द।
अपने िनकटतम टाटा-िहताची डीलर से संपक कर।

S-34
 सु

वे ग
ं या तापन काय करने से पहले पट(रं ग) हटाय
वे ग
ं , टांके या टॉक से पट(रं ग) गरम होने पर खतरनाक गैस
िनकल सकती है। यिद यह गैस से अंदर चली गई, तो आप
बीमार हो सकते ह।
संभािवत गैस व धूल से बच।
इस तरह के सभी काय खुली जगह या पया हवादार जगह म
कर। पट(रं ग) व ट को सही तरीके से कर।
वे ग
ं या तापन काय करने से पहले पट िनकाल द:
1. यिद आप पट(रं ग) को रगड़ते ह या ंड करते ह, तो इसकी
ू को सांस के अंदर न ल। अनम
धल ु ोिदत ं पहन।
2. यिद आप ट या पट का ेमाल करते ह, तो
वे ग
ं काय करने से पहले साबुन व पानी से को हटाय। SA-029
इस े से ट या पट कंटे नर को िनकाल द।
वे ग
ं या तापन काय करने से पहले कम से 15 िमनट तक
गैस िततर-िबतर होने द।

े व िसिलकॉन धूल और िू षत से
सावधान रह
रह िक काय म धूल को के जिरये अंदर न
ल। े फाइबर को के जिरये अंदर लेने से फेफडे का
कसर हो सकता है । िसिलकॉन धल
ू या िू षत पदाथ के
जिरये अंदर जाने से बीमार हो सकते ह।
काय के आधार पर, े फाइबर,
िसिलकॉन धल
ू या िू षत पदाथ होने का खतरा
हो सकता है । े फाइबर, िसिलकॉन धूल या
िू षत पदाथ को हवा म फैलने से रोकने के िलए पानी का SA-029

िछड़काव कर। े (संपीिड़त) हवा का ेमाल न कर।

जहाँ े फाइबर, िसिलकॉन धूल या िू षत पदाथ
हो उस जगह पर मशीन करते समय, मशीन को हवा
आने की िदशा की तरफ कर और े फाइबर,
िसिलकॉन धूल या िू षत पदाथ को रोकने के िनधािरत
पहन।
के दौरान तमाशाई को काय से बाहर रख।
नकली स म े फाइबर हो सकते ह। इसिलए िसफ
जे ूअन टाटा-िहताची स ही ेमाल कर।

S-35
 सु

बै को होने से बचाय
बै गैस से हो सकता है ।
बै के ऊपरी िसरे से िचंगारी, जलती हुई मािचस, और आग की
को दरू रख।।
िकसी धातु की ु को आरपार ( ंभ) पर रखते हुए बै
चाज की जाँच न केरं । या का ेमाल
कर।
ठं ड से जमी हुई बै को चाज न कर; यह हो
सकती है । पहले बै को 16 °C ( 60 °F) पर गम कर।
इले िनधािरत सीमा से कम होने पर बै का
िनरं तर ेमाल या चाज न कर। इससे बै म हो
सकता है ।
ढ़ीले टिम से िचंगािरयां हो सकती है । सभी
SA-032

टिम को मजबूती के साथ कस।

टिमनल को उिचत इले से कने कर। ऐसा न
करने पर इले स खराब हो सकते ह या आग लग
सकती है ।
बै इले जहरीली होती है । यिद बै हो जाय, तो
बै की इले उछलकर आँ म िगर सकती है और इससे
अँधे हो सकते ह।
इले गु की जाँच करते समय ने सु के
उपकरण पहन।

वातानुकूिलत की सु से सिवस करना

यिद रे ट पर िगर गई तो े बन(बफ से
जलना) हो सकती है ।
रे ट के संचालन के समय कंटे नर के उिचत म
विणत िनद का पालन कर।
वातावरण म रे ट के िरसाव को रोकने के िलए िरकवरी व
िरसाइिकल का ेमाल कर।
रे ट को कभी-भी न छूय।
SA-405

S-36
 सु

रसायिनक का सु संचालन
खतरनाक रसायिनक के सीधे संपक म जाने से गंभीर
हो सकते ह। मशीन म ु संभािवत खतरनाक रासायिनक
म लु , कूलंट, पट और एडहिसव को शािमल िकया जाता है ।
सु डेटा शीट (एमएसडीएस) म रासायिनक :
शारीिरक व संबंधी खतर, सु , और
आपतकालीन के बारे म जानकारी दी
जाती है ।
िकसी भी खतरनाक रासायिनक के म
े ाल से कोई भी
काय ं भ करने से पहले एमएसडीएस को दे ख ल। इस िविध
से आपको इस बात की जानकारी िमलेगी िक कौन-
कौन से खतर ह और िनयत काय को सु तरीके से कैसे
कर। इसिलए का पालन कर और िनधािरत का
कर। SA-309

अपनी मशीन म ु रासायिनक के बारे म

एमएसडीएस (िसफ अं ेजी म ) करने के िलए
ृ त डीलर से संपक कर।

का उिचत
का गलत करने से पयावरण व
-तं के िलए खतरा हो सकता है । टाटा-िहताची
के साथ ु संभािवत हािनकारक म
ऑयल, , कूलंट, ेक ूड, , और बै शािमल होती है ।
ड
ू खाली करते समय िरसावरोधक कंटे नर का ेमाल कर।
या पेय के कंटे का ेमाल न कर
कुछ लोग होकर पी सकते ह।
बै म खतरनाक लेड व तेजाब होती है ; इसे ेमाल करने के SA-226

बाद न कर। कृपया बै के के िलए इसे

के ष
ू ण िनयं के ृ त िरसाइकलर या
डीलर के पास लौटा द।
पदाथ को जमीन, नाली या िकसी भी म न
डाल।
हवा म एयरकंिडशिनंग रे ट िनकलने से प ृ के वातावरण
को नुकसान पहुँचा सकता है । सरकार के के अनुसार
ु एयर कंिडशिनंग रे ट को ठीक करने व िरसाइकल
करने के िलए इसे एयर कंिडशिनंग सिवस सटर के
पास भेज सकते ह।
अपने वातावरण या िरसाइकल सटर, या ृत
डीलर से पदाथ को उिचत तरीके से िरसाइकल या
करने के िलए कह।

S-37
 सु

अटै चमट पर कभी-भी न चढ़

अटै चमट या लोड पर िकसी भी को चढ़ने न द। यह सबसे
खतरनाक तरीका है ।

ूिनकेशन टिमनल के िलए बरती जाने वाली सावधािनयाँ

ूिनकेशन टिमनल से संचािरत ुत तरं ग से इले
उपकरण खराब हो सकते ह।
ूिनकेशन टिमनल के पास इले उपकरण का ेमाले करने
पर त
ु ीय तरं ग बाधा के बारे म उपकरण िविनमाता से पछ
ू ।

S-38
 सु

ूिनकेशन टिमनल उपकरण के िलए बरती जाने वाली

सावधािनयाँ
इस मशीन म सीट के पीछे िरयर े के अंदर
ूिनकेशन टिमनल उपकरण ुतीय तरं का न करता है ।
ूिनकेशन टिमनल उपकरण से त ुतीय तरं से कािडक
पेसमेकर जैसे उपकरण सिहत मेिडकल उपकरण भी
होकर खराब हो सकते ह।
उपयु मेिडकल उपकरण लगाये हुए कोई भी इस मशीन का
ेमाल न कर, और यिद ऐसा न हो तो मेिडकल उपकरण और िरयर े SA-2302

के बीच हर कम से कम 22 सटीमीटर (8.662 इंच) की दरू ी रख।

यिद ऐसी न िमल, तो कृपया अपनी के िनकटतम डीलर
से संपक कर और से ूिनकेशन टिमनल उपकरण के
काय को पूणतया बंद करा द तथा यह दे ख ल िक यह ुतीय तरं ग
नहीं कर रही हो।
िू नकेशन टिमनल उपकरण की िवशेष अवशोषण दर ("एसएआर")
( यूिनट 10 g माप होती है ):
E-GSM900 0.573 W/Kg (914.80 MHz)
DCS-1800 0.130 W/Kg (1710.20 MHz)
WCDMA बड I 0.271 W/Kg (1950.00 MHz)
*इस डेटा म ेक के िू नकेशन टिमनल उपकरण की माप है ,
जैसे इस मशीन म ु ूिनकेशन टिमनल उपकरण को मानव
शरीर से 3सेमी (1.18 इंच) दरू रखा गया है ।
*मोबाइल फोन जैसे बेतार अनु का ेमाल करते समय शरीर
अवशोिषत रे िडयो आव ृ ऊजा की माप एसएआर होती है ।

जापान म: *जापान रे िडयो अिधिनयम व ंिगक जापानी

के अंतगत, अिधकतम एसएआर मान 2 W/kg (माच 2010 के अनुसार)
है ।
यूरोपीय संघ म: *पिरषद िरफािरश 1999/519/EC 12 जल
ु ाई
1999 के अंतगत; अिधकतम एसएआर मान 2 W/kg (माच 2010 के
अनुसार) है ।

S-39
 सु

ूिनकेशन टिमनल, एंटीना या केबल को खोलकर अलग करने,

करने, ंतिरत करने या हटाने का न कर। इसका
ंघन करने पर मशीन या ूिनकेशन टिमनल बेस म नुकसान
या इसम आग लग सकती है । ( ूिनकेशन टिमनल को िनकालना
हो, तो अपने िनकटतम टाटा-िहताची डीलर से संपक कर।
केबल, डोरी या कने म न तो िपन चुभाय और न ही जोर
लगाकर खींच। इसका ंघन करने पर शॉट सिकट या सिकट
हो सकता है िजससे मशीन या ूिनकेशन टिमनल बेस म
नक
ु सान या इसम आग लग सकती है

S-40
 सु

यहाँ मशीन पर लगे हुए सभी सु संकेत व उनके के बारे म समझाया गया है । सु संके म विणत को परू ी तरह
पढ़कर मशीन पर लगे संके के बारे म सु कर ल तािक मशीन का सु िकया जा सक। हमेशा सभी सु
संके को साफ रख। यिद कोई सु संकेत टूट जाता है या गम
ु जाता है , तो तुरंत बदल कर नया कर और पुनः मशीन पर उसी
म लगा द। जब टाटा-िहताची डीलर से इसका ऑडर कर तो े क सु संकेत के दाये कोने के नीचे सूिचत पाट नं. का
कर।

S-41
 सु

1.
चेतावनी!

मशीन का , रखरखाव, खोलकर अलग करने (िडसअसे ग

ं ),
और पिरवहन करने से पहले ऑपरे टर िनदिशका को पढ़कर समझ ल।

SS4420332

2.
यिद पाक (खड़ी की हुई) मशीन अचानक चलने लगे, तो कुचलने के
कारण गंभीर चोट या मौत हो सकती है । मशीन को अकेला छोड़ने से
पहले ं ट अटै चमट को जमीन पर िटका द, कं लीवर को लॉक कर,
और इंजन की चाबी को िनकाल ल।

SS4420333

3.
यह संकेत, यिद मशीन िबजली की ुत के बहुत नजदीक आ
जाय तो िबजली से मरने के खतरे के बारे म सूिचत करता है ।
िबजली की ुत से पया दरू ी बनाये रख।

SS4420334

4.
यह संकेत िखड़की िगरने के खतरे के बारे म सूिचत करता है ।
िखड़की ऊपर करने के बाद, इसे लॉक िपन से लॉक करके कर।

SS4420335

S-42
 सु

5.
सीट की ऊँचाई या लीवर को नीचे िखसकाते समय, ऊपरी साइड से
लीवर को हाथ से दबाएँ। लीवर को करने के िलए लीवर
को पकड़े नहीं, इससे सीट ड म अंगु को िचकोटी आ सकती
है ।

SS4371371

6.
यिद मशीन पलटती है , तो ऑपरे टर हो सकता है या कैब से
िनकलकर बाहर आ सकता है या पलटी हुई मशीन के नीचे दब सकता है ।

SS4654287

7.
िखड़की से अपने हाथ या िसर को आगे न बढ़ाय। आपके हाथ या िसर
बूम म फंस सकते ह।

के दौरान मशीन से दरू रह।

SS4459990

8.
यह संकेत, मशीन के काम करते हुए उपकरण से टकराने के खतरे के बारे
म सिू चत करता है ।

के दौरान मशीन से दरू रह।

SS3089581

S-43
 सु

9.
यह संकेत, ेक से उछलते हुए से चोट लगने के खतरे के
बारे म सूिचत करता है ।
ेक करने से पहले सु व उिचत संचालन के बारे म
िनदिशका पढ़।

SS3086091

10.
यह संकेत, यिद के दौरान ऑयल इनलेट को खोल िलया जाता है A
तो े एयर व गम तेल उछलने से जलने के खतरे के बारे म सूिचत
करता है ।
सु व उिचत संचालन के िलए िनदिशका पढ़।

B
SS4459928

यह संकेत, यिद रे िडयटर या टक गम है और इसके कैप को

खोल िलया जाता है , तो गम पानी या ऑयल उछलने से जलने के खतरे
के बारे म सूिचत करता है ।
कैप िनकालने से पहले रे िडयटर या टक को ठं डा होने द।

SS4420336

11.
यह संकेत, िगरने के खतरे के बारे म सूिचत करता है ।
इस पर खड़ा न हो।

SS3092126

S-44
 सु

12.
यह संकेत, फडर या हूड से िगरने के खतरे के बारे म सूिचत करता है ।
कभी-भी िकनारे के िनकट खड़ा न हो।

SS3092125

13.
यह संकेत, मशीन के को घम
ू ने से कुचलने के खतरे के बारे
म सूिचत करता है ।

मशीन के ंिगंग े से दरू रह।

SS3086090

14.
यह संकेत, यिद रे िडयटर या ऑयल टक गम है और इसके
कैप को खोल िलया जाता है , तो गम पानी या ऑयल उछलने से जलने
के खतरे के बारे म सूिचत करता है ।

कैप िनकालने से पहले रे िडयटर या ऑयल टक को ठं डा होने

द।

SS4420336

S-45
 सु

15.
यह संकेत, बे जैसे घूमते हुए स के खतरे के बारे म सूिचत करता
है । व रखरखाव करने से पहले बंद कर।

SS3092127

SSYA00008776

S-46
 सु

16.
A
यह संकेत, केबल का संचालन करने से िबजली के खतरे के बारे म सूिचत
करता है । सु व उिचत संचालन के िलए िनदिशका पढ़।

SS4459714

होने के खतरे का संकेत है ।

B

इस े से व खुली आग दरू रख।

SS4460067

इले के संपक म आने से जल जायगे। आँ म इले C

िगरने से अँधे हो जायगे। रह िक इले को न छूय।

SS4460056

17.

सावधान
ं ट िवंडो को खोलने व बंद करने के िलए ही हडल का योग कर। कैब म ेश करने या बाहर िनकलने के िलए हडल का ेमाल
न कर। यिद िवंडो लॉक नहीं है , तो इससे आपका संतुलन िबगड़कर िगर सकते ह। 4467093

SS4467096

S-47
18.

सावधान
कािडक पेसमेकर जैसे उपकरण
सिहत कोई भी मेिडकल उपकरण लगाये
हुए ,कृपया इस िनदिशका को
ूवक पढ़ और इस मशीन को
करने से पहले िनद का पालन कर।
YA00000341

19.
चेतावनी

इसम यु है ।
इसके िनकट आग या तापन काय न कर। इसे खोलकर अलग करने
की कोिशश न कर।
ने सु उपकरण पहन और इसे करने से पहले गैस दाब
को िनकालन के िलए x ि ु पर ही सावधानीपूवक छे द कर।

S-48
 COMPONENTS NAME

Components Name
1- Bucket
2- Bucket Cylinder 4

3- Arm 3

4- Arm Cylinder 2
5- Boom Cylinder 5

6- Boom
6
7- Fuel Tank
8- Hydraulic Oil Tank 7
8
9- Engine 9
1
10- Counterweight
11- Travel Device
12- Track 14
13- Front Idler
14- Cab 13

10
12

11 M1U1-01-005

1-1
 GETTING ON/OFF THE MACHINE

Getting ON/OFF the Machine 4 5 3

Foot holds (1) and handrails (2) are provided in and around the
machine.
These are used to get on and off the cab safely as well as to do
inspection and maintenance of the machine safely.
Never jump on or off the machine as it is very dangerous.

WARNING: 2

Never attach a wire on the foot holds (1) to lift the

cab or main body or while transporting the machine
on a truck or trailer as it is dangerous.
1 MDAA-01-329
The door handle (3) is not a handrail. Do not use the
door handle (3) as a handrail when getting on and
off the machine.
Do not hold the control levers (4) or control shut-off
lever (5) when getting on and off the machine.

MDAA-01-338

1-2
 OPERATOR'S STATION

Cab Features
1 2 3 4 5 6
1- Left Control Lever/Horn Switch
2- Left Travel Pedal 7
3- Left Travel Lever
4- Right Travel Lever
5- Right Travel Pedal 14
8
6- Right Control Lever/Power Boost Switch
7- Monitor Panel 9

8- Switch Panel 10

9- Key Switch 11

10- Radio 13

11- Air Conditioner Panel

12- Operator's Seat
13- Cab Door Release Lever 12 MDCR-01-002
14- Pilot Control Shut-Off Lever
15- Glove Compartment (Hot and Cool Box) 15 16 17

16- Glove Compartment

17- Cigar Lighter 18

18- Fuse Box

19- Switch Panel (for Optional Equipments)
20- Ash Tray
19
21- Engine Stop Switch
22- Handle (Emergency Engine Stop) 20

MDCR-01-003

21 22 MDCR-01-004

1-3
 OPERATOR'S STATION

Monitor Panel
1- Coolant Temperature Gauge 1 2

2- Fuel Gauge
3- LCD (Hour Meter, etc.)
4- Digging Mode Indicator
5- Attachment Mode Indicator
6- Air Filter Restriction Indicator
7- Remaining Fuel Indicator
8- Pilot Control Shut-Off Lever Indicator 3
17
9- Hydraulic Oil Filter Restriction Indicator
16
4
10- Preheat Indicator
15
11- Engine Trouble Indicator 5

12- Alternator Indicator 14 6

13- Overheat Indicator
13
7
14- Low Engine Oil Pressure Indicator
15- Auto-Idle Indicator 12

16- ECO Mode Indicator 11 8

17- PWR Mode Indicator

MDCR-01-027
10 9

1-4
 OPERATOR'S STATION
Coolant Temperature Gauge
The engine coolant temperature is indicated with a needle.
Normally the needle is around the center of the scale during
operation.

M178-01-104

Fuel Gauge
The remaining fuel amount is indicated by the needle.
Refuel before the needle reaches "E".

M178-01-105

Auto-Idle Indicator
The indicator lamp lights ON in green when the auto-idle
switch is turned to the A/I ON position.

MDCR-01-006

ECO Mode Indicator

The indicator lamp lights ON in green when the power
mode switch is turned to the ECO position.

MDCR-01-007

PWR Mode Indicator

The indicator lamp lights ON in green when the power
mode switch is turned to the PWR position.

MDCR-01-008

1-5
 OPERATOR'S STATION
Digging Indicator
The indicator lights ON in green when the work mode
switch is turned to the bucket mark.

MDCR-01-009

Attachment Indicator
The indicator lights ON in green when the work mode
switch is turned to the ATT1 or ATT2 position.

MDCR-01-010

Remaining Fuel Indicator

When the remaining fuel indicator lights ON at a flat
ground, remaining fuel level is approximately 40 litters. Refill
fuel as soon as possible.
M178-01-034

Air Filter Restriction Indicator

The indicator warns restriction of air cleaner elements. Clean
or replace the filter when the red lamp lights ON.
M178-01-035

Overheat Indicator
This indicator warns abnormally increased coolant
temperature. The red lamp lights ON and overheat buzzer
sounds simultaneously. When the red lamp lights ON and
the buzzer sounds, immediately stop machine operation,
M178-01-036
run the engine at slow idle speed and lower the coolant
temperature.
When the engine runs at slow idle speed, the buzzer stops.

1-6
 OPERATOR'S STATION
Low Engine Oil Pressure Indicator
This indicator warns low engine oil pressure. The red lamp
lights ON and buzzer sounds simultaneously. When the red
lamp lights ON and the buzzer sounds, immediately stop
M178-01-037
the engine, check the engine oil system and oil level.

Alternator Indicator
This indicator warns abnormality of the electric system
while running the engine. When the alternator voltage falls
out of the specified range, the red lamp lights ON. M178-01-038
Check alternator and battery system.

Preheat Indicator
When the orange lamp is lit, the engine is preheating; when
the lamp turns off, the preheating is completed.
M178-01-041

Hydraulic Filter Indicator (Optional)

This indicator warns restriction of the hydraulic filter. Clean
or replace the filter when the red lamp lights ON.
M1CC-01-039

1-7
 OPERATOR'S STATION
Engine Trouble Indicator
Engine or engine related parts are abnormal. Consult your
authorized Hitachi dealer when the indicator lights ON in
red.
MDCR-01-011

Pilot Control Shut-Off Lever Indicator

Pilot control shut-off lever system is abnormal. Consult your
authorized Hitachi dealer when the indicator lights ON in
red.
MDCR-01-012

1-8
 OPERATOR'S STATION
LCD
"Hour Meter" can be displayed on LCD (3) as the standard
mode.

LCD (3) is capable of displaying "Engine Speed" and

"Hydraulic Oil Temperature" as the user mode.

NOTE: The user mode is hidden when the machine is shipped

3
out from the factory. Consult your authorized Hitachi dealer
to display the user mode.

MDCR-01-027

Display Selector
Display
When the display is set to the user mode, each time the Selector
selector is pressed, display changes "Hour Meter", "Engine
Speed" and "Hydraulic Oil Temperature".

MDCR-01-015
Hour Meter
Accumulated machine operation hours is displayed on LCD
(3). One digit after the decimal point indicates tenths of an
hour (6 minutes).
The hour meter mark comes ON when the hour meter is
displayed. The decimal point blinks during the machine
operation.
Hour Meter Display M178-01-006

1-9
 OPERATOR'S STATION

Switch Panel
1- Engine Control Dial
1
2- Auto-Idle Switch
3- Power Mode Switch
4- Travel Mode Switch 2

5- Work Mode Selector

3
6- Work Light Switch
7- Wiper/Washer Switch
4

MDCR-01-016
5

Engine Control Dial

Use the engine control dial to adjust engine speed.
Fast Idle
The fully clockwise position : Fast Idle
Counterclockwise : Slow Idle

Slow Idle

M178-01-011

1-10
 OPERATOR'S STATION
Auto-Idle Switch
The auto-idle Switch sets the engine speed control mode to
the "Auto-Idle".
MDCR-01-017
Auto-Idle
When the auto-idle switch is turned to "A/I ON" position,
the engine speed decreases to the idle after approximately
4 seconds at the state in which the work lever is turned to
neutral.
This function saves fuel consumption.
When the auto-idle mode is selected, auto-idle indicator (1)
on the monitor panel comes ON.

MDCR-01-027

1-11
 OPERATOR'S STATION
Power Mode Switch
Two engine speed modes, "ECO" and "PWR" modes are
selected by operating the power mode switch.

ECO (Economy) Mode

Although production is slightly reduced more than in the
PWR mode, the fuel consumption and noise levels are
reduced, allowing the machine to operate efficiently.
MDCR-01-001
PWR (Power) Mode
Operate the machine in this mode when performing normal
work.

Travel Mode Switch

Two travel modes, FAST and SLOW, are selected by turning
the travel mode switch to either position.

Mark (Fast Speed Mode)

Mark (Slow Speed Mode)

MDCR-01-024

1-12
 OPERATOR'S STATION
Work Mode Switch
Work mode switch selects "Digging Mode", "Attachment
Mode 1" or "Attachment Mode 2".

Digging Mode
MDCR-01-018
Operate the machine in this mode when performing normal
digging work. Digging indicator (2) comes ON when this
mode is selected.

Attachment Mode 1
Operate the machine in this mode when an optional
attachment 1 is installed. Attachment indicator (3) comes
ON when this mode is selected.

Attachment Mode 2
Operate the machine in this mode when an optional
attachment 2 is installed. Attachment indicator (3) comes
ON when this mode is selected.
2
NOTE: Attachment mode 1 and 2 are set for the breaker
3
when the machine is shipped. Consult your authorized Hitachi
dealer to change to other attachment.

MDCR-01-027

1-13
 OPERATOR'S STATION
Work Light Switch
Work light switch has the following positions.

1 Position : Work light (1) on the base machine will light.

2 Position : Work light (2) mounted on the boom and
work light (1) on the right side of the machine
will light. Also, the switch panel illumination MDCR-01-025
becomes dark.
OFF : Work light (1) and (2) go OFF.

M157-01-146

1-14
 OPERATOR'S STATION
Wiper/Washer Switch
The wiper and the window washer are operated using the Slow
wiper/washer switch. Mid
Fast
Wiper
Turn the wiper/washer switch to the specified position to
operate the wiper.
MDCR-01-026
OFF Position The wiper stops and is retracted.
INT Position The wiper operates intermittently at the
interval selected by the switch position as
described below. INT has three positions of
operating speed as shown below.
INT (Slow): The wiper operates at 8-second interval.
INT (Mid): The wiper operates at 6-second interval. Wiper
INT (Fast): The wiper operates at 3-second interval.
ON The wiper operates continuously.

NOTE: When the front window (upper) is opened, the wiper

and washer will not operate. If the front window is opened
while operating the wiper, the wiper stops.

Washer
Press and hold the wiper/washer switch to squirt washer
fluid onto the front window. When the wiper/washer switch
is pressed for more than 2 seconds, the wiper operates until
the switch is released. When the wiper/washer switch is
released, the wiper automatically retracts.
While operating the wiper in the INT mode, when the
wiper/washer switch is pressed, the wiper operation mode
is changed to the continuous operation mode.

NOTE: The wiper motor protection function stops wiper

operation to prevent the wiper motor to be seized when the
wiper is operated long period of time under high load. When M1U1-01-018
the wiper stops, do not change the arm position and wait
several minutes until the wiper starts operation again.

IMPORTANT: The washer motor in the washer fluid tank

may be damaged if washer fluid is kept squirted for
more than 20 seconds or the motor is continuously
operated with the washer fluid tank empty. Monitor
the washer fluid squirting time and the fluid level in
the washer reservoir.

1-15
 OPERATOR'S STATION

Switch Panel (for Optional Equipments) Armrest

NOTE: The optional switch locations differ depending on the

kinds of optional devices are equipped.
Before using the switches, make sure what kinds of optional
devices are equipped. Raise the armrest when operating the
optional switch. All available optional devices are shown
below.

Travel Alarm Deactivation

Swing Alarm Deactivation

Optional Switch MDCR-01-015

Travel Alarm Deactivation Switch (Optional) 1

The travel alarm buzzer sounds during travel operation.
When pressing the mark of travel alarm deactivation
switch (1), the travel alarm buzzer function is deactivated.

M1U1-01-035

Swing Alarm Deactivation Switch (Optional) 2

The swing alarm system sounds the buzzer and turns the
beacon light ON during swing operation.
When pushing the mark of swing alarm deactivation
switch (2), the swing alarm buzzer function is deactivated.

M1U1-01-036

1-16
 OPERATOR'S STATION

Key Switch 1 2 3 4

1- OFF (Engine Off )

2- ACC (Horn, Radio etc.)
3- ON (Engine ON)
4- START (Engine Start)

M178-01-049

Power Boost Switch

Power boost switch (5) is provided on the top of the right
control lever.
When power boost switch (5) is pushed, increased front
attachment power will be supplied for about 8 seconds. 5

MDCR-01-019

Horn Switch
Horn switch (6) is located on the top of the left control lever.
The horn continuously sounds as long as the switch is pushed.
6

MDAA-01-345

1-17
 OPERATOR'S STATION

Cigar Lighter 1

Using Cigar Lighter

IMPORTANT: In case the cigar lighter does not pop out
automatically 30 seconds after pushing the cigar
lighter in, pull out the cigar lighter manually. Then,
consult the your nearest Hitachi dealer.

1. Turn key switch (1) to the ACC or ON position.

2. Press and release the lighter knob. M178-01-049

3. The cigar lighter knob will return to the original position

when the lighter becomes usable. Pull the cigar lighter
Cigar Lighter
out to use.
4. After using the cigar lighter, insert the cigar lighter into
the panel until the knob is seated in the original position.

Using Cigar Lighter Port as External Power Source

Use the cigar lighter port to supply power to lighting
equipment for servicing the machine.

IMPORTANT: Only 24 V electric power is available from

the cigar lighter port on this machine.
MDAA-01-297
Never connect accessories that use power other than
24 V. Damage to the batteries and accessories may
result.
Do not supply power to accessories for a long time
without running the engine. Failure to do so may
discharge the batteries.

1. Pull the lighter knob out.

2. Correctly insert the accessory socket into the cigar
lighter port.
3. Turn key switch (1) to the ACC or ON position. Power is
supplied to the connected accessory.
4. After using the accessory, disconnect the accessory
socket and insert the cigar lighter into the port.

1-18
 OPERATOR'S STATION

Cab Light Switch 1

Push switch (1) on the cab light to turn the cab light ON.

ON : The cab light comes and stays ON.

(The light does not turn ON while the key OFF.)
OFF : The light goes OFF.
Neutral : The light goes OFF.

MDAA-01-305

MDAA-01-318

1-19
 OPERATOR'S STATION

Pilot Control Shut-Off Lever 1

Pilot control shut-off lever (1) functions to prevent the

machine from being mistakenly operated when the operator is
getting on or off the machine.

WARNING:
Always pull pilot control shut-off lever (1) into the
full LOCK position. Unless pilot control shut-off lever
(1) is fully moved to the LOCK position, the control
lever is not locked, possibly creating a hazardous
situation.
When leaving the machine, always stop the engine. LOCK position MDCR-01-020
Then, pull the pilot control shut-off lever up to the
LOCK position. 1
Always check to be sure that the pilot control shut-
off lever is pulled up to the LOCK position before
transporting the machine or leaving the machine at
the end of the shift.
Confirm that the pilot control shut-off lever is in the
LOCK position before starting the engine. The engine
will not start in other than the LOCK position.

UNLOCK position MDCR-01-021

1-20
 OPERATOR'S STATION

Engine Stop Switch

In case the engine does not stop even if the key switch is
turned OFF due to failure of the machine, remove cover (1)
located at the front-left side of the seat stand and move switch
(2) downward to stop the engine.
After operating switch (2), be sure to return the switch back to
the upward position and install cover (1).

2 MDCR-01-004

Handle (Emergency engine stop)

In case the engine does not stop even if the key switch is
turned OFF due to failure of the machine, fully pull handle
(3) located at the front-left side of the seat stand to stop the
engine.

IMPORTANT: Stop the engine by using the handle in

emergency situations.
NOTE: If handle (3) is pulled in a halfway, the fuel cut lever in
the governor is also pulled, the engine may not start or stop
1 3 MDCR-01-022
during operation. Be sure to return handle (3) to its original
position.

1-21
 OPERATOR'S STATION

Fuse Box

10- CONTROLLER 20- OPTION3

5A 5A

9- BACKUP 19- HORN

10 A 10 A
8- ECF 18- -
5A
7- ROOM LAMP 17- POWER ON
5A 5A
6- OPTION2 16- GLOW. R
20 A 5A
5- OPTION1 15- AUXILIARY
MDAA-01-297
5A 10 A
4- SOLENOID 14- MONITOR
10 A 5A 10 20
3- HEATER 13- LIGHTER 9 19
20 A 10 A
8 18
2- WIPER 12- RADIO
7 17
10 A 5A
6 16
1- LAMP 11- EC MOTOR
20 A 10 A 5 15
4 14
3 13
2 12
1 11

M1GR-01-003

1-22
 OPERATOR'S STATION

Auto Air Conditioner

Features:
Full Auto-Temperature Control:
Automatically controls the cab temperature to maintain
the temperature set by the temperature control switch
regardless of outside air temperature and insolation.

Max. Cooling and Heating:

Maximum cooling or heating can be obtained by moving
the temperature control switch to the full right or left
respectively.

Preheating:
During preheating the cab in winter with the foot vent
selected, the air volume is reduced to Low until the coolant
temperature rises to prevent cool air from entering the cab.

NOTE: Even in the summer season, the high idle speed may
be higher than the normal speed due to the above control.

1-23
 OPERATOR'S STATION
Components Name
1
1- Front Vent
2- Foot Vent
3- Defroster Vent
4- Rear Vent
5- Air Conditioner Panel
6- OFF Switch
7- Liquid-Crystal Display (LCD)
8- Circulation Air/Fresh Air Selector Switch
9- Mode Switch MDCR-01-020
3 2
10- Blower Switch
11- Temperature Control Switch 4
12- AUTO Switch
13- Air Conditioner Switch

NOTE: Air flow direction can be changed by controlling the

louvers at all air vents except for foot vents (2). In addition,
the louvers on front vent (1) and defroster vent (3) can be
completely opened and closed by hand.
5

MDCR-01-003

6 7 8

13 12 11 10 9
MDCR-01-023

1-24
 OPERATOR'S STATION
Controller Part Name and Function
Mode Switch (9) 7 10
Selects the air vent. The selected air vent is indicated on LCD
(7).
Air flows out of front vent and the defroster vents.
(Including defroster vent)

Front and Rear Vents 12 11 9 MDCR-01-023

(Including defroster vent)
Air flows out of the front, rear, foot and the
defroster vents.
(Including defroster vent)

Foot Vent Mode

Each time mode switch (9) is pressed, the vent location can be
changed in four stages as illustrated below.

AUTOl l l l

When switch (12) is selected in AUTO:

The air vent location is automatically selected.

Temperature Control Switch (11):

Sets temperature in the cab.
Temperature in the cab can be set from 18.0 to 32.0 °C.
Temperature can be set by 0.5 °C increments.
The set-temperature is displayed on LCD (7).

1-25
 OPERATOR'S STATION
Blower Switch (10):
When the "AUTO" is indicated on the LCD (7), the blower 7 AUTO Indicator
speed is automatically controlled.
When the "AUTO" is not indicated on the LCD (7), the
blower speed is controlled in 6 steps.
Press of blower switch (10) to increase blower speed.
Press of blower switch (10) to decrease blower
speed.
LCD (7) indicates the corresponding blower fan speed. 10 MDCR-01-023

Air Conditioner (A/C) Switch (13):

6 7
When the air conditioner switch is pressed while A/C
indicator on LCD (7) is OFF, the switch turns ON and A/C
indicator on LCD (7) comes ON.

OFF Switch (6):

Press OFF switch (6) to turn the blower and the air
conditioner OFF. 13 12 A/C Indicator MDCR-01-023

AUTO Switch (12):

Press AUTO switch (12) to turn the AUTO indicator on LCD
(7) comes ON and the air flow-in temperature at the vents,
blower speed, locations of vents, and fresh air suction ports
are automatically controlled.

Circulation Air/Fresh Air Selector Switch (8): 8

Each time circulation air/fresh air selector switch (8) is
pressed, circulation air and fresh air mode is selected.
The fresh air mode allows fresh air to flow in.

MDCR-01-023

1-26
 OPERATOR'S STATION
Cab Heater Operation
8
1. AUTO Switch (12):
According to signals sent from various sensors, the air
conditioner amplifier automatically selects the air flow-in
vents, air suction ports, and air flow-in temperature at
the vent, and controls the blower speed.
2. Temperature Control Switch (11): 12 11 10 9
Adjust temperature control switch (5) so that "25.0" is MDCR-01-023
indicated on the monitor. Control air temperature inside
cab using this switch as necessary.
3. As Necessary:
Operate Mode switch (9) to manually select the air vent.
Operate blower switch (10) to manually control the
blower speed.
Operate circulation air/fresh air selector switch (8) to
maintain the air vent in the fresh air mode or circulation
mode.

Usually the cab heater turns the dehumidifier function OFF,

however, it turns ON by switching the air conditioner switch
to ON.

1-27
 OPERATOR'S STATION
Cooling Operation
8
1. AUTO Switch (12):
Press AUTO switch (12) to set the air conditioner AUTO
mode. According to signals sent from various sensors,
the air conditioner amplifier automatically selects
the air flow-in vents, air suction ports, and air flow-in
temperature at the vent, and controls the blower speed.
12 11 10 9
2. Operate Temperature Control Switch (11).
MDCR-01-023
Adjust temperature control switch (5) so that "25.0" is
indicated on the monitor. Control air temperature inside
the cab using this switch as necessary.
3. As Necessary:
Operate Mode switch (9) to manually select the air vent.
Operate blower switch (10) to manually control the
blower speed.
Operate circulation air/fresh air selector switch (8) to
maintain the air vent in the fresh air mode or circulation
mode.

In case the front window (lower) becomes clouded,

manually close the defroster vent (3). (It can be closed
manually.)

3 MDAA-01-295

1-28
 OPERATOR'S STATION
Defroster Operation
1. Press AUTO Switch (12). Temperature-controlled air
blows out. During cold weather season when starting
the engine, the engine coolant temperature and air
temperature in the cab are low. The Heater Start-
Operation Control System controls the blow rate to the
minimum (LO) in order to restricts cool air from flowing
into the cab. 12 11 10 9
MDCR-01-023
2. Adjust temperature control switch (11) so that "25.0" is
indicated on the monitor. Set the fresh air circulation
mode from air conditioner setting screen on the monitor.
3. Select the front vents or the front and rear vents
using mode switch (9).

Control air flow direction by adjusting the louvers at the 1

front vent (1) and the defroster vent (3).

Control air temperature in the cab by using temperature

control switch (11).
If the windowpanes become clouded in rainy season or
when dehumidifying, turn the air conditioner switch ON.

Cool Head/Warm Feet Operation

Cool and warm air is simultaneously supplied to the head
vents and feet vents respectively.
3 MDAA-01-295
1. Press blower switch (10) to adjust the blower speed.
2. Press MODE switch (9) to display the mark on the
LCD.
Turn the air conditioner switch ON.

Control air temperature inside the cab by operating

temperature control switch (11).

1-29
 OPERATOR'S STATION

Tips for Optimal Air Conditioner Usage

For Rapid Cooling
Temperature in the cab may rise over 80 °C (176 °F) when
the machine is exposed to sun light in the summer.
In this case, ventilate air in the cab first by opening the
windows for rapid cooling.
After starting the engine, press AUTO switch (12). Set
temperature indicator to "18.0" by using temperature 12 11 MDCR-01-023
control switch (11). Turn the circulation air/fresh air selector
switch to the circulation mode.
Close the window when the cab cools down to the ambient
temperature.

When Windows Become Clouded

If the insides of the windows become clouded during rainy
weather or on humid days, operate the air conditioner to
aid in keeping the windows clear. When the atmosphere is
very damp, and if the air conditioner has run excessively,
the outside of the windows may become clouded. If
this happens, turn off the air conditioner to adjust the
temperature in the cab.

Off-Season Air Conditioner Maintenance

To protect each part of the compressor from a lack of
lubricant, operate the air conditioner at least once a month
for several minutes with the engine running at a slow speed Air Conditioner Sensor
during off-season.

IMPORTANT: Do not suddenly increase the engine speed.

Failure to do so may damage the compressor.
Refer to the item "Check Air Conditioner Filter" in
the Maintenance Section for maintenance of the air
conditioner filters.
Always clean the auto air conditioner sensor for
effective air conditioner performance. Avoid placing
any obstructions around the sensor.

MDCR-01-019

1-30
 OPERATOR'S STATION

AM/FM Radio Operation

CAUTION: Refrain from listening to the radio in the

cab while operating the machine.
3 6 4 2

Controls on the radio

1- Power Switch
2- Volume Control Switch
3- AM/FM Selector
Each time the switch is pressed, AM/FM is changed as
7 5 8 1 M1U1-01-119
follows: FM1 l FM2 l AM l FM1….
4- Station Presets
Press this button to select a preset station or registering
a station for preset.
5- UP/DOWN Buttons
This button is used to change the radio wave frequency,
adjust the sound parameter and clock setting.
6- Display Mode Change Switch
Each time this button is pressed, display changes
alternately to "Clock" and "Radio Receiving Frequency".
7- Digital Display
8- Sound Button
Press this switch to adjust sound (Balance/Bass/Treble).

1-31
 OPERATOR'S STATION
Tuning Procedure
Manual Tuning Procedure
Repeatedly tap UP or DOWN button (5) until the desired
station is reached. Each time the switch is pressed, the
frequency changes at an interval.
To go up to the next higher frequency station, press the
[UP] button.
To go down to the next lower frequency station, press the 7 5 M1U1-01-119
[DOWN] button.
Automatic Search Function
Press and hold UP/DOWN buttons (5), then release.
When a station is received, the auto-seeking function is
deactivated automatically.
To go up to the next higher frequency station, press the
[UP] button. To go down to the next lower frequency
station, press the [DOWN] button.
In order to deactivate the automatic search function
while it is operating (while searching the next available
frequency station), simply tap UP or DOWN button (5)
again. If the receiving radio waves are weak, i. e. such
as when the machine is located between high rising
buildings, etc., use the manual tuning procedure to select
the desired station.

Station Presetting Procedure

4
1. Select the desired station by using UP/DOWN buttons
(5). Refer to the "Tuning Procedure" in the previous
section.
2. Hold down one of PRESET buttons (4) to preset the
current station to the selected PRESET button (4). When
the preset procedure completes, the preset No. (such as
"P-1") flashes 3 times on LCD (7).
7 5 M1U1-01-119
Once the presetting is complete for a station preset
button (4), the radio will be tuned to the preset station
when one of a PRESET buttons (4) is tapped.

1-32
 OPERATOR'S STATION
To change the preset stations, follow the same
procedure as when newly presetting stations.
Deletion of Preset Memory
If the battery power is disconnected while servicing the
machine or by removing the radio, the preset memory in
PRESET buttons (4) will be deleted. In this case, preset the
stations again.

Digital Clock Setting Procedure

In order to set the clock, digital display (7) must be in the
time display mode.

NOTE: If the battery power is disconnected due to battery

running out, the clock displays "12:00" when restarting the
machine.

Time Adjustment
1. Tap display button (6) to indicate the hour on display (7). 6

2. Hold down display button (6) to flash "hour" part of

display (7). Set the "hour" part with UP/DOWN buttons
(5).
When the "UP" button is pressed while "hour" part
indicates "12", it returns to "1". The time is displayed in 12
hour standard.
7 5 M1U1-01-119
3. Tap display button (6) to flash "second" part of display
(7). Set the "second" part with UP/DOWN buttons (5).
When the UP button is pressed while "second" part
indicates "59", it returns to "00". However, the hour
display remains unchanged in this case.
4. Tap display button (6) again to complete time setting.
The time display stops flashing and changes to stay ON.

1-33
 OPERATOR'S STATION
Sound Adjustment
1. Tap sound button (8) to display "BAL" on the top of
display (7).
2. Adjust volume balance of left and right speaker with UP/
DOWN buttons (5).
Press DOWN button to increase the volume of left side
speaker, press UP button to increase the volume of right
side speaker.
3. Tap sound button (8) to display "TRE" on the top of 7 5 8 M1U1-01-119
display (7).
4. Adjust treble with UP/DOWN buttons (5).
5. Tap sound button (8) to display "BAS" on the top of
display (7).
6. Adjust bass with UP/DOWN buttons (5).
7. Tap sound button (8) to finish the sound adjustment.

NOTE: If the battery power is disconnected due to battery

running out, all set values will be set to "0" when restarting the
machine.

1-34
 OPERATOR'S STATION

Cab Door Release Lever

CAUTION:
Open the cab door all the way until it securely locks
in the latch on the side of the cab.
Do not unlock the cab door when the machine is
parked on a slope or while the wind is blowing hard.
The cab door may close accidently, possibly resulting
in personal injury.
When opening or closing the cab door, take extra
care not to catch fingers between the base machine
and the cab door.

1 MDAA-01-320
To unlock the door, push down on lever (1).

1-35
 OPERATOR'S STATION

Opening/Closing and Removing Cab Inside

Window

WARNING: 1

Open, close or remove the upper-front cab window,

overhead window, cab door window or lower-front
window only after lowering the front attachment
to the ground and pulling up pilot control shut-off
lever (1) to the LOCK position. Failure to do so may
allow the machine to move unexpectedly if a control
lever or pedal is touched with a part of the body
by mistake, possibly resulting in personal injury or
death.
Park the machine on a level and solid ground and
stop the engine before opening and closing the
MDCR-01-020
upper front window.
To open the upper front window, hold the window by
hands, hold it until the window is locked.
When closing the window, it may accidently fall by
its own weight. Hold the window by hands until it is
completely closed. Since the window stops before
it completely closes, do not operate the machine at
the position with the window being stopped. The
window is not locked at that position, having the
possibility of suddenly dropping.

1-36
 OPERATOR'S STATION

Opening Upper Front Window

Opening Upper Front Window
1. Press lock release lever (1) at the upper center to release
the upper front window lock.
1
2. Holding lock release lever (1) at the upper center and 2
lower handle on the upper front window, pull the upper
front window up and back until it securely catches into
auto locks (3).
3. After confirming that the window securely catches into
auto locks (3), slide lock pin (2) into the left bracket boss
hole to lock the window in position. M1U1-01-028
Front Window Close Front Window Open
NOTE: When the upper front window is opened, the wiper LOCK Position LOCK Position
and washer are inoperable.

CAUTION:
Slowly close the upper front window so that not to
catch your fingers. Upper Front Window
Suspended Position
Always secure lock pin (2) in the lock position after
the upper front window is opened.

4. To close the upper front window, by following the steps

1 to 3 in the reverse order. The window stops before it
completely closes, so close the front window by pushing
release lever (1) upward. MDAA-01-328

Push release lever (1) downward to release auto lock (3).

NOTE: Unless the upper front window is securely closed, the

wiper and washer will not operate.
2

3 MDAA-01-306

1-37
 OPERATOR'S STATION

Removing and Storing Lower Front Window

CAUTION: Take care not to pinch yours fingers when

handling the lower front window.

Removing and Storing Lower Front Window

1. Open the upper front window beforehand when
removing the lower front window.
2. While pulling the lower front window inward, raise it to
remove.
3. Store the removed windowpane in the storing position.
After inserting the windowpane into rubbers (2 and 3), MDAA-01-298
slide it sideways securely into rubber (4). Then, push
4 1
fastener (1) to lock.

3
2

MDAA-01-299

1-38
 OPERATOR'S STATION

Opening Side Windows 1

Hold handle (1) and slide rear pane to open the side window.

Side Window M178-01-061

1-39
 OPERATOR'S STATION

Opening/Closing Overhead Window 1

Move lock levers (1) toward center of window. Hold handle
(2) and lift window until it rises upright. With the window
positioned upright, it will be secured in position by dampers
(3).
Hold handle (2) and pull window down until "click" sound is
heard from left and right locks (1).
Note that the overhead window can be used as an emergency
exit.

2
MDAA-01-302

MDAA-01-303

1-40
 OPERATOR'S STATION

Emergency Exit
1
Escape from the cab in emergency in the following methods:

CAUTION: The danger of downfall is always present

when escaping from the cab in emergency, possibly
resulting in serious personal injury. Escape from the
cab as safely as possible, depending on the posture of
machine and the outside situation.

1. Open the cab door. Escape through the door.

2. If the cab door should be difficult to open or use, open
the upper front window. Escape through the window.
MDAA-01-321

NOTE: Emergency exit decals (2) are affixed to the front and
rear windows. See page "OPENING UPPER FRONT WINDOW"
for the opening method of the upper front window.

CAUTION: If decal (3) is affixed to the front window

glass, the glass can be broken. However if decal (3) is
not affixed to the front window glass, the glass cannot
be broken with emergency evacuation hammer (1).
Take care not to be injured with pieces of broken glass.
3 2

M1U4-01-012

3 2

MDAA-01-322

1-41
 OPERATOR'S STATION
3. If upper front window should be difficult to open, check
the decal (3) affixed to the window glass.
If decal (3) is affixed to the front window glass, break the
front window glass using the emergency evacuation tool
(1) installed the cab left side. Then escape through the
broken window.
4. If decal (3) is not affixed to the front window glass, or if
the front window is not available for escaping, break the
rear window glass using the emergency evacuation tool
(1). Then escape through the broken window.
5. If neither of front and rear windows is available for
emergency exit, open the overhead window to escape
from the cab.

1-42
 OPERATOR'S STATION

Adjusting the Seat

WARNING: Adjust the seat only after lowering the

front attachment on the ground and pulling up the
pilot control shut-off lever to LOCK position. Failure to
do so may allow the machine to move unexpectedly
if a control lever or pedal is touched with a part of the
body by mistake, possibly resulting in personal injury
or death.
CAUTION: Avoid possible injury while operating
height/tilt lever (1). When pushing down lever (1), do SS-955
not grab it. Fingers may be pinched between lever (1)
and the seat stand. Be sure to push on the upper face
of lever (1) by your palm. Do not grasp the lever grip 4
to operate the lever, possibly resulting in pinch of your
fingers into the seat stand.

Seat Height and Angle Adjustment

Seat height adjustment range is 60 mm (2.4 in) with steps
every 15 mm (0.6 in) (5 positions in total).
Push down lever (1): to adjust front part of the seat.
Pull up lever (1): to adjust rear part of the seat.

3 2 1 MDCD-01-001
Console and Seat Fore-aft Adjustment
Operate console slide lever (2) to adjust the seat and both
right and left consoles to desired distance from the travel
pedals and levers. Seat and console fore-aft adjustment
range is 160 mm (4.7 in) with steps every 20 mm (0.8 in).

Seat Fore-Aft Adjustment

Operate console slide lever (3) to adjust the seat and both
right and left consoles to desired distance from the travel
pedals and levers. Seat and console fore-aft adjustment
range is 200 mm (4.7 in) with steps every 10 mm (0.8 in).

Backrest Adjustment
Pull up lever (4) to release backrest lock. Move backrest to
the desired position and release lever (4).

1-43
 OPERATOR'S STATION
Armrest Adjustment
Armrest (5) can be pulled upright by hand 90°. Pull the
armrest upright by hand to get on and off the machine
5
easily. The angle of armrest (5) can be adjusted to the
desired position by turning adjusting dial (6) located on the
bottom of armrest (5). 6

M1G6-01-017

1-44
 OPERATOR'S STATION

Adjusting Operator's Seat (Optional)

WARNING: Adjust the seat only after lowering the

front attachment on the ground and pulling up the
pilot control shut-off lever to the LOCK position.
Failure to do so may allow the machine to move
unexpectedly if a control lever or pedal is touched with
a part of the body by mistake, possibly resulting in
personal injury or death.
CAUTION: Avoid possible injury while operating
height/tilt lever (1). When pushing down lever (1), do SS-955
not grab it. Fingers may be pinched between lever (1)
and the seat stand. Be sure to push on the upper face
of lever (1) by your palm. Do not grasp the lever grip
to operate the lever, possibly resulting in pinch of your
fingers into the seat stand.
5 1
Seat Height and Angle Adjustment
Seat height adjustment range is 60 mm (2.4 in) with steps
every 15 mm (0.6 in) (5 positions in total).
Push down lever (1): to adjust front part of the seat.
Pull up lever (1): to adjust rear part of the seat.

4
Console and Seat Fore-aft Adjustment
Operate console and seat slide lever (2) to adjust the seat 2 4 3 MDAA-01-331
and both right and left consoles to desired distance from
the travel pedals and levers. Seat and console fore-aft
adjustment range is 160 mm (4.7 in) with steps every 20 mm
(0.8 in).

Seat Fore-Aft Adjustment

Operate seat slide lever (3) to adjust the seat to desired
distance from the travel pedals and levers. Seat and console
fore-aft adjustment range is 160 mm with steps every 10
mm.

Suspension Adjustment
Rotate knob (4) to adjust the suspension.
Rotate knob (4) clockwise (+ direction) to increase
suspension stiffness.
Rotate knob (4) counterclockwise (- direction) to decrease
suspension stiffness.

1-45
 OPERATOR'S STATION
Backrest Adjustment
Pull up lever (5) to release backrest lock. Move backrest to
the desired position and release lever (5).
5

MDAA-01-331

Armrest Adjustment
Armrest (6) can be pulled upright by hand 90°. Pull the
armrest upright by hand to get on and off the machine
easily. The angle of armrest (6) can be adjusted to the
6
desired position by turning adjusting dial (7) located on the
bottom of armrest (6).
7

M1G6-01-017

1-46
 OPERATOR'S STATION

Installation and Adjustment of Mirrors

WARNING: Adjust the mirrors before operating the 1m

machine. Improper adjustment of the mirrors provides
poor visibility, which may cause serious human injury
or death.

IMPORTANT: When operating the machine, pay thorough

attention to the surrounding situation.

Adjust the mirrors so that persons standing within 1 m from

the machine (or object with height of 1.5 m and 30 cm in
diameter) can be recognized from the operator's seat.

MDAA-01-334

1-47
 OPERATOR'S STATION

Seat Belt
2 1
WARNING:
Be sure to use seat belt (1) when operating the
machine.
Before operating the machine, be sure to examine
seat belt (1) and attaching hardware for any failure.
If any damage and/or wear are found, replace the
part concerned.
Replace seat belt (1) every 3 years regardless of
appearance.

Seat Belt M1U1-01-031

1. Confirm that seat belt (1) is not twisted. Securely insert 2 1

the end of seat belt (1) into buckle (2). Lightly pull on the
belt to confirm that the buckle latches securely.
2. Push button (3) on buckle (2) to unfasten seat belt (1).

Replace the seatbelt if they are damage or worn, or if the

seatbelt had external damaged such as an accident.

3
M1U1-01-032

1-48
 BREAK-IN

Observe Engine Operation Closely

IMPORTANT: Be extra cautious during the first 50 hours,
until you become thoroughly familiar with the sound
and feel of your new machine.

1. Operate the machine only in economy (ECO) mode and

limit the engine horsepower up to about 80 % of full
load.
2. Avoid excess engine idling.
3. Check indicator lights and gauges frequently during
operation.

Every 8 Hours or Daily

1. Perform 8-hour or daily service. (See Maintenance guide
-- 8 hours.)
2. Watch for fluid leaks.
3. Lubricate working tool pivots every 8 hours for the first
50 hours, and every 8 hours when working in mud and
water.

After the First 50 Hours

1. Perform 50-hour service. (See Maintenance guide -- 50
hours.)
2. Check accessible hardware torque. (See Hardware Torque
Specifications in Maintenance chapter.)

After the First 100 Hours

Perform 50-hour and 100-hour service. (See Maintenance
Guide -- 50 hours and 100 hours.)

2-1
 OPERATING THE ENGINE

Inspect Machine Daily Before Starting

Perform the required daily check before starting the engine.

Refer to "Maintenance" section for detailed information.

Check Points Check Points
1. Level and contamination of engine oil and coolant 1. Sag, wear and break of crawler

Undercarriage
2. Starting easiness, exhaust gas color, and noise 2. Oil leaks and wear on upper/lower rollers and front
idlers
3. Oil and water leaks, damage to hoses and pipe 3. Oil leaks from travel devices
Engine

lines
4. Clogging and damage to radiator, oil cooler and 4. Looseness and missing of mounting bolts and nuts
intercooler 1. Check cylinders, pipe lines and hoses for oil leaks and
damages.
5. Clean around muffler 2. Wear and damage of the bucket
6. Looseness and missing of mounting bolts and nuts 3. Check bucket teeth for looseness, wear and missing
1. Fuel level, leaks and contamination of fuel in tank 4. Lubrication state of the working device
Working Device

2. Hydraulic oil level, leaks and contamination of 5. Check for pin anti-extraction pins, stoppers, rings and
hydraulic oil tank bolts for damage
3. Movement, play and operating force of all control
levers
4. Operation of all hydraulic components, oil leaks 6. Looseness and missing of mounting bolts and nuts
and damage to pipe lines and hoses
Upperstructure

5. Deformation, break and abnormal noise of upper

structure
6. Looseness and missing of mounting bolts and nuts
7. Washer Fluid
1. Operation of instruments, switches, lights and buzzer/
horn
Others

2. Function of parking brake

3. Deformation and break of head guard
4. Abnormal outside appearance of machine
5. Wear and damage of the seat belt

3-1
 OPERATING THE ENGINE

Before Starting Engine 1

1. Confirm that pilot control shut-off lever (1) is in the LOCK

position.
2. Confirm that all control levers are placed in neutral.
3. Checking blowout of indicators
When key switch (2) is turned ON, all indicators and the
warning lights turn ON and stay lit for 3 seconds and
then turn OFF. Indicators and warning lights that did not
light within the period are blown out.
Blowout of hydraulic filter restriction indicator (5)
is checked only on the machines having the high MDCR-01-020
LOCK position
performance element (optional).
However, alternator indicator (3) and low engine oil
pressure indicator (4) will continue to stay lit.
2

IMPORTANT: The monitor panel displays control state

of the machine. If the machine is operated with some
blown out indicators, the warning will not be displayed
on the monitor even when there was an abnormality
of the machine. Immediately consult your authorized
Tata-Hitachi dealer if any indicator is blown out. M178-01-049
Besides, if alternator indicator (3) or low engine oil
pressure indicator (4) light was off after indicators'
blowout check, the machine is abnormal. Immediately
consult your authorized Tata Hitachi dealer.

4. Adjust the seat to allow full pedal and control levers

stroke with operator's back against the backrest. Fasten
the seat belt.

NOTE: The monitor surface is a resin product. When the

surface becomes dusty, lightly wipe the surface with a wet
cloth. Never use an organic solvent.

MDCR-01-027
5

3-2
 OPERATING THE ENGINE

Starting the Engine 1

Starting the Engine

1. Confirm that pilot control shut-off lever (1) is in the LOCK
position.
2. Insert key switch (2). Turn it to ON position.
3. Sound horn to alert bystanders
4. Turn engine control dial (3) to the slow idle position.
5. Turn key switch (2) to "START" position to rotate the
starter. The engine will start.
IMPORTANT: Never operate the starter for more than 10 MDCR-01-020
seconds at a time. If engine fails to start, return key LOCK Position
switch to "OFF". Wait for more than 30 seconds, then
try again.
Failure to do so may cause damage to the starter and/ 2
or discharging the batteries.

6. Release key switch (2) immediately after the engine has

started. The key switch will automatically return to the
"ON" position.

M178-01-049

Slow Idle

3
M1U1-01-033

3-3
 OPERATING THE ENGINE
Starting the Engine in Cold Weather
Preheating 1
1. Confirm that pilot control shut-off lever (1) is in the LOCK
position.
2. Turn engine control dial (3) to around the middle
between the L and H position.
3. Turn key switch (2) to the "ON" position.
4. The machine will automatically check if preheating is
required or not. When preheating is required, preheat
indicator (4) will be lit for 8 seconds.

NOTE: In case, preheat indicator (4) does not turn ON,

preheating is not required. LOCK Position MDCR-01-020

5. As soon as preheat indicator (4) turns OFF, turn key

switch (2) to "START" position to rotate the starter.
Release key switch (2) immediately after the engine has
started.
2

Slow Idle

3
M178-01-049 M1U1-03-003

MDCR-01-027
4

3-4
 OPERATING THE ENGINE

Check Instruments After Starting

IMPORTANT: In case any abnormality is found on the
monitor unit, immediately stop the engine. Inspect the
cause of the trouble.

Checking instruments through Monitor Functions

1. Check that alternator indicator (1) is OFF.
In case alternator indicator (1) stays ON, immediately
stop the engine. Inspect the alternator and battery
system for problems.
2. Check whether low engine oil pressure indicator (2) is
OFF.
In case low engine oil pressure indicator (2) stays ON, 2
immediately stop the engine. Inspect the engine oil
pressure system and the oil level.
1

Check engine noise and exhaust gas color:

Check that the engine noise and exhaust gas color is
normal.
MDCR-01-027
NOTE: Check the exhaust gas color as follows. (After warm-
up operation, run the engine with no loads.)
Clear or light blue : Normal (Perfect combustion)
Black : Abnormal (Imperfect combustion)
White : Abnormal (Oil is leaking into the
combustion chamber)

NOTE: White smoke may occur for several minutes after the
engine start, this is not a malfunction.

3-5
 OPERATING THE ENGINE

Using Booster Batteries

IMPORTANT: The machine electrical system is a 24 volt
negative (-) ground. Use only 24 volt booster batteries
with sufficient capacity.

CAUTION:
An explosive gas is produced while batteries are in
use or being charged. Keep open flames and sparks
away from the battery area. Do not continue to use
or charge the battery when electrolyte level is lower
than specified. Explosion of the battery may result.
SA-032
Park the machine and a machine with the booster
batteries on a dry or concrete surface, not on steel
plates. If the machine is parked on steel plates,
dangerous sparks may be unexpectedly created on
the machine.
Never connect a positive terminal to a negative
terminal, as a dangerous short circuit will occur.

When the machine batteries are exhausted, start the engine

using booster batteries as shown below.

Connecting the booster batteries 1 Connect First

1. Stop the engine of the machine on which booster

batteries are mounted. (Red)

2. Connect one end of red cable (1) to the positive (+)

terminal of the machine batteries, and the other end to
the positive (+) terminal of the booster batteries.
3. Connect one end of black cable (2) to the negative (–)
terminal of the booster batteries, and then make ground
connection to the frame of the machine to be started Booster Batteries Machine Batteries
with the other end of black (–) cable (2). In the last
connection to frame, sparks may fly. Be sure to connect (Black)
the cable end as far away from the machine batteries as To Upperstructure Frame of the Machine
possible. 2
Connecting the booster batteries M104-03-002
4. After securely connecting the booster cables, start the
engine of the machine on which booster batteries are
mounted.
5. Start the engine of the troubling machine.
6. After the engine starts, disconnect cables (2) and (1),
following the procedure below.

3-6
 OPERATING THE ENGINE
Disconnecting the booster cables 1

1. Disconnect black negative (-) cable (2) from the machine

frame first. (Red)

2. Disconnect the other end of black negative (-) cable (2)

from the booster batteries.
3. Disconnect red positive (+) cable (1) from the booster
batteries.
4. Disconnect red positive (+) cable (1) from the machine
batteries. Booster Batteries Machine Batteries

(Black)
To Upperstructure Frame of the Machine
2 Disconnect Booster Cable from
Frame First
M104-03-002
Disconnecting the booster cables

3-7
 OPERATING THE ENGINE

Stopping the Engine

Engine stop procedure
1. Except for special cases, before stopping the engine,
lower the bucket to the ground.
2. Pull pilot control shut-off lever (3) to LOCK position.
3. Turn engine control dial (1) to the slow idle position and
run the engine for 5 minutes to cool the engine. SA-390
3

IMPORTANT: If the engine equipped with a turbocharger

is stopped without first performing the cool down
operation, the lubricant on the turbocharger bearing
surfaces may desiccate due to the intense heat present
inside the turbocharger, possibly causing damage to
the turbocharger.

4. Turn key switch (2) OFF to stop the engine.

If the engine does not stop, even if the key switch is

MDCR-01-020
turned to the "OFF" position.
In case the engine does not stop even if key switch (2) is
turned OFF due to failure of the machine, fully pull handle
(4) located at the front-left side of the seat stand to stop the
engine. 1

NOTE: If handle (4) is pulled half way, the fuel cut lever in the Slow Idle
governor is also pulled, and the engine may not start or stop
during operation.
Be sure to return handle (4) to its original position.
M1U1-01-033

M178-01-049

4 MDCR-01-004

3-8
 DRIVING THE MACHINE

Drive the Machine Carefully

IMPORTANT: During freezing weather, park machine on
a hard surface to prevent tracks from freezing to the
ground. Clean debris from tracks and track frame.
If tracks are frozen to the ground, raise tracks using
boom, move machine carefully to prevent damage to
drive train and tracks.

Select a route that is as flat as possible. Steer machine

as straight as possible making small, gradual changes in
direction.

When driving over rough terrain, reduce the engine speed to

lessen possibility of undercarriage damage.

NOTE: An arrow-mark seal is stuck on the inside surface of

the side frame to indicate the machine front direction.

Arrow-mark
M178-03-001

4-1
 DRIVING THE MACHINE

Steering the Machine Using Pedals

WARNING: In the standard travel position, the front Front Idler

idlers are positioned at the front of the machine and Cab
the travel motors at the rear. If the travel motors are
positioned at the front of the machine, the control
actions of the travel pedals will be reversed. Be sure
to confirm the position of the travel motors before
traveling.

FORWARD TRAVEL
Travel Motor
Push down on front (A) of both pedals.
M104-01-038
REVERSE TRAVEL
Push down on rear (B) of both pedals.
NEUTRAL POSITION (C)
When the travel pedals are placed in neutral, travel
brakes automatically will stop and/or hold the
machine. A
D
RIGHT TURN
A C
Push down on front of left pedal. B
LEFT TURN D
C
Push down on front of right pedal. B
Forward and Reverse
M104-04-009 M104-04-003
SHORT TURN (Spin turn)
Push down the front of one pedal and the rear of the
other.

NOTE: For long-term traveling, push down on pedal tabs (D)

and rest feet on the footrests.

Pivot Turn
M104-04-010 M104-04-005

Spin Turn M104-04-007

M104-04-011

4-2
 DRIVING THE MACHINE

Steering the Machine Using Levers

WARNING: In the standard travel position, the front

Front Idler
idlers are positioned at the front of the machine and Cab
the travel motors at the rear. If the travel motors are
positioned at the front of the machine, the control
actions of the travel levers will be reversed. Be sure
to confirm the position of the travel motors before
traveling.

FORWARD TRAVEL
Travel Motor
Push both levers forward (A).
M104-01-038
REVERSE TRAVEL A
Pull both levers rearward (B). A C
NEUTRAL POSITION (C)
C
When the travel levers are placed in neutral, travel B
brakes automatically will stop and/or hold the B
machine.
D
RIGHT TURN
Push left lever forward.
LEFT TURN D

Push right lever forward.

Forward and Reverse
M104-04-009 M104-04-003
SHORT TURN (Spin turn)
Push one lever forward and pull the other rearward.

NOTE: For long-term traveling, push down on pedal tabs (D)

and rest feet on the footrests.

Pivot Turn
M104-04-010 M104-04-005

Spin Turn M104-04-007

M104-04-011

4-3
 DRIVING THE MACHINE

Travel Mode Switch

WARNING: Tipping-over accidents can cause serious

personal injury. Do not change travel mode switch (1)
while traveling; especially, changing to fast mode (2)
when descending slopes will create a very dangerous
situation. Always stop the machine before changing
the travel speed mode.
1
Turn travel mode switch (1) on the switch panel to the
specified position to select the travel mode (Fast/Slow).

• Fast Mode: Turn travel mode switch (1) to mark (2) MDCR-04-001
position.
• Slow Mode: Turn travel mode switch (1) to mark (3)
position. 2 1

Mark (Fast Speed Mode) 3

Mark (Slow Speed Mode)
M183-01-055

Travel Alarm (Optional)

During travel operation, the travel alarm sounds to warn the

people near the machine that the machine is traveling.

Deactivating Travel Alarm

More than 12 seconds after starting to travel the machine,
raise the armrest and push the travel alarm deactivation
switch to stop the travel alarm. ( Within 12 seconds, the
travel alarm deactivation switch is inoperable.)
Once the machine stops traveling and when restarting to
travel, the travel alarm will sound again. If desired to stop
the alarm, operate the deactivation switch once more.
Optional Switch MDCR-01-015
NOTE: The optional switch locations differ depending on
what kinds of optional devices are equipped. Before using
the switches, make sure what kinds of optional devices are
equipped.

4-4
 DRIVING THE MACHINE

Operating on Soft Ground

• Avoidtravelingonverysoftgroundthatdoesnothave
sufficient strength to firmly support the machine.
• Ifthemachineisoperatedonverysoftgroundor
becomes stuck, it may be necessary to clean the track
frame area.
• Swingtheupperstructure90°andlowerthebucket
to raise one track off the ground. Make sure to keep
the angle between the boom and arm 90 to 110 ° and
position the bucket’s round side on the ground.
• Rotatetheraisedtrackbackandforthtoremovemudand
dirt.
• Afterloweringthetracktotheground,selectslowtravel
speed. Carefully move the machine to firm ground.
• Utilizetheboomandarmfunctionstopullthemachine M104-05-012
toward firm ground.
• Towthemachineifthemachinebecomesstuckbutonly
if the engine is still operating. Be sure to attach a tow
line correctly. (Refer to the “TOWING MACHINE A SHORT
DISTANCE” section on the next page.)

Raise One Track Using Boom and Arm

WARNING: Keep the angle between boom and arm

90 to 110 ° and position the bucket’s round side on the
ground.

90 to 110 °
Swing the upperstructure 90 ° and lower the bucket to raise
track off ground. Do not dig bucket teeth into the ground
when using the hoe bucket reversed.

Place blocks under machine frame to support the machine.

IMPORTANT: When the machine is modified as a face

90 to 110 °
shovel by installing the hoe bucket in reverse, avoid
raising the machine above the ground using the front
attachment with the bucket cylinder fully extended.
Excessive loads will be applied to the pins around the
bucket and the bucket cylinder, resulting in breakage M104-05-013
of the pins.
WRONG

SA-817

4-5
 DRIVING THE MACHINE

Towing Machine a Short Distance

Soft Protector RIGHT
CAUTION: Cables, straps, or ropes can break causing
serious injury. Do not tow machine with damaged
chains, frayed cables, slings, straps, or wire ropes.
Always wear gloves when handling cable, straps or
wire ropes.

When your machine becomes struck but the engine is still

operational, attach wire ropes to the machine as illustrated Wire Rope
at right, and slowly tow your machine to firm ground using
another machine. M104-05-010
Be sure to attach the wire ropes around the track frames of
both machines as illustrated. Shackle hole WRONG
for towing
To prevent the wire ropes from being damaged, place some lightweight
protective material between the track frame and the wire objects.
ropes.

IMPORTANT: Do not use the shackle holes on the track

frame for towing the machine. Wire Rope
A center shackle hole on the track frame is provided to
pull only lightweight objects. Refer to the instructions Shackle
on page 5-30 for using the center shackle hole
appropriately.
M104-05-011

4-6
 DRIVING THE MACHINE

Operating in Water or Mud

The machine can be operated in water up to the upper edge of
the upper rollers only if worksite footing has sufficient strength
to prevent the machine from sinking past the upper edge of
the upper roller, and only if the water is flowing slowly.

When operating in such conditions, check the machine’s

position often. Reposition the machine if necessary. A

Avoid submerging the swing bearing, swing gears and center M104-05-009
joint.
Model A
If the swing bearing, swing gears and center joint are
ZX210LC-GI 770 mm
submerged, remove the drain plug to drain mud and water.
Clean swing area. Install plug. Lubricate swing internal gear
and swing bearing.

Swing Internal Gear Capacity: 17 L

Lubricate swing bearing. (See Maintenance Guide, 500 hours)

4-7
 DRIVING THE MACHINE

Parking the Machine on Slopes

WARNING: Avoid parking machine on slopes. The

machine may tip over, possibly resulting in personal
injury.

If parking the machine on a slope is unavoidable:

Thrust the bucket teeth into the ground.
Return the control levers to neutral and pull pilot control
shut-off lever (2) to the LOCK position. M104-05-014
Block both tracks.

Parking the Machine

1
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
Slow Idle
3. Turn the auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if the

engine is not properly shut down.
M1U1-01-033
4. Turn engine control dial (1) counterclockwise to the stop
(the slow idle position). Run the engine approximately 5 2
minutes to cool the engine.
5. Turn the key switch to OFF. Remove the key from the key
switch.
6. Pull pilot control shut-off lever (2) to the LOCK position.

IMPORTANT: Protect cab electrical components from bad

weather. Always close windows, roof vent and cab door
when parking the machine.

7. Close windows, roof vent, and cab door.

8. Lock all access doors and compartments. Lock Position MDCR-01-020

4-8
 OPERATING THE MACHINE

Control Lever (ISO Pattern)

WARNING:
Never place any part of body beyond window frame.
It could be crushed by the boom if boom control 1 5
lever is accidentally bumped or otherwise engaged.
Never remove the window sash bar.
Make sure you know the location and function of 4 3 7 8
each control before operating.
Do not change the control lever operation pattern. 2 6
Failure to do so may result in operation mistake of
the machine.

A label showing the control patterns of the levers and pedals is

attached on the right side in the cab.

When a lever is released, it will automatically return to neutral,

and that machine function will stop.
MDCR-01-002
1- Arm Roll-Out
2- Arm Roll-In
3
3- Swing Right 1

4- Swing Left 4

5- Boom Lower 2
6- Boom Raise
7- Bucket Roll-In
8- Bucket Roll-Out
M104-05-001

7 5
8

M104-05-002

5-1
 OPERATING THE MACHINE

Control Lever (HITACHI Pattern) (Optional)

WARNING:
Never place any part of body beyond window frame.
It could be crushed by the boom if boom control 1 5
lever is accidentally bumped or otherwise engaged.
Never remove the window sash bar.
4 3 7 8
Make sure you know the location and function of
each control before operating.
2 6
A label showing the control patterns of the levers and pedals is
attached on the right side in the cab.

When a lever is released, it will automatically return to neutral,

and that machine function will stop.

1- Swing Right
2- Swing Left MDCR-01-002
3- Arm Roll-In
4- Arm Roll-Out
1
5- Boom Lower 4

6- Boom Raise 2

7- Bucket Roll-In 3
8- Bucket Roll-Out

M104-05-001

7 5
8

M104-05-002

5-2
 OPERATING THE MACHINE

Attachment Pedal (Hydraulic Breaker) (Optional)

1
The breaker can be operated using attachment pedal (1)
located on the right front of the seat, as illustrated.

CAUTION: Be sure to lock attachment pedal (1) with

pedal lock (2) when the attachment pedal is not in
use. Do not allow your foot to rest on the pedal when
the attachment pedal (1) is not in use. When changing
pedal lock (2) position, pull the pilot control shut-off
lever up to the LOCK position.

1. Select attachment 1 by work mode selector (3) on the MDAA-05-007

switch box. Refer to the descriptions about the work
mode on page 5-9 for work mode setting procedures.
2. Move pedal lock (2) forward to the UNLOCK position.
3. Push down on attachment pedal (1) to operate the
breaker.
3
Loosen stopper bolt (4) until stopper bolt (4) comes in
contact with the bracket in attachment pedal (1) neutral
to prevent attachment pedal (1) from being stepped
backward.
MDCR-05-001
4. Remove foot from attachment pedal (1) to stop the
breaker.
1
5. Always keep attachment pedal (1) locked with pedal lock
(2) when attachment pedal (1) is not in use.

M1J1-13-002
Locked Attachment Pedal

Unlocked Attachment Pedal

M1J1-13-003

5-3
 OPERATING THE MACHINE

Pilot Control Shut-Off Lever

1
Pilot control shut-off lever (1) functions to prevent
misoperation of the machine from occurring if the control
levers are accidentally moved when leaving the operator's seat
or when entering the cab.
WARNING: Always pull pilot control shut-off lever
(1) into the full LOCK position. Unless front control
lever lock (1) is fully moved to the LOCK position, the
front control lever is not locked, possibly creating
a hazardous situation. When leaving the machine,
always stop the engine. Then, pull the pilot control
shut-off lever up to the LOCK position. Always check to
be sure that the pilot control shut-off lever is pulled up
to the LOCK position before transporting the machine LOCK position MDCR-01-020
or leaving the machine at the end of the shift.

Before Leaving the Machine

1. Park the machine on a firm, level surface. Lower the
bucket to the ground. Return all control levers to neutral.
Properly shut down the engine.
2. Pull pilot control shut-off lever (1) up into the full LOCK
position.

Before Starting Operation: 1

Confirm that pilot control shut-off lever (1) is pulled up to
the LOCK position before starting the engine. The engine
will not start in other than the LOCK position.
Slowly push down control shut-off lever (1) to UNLOCK
position before starting operation.
Confirm that all control levers and pedals are in neutral and
that no part of the machine is in motion.
WARNING: If any part of the machine (any actuator)
moves when pilot control shut-off lever (1) is
lowered to the UNLOCK position despite the fact
that all controls are placed in neutral, the machine is
malfunctioning. Immediately pull pilot control shut-
UNLOCK Position MDCR-01-021
off lever (1) back to the LOCK position, and stop the
engine. Then, see your authorized dealer.

5-4
 OPERATING THE MACHINE

Warming Up Operation
In cold weather, warm up the machine until coolant and
hydraulic oil temperature increases to the appropriate
operating temperature. 1
Slow Idle
IMPORTANT: The appropriate hydraulic oil operating
temperature on this machine is 50 to 80 °C. Hydraulic
components may be seriously damaged if the machine
is operated with low temperature hydraulic oil. In case
warming up the machine by relieving the hydraulic
system, continuously relieve the relief valve for 10 to M1U1-01-033
15 seconds while taking a pause for 5 to 10 seconds.

1. Turn engine control dial (1) to the slow idle position.

(Do not operate the machine until the needle of coolant
temperature gauge (2) starts swinging.)
2. After the needle of coolant temperature gauge (2) starts 2
swinging, turn engine control dial (1) to approx. medium
position.
M178-01-001
3. Operate the boom, arm and bucket cylinders slowly to
each stroke end several times.
4. Operate the travel and swing functions slowly to allow
hydraulic oil to circulate through the systems.
5. Warming up operation ends after the above operation is
completed.

NOTE: During cold weather season, the warm-up operation

system automatically operates so that the engine speed
increases for a moment even though the engine control dial is
in the slow idle position.
M1U1-03-006

5-5
 OPERATING THE MACHINE

Engine Speed Control

1
Increase and decrease the engine speed using engine control
dial (1) located on the switch panel, as illustrated.

Turn engine control dial (1) clockwise to increase the engine

speed. Turn engine control dial (1) counterclockwise to
decrease the engine speed.

Note that the auto-idle function will be deactivated if

engine control dial (1) is operated while the engine is
running at the auto-idle setting.
MDCR-04-001
Before stopping the engine, always turn engine control dial
(1) counterclockwise to the stop (to the slow idle setting).
Run the engine five minutes to cool the engine. Then, turn Fast Idle
the key switch to OFF position to stop the engine.

1
Slow Idle

M1U1-01-033

5-6
 OPERATING THE MACHINE

Auto-Idle
Auto-Idle Function
With auto-idle selector (3) turned to the A/I ON position,
approximately 4 seconds after all control levers are returned
to neutral, the engine speed decreases to the auto-idle
setting to save fuel consumption.
The engine speed will immediately increase to the speed
set by engine control dial (2) when any control lever is
operated.

IMPORTANT:
Always check if auto-idle indicator (1) is turned ON or
OFF before starting operation. If the indicator is ON,
1
the auto-idle function will be activated.
Always be aware of engine control dial (2) setting
when auto-idle selector (3) is turned to the A/I ON
position. If the engine speed is set high with engine
control dial (2), and if the operator is not aware of
the high engine speed setting, the engine speed
will unexpectedly increase when any control lever is
operated, causing unexpected machine movement,
thus possibly resulting in serious personal injury.
MDCR-01-027
WARNING: Prevent the machine from unexpected
movement. Be sure to turn auto-idle selector (3) to the
A/I OFF position when unexpected machine movement 2
is undesirable, especially when loading/unloading the
machine for transportation.
3

MDCR-04-001

5-7
 OPERATING THE MACHINE
Auto-Idle ON/OFF
Note that auto-idle function can be turned ON or OFF by
using auto-idle selector (3) only when the key switch is in
ON position.
Always check if the auto-idle function is turned ON or OFF
with auto-idle indicator (1).

Auto-Idle Indicator (1) ON : Auto-Idle Function ON

Auto-Idle Indicator (1) OFF : Auto-Idle Function OFF

When auto-idle selector (3) is turned OFF with auto-idle

indicator (1) ON, indicator (1) will go OFF and the auto-idle
system is deactivated.
1
Even if the engine is stopped by turning the key switch
with auto-idle selector (3) in the A/I ON position [indicator
(1) ON], the auto-idle system is not deactivated. When the
engine is restarted, the auto-idle system remains activated,
allowing auto-idle indicator (1) to flash for 5 seconds and
stay ON later.

MDCR-01-027

MDCR-04-001

5-8
 OPERATING THE MACHINE

Work Mode
Operate the work mode switch to choose the appropriate
front attachment and swing speed for work.

When the engine is started, the digging mode is automatically 3

set. Switch work mode switch (1) to select other 2 work modes.
2
Digging Mode
Attachment Mode

The selected work mode is displayed on attachment mode

indicator (2) and digging mode indicator (3).
Select the work mode corresponding to the work in which the MDCR-05-006
machine is engaged while referring to the table below.

MDCR-05-001

Work Mode Description

Digging Mode Select this mode for normal digging operation or loading operation.

Attachment Mode 1 Select this mode when using a breaker.

The initial setting is same as the attachment mode 1. When it is required to

Attachment Mode 2
change the setting, consult your authorized Hitachi dealer.

Power Boost Switch

Power boost switch (4) is located on the top of the right
control lever.

When power boost switch (4) is pushed, increased front

attachment power will be supplied for about 8 seconds.

MDCR-01-019

5-9
 OPERATING THE MACHINE

Power Mode
Two engine speed modes, "ECO" and "PWR" modes are
selected by operating the mode switch.

ECO (Economy) Mode

This mode slightly reduces the engine speed according to
the operating condition. Digging power is same as the PWR
mode. Although production is slightly reduced more than 1
in the PWR mode, the fuel consumption and noise levels are
reduced, allowing the machine to operate efficiently.

PWR (Power) Mode

Operate the machine in this mode when performing normal
work.

MDCR-01-016

5-10
 OPERATING THE MACHINE

Operating Backhoe
Use the appropriate arm and bucket for the work.
(Refer to the "Bucket Types and Applications" in the
Specifications section.)
Pull the bucket toward the machine using the arm as the
main digging force.
When soil sticks to the bucket, remove it by moving the
arm and/or bucket rapidly back and forth.
Place the bucket teeth on the ground with the bottom of
the bucket at a 45 degree angle to the ground.
When trenching a straight line, position the tracks parallel
M107-05-037
to the trench. After digging to the desired depth, move
the machine as required to continue the trench.
When operating the arm, avoid bottoming the cylinder to
prevent cylinder damage.

IMPORTANT:
When digging at an angle, avoid striking the tracks
with the bucket teeth.
When lowering the boom, avoid sudden stops that
may cause shock load damage to the machine.
When digging a deep excavation, avoid striking the
boom or bucket cylinder hoses against the ground.

5-11
 OPERATING THE MACHINE

Shovel
Backhoe operation digs the ground using the bucket in a roll-
in motion. On the other hand, face shovel operation digs the
ground using the arm cylinder in a scraping motion.

WARNING: Take care not to hit the cab when rolling in

the arm with the reversed-installed bucket.
Watch out!
(Take care not to hit
IMPORTANT: If a bucket hook is mounted, take care the cab with bucket)
not to hit the arm with the hook when rolling in the
bucket.
M107-05-045
For face shovel operation, dig the ground using the arm
cylinder in a scraping motion.
When underground water is expected, make a slope
angle of 2 to 3° to drain this water as shown.

NOTE: Because of the hydraulic cylinder structure, digging

force of the face shovel operation is smaller than the backhoe
operation.
2 to 3 °

M104-05-020

5-12
 OPERATING THE MACHINE

Grading Operation
Operate the boom, arm, and the bucket in such a way so that
the bucket teeth move horizontally, constantly keeping them
perpendicular to the ground at the grading operation.

IMPORTANT: Do not pull or push dirt with the bucket

when traveling. Excess force will be applied on each
part, and the machine may be damaged.

1. Operate arm roll-in function while slowly raising the

boom. Once the arm moves past the vertical position,
slowly lower the boom to allow the bucket to maintain a M104-05-017
smooth surface.
2. Arm roll-out operation is performed in the reverse way of
step 1.
3. Do the slope finishing work in the same procedure as
described in steps 1 and 2.

5-13
 OPERATING THE MACHINE

Do not strike the ground with bucket teeth

WARNING: Forcibly striking the bucket teeth on the

ground may result in personal injury by the flying
debris. Also, this operation will shorten the service life
of each part on the front attachment.

If the bucket teeth are forcibly struck on the ground, it

shortens the service life of the front attachment parts
(especially the bucket).
When digging a hard gravel stratum, use dig up force of the
bucket. Operate the boom, arm and the bucket simultaneously
so that the bucket teeth efficiently bite into the ground.
Flying debris may result in personal injury.

Avoid Hammer Work

WARNING: As the bucket body has the curved surface

, hammer work or piling work is very dangerous. Doing
so may damage the bucket and front attachment.

Do not attempt to use the bucket for hammer work and pilling
work.
Doing so may damage the bucket and front attachment,
causing personal injury.

M104-05-019

5-14
 OPERATING THE MACHINE

Avoid Abusive Operation

Do not use travel and do not raise rear of the machine to use
the machine's weight as additional digging force. Severe
machine damage may result.

M104-05-018

Avoid Side Load the Bucket

Do not side load the bucket. For example, do not swing the
bucket to level material or do not strike objects from the side
with the bucket.
Doing so may damage the front attachment and the swing
system.

M161-05-006

5-15
 OPERATING THE MACHINE

Do not use wide track shoes on rough ground.

Never use wide track shoes on rough ground such as rocks,
sand or gravel. Wide track shoes are designed for soft ground.

Failure to do so may result in shoe bending and/or shoe bolt

loosening, and may damage other undercarriage components
such as track link and rollers.
(Refer to the "Shoe Types and Applications" in the
Specifications section.)

5-16
 OPERATING THE MACHINE

Hydraulic Breaker, Hydraulic Crusher and Quick

Coupler
Selecting a breaker or crusher
Select a breaker, crusher or quick coupler with the correct
size and weight for your machine, considering the stability
of the machine, hydraulic oil pressure and flow rate of the
breaker, crusher or quick coupler. See your authorized
dealer for correct breaker information.

Precautions for Operation

Carefully study the operation manuals of the breaker,
crusher and quick coupler.
To avoid damaging the machine, hydraulic breaker, crusher
or quick coupler, follow the precautions given below.

Precautions for connecting breaker or crusher piping.

Do not allow impurities to enter into the system when
switching the breaker, crusher or the quick coupler with the
bucket.
When the breaker, crusher or quick coupler is not used,
apply the cover to the pipe opening on the arm top and
install the plug or cap into the hose end of the breaker,
crusher or the quick coupler to prevent impurities from
entering the system.
Be sure to provide spare covers and plugs in the tool box so
that they will be available when needed.
After connecting, check the connecting seal fitting for oil
leakage, and pipe clamp bolts for looseness.

5-17
 OPERATING THE MACHINE

Piping for Breaker and Crusher (Optional) Close

Operational procedures for stop valves and

Stop Valve A, B
selection valve.
Open

B Close
A C

Stop Valve C
B
D
A
Open

When using breaker

Tank
M107-05-003

Front
Selector Valve D

Rear
Selector
Stop Valve A Stop Valve B Stop Valve C
Valve D When using crusher
Close: When not using Close: When using crusher Close: When using
attachment or is or NPK breaker. crusher or other Valve
Refer to the
detached. than NPK breaker.

Front
illustration

Rear
Open: When using Open: When using breaker Open: When using NPK
attachment (other than NPK) breaker

ATTACHMENT PEDAL
ATTACHMENT Arm BOOM MAIN BODY
HIGH PRESSURE
ACCUMULATOR

LEFT SIDE
OF FRONT PUMP
ATTACHMENT
CONTROL VALVE

CLOSE: CRUSHER AND

NPK BREAKER STOP RELIEF
OPEN: BREAKER VALVE B VALVE
(OKADA etc.)
RIGHT SIDE
OF FRONT
ATTACHMENT HYDRAULIC
OPEN: BREAKER STOP DRAIN OIL TANK
CLOSE: CRUSHER VALVE C
SELECTOR VALVE D
CLOSE: WHEN NOT USING LOW PRESSURE
ATTACHMENT ; BREAKER: RETURN TO
Stop ACCUMULATOR
OR IS DETACHED. TANK
Valve A
OPEN: WHEN USING ATTACHMENT ; CRUSHER: RETURN TO
VALVE MDCD-05-001

IMPORTANT: Close the stop valve of the low pressure

accumulator when using a crusher.
If a crusher is used with opening the valve, inside of
the accumulator may be damaged.

5-18
 OPERATING THE MACHINE

Secondary Relief Pressure Adjustment

Depending on the breaker model, the secondary relief valve
relief set pressure differs.
Consult your nearest Hitachi dealer for installing a breaker.

5-19
 OPERATING THE MACHINE

Precautions for Breaker Operation

WARNING: Machine stability is reduced as the

breaker is much heavier than the bucket. When using
a breaker, the machine is more apt to tip over. Also,
flying objects may hit the cab or other part of the
machine. Observe the following precautions and take
any other precautions necessary to prevent accidents
and machine damage from occurring.

Avoid hitting objects with breaker.

The breaker is heavier than the bucket, causing the breaker
to lower faster.
Take care not to hit any objects with breaker. Doing so will
result in damage to the breaker, the front attachment, and/
or the upperstructure. Always move (lower) the breaker
slowly to position the tip of the chisel on the object to be
broken before starting breaker operation. M104-05-055

Avoid moving objects with breaker.

Do not use the breaker and/or the bracket to move objects.
Damage to the boom, arm, and/or breaker may result.
Do not use the breaker and/or the swing function to move
objects. Damage to the boom, arm, and/or breaker may
result.
M104-05-056

Avoid operating breaker at cylinder stroke end

Always operate the breaker by positioning the cylinder rods
100 mm or longer before the stroke end position.
When operating the breaker with cylinders fully retracted
or extended, hydraulic cylinders, arm or boom may be
damaged.

M104-05-057

5-20
 OPERATING THE MACHINE
Stop operation if breaker hydraulic hoses jump Hose jumping
abnormally. abnormally
Accumulator
Change in breaker accumulator pressure or a damaged
accumulator will cause abnormal hose jumping and may
cause breaker and/or machine damage.
Immediately stop the machine operation. Failure to do
so may result in serious failure in the hydraulic system
including pumps. Hose jumping
abnormally
Contact your nearest Tata Hitachi dealer.
M104-05-058

Do not operate the breaker in water. Do not operate the

breaker in water.
Doing so will cause rust and seal damage, resulting in
damage to the hydraulic system components.
Rust, dust and water may enter into the hydraulic oil Rod
through the broken seal, damage to the hydraulic system
may result.

M104-05-059

Do not use breaker for lifting operation.

The machine tipping over and/or breaker damage may
result.

M104-05-060

Do not operate the breaker to the side of the machine.

The machine may become unstable and undercarriage
component life may shorten as a result from operating the
breaker to the side of the machine.
OK OK

M104-05-061

5-21
 OPERATING THE MACHINE
Operate the hydraulic excavator carefully to avoid
hitting the boom.
When the arm rolled in with the breaker equipped, the
chisel may come in contact with the boom.

Watch Out!
Take care not to hit the
boom with the crusher

M104-05-062

Do not operate breaker with the arm positioned

vertically.
Excessive vibration to the arm cylinder will occur, causing oil
leakage.

M147-05-013

Press the breaker so that the chisel (the axis) is

positioned and thrusted perpendicular to the object.
Failure to do so may damage the chisel or may cause seized
piston.

M147-05-014

Do not operate the breaker continuously longer than

one minute.
Failure to do so may result in premature wear of the chisel.
If an object could not be broken within one minute, apply
the chisel to other locations, less than one minute for each
location. If an object could not
be broken within one
minute, apply the chisel
to other locations.
M147-05-015

5-22
 OPERATING THE MACHINE
Raising the front part of the undercarriage by pressing
down the breaker may cause damage to the front
attachment.
Never raise the front edge of the undercarriage higher than
150 mm (6 in) by pressing the breaker down.
Pressing Raising
Down 100 to 150 mm

M147-05-016

5-23
 OPERATING THE MACHINE

Change Hydraulic Oil and Replace Full-Flow Filter

Element
Hydraulic breaker operation subjects the hydraulic system to
become contaminated faster and to quickly deteriorate the
hydraulic oil.
Failure to adhere to proper maintenance intervals may result in
damage to the base machine and the breaker.
In order to extend the service life particularly of the hydraulic
pump, change the hydraulic oil and the full-flow filter element
at the specified frequency given below. (Refer to the “Hydraulic
System” in the “MAINTENANCE” Section.)

Replacement intervals differ depending on the brand of

hydraulic oil used. Refer to the Hydraulic System in the
MAINTENANCE section.
Use the high performance element (micro-glass) on excavators
engaged in demolition and logging work.

5-24
 OPERATING THE MACHINE

Precautions for Crusher Operation

Prevent machine tipping over and damage to the front
attachment. Observe the following precautions for crusher
operation.

WARNING: Machine stability is reduced as crusher

is much heavier than bucket. When operating with a
crusher, the machine is more apt to tip over. Falling
or flying objects may hit the cab or other part of the
machine. Observe the following precautions and take
any other precautions necessary to prevent accidents
and machine damage from occurring.

Do not allow the machine's weight to be supported by

the crusher or bucket cylinder with the bucket cylinder
fully extended or retracted. Failure to do so may result
in damage to the front attachment. In particular, avoid
doing so with the bucket cylinder fully extended, as the
front attachment will be easily damaged.
Take care to prevent this from happening when
dismantling foundation structures using the crusher.

Using the front attachment, do not raise the base

machine off the ground with the arm cylinder fully
M107-05-046
extended. Failure to do so may result in damage to the
arm cylinder.

When a heavyweight attachment such as a crusher is

installed, avoid quickly starting or stopping the front
attachment. Failure to do so may result in damage to the
front attachment.

Do not attempt to perform crushing on either side of the

machine. Always perform crushing operations to the fore
or rear, parallel with the tracks. Otherwise, tipping over
may occur. M107-05-047

5-25
 OPERATING THE MACHINE
When the arm rolled in with the crusher equipped, the
crusher may come in contact with the boom.

Watch Out!
Take care not to
hit the boom with
the crusher

M1G6-05-009

When operating the crusher up high with the boom fully

raised, be careful of falling objects.

M107-05-048

When operating the crusher on a floor in a building, first

confirm that the floor has sufficient strength to support
the load caused by crushing, in addition to the machine
weight.
The load equivalent or higher than the machine weight
may be applied on floor depending on the operation
method.

M107-05-049

5-26
 OPERATING THE MACHINE
Always operate the crusher on a stable, level surface, not
on a slope or on crushed scraps.
Do not use the crusher to haul or load crushed scraps.
If a multiple number of attachments, such as crusher
and bucket, or crusher and breaker, are used, replacing
them with each other at intervals, impurities are more
apt to enter the hydraulic system and the hydraulic oil
deteriorates quickly. For this reason, replace the hydraulic
oil tank filter and change the hydraulic oil at the intervals
specified in the breaker time sharing diagram in the
previous section.
Always remove the crusher from the excavator before
transporting the machine. Do not fully extend the bucket
cylinder when transporting, as this may damage the front
attachment, when vibrations arise during transportation.

5-27
 OPERATING THE MACHINE

Attachment
Allowable Weight Limits of Installed Attachment
When an attachment other than the standard bucket is
installed on the machine, the machine stability will be
different.
If a heavy attachment is used, not only will controllability
be affected but also machine stability will be reduced,
possibly causing safety hazard.
Before installing attachments such as hydraulic breaker,
crusher (concrete crusher), or pulverizer, take machine
controllability into account when selecting the weight of
the attachment by referring to the table below.
(Unit: kg)
Base Machine Breaker Crusher/Pulverizer

Model Arm Std.Weight Max.Weight Std.Weight Max.Weight

ZX210LC-GI Std. 1850 2000 2200 2600

5-28
 OPERATING THE MACHINE
Breaker operation speed is faster than crusher operation
so that the recommended breaker max. weights are
reduced more than those of the crushers.
The weight is not the only factor to be considered when
selecting a breaker. Select proper manufacturer's breaker
models while referring to the table on the next page.
Avoid installing an attachment with a long overall length.
Damage to the front attachment may result.
When an attachment of the max. weight is installed,
always operate the attachment over the front or rear
side of the machine. In addition, avoid operating the
attachment at the maximum reach.
Crushers are heavier than breakers. Slowly move the
control lever when operating a crusher.

5-29
 OPERATING THE MACHINE

Precaution For Arm Roll-In/Bucket Roll-In

Combined Operation
When Installing an Attachment Longer Than Standard
Bucket

WARNING: When an attachment (such as a hydraulic

breaker, crusher or quick coupler), the overall length of
which is longer than that of the bucket, is installed, the Watch Out!
attachment may come in contact with the cab and/or Take care not to
hit the boom with
the boom. Operate the machine with care not to allow the crusher
the tip of the front attachment to hit the cab and/or
M1G6-05-009
the boom while rolling in the front attachment.

Shackle Hole Usage

Shackle hole for towing light
A shackle hole is provided on the track frame to tow light weight objects.
weight objects as specified below.

IMPORTANT: Be sure to conform to the restrictions and

precautions stated below when towing a light weight
object using the shackle hole provided on the track
frame. The track frame and/or the shackle hole may be Wire Rope
damaged otherwise.
Shackle
The maximum drawbar pull.
Model Maximum Drawbar Pull M104-05-011
ZX210LC-GI 73600 N (7500 kgf ) or less

Be sure to use a shackle.

Keep the tow line horizontal, straight, and parallel to the
tracks.
Select the slow travel mode. Slowly drive the machine when
towing.

5-30
 OPERATING THE MACHINE

How to Lower Boom In Case of Emergency and 2

When Engine Stops
In case the engine suddenly stops and the engine cannot
restart, lower the boom in the following procedures. 1

IMPORTANT: Never loosen screw (2) more than 2 turns.

Screw (2) may come off.
1. Loosen lock nut (1) in the control valve at the right.
Loosen screw (2) one half of a turn. The boom lowering
speed can be somewhat adjusted by loosening screw (2)
more.
T1V1-03-03-073
IMPORTANT: Excessive leakage may result if the screw
and the lock nut are tightened insufficiently. Be sure to
retighten the screw and the lock nut to specifications.
2. After the boom is lowered, tighten screw (2) and tighten
lock nut (1) to the specifications below.

Locknut (1)
Tightening Torque:13 N·m (1.3 kgf·m)
Bolt (2) Emergency Valve
Tightening Torque:7 N·m (0.7 kgf·m)

T1V1-03-03-038

5-31
 OPERATING THE MACHINE

Precautions for After Operations

After finishing the day's operation, drive the machine to
a firm, level ground where no possibility of falling stones,
ground collapse, or floods are present.
(Refer to the group for "PARKING MACHINE" in the
DRIVING MACHINE section.)
Fully refill the fuel in the fuel tank.
Clean the machine.

5-32
 TRANSPORTING

Transporting by Road
When transporting the machine on public roads, be sure to
first understand and follow all local regulations.

When transporting the machine using a trailer, check

the width, height, length and weight of the trailer with
the machine loaded. Note that transporting weight and
dimensions may vary depending on the type of shoe or M1V1-06-001
front attachments installed.
Investigate beforehand the conditions of the route to be
traveled, such as dimensional limits, weight limits, and
traffic regulations.

In some cases, getting the permission from the local authority

concerned or disassembling the machine to bring it within
dimensional limits or weight limits of local regulations may
become necessary.
Notify the nearest dealer that you are transporting the unit.

6-1
 TRANSPORTING

Loading/Unloading on a Trailer
Always load and unload the machine on a firm, level
surface.

WARNING: Be sure to use a loading dock or a ramp

for loading/unloading. Never load or unload the
machine onto or off a truck or trailer using the front
attachment functions when driving up or down the
ramp.

Ramp/Loading Dock:
1. Before loading, thoroughly clean the ramps, loading
dock and flatbed. Dirty ramps, loading docks, and
flatbeds with oil, mud, or ice on them are slippery
and dangerous.
2. Place blocks against the truck and trailer wheels
while using a ramp or loading dock.
3. Ramps must be sufficient in width, length, and
strength. Be sure that the incline of the ramp is less
than 15 degrees.
4. Loading docks must be sufficient in width and
strength to support the machine and have an incline
of less than 15 degrees.
5. When loading the machine equipped with pat
crawler or rubber pad shoes, take sufficient care not
to allow the machine to slip since the surface of the
rubber pad shoe is flat.
Load the machine only after removing soil or clay
adhered to the machine.
6. When transporting the machine equipped with a
blade, take care not to hit the blade.

6-2
 TRANSPORTING
Loading/Unloading

WARNING:
Always turn the auto-idle switch OFF when loading
or unloading the machine. In the auto-idle mode,
speed may automatically increase.
Always select the slow speed mode with the travel
mode switch.
Never steer while driving up or down a ramp as it is
extremely dangerous and may cause the machine to
turnover. NEVER attempt to change directions whilst
positioned on the ramp. If repositioning is necessary,
first move back to the ground or flatbed, modify
traveling direction, and begin to drive again.
The top end of the ramp where it meets the flatbed
is a sudden bump. Take care when traveling over it
as the balance may be lost. If the front attachment is
not fitted, reverse onto the trailer.
Extreme care must be taken when swinging the
upper structure when the machine is on the trailer
flatbed.If the front attachment is fitted, swing slowly
with the arm fully roll-in underneath the boom being
careful not to loose the balance of the machine.

Loading
If the front attachment is fitted, load with the front faced
towards the front, if the front attachment is not fitted,
reverse onto the trailer.

1. Load the machine so that the centerline of the machine

aligns with the centerline of the trailer flatbed.
2. Drive the machine onto the ramp slowly.

M1G6-06-002

15 ° or less

M107-06-018

6-3
 TRANSPORTING
3. When the front attachment is fitted
3.1 Determine a position for the bucket in line with the
trailer. Adjust the angle of the boom and the arm at 90
to 110 °.
3.2 Lower the bucket onto to the deck of the trailer before
the unit passes over the end of the ramp for support.
3.3 Lift the bucket slightly off the deck of the trailer after
the unit has moved to the designated space. With the
arm lifted inwards, slowly swing the upper structure
M107-06-012
place around 180 °.
3.4 Rest the front attachment on supports such as wooden
blocks placed on the trailer flatbed. Also lower the
blade onto the deck at this time (if fitted).
4. Stop the engine. Remove the key from the key switch.
5. Place the locking lever in the LOCK position.
6. Close cab windows, roof vent and door, and cover the
exhaust opening, to prevent entry of wind and water.
Place a cover over the exhaust outlet. Lock all doors,
covers and caps if they have a lock. M107-06-013
7. House all mirrors and the radio antenna away correctly.

CAUTION: In cold weather, be sure to warm up the

machine before loading or unloading it.

6-4
 TRANSPORTING

Fastening Machine for Transporting

WARNING: Fasten the machine frame to the deck

securely with chains and cables. While traveling, loads
may shake around, move forward or backward or to
the sides.

1. Place cog stoppers or blocks in front of and behind the

tracks to help secure the unit.
M1V1-06-001
2. Fasten each corner of the machine and front attachment
to the trailer with appropriate strength of chains or
cables.

Unloading

WARNING: The rear end of the flatbed where it meets

the ramp is a sudden bump. Take care when traveling
over it.

IMPORTANT: Make sure that the angle of the boom and

the arm is kept between 90 to 110 ° when unloading
the unit. M107-06-014
Damage to the unit is possible if the arm is kept in a
suspended state during unloading.

1. Travel extremely slowly with the bucket on the ground

and the angle of the arm and the boom kept at between
90 to 110 ° when moving from the edge of the trailer
onto the ramp.
IMPORTANT: When driving the machine over the ramp,
do not allow the machine to hit the ground too hard
with the arm. Possible damage to the hydraulic
cylinders may result.

6-5
 TRANSPORTING
2. The bucket must be on the ground before the machine
begins to tip forward.
3. As the machine moves forward, raise the boom and
extend the arm until the machine is completely off the
ramp.

M107-06-015

6-6
 TRANSPORTING

Lifting Machine

WARNING:
Use lifting cables and other lifting tools being free
from any damage and/or aging, and having sufficient
strength.
Consult your nearest Tata-Hitachi dealer for correct lifting
procedures, and the size and types of lifting cable
and tools.
Pull the pilot control shut-off lever to the LOCK
position so that the machine does not accidentally
move while being lifted.
Incorrect lifting procedure and/or incorrect wire rope
attachment will cause the machine to move (shift)
while being lifted, resulting in machine damage and/
or personal injury.
Do not lift the machine quickly. Excessive load will be
applied to the lifting wire ropes and/or lifting tools,
possibly causing them to break.
Do not allow anyone to come close to or under the
lifted machine.
The indicated gravity center is for the standard
specification machine. The gravity center will vary
depending on the kinds of attachments and/or
optional equipment to be installed or their position
to be taken. Therefore, take care not to lose the
balance of the machine while lifting.

6-7
 TRANSPORTING
Lifting
1. Fully extend the arm and bucket cylinders. Lower
the boom until the bucket comes in contact with the Support Bar
ground.
Center of
2. Pull the pilot control shut-off lever to the LOCK position. Gravity

3. Stop the engine. Remove the key from the key switch.
4. Close and lock all doors and covers.
5. Use wire ropes and support bar of sufficient length so M1G6-06-001
that they do not come in contact with the machine while
lifting.
Wrap some protectors around wire ropes and/or support
bar as required to prevent the machine from being
damaged.
6. Set a crane in an appropriate position.
7. Thread the wire rope through and under both sides of
the track frames as illustrated. Attach the wire ropes to
the crane.

6-8
 MAINTENANCE

Correct Maintenance and Inspection Procedures

Learn how to service your machine correctly. Follow the
correct maintenance and inspection procedures shown in this
manual.

Inspect machine daily before starting.

Check controls and instruments.
Check coolant, fuel and oil levels.
Check for leaks, kinked, frayed or damaged hoses and
lines.
Walk around machine checking general appearance,
noise, heat, etc.
Check for loose or missing parts. SA-005

If there is any problem with your machine, repair it before

operating or contact your authorized dealer.

IMPORTANT:
Use only recommended fuel and lubricants.
Be sure to use only genuine Tata Hitachi parts. Failure to
do so may result in serious injury or death and/or
machine breakdown.
Failure to use recommended fuel, lubricants, and
genuine Tata Hitachi parts will result in loss of Tata Hitachi
product warranty.
Never adjust engine governor or hydraulic system
relief valve.
Protect electrical parts from water and steam.
Never disassemble electrical components such as
main controller, sensors, etc.
Never adjust parts of engine fuel system or hydraulic
equipment.
Using bad quality fuel, drainage agent, fuel
additives, gasoline, kerosene or alcohol refueled
or mixed with specified fuel may deteriorate
performance of fuel filters and injector nozzles dirty.
It also affects the engine, leading to malfunction.
Use Tata Hitachi genuine high performance filter.

7-1
 MAINTENANCE

Body Information Controller

This machine provides a body information controller
that stores machine operation information for
preventive aintenance.
When maintaining the machine, our authorized service
man may down load the stored information.
Consult with your nearest Tata Hitachi dealer for
detailed function of this device.
Communication Terminal Operation
It is not necessar y to check or operate the
communication terminal however if any abnormality is
found, consult your nearest Tata Hitachi dealer.
Before installing any covering attachment such as a
head guard, consult your nearest Tata Hitachi dealer.
Never spray water on the communication terminal and
the wirings.
Inquire on the proper way to recycle or dispose of oil,
fuel, coolant, filters, batteries and other waste from your
local environmental or recycling center, or from your

7-2
 MAINTENANCE

Check the Hour Meter Regularly

Refer to the List of Check and Maintenance for information
about lubricants, check and adjustment intervals. The
maintenance guide table is affixed in the back of the tool box
cover. Refer to 7-5 page.

Check and maintenance intervals shown in this manual

are those for the machines to be operated under normal
conditions. In case the machine is operated under more severe
conditions, shorten the intervals.

7-3
 MAINTENANCE

Layout

5
6

7
4
8
35 9
10
3 11
12
2 34

37 36
33
32
13
28
14
15
31
16
30
29 17
27
26 18
25 20
19
24 21 M1U1-01-005
23
22

1- Bucket 11- Control Valve 21- Track Link 31- Front Idler
2- Link A 12- Hydraulic Oil Tank 22- Shoe 32- Control Lever
3- Link B 13- Engine Oil Filter 23- Track 33- Cab
4- Bucket Cylinder 14- Pilot Filter 24- Travel Device 34- Boom Cylinder
5- Arm 15- Pump 25- Lower Roller 35- Work Light
6- Arm Cylinder 16- Counterweight 26- Upper Roller 36- Tooth
7- Boom 17- Engine 27- Air Cleaner 37- Side Cutter
8- Center Joint 18- Radiator, Oil Cooler 28- Swing Bearing
9- Swing Device 19- Washer Tank 29- Tank Flame
10- Fuel Tank 20- Battery 30- Track Adjuster

7-4
 MAINTENANCE
Maintenance Guide Table
The maintenance guide table is affixed to the reverse side
of the tool box cover. Lubricate and/or service the parts at
the intervals as instructed in the table so that all necessary
maintenance can be performed regularly.

Symbol Marks
The following marks are used in the maintenance guide
table.

Grease Hydraulic oil filters

(Front Joint Pin, Swing Bearing, Swing (Pilot Filter, Hydraulic Oil Tank Filter,
Gear) Suction Filter)

Gear Oil
(Pump Transmission, Travel Reduction Air Cleaner Element
Device, Swing Reduction Device)

Coolant
Engine Oil
(Long-Life Coolant)

Fuel Filter
Engine Oil Filter
(Fuel Main Filter, Pre-Filter)

Hydraulic Oil

7-5
 MAINTENANCE
Maintenance Guide Table

9 11 6 4

14

10

12 4

13

8 1

2
4
16

15

MDCR-07-001
Lubrication Interval 4 5 3
(hours)

Item Page Item Page

1 Engine Oil 7-20 9 Hydraulic Oil Filter (Full Flow) 7-34
2 Coolant (Long-Life Coolant) 7-56 10 Hydraulic Oil Filter (Pilot) 7-39
3 Grease 7-17 11 Hydraulic Oil Filter (Air Breather) 7-40
4 Grease 7-15 12 Engine Oil Filter 7-20
5 Grease 7-18 13 Gear Oil (Pump Transmission) 7-22
6 Hydraulic Oil 7-31 14 Fuel Filter (Main/Pre) 7-50
7 Gear Oil ( Travel Device) 7-25 15 Gear Oil (Swing Reduction Gear) 7-23
8 Hydraulic Oil Filter (Suction) 7-33 16 Air Cleaner Element 7-54

7-6
 MAINTENANCE

Preparations for Inspection and Maintenance

Except in special cases, park the machine by following the
procedure before servicing the machine.

1. Park the machine on a level surface.

2. Lower the bucket to the ground.
M104-07-021
3. Turn the auto-idle switch OFF.
4. Turn engine control dial (1) to the slow idle position and
run the engine for 5 minutes to cool the engine.
5. Turn the key switch OFF to stop the engine. Remove the
key. Be sure to place pilot control shut-off lever (1) to the
LOCK position.
6. After putting a tag (2) for "Under Serving" on the easy-to- 1
see cab door or control lever, begin the work.
2
WARNING: Never attempt to maintain the machine
when the engine is running in order to prevent the
accident. If maintenance work while engine running is
unavoidable, strictly comply with the following items.
One person should take the operator's seat
to be ready to stop the engine any time while
communicating with other workers.
MDAA-07-028
When working around moving parts is unavoidable,
pay special attention to ensure that hands, feet, and
clothing do not become entangled.
If parts or tools are dropped or inserted into the fan
or the belt, they may fly off or be cut off. Do not drop
or insert parts and tools into the moving parts.
Move pilot control shut-off lever (1) to LOCK position
so that the front attachment will not move.
Never touch the control levers and pedals.
If operating the control levers or pedals is
unavoidable, signal co-workers to evacuate to safer
place.
SA-2294

SA-026

7-7
 MAINTENANCE

Hood and Access Covers 1

WARNING:
Do not keep the hood and access covers open when
the machine is parked on a slope, or while the wind
is blowing hard. The hood or access covers may close
accidentally, possibly resulting in personal injury.
2
When opening or closing the hood and access covers,
take extra care not to catch fingers between the base
machine and the hood or access covers.

Holding the handle on the access cover, raise the cover until Engine Cover MDCD-07-003
the cover is secured with catch (1). 3 4

After opening the right and/or left access cover, be sure to

insert rod (3) into cover lock hole (4) to hold the cover.

When opening the rear left cover, open the front left cover
first. Then, pull to open the rear left cover as illustrated.

Do not attempt to start the engine when fan guard (2) is

open.

Right Cover MDCD-07-004

3 4

Front Left Cover MDCD-07-005

Rear Left Cover MDCD-07-006

7-8
 MAINTENANCE

Recommended Oil & Lubricants - ZX220LC GI

Change
Application Where to use Interval Grade Brand Name
5000Hrs.** ISO VG 46 TATA-HITACHI GENUINE HYDRAULIC
OIL SUPER EX 46HN (FACTORY FILLED)
Hydraulic System &
Hydraulic Oil 2500Hrs.** ISO VG 46 TATA-HITACHI Supreme 46P
Steering System
TATA-HITACHI Super 46S

1500Hrs.** ISO VG 46 Mobil DTE 10 Excel 46 (Exxon Mobil)

Tellus S3V 46 (Shell India)

TATA-HITACHI Engine Plus

SAE 15W40 CH4 Mobil Delvac Super 1400 (Exxon Mobil)

Rimula T3 15W40 (Shell India)

Engine Oil FIP, Engine Crank case 500Hrs.
Mobil Delvac MX 15W40 (Exxon Mobil)

SAE 15W40 CI4 Rimula T4 15W40 (Shell India)

Rimula T5 10W30 (Shell India)
Pump Transmission 1000Hrs.

Swing Device API GL 5 TATA-HITACHI Gear Oil

Gear Oil 1000Hrs.
SAE-90 Mobilube HD 80W90 GL5 (Exxon Mobil)
Travel Device 2000Hrs
Swing Gear, Swing Bearing etc. 500Hrs. TATA-HITACHI Heavy Duty Grease
Grease NLGI-2
Pivot Points, Pins & Bushes 8Hrs. Mobilux EP2 (Exxon Mobil)
Gadus S2V 220 2 (Shell India)
TATA-HITACHI Super Cool
2000hrs. or
Coolant Radiator JIS K2242 (Premixed coolant. Don't mix
1 Year
water- fill directly in Radiator)

** For Rockbreaker application Hydraulic Oil change interval will be 500 Hrs. with standard Paper Filter & 1000Hrs. with High
Performance Filter, Irrespective of grade of oil used.

Pilot Oil filter should get replace at every 1000Hrs.

Fuel filter should get replaced at every 250Hrs.
Never mix two different brand of Oils.

A. Greasing
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
OTHERS 11NOS.
FRONT JOINT PINS
BUCKET & LINK PINS 9NOS.
SWING BEARING 2NOS.
SWING INTERNAL GEAR 1NO.

In case of excavations are performed in water, grease the pin after operation is complete.
Maintenance also required when operation under extremely severe condition.
NOTE: Grease bucket and link pivots every day until break - in operation (50 hours) is complete.

7-9
 MAINTENANCE

Maintenance Guide
B. Engine
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
ENGINE OIL LEVEL CHECK 1NO.
ENGINE OIL (PAN-21.5+FILTER-2+OIL LINE 1.5) CHANGE 25L
ENGINE OIL FILTER CHANGE 1NO.
ENGINE VALVE CLEARANCE CHECK & ADJUST --
FAN BELT TENSION CHECK & ADJUST --

C. Transmission
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
CHECK LEVEL 1NO.
PUMP TRANSMISSION OIL
CHANGE 1.0L
CHECK LEVEL 1NO.
SWING DEVICE OIL
CHANGE 6.2L
CHECK LEVEL 2NOS.
TRAVEL REDUCTION GEAR OIL
CHANGE

D. Hydraulic System
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
HYDRAULIC OIL LEVEL CHECK --
HYDRAULIC OIL TANK SUMP DRAIN --
HYDRAULIC OIL
CHANGE 200L
(BUCKET APPLICATION)
TANK FILTER - BUCKET APPLICATION
REPLACE 1NO.
(STANDARD PAPER FILTER)
TANK FILTER - BUCKET APPLICATION
REPLACE 1NO.
(HIGH PERFORMANCE FILTER)
SUCTION FILTER CLEAN 1NO. EACH TIME WHEN HYDRAULIC OIL IS CHANGED
PILOT FILTER REPLACE 1NO.
AIR BREATHER ELEMENT REPLACE 1NO.
HOSES & LINES FOR LEAKS & LOOSENESS CHECK --
HOSES AND LINES FOR CRACKS & BENDS CHECK --
ROCK BREAKER APPLICATION WITH LINE FILTER
HYDRAULIC OIL
CHANGE 200L
(STANDARD PAPER FILTER) in Tank
HYDRAULIC OIL CHANGE 200L
(HIGH PERFORMANCE FILTER) in Tank
TANK FILTER -
REPLACE 1NO.
(STANDARD PAPER FILTER)
TANK FILTER
REPLACE 1NO.
(HIGH PERFORMANCE FILTER)
TANK FILTER
(WITH HIGH PERFORMANCE FILTER & ROCK REPLACE 1NO.
BRAKER LINE FILTER)
ROCK BRAKER LINE FILTER REPLACE 1NO.

For Bucket application, hydraulic oil change interval may differ according to the kind of hydraulic oil used.
For Rockbreaker application, hydraulic oil must be changed at this interval, irrespective of grade of oil used

7-10
 MAINTENANCE

E. Fuel System
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
FUEL TANK SUMP DRAIN --
WATER SEPARATOR CHECK 1NO.
FUEL FILTER CARTRIDGE (PRE+MAIN FILTER) REPLACE 1NO.
FUEL FEED PUMP STRAINER CLEAN 1NO.
HOSES & LINES FOR LEAKS & LOOSENESS CHECK --
HOSES AND LINES FOR CRACKS & BENDS CHECK --

F. Air Cleaner
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
CLEAN -- CLEAN EVERY 250HRS. OR WHEN INDICATOR LIT. WHICHEVER IS EARLIER
AIR CLEANER OUTER ELEMENT
REPLACE 1NO. AFTER 6 TIMES OF CLEANING OR 1500 HRS. WHICHEVER IS EARLIER
AIR CLEANER INNER ELEMENT REPLACE 1NO. IT SHOULD NOT BE CLEANED IT SHOULD GET REPLACED ONLY
WHEN OUTER ELEMENT IS REPLACED

G. COOLING SYSTEM
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
LEVEL CHECK --
COOLANT
CHANGE 26L
RADIATOR, OIL COOLER & OUTSIDE
CLEAN
INTERCOOLER CORE INSIDE 1NO. ONCE A YEAR
RADIATOR INTERIOR CLEAN 1NO. WHEN CHANGING COOLANT
RADIATOR, OIL COOLER, INTER COOLER
CLEAN
FRONT SCREEN 1NO.
AIR CONDITIONER CONDENSER CLEAN 1NO.
When genuine TATA-HITACHI long life coolant is used, replace it every 1 year or 2000hrs. Whichever is earlier.

H. Electrical System
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
BATTERY ELECTROLYTE LEVEL CHECK --
BATT. ELECTROLYTE SPECFIC GRAVITY CHECK --
LOOSE TERMINALS / CONTACTS CHECK --
BATT. CABLES
HARNESS SHEATH / COVER CHECK --
AND WIRES
HARNESS CLIP CHECK --

Note - TATA-HITACHI recommend to use petrolium jelly to lubricate battery terminals. Grease shouldn’t be used.
Wire Harness should not be in contact with Hydraulic Hoses, Air Conditioner Hoses, Oil, Grease etc.
In no case Harness should lie on the main frame base plate - Oil Spilt on the main frame shall harden the
harness sheath & damage the same.

7-11
 MAINTENANCE

I. Miscellaneous
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
BUCKET TEETH FOR WEAR & LOOSE CHECK --
BUCKET LINKAGE ADJUST -- AS REQURIED
TRAVEL LEVER REMOVE 2NOS. AS REQURIED
SEAT BELT REMOVE 1NO. EVERY 3 YEARS
TRACK SAG CHECK 2NOS.
CLEAN 1NO. CLEAN AFTER EVERY 250HRS. OR WHEN EXCESSIVELY CHOCKED
AIR CONDITIONER CIRCULATING FILTER
REPLACE 1NO. AFTER CLEANING 6 TIMES
CLEAN 1NO. CLEAN AFTER EVERY 250HRS. OR WHEN EXCESSIVELY CHOCKED
AIR CONDITIONER FRESH AIR FILTER
REPLACE 1NO. AFTER CLEANING 6 TIMES
AIR CONDITIONER GAS QUANTITY CHECK --
COMPRESSOR BELT TENSION CHECK 1NO.
CONDENSER CORE CLEAN 1NO.
INJECTION NOZZLE CHECK
CYLINDER HEAD BOLT TIGHTHESS CHECK *AS REQURIED
INJECTION TIMING CHECK *AS REQURIED
ENGINE COMPRESSION PRESSURE CHECK
STARTER AND ALTERNATOR CHECK
WATER PUMP GREASE REPLACE
GAS DAMPER CHECK *AS REQURIED
TIGHTENING TORQUE OF BOLTS & NUTS CHECK Initial
Contact your nearest TATA-HITACHI dealer for maintenance.

7-12
 MAINTENANCE

Periodic Replacement of Parts

To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed below,
if defective, may pose serious safety/fire hazards.
These parts may cause serious safety/fire hazards due to
deterioration, wear, or fatigue being attributed to material
aging or repeated operation. It is very difficult to gauge the
extent of deterioration, fatigue, or weakening of the parts
listed below simply by visual inspection alone. For this reason,
replace these parts at the intervals shown in the table below.
Consult your authorized dealer for correct replacement.

Periodic Replacement Parts Replacement Intervals

Fuel hose (Fuel tank, Filter to Engine) Every 2 years
Engine

Fuel hose (Engine, Fuel cooler to Fuel tank) Every 2 years

Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years or 4000 hours whichever comes first
Pump delivery hose Every 2 years or 4000 hours whichever comes first
Base Machine

Swing hose Every 2 years or 4000 hours whichever comes first

Travel high pressure hose Every 2 years or 4000 hours whichever comes first
Hydraulic System

Attachment Line Hose Every 2 years or 4000 hours whichever comes first
Hydraulic Fan Suction Hose Every 2 years or 4000 hours whichever comes first
Hydraulic Fan Delivery Hose Every 2 years or 4000 hours whichever comes first
Working Device

Boom cylinder line hose Every 2 years or 4000 hours whichever comes first

Arm cylinder line hose Every 2 years or 4000 hours whichever comes first

Bucket cylinder line hose Every 2 years or 4000 hours whichever comes first
Seat Belt Check every 8 hrs. and must be replaced after 3 years
NOTE: Be sure to replace seals, such as O-rings and gaskets,
when replacing hoses.

7-13
 MAINTENANCE
Recommended Oil Viscosity

Oil Recommendation for Atmospheric

Parts Kind of Oil Temperature (°C)
-30 -20 -10 0 10 20 30 40

Engine Oil Pan Engine Oil

Pump Transmission Engine Oil

Swing Device
Gear Oil
Travel Device
Hydraulic System
Hydraulic Oil
(Hydraulic Oil Tank)

Fuel Tank Diesel Oil

Grease Nipple Lithium Grease

Radiator Coolant

7-14
 MAINTENANCE

A. Greasing
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
OTHERS 11NOS.
FRONT JOINT PINS
BUCKET & LINK PINS 9NOS.
SWING BEARING 2NOS.
SWING INTERNAL GEAR 1NO.

In case of excavations are performed in water, grease the pin after operation is complete.
Maintenance also required when operation under extremely severe condition.
NOTE: Grease bucket and link pivots every day until break - in operation (50 hours) is complete.

Front Joint Pins

Bucket and Link Pins --- every 50 hours
Others --- every 125 hours
Lubricate all fittings shown in the figure.

M178-07-007

Boom Cylinder Bottom Side

M157-07-156

Boom Foot

M157-07-155

7-15
 MAINTENANCE
Boom and Arm Joint Pin, Arm Cylinder Rod Pin and Bucket
Cylinder Bottom Pin.

M157-07-157

Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin.

M157-07-155

7-16
 MAINTENANCE
Swing Bearing
--- every 500 hours

CAUTION: Before lubricating the machine, lower the

bucket on the ground, stop the engine and pull the
pilot control shut-off lever to the LOCK position.

There is two grease fittings (1).

Greasing Method
1. Before lubricating the machine, lower the bucket on the
M157-07-159
ground, stop the engine and pull the pilot control shut-
1
off lever to the LOCK position.
2. Raise the bucket several inches off the ground and rotate
the upperstructure 45° (1/8 turn).
3. Repeat steps 1 and 2 three times.
4. Apply grease to the swing bearing until grease can be
seen escaping from the swing bearing seals.
Grease Capacity: 0.30 L
Take care not to supply excessive grease.

7-17
 MAINTENANCE
Swing Internal Gear
--- every 500 hours

CAUTION: Before lubricating the machine, lower the

bucket on the ground, stop the engine and pull the
pilot control shut-off lever to the LOCK position.

1. Remove cover (2) from upperstructure. Check if the

swing gear is properly lubricated by grease. Add
approximately 0.5 kg of grease, if required.
MDAA-07-021
2
If the grease is contaminated, remove grease by opening cover
(3) at the undercarriage side and replace with clean grease.
Grease Capacity: 17 L
3

M157-07-161

7-18
 MAINTENANCE

B. Engine
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
ENGINE OIL LEVEL CHECK 1NO.
ENGINE OIL (PAN-21.5+FILTER-2+OIL LINE 1.5) CHANGE 25L
ENGINE OIL FILTER CHANGE 1NO.
ENGINE VALVE CLEARANCE CHECK & ADJUST --
FAN BELT TENSION CHECK & ADJUST --

Engine Oil Level

--- check daily

IMPORTANT: An incorrect engine oil level may cause 2

trouble on the engine (The oil level should be between 1
the upper and lower marks on oil level gauge (1)). Even
if the engine oil level exceeds the upper limit, control
the oil level to the proper quantity before starting the
engine.

Check oil level before starting the engine.

M1U1-07-044
Open the engine cover and pull out oil level gauge (1). Wipe oil
level gauge (1) with cloth, re-insert it into the pipe to the end,
and then pull it out again. 1
The oil level should be between the upper and lower marks on
dipstick (1).

If oil level is below the lower limit mark, add the recommended
engine oil via oil filler (2).
If oil level exceeds the upper limit mark, remove plug (3) to Max.
drain oil. Min.

M178-07-011
CAUTION: Do not spill oil while changing oil. Spilled
fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammable materials may cause
fires. 3

M178-07-010

7-19
 MAINTENANCE

Change Engine Oil, Replace Engine Oil Filter

--- every 500 hours
2

CAUTION:
Immediately after the machine was operated, all
engine parts are hot. Wait for the engine to cool
before starting any maintenance work.
Do not spill oil while changing oil. Wipe off any
spilled oil. Spilled fuel and oil, and trash, grease,
debris, accumulated coal dust, and other flammable
materials may cause fires. M1U1-07-044

IMPORTANT: Change 250 operating hours depending

on environmental conditions. Consult your nearest 3
Tata Hitachi dealer for the details.

1. Arrange a container to receive the drain oil (50 L).

2. Remove oil filler cap (2).
3. Remove plug (4) of engine oil tank (3) to drain engine oil.
4. After all oil has been drained, inspect the cloth for any
debris such as small pieces of metal.
5. Securely tighten plug (4).
4 M178-07-010
Tightening Torque: 78 N·m (8 kgf·m)
Wrench size: 30 mm

Oil Pan

Clean Cloth

Container

M104-07-010

7-20
 MAINTENANCE
6. Cartridge element (5) of the engine oil filter is located
next to the pump device.
7. Remove the filter cartridges of engine oil filter (5) by
turning it counterclockwise with the filter wrench.
8. Feed new oil from oil passage (6) of the new cartridge
while being careful not to overflow oil. Do not feed oil
from oil passage (7).
9. Apply a thin film of clean oil on the gasket (O-ring) of
the new filter. Install new filter. Turn the filter cartridge
clockwise by hand until the gasket touches the contact
area.
5 MDCD-07-008
10. Tighten the filter 3/4 to 1 turn more using the filter
wrench. Be careful not to overly tighten the cartridge
element. Deformation of the cartridge may result.
11. Fill the engine with recommended oil through the oil
filler.
12. Check that the oil level is between the minimum and
maximum level scales on the dipstick. Then, start the 7
engine. 6
13. After starting the engine, check no oil is leaking from the
sealing surface.
14. After running the engine at slow idle speed for
approximately 5 minutes, stop the engine. Then,
recheck the oil level 15 minutes later and add or drain
oil to maintain proper oil level. (The oil level should be MDCR-07-007
between the upper and lower limit marks on the oil level
gauge.) (Refer to 7-22).

IMPORTANT:
When filling new oil, take care not to allow foreign
matter to enter the engine.
Do not re-use cartridge element (5).
An incorrect engine oil level may cause trouble
on the engine. Even if the engine oil level exceeds
the upper limit, control the oil level to the proper
quantity before starting the engine.

7-21
 MAINTENANCE

C. Transmission
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
CHECK LEVEL 1NO.
PUMP TRANSMISSION OIL
CHANGE 1.0L
CHECK LEVEL 1NO.
SWING DEVICE OIL
CHANGE 6.2L
CHECK LEVEL 2NOS.
TRAVEL REDUCTION GEAR OIL
CHANGE

2
Pump Transmission
1
Check Oil Level --- every 250 hours
1. Park the machine on a solid level surface. Lower the
breaker to the ground. Stop the engine.
3
2. When the oil level is correct, it can be seen between
marks on level gauge (1). If necessary, remove filler plug
(2) and add oil.

Change Gear Oil --- every 1000 hours M178-07-085

CAUTION: Oil may be hot just after operation. Wait

for the engine to cool before starting any maintenance
work.

1. Park the machine on a solid level surface. Lower the

breaker to the ground. Stop the engine.
2. Remove filler plug (2) located at the top of the pump
transmission.
3. Remove drain plug (3) located at the bottom of the
pump transmission to drain oil.
4. Reinstall drain plug (3). Refill oil through the filler port.
5. Check oil level with level gauge (1). The oil level should Specified Range
be between the upper and lower marks on level gauge
(1). Refill as necessary. 1
6. Reinstall filler plug (2).

M1G6-07-004

7-22
 MAINTENANCE

Swing Device

Check Oil Level --- every 500 hours

1. Park the machine on a solid level surface. Lower the
breaker to the ground. Stop the engine.
2. When the oil level is correct, it can be seen between
marks on level gauge (1). Refill as necessary.

Change Gear Oil --- every 1000 hours 2 1

CAUTION: Oil may be hot just after operation. Wait M178-07-086

for the engine to cool before starting any maintenance
work.

1. Park the machine on a solid level surface. Lower the

breaker to the ground. Stop the engine.
1
2. Remove the drain plug mounted at the tip of the drain
hose under the swing reduction gear to drain gear oil.
3. Reinstall drain plug. Remove cap (2) from the filler port
and refill oil.
4. Check oil level with level gauge (1). The oil level should
Specified Range
be between the upper and lower marks on level gauge M104-07-017
(1). Refill as necessary.

7-23
 MAINTENANCE

Travel Reduction Gear

WARNING:
Immediately after operation, the parts of the travel
device are very hot. Wait for the engine to cool
before starting any maintenance work.
There may be pressure accumulated inside of the
travel device. Remove the plug only after releasing
pressure by slowly loosening the air bleed plug two
to three turns.
Failure to do so may cause the plug to fly off or the Air Release Plug
gear oil to gush out, possibly resulting in personal (Oil Supply Plug)
injury. Keep body and face away from the air release
plug. Oil Level Check
Plug
Horizontal
Check Oil Level --- every 500 hours Oil Level

1. Park the machine on solid and level ground. Rotate the

travel motor until plug (1) (air release and oil supply) is
Drain Plug
in the top position as shown in figure right. Lower the
bucket on the ground. Stop the engine. MDAA-07-047

2. Slowly loosen plug (1) to release air pressure.

3. Remove plugs (1 and 2). When the oil level is correct, the 1
gear oil will flows out of the tapped hole of plug (2). Refill
as necessary.
4. Clean plugs (1) and (2). Wrap the threads of oil level 2
check plug (2) and air release plug (1) with sealing-type
tape. Reinstall the plugs. Tighten the plug.
Tightening Torque:50N•m(5kgf•m)

M157-07-170

7-24
 MAINTENANCE
Change Gear Oil --- every 2000 hours
1. Park the machine on solid and level ground. Rotate
the travel motor until plug (1) is in the top position as 1
illustrated in the right. Lower the bucket on the ground.
Stop the engine.
2. After gear oil has cooled, slowly loosen air release plug 2
(1) to release pressure, and temporarily retighten plug
(1).
3. Remove drain plug (3) and plug (1), in that order, to drain 3
oil.
4. Clean drain plug (3). Wrap the threads of the drain plug
with sealing-type tape. Install the plug. Tighten the plug. M157-07-170

Tightening Torque:50 N·m (5 kgf·m)

5. Refill gear oil though the tapped hole for plug (1).
6. Remove plug (2). When the correct gear oil amount is
refilled, gear oil will flow out of the tapped hole for plug
(2).
7. Clean plugs (1) and (2). Wrap the threads of oil level
check plug (2) and air release plug (1) with sealing-type
tape. Reinstall the plugs. Tighten the plug.
Tightening Torque:50 N·m (5 kgf·m)

7-25
 MAINTENANCE

D. Hydraulic System
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
HYDRAULIC OIL LEVEL CHECK --
HYDRAULIC OIL TANK SUMP DRAIN --
HYDRAULIC OIL
CHANGE 200L
(BUCKET APPLICATION)
TANK FILTER - BUCKET APPLICATION
REPLACE 1NO.
(STANDARD PAPER FILTER)
TANK FILTER - BUCKET APPLICATION
REPLACE 1NO.
(HIGH PERFORMANCE FILTER)
SUCTION FILTER CLEAN 1NO. EACH TIME WHEN HYDRAULIC OIL IS CHANGED
PILOT FILTER REPLACE 1NO.
AIR BREATHER ELEMENT REPLACE 1NO.
HOSES & LINES FOR LEAKS & LOOSENESS CHECK --
HOSES AND LINES FOR CRACKS & BENDS CHECK --
ROCK BREAKER APPLICATION WITH LINE FILTER
HYDRAULIC OIL
CHANGE 200L
(STANDARD PAPER FILTER) in Tank
HYDRAULIC OIL CHANGE 200L
(HIGH PERFORMANCE FILTER) in Tank
TANK FILTER -
REPLACE 1NO.
(STANDARD PAPER FILTER)
TANK FILTER
REPLACE 1NO.
(HIGH PERFORMANCE FILTER)
TANK FILTER
(WITH HIGH PERFORMANCE FILTER & ROCK REPLACE 1NO.
BRAKER LINE FILTER)
ROCK BRAKER LINE FILTER REPLACE 1NO.

For Bucket application, hydraulic oil change interval may differ according to the kind of hydraulic oil used.
For Rockbreaker application, hydraulic oil must be changed at this interval, irrespective of grade of oil used
Inspection and Maintenance of Hydraulic
Equipment
IMPORTANT: Never adjust parts of engine fuel system or
hydraulic equipment.
CAUTION: When checking and/or servicing the
hydraulic components, pay special attention to the
following points.
1. Be sure that the machine is parked on a level, firm
surface before servicing hydraulic equipment.
2. Lower the bucket to the ground and stop the engine.
3. Begin servicing hydraulic components only after
components, hydraulic oil and lubricants are completely
cooled, and after releasing residual pressure.

7-26
 MAINTENANCE
3.1 Before checking and/or servicing the hydraulic system,
be sure to release the residual pressure from the
cylinder circuits of the boom, arm and the bucket,
swing piping and pilot piping. An accumulator can be
installed on some models of this machine as an option
to be capable of moving the front attachment for
specified time (around 10 seconds) after stopping the
engine.
3.2 Bleed air from the hydraulic oil tank to release internal
pressure.
3.3 Immediately after operation, all hydraulic components
and hydraulic oil or lubricants are hot and highly
pressurized. Begin inspection and/or maintenance
work only after the machine has cooled down.
Servicing heated and pressurized hydraulic
components may cause plugs, screws and/or oil to fly
off or escape suddenly, possibly resulting in personal
injury. Hydraulic components may be pressurized even
when cooled.
Keep body parts and face away from the front of plugs
or screws when removing them.

3.4 Even after air pressure in the hydraulic oil tank is

released, when the machine is parking on a slope, the
oil pressure in the travel motor and the swing motor
circuits are maintained at high pressure as the reaction
force of the machine weight is constantly applied
to the travel motor. Never check and/or service the
machine parking on a slope.

IMPORTANT:
When connecting hydraulic hoses and pipes, take
special care to keep seal surfaces free from dirt and
to avoid damaging them.
Wash hoses, pipes, and the tank interior with a
washing liquid and thoroughly wipe it out before
reconnecting them.
Only use O-rings that are free of damage or defects.
Be careful not to damage them during reassembly.
Do not allow high pressure hoses to twist when
connecting them. The life of twisted hoses will be
shortened considerably.

IMPORTANT:
Do not use hydraulic oils other than those listed in
the table "Brand names of recommended hydraulic
oil".
When adding hydraulic oil, always use the same
brand of oil; do not mix brands of oil. When using
another manufacturer's hydraulic oil, be sure to
change the full amount.

IMPORTANT: Never run the engine without oil in the

hydraulic oil tank.

7-27
 MAINTENANCE
Check Hydraulic Oil Level
---daily
1. Park the machine on solid and level ground with the
bucket cylinder fully extended and the arm cylinder fully
retracted. Lower the bucket on the ground as shown to
the right. Stop the engine.
2. Check oil level with level gauge (1) at the side of the M104-07-021
hydraulic oil tank. When the oil level is correct, it can be
seen between marks on level gauge (1).
1

M1U1-07-048

7-28
 MAINTENANCE

Change Hydraulic Oil

CAUTION: Hydraulic oil becomes hot and pressurized

during operation. Severe burns may result if
skin comes in contact with escaping hydraulic oil
immediately after operation. Wait for the oil to cool
before starting any maintenance work. M104-07-117

2 1
IMPORTANT: Changing interval differs according to the
brand of hydraulic oil used, kind of filter element or
average attachment operating availability.

Change Hydraulic Oil

1. Park the machine on solid and level ground. Swing Level Gauge
the upperstructure to make a work space under the
hydraulic oil tank. Fully extend the bucket cylinder and Specified Range
fully retract the arm cylinder. Lower the bucket on the
ground. Stop the engine.
2. Push air bleed valve (1) to bleed air from the hydraulic oil M157-07-016
tank.
3. Remove filler port cover (2) from the top of the hydraulic
oil tank.
4. Arrange a container with the hydraulic oil capacity.
Remove oil by using a suction pump.
5. Slowly remove drain plug (3) on the bottom of the fuel
tank to drain remaining oil from the fuel tank.
3
6. Clean, install and tighten drain plug (3).
7. Refill hydraulic oil from the filler port on the top of the
hydraulic oil tank.
Refill hydraulic oil while checking oil level with the level
gauge.
8. Install filler port cover (2) with bolts (6 used).
Tightening Torque:50 N·m (5 kgf·m)

IMPORTANT: When changing hydraulic oil, take care not

to allow foreign matter like dust, water, or grit to enter M1U1-07-047
the hydraulic oil tank.

9. Be sure to bleed air form the system following the

procedures shown next page.

7-29
 MAINTENANCE
Bleed Air from the Hydraulic System
After changing hydraulic oil, bleed air from the hydraulic
system by following the procedures below.

IMPORTANT: If the hydraulic pump is not filled with oil, it 4

will be damaged when the engine is started. Bleed air
from the pump.

Bleeding Air from Pump

1. Remove air bleed plug (4) on each pump. Fill the pump
with oil through air bleed plug (5) hole.
2. After hydraulic oil is filled in the pump, provisionally
tighten plug (4). Start to run the engine at slow idle
speed.
3. Slightly loosen plug (4). Allow air to bleed from
the pump through the clearance until hydraulic oil
permeates around the plug. MDCD-07-009
4. After bleeding air, tighten plug (4) to specification.

Bleeding Air from Hydraulic Circuit

1. After filling hydraulic oil, start the engine. While moving
all cylinders and the swing motor evenly, lightly operate
the machine for 10 to 15 minutes.
As the air bleeding device is provided in the pilot circuit,
air will be released by conducting above operation for 5
minutes.
2. Rest the bucket on the ground to resume the hydraulic
oil level check position.
3. Stop the engine. Check the oil level. Add oil as needed.

7-30
 MAINTENANCE
Suction Filter Cleaning
---each time when hydraulic oil is changed
1

The suction filter is located on the bottom of the hydraulic oil

tank.
Clean the suction filter when changing hydraulic oil. 4

1. After removing hydraulic oil from the hydraulic oil tank,

remove cover (1) and rod assembly (2).
2. Clean the inside of the hydraulic oil tank and the suction
filter. 2

3. Before installing the suction filter, check the dimension

of rod assembly (2) shown in figure right. Securely insert
rod assembly (2) into pipe (3).
4. Before securing cover (1) with bolts, ensure the top edge
of the rod assembly (2) is completely inserted into the
hole of support (4).
5. Bleed air from the hydraulic system. 3
( Refer to " Bleed Air from the Hydraulic System".)

M157-07-062

889 mm

20 mm

Rod Assembly M107-07-070

7-31
 MAINTENANCE
Replacement of Full-Flow Filter (Standard Paper Filter)
— every 500 hours (For Bucket Application)
— every 125 hours (For Breaker Application)

CAUTION: Hydraulic oil becomes hot and pressurized

during operation. Severe burns may result if
skin comes in contact with escaping hydraulic oil
M104-07-021
immediately after operation. Wait for the oil to cool
before starting any maintenance work. 2 3 1

Procedures:
1. Park the machine on solid and level ground. Fully extend
the bucket cylinder, fully retract the arm cylinder, and 4
lower the bucket to the ground as illustrated in the right.
Stop the engine.
2. Before replacing the element, be sure to bleed air
pressure from the hydraulic oil tank by pressing the air
bleed valve on the hydraulic oil tank.
3. Loosen bolts (1) (6 used) to remove cover (2) and O-ring
MDAA-07-004
(3).
4. Remove the filter element assembly (4). 5
5. Remove ring (5) and grip plate (6) from the filter element
assembly (4). 6

6. Take extra care never to allow water or dust to enter the

filter case.

M1U1-07-064

7-32
 MAINTENANCE
7. Replace O-ring (7) of element (4) and grip plate (6) with
new one. Be careful not to damage element (4) and
O-ring (7).
Broken element (4) is unusable.
8. Check the concavity and convexity position of logo (8) 4
on filter element (4) and logo (9) on grip plate (6).
Fit the grip plate (6) assembly with filter element (4) so
that concavity of filter element (4) logo and convexity
of the grip plate (6) assembly logo; convexity of filter
element (4) logo and concavity of the grip plate (6)
assembly logo are engaged.

M1U1-07-065

M1U1-07-066
8

M1U1-07-067

M1U1-07-068

7-33
 MAINTENANCE
9. Install ring (5).
5
10. Install cover (2) with bolts (1) (6 used).
Tightening Torque: 50 N·m (5 kgf·m)
11. Bleed air from the pump after replacing the element.
( Refer to " Bleed Air from the Hydraulic System".)
If the machine is operated with air mixed in the hydraulic
circuit, damage to the pump may result. 4

12. Replace element (4) at the regular interval to keep

hydraulic oil clean and to extend the service life of the
hydraulic components.

M1U1-07-069

2 1

MDAA-07-004

7-34
 MAINTENANCE
Replacement of High Performance Full-Flow Filter
— every 1000 hours (For Bucket Application)
— every 250 hours (For Breaker Application)
— every 500 hours (For Breaker Application if
Rock Breaker Line filter attached with it)
Note : Replace Rock Breaker Line Filter at every 500 hours. M104-07-021

When the hydraulic oil filter alarm on the monitor panel is lit,
immediately replace the filter element.

CAUTION: Hydraulic oil becomes hot and pressurized

during operation. Severe burns may result if
skin comes in contact with escaping hydraulic oil
immediately after operation. Wait for the oil to cool
before starting any maintenance work.

IMPORTANT: Changing interval differs according to the

brand of hydraulic oil used, kind of filter element or
average attachment operating availability.
7

IMPORTANT: Precautions for the filter element

Excavators engaged in demolition and logging work
use full-flow filter with high performance (micro-
glass) element.
When replacing the element, use the same kind of
high performance element.
In case a filter-paper element is unavoidably used,
change hydraulic oil and replace full-flow filter
element by referring to the "Change Hydraulic MDAA-07-005
Oil and Replace Full-Flow Filter Element" in the
OPERATING THE MACHINE section.
If a filter-paper element is used, the full-flow filter
restriction indicator does not operate. Isolate the
circuit for full-flow filter restriction indicator (7).

7-35
 MAINTENANCE
Procedures:
1. Park the machine on solid and level ground with the
bucket cylinder fully extended and the arm cylinder fully
retracted. Lower the bucket on the ground as shown to
the right. Stop the engine.
2. Before replacing element (5), be sure to bleed air
pressure from the hydraulic oil tank by pressing the air M104-07-021
bleed valve on the hydraulic oil tank.
3. Loosen bolts (1) (6 used) to remove cover (2) and O-ring
(3).When removing cover (2), slowly remove the cover
while pressing the cover downward so that spring (4)
does not fly off.
4. Remove spring (4), and element (5).
1
5. When installing new element (5) into the hydraulic oil
tank, replace O-ring (3) with a new one at the same time.
2
6. Install cover (2) with bolts (1) (6 used).
Tightening Torque: 50 N·m (5 kgf·m)

MDAA-07-005

4 2 3 1

MDAA-07-004

7-36
 MAINTENANCE
Replace Pilot Oil Filter
— every 1000 hours (Both Bucket & Breaker Application)

CAUTION: Hydraulic oil becomes hot and pressurized

during operation. Severe burns may result if
skin comes in contact with escaping hydraulic oil
immediately after operation. Wait for the oil to cool
M104-07-021
before starting any maintenance work.

1. Park the machine on solid and level ground with the

bucket cylinder fully extended and the arm cylinder fully
retracted. Lower the bucket on the ground as shown to
the right. Stop the engine.
2. Before replacing element (2), be sure to bleed air
pressure from the hydraulic oil tank by pressing the air
bleed valve on the hydraulic oil tank.
3. Rotate the hexagonal section on the bottom of pilot
filter cartridge element (2) counterclockwise by using
a spanner to remove cartridge element (2) from head
cover (1). Pilot Filter MDCD-07-008
4. Apply clean hydraulic oil on the gasket of new cartridge
element (2). Taking care not to damage element (2)
and while rotating the element, completely install the
element on head cover (1).
5. Install cartridge element (2) into head cover (1) while
rotating cartridge element (2) clockwise.
6. After replacing the filter element, bleed air from the 1
hydraulic system and check the oil level in the hydraulic
oil tank.
( Refer to " Bleed Air from the Hydraulic System".)
If the machine is operated with air mixed in the hydraulic
circuit, damage to the pump may result.
7. Replace element (2) at the regular interval to keep
hydraulic oil clean and to extend the service life of the 2
hydraulic components.

M1U1-07-050

7-37
 MAINTENANCE
Replace Air Breather Element
--- every 5000 hours

CAUTION: Hydraulic oil becomes hot and pressurized

during operation. Severe burns may result if
skin comes in contact with escaping hydraulic oil
immediately after operation. Wait for the oil to cool
before starting any maintenance work. M104-07-021

Procedures:
1. Park the machine on solid and level ground with the
bucket cylinder fully extended and the arm cylinder fully
retracted. Lower the bucket on the ground as shown to
the right. Stop the engine.
2. Before replacing element (3), be sure to bleed air
pressure from the hydraulic oil tank by pressing the air
bleed valve on the hydraulic oil tank. M1U1-07-076
3. Rotate cover (2) clockwise approx. 1/4 turns. Remove cap
(1) by rotating it counterclockwise.
1
4. Rotate cover (2) counterclockwise and remove it.
Remove element (3).
5. Install new element (3). Tighten to install cover (2) until
cover (2) comes in contact with element (3). Then,
further tighten the cover 1/4 turn. 2
6. Securely tighten cap (1) clockwise by hand. While
holding cap (1) by hand so that cap (1) does not rotate,
3
securely tighten cover (2) by rotating counterclockwise 5
to 10° by hand.
7. Take care never to allow water and/or contaminant to
stay between cover (2) and body (4) (air breathing port). 4
8. Replace element (3) at the regular interval to keep
hydraulic oil clean and to extend the service life of the
hydraulic components. M1G6-07-001

7-38
 MAINTENANCE
Check Hoses and Lines
--- daily
--- every 250 hours

WARNING:
Hydraulic oil and lubricant leaks can lead to fire that
may result in serious injury. Check for missing or
loose clamps, kinked hoses, lines or hoses that rub
against each other, damaged oil cooler, and loose oil
cooler flange bolts, for leaks.
Escaping oil under pressure can penetrate the skin SA-031
causing serious injury. To avoid this hazard, search
for oil leaks with a piece of cardboard. Take care to
protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor familiar with this
type of injury immediately.
Tighten, repair or replace any missing, loose or
damaged clamps, hoses and lines.
Do not bend or strike high-pressure lines.
Never install bent or damaged hoses or lines.

According to the check points shown below, check hoses and

SA-292
lines for oil leaks and damage.
If any abnormality is found, replace or retighten as instructed
in the table.

SA-044

Hose
Interval Check Points Abnormalities Remedies 3 2 3 2
(hours)
Daily Hose covers Leak (1) Replace 1 1
Check Hose ends Leak (2) Replace 2 2

Fittings Leak (3) Retighten or replace hose 3 3

or O-ring
M137-07-008 M115-07-145

7-39
 MAINTENANCE

7
Interval Check Points Abnormalities Remedies 4
6
(hours)
5
Every 250 Hose covers Damage or leak (4) Replace
hours Hose ends Damage or leak (5) Replace
Hose covers Exposed reinforcement (6) Replace
M115-07-146 M115-07-147
Hose covers Crack or blister (7) Replace
Hose Bend (8), Collapse (9) Replace 9
8
Hose ends and Deformation or corrosion (10) Replace
Fittings
10
M115-07-148 M115-07-149
Lines
Interval Check Points Abnormalities Remedies
(hours) 12 12
13 13
Daily Contact surfaces of Leak (11) Replace 11
Check flange joints
Bolts Loose or leak (11) Retighten or
M137-07-001 M137-07-007
replace O-ring
Welded surfaces on Leak (12) Replace
flange joints
Every 250 Flange joint neck Crack (13) Replace
hours Welded surfaces on Crack (12) Replace
flange joints
Clamps Missing or Replace or
deformation Loose retighten
bolts

Hose and Lines

Interval Check Points Abnormalities Remedies
(hours)
Daily Flexible master Leak (14) Replace or
Check coupling retighten
14
MDCD-07-044

Oil Cooler
Interval Check Points Abnormalities Remedies
16
(hours)
Every 250 Coupling Leak (15) Retighten or
hours replace 15
Oil Cooler Leak (16) Replace

M1U1-07-051

7-40
 MAINTENANCE
Service Recommendations for Hydraulic Fittings
Two hydraulic fitting designs are used on this machine.

Flat Face O-ring Seal Fitting (ORS Fitting)

O-ring (1) is used on the sealing surfaces of adapter (2) to 2 1 4 5
prevent oil leakage.

Precautions for Use

1. Replace O-ring (1) with a new one when assembling
fittings.
2. Check that O-ring (1) is properly fitted in O-ring groove 3 6
M104-07-033
(3). Tighten union (4).
Tightening union (4) with O-ring (1) out of the groove
may damage O-ring (1) and cause oil leak.
3. When assembling fittings, take care not to make a dent
on O-ring groove (3) of adaptor (2) and sealing surface
(6) on hose (5) or valve side. Failure to do so may result in
damage to O-ring (1) leading to oil leak.
4. If oil leaks from a loose connection of union (4), do not
tighten fitting (2). Open the connection, replace O-ring
(1) with new one and check for correct O-ring position
before tightening the connection.

Tightening Torque:
Tighten fittings to the torque values shown below.
±10 %
Wrench size (mm) 27 32 36 41, 46
Tightening N·m 95 140 180 210
torque (kgf·m) (9.5) (14) (18) (21)

7-41
 MAINTENANCE
Metal Face Seal Fittings
7 9 8 10 5
Tight contact between metal flares on adaptor (7) and metal
connector (8) of hose (5) prevents pressure oil leakage. This
type of fittings is used on smaller diameter joint.

Precautions for Use

Connect or disconnect fittings with care not to damage seat
surfaces (9 and 10).
M202-07-051

Tightening Torque:
Tighten fittings to the torque values shown below.
Wrench size (mm) 17 19 22 27
Tightening N·m 25 30 40 80
torque (kgf·m) (2.5) (3) (4) (8)

Bent Tube
Tighten bent tube (11) mounted on the signal control valve 11
to the torque values shown below.
Wrench size (mm) 17, 19
Tightening N·m 35
torque (kgf·m) (3.5)

To Signal Control Valve

M1U1-07-043

7-42
 MAINTENANCE

E. Fuel System
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
FUEL TANK SUMP DRAIN --
WATER SEPARATOR CHECK 1NO.
FUEL FILTER CARTRIDGE (PRE+MAIN FILTER) REPLACE 1NO.
FUEL FEED PUMP STRAINER CLEAN 1NO.
HOSES & LINES FOR LEAKS & LOOSENESS CHECK --
HOSES AND LINES FOR CRACKS & BENDS CHECK --

CAUTION: Beware of fire.

Fuel is flammable. Keep fuel away from fire hazards.

Recommended Fuel
Use high quality DIESEL FUEL only (JIS K-2204) (ASTM
D-975). Kerosene must NOT be used.
Besides, using bad quality fuel, drainage agent, fuel
additives, gasoline, kerosene or alcohol refueled or mixed
with specified fuel may deteriorate performance of fuel
filters and cause sliding problem at lubricated contacts
in the injector. It also affects the engine parts, leading to
malfunction.

7-43
 MAINTENANCE
Refueling 1
1. Park the machine on a level surface. Lower the bucket to
the ground. Check the fuel level with fuel gauge (1).
If the fuel level is low, stop the engine. Refuel by
removing cap (2) on the fuel tank.
2. Remove cap (2) of filler port.
[Cap (2) unlock procedures]
Release the key lock.
Pull up handle (3) and turn handle (3) counterclockwise
for releasing cap (2) lock.
Remove cap (2).
3. To avoid condensation, fill the tank at the end of each MDCR-05-006
day's operation. Fuel tank capacity is 400 liters 2
Do not fill the tank more than specified. Stop filling when
a yellow mark on fuel level gauge (4) becomes visible.
Position the oil filler gun so that the gun will not
encumber the movement of the level gauge (4) float.
4. Immediately after fueling, install and lock filler cap (2) to
prevent vandalism and loss.
5. Install cap (2) of filler port.
[Cap (2) lock procedures]
Install cap (2).
Turn handle clockwise until cap (2) is locked, and push MDCF-07-032
down handle (3).
Lock the key.
LOCK UNLOCK
IMPORTANT:
Take care not to allow dirt and/or water to enter the 3
fuel tank.
Wipe off any spilled fuel.
Never fail to remove filler cap (2) when refueling with
the automatic fueling device and be sure to stop
fueling when the yellow mark on the float of level
gauge (4) becomes visible.

MLBA-07-094 MLBA-07-093

Yellow Mark

M157-07-060

7-44
 MAINTENANCE
Drain Fuel Tank Sump
--- daily
Before starting operation, open drain valve (4) in the pump
room to drain water and/or sediment from the fuel tank.
1. Place 0.5 liters or larger capacity container under drain
hose (5) to collect the drained water.
2. Open drain valve (4) and drain water and sediment
through the drain hose.
3. After draining water, securely tighten drain valve (4).

5 4 MDAA-07-015

7-45
 MAINTENANCE
Check Water Separator
--- every 50 hours
Water separator (1) is a device designed to separate water from
the fuel. There is a float inside the case which buoys when 2
water accumulates.
When the float rises to the water draining level, drain water. 1
3
Drain Procedures
1. Water separator (1) is located at the front side of the
pump.
Open the right cover and secure it with the rod.
2. Close the cock located at lower part of the fuel tank to
stop feeding fuel.
3. Loosen plug (2) at upper part of water separator (1). MDCR-07-008
Loosen drain plug (3) at lower part of the case to drain
water.
4. After draining water, securely tighten drain plug (2) and
plug (3).
5. Return the fuel cock to its original position (open).

NOTE: After draining water mixed in fuel, bleed air from

the fuel supply system. (Refer to the "Bleed Air from the Fuel
System".)
In case fuel contains water, check and drain water at shorter
service interval.

7-46
 MAINTENANCE
Bleed Air from the Fuel System
Air in the fuel system may make the engine hard to start or
make it run irregularly.
After draining water and sediment from the water separator,
replacing the fuel filter, cleaning the fuel solenoid pump
strainer or running the fuel tank dry, be sure to bleed the air
from the fuel system.

Main Points to Bleed Air 4

1. Make sure that the plug on top of the water separator

and the drain plug are closed.
2. Check that fuel cock (4) on the bottom of the fuel tank is
MDAA-07-007
opened.
3. Loosen air bleed plug (5) of the fuel main filter. Move 5
feed pump (6) up and down until no bubble comes out.

NOTE: Do not loosen plug (2) on top of water separator (1)

and plug (8) on top of the fuel pre-filter (7) when bleeding air.
If plug (2) is loosened, air can not be bled.

4. Tighten air bleed plug (5) on the fuel filter.

Move feed pump (6) up and down until its operation
force gets heavier, tighten the air bleed plug.
6
5. Start the engine. Check the fuel supply system for fuel
leaks.
MDCR-07-009

MDCR-07-008

7-47
 MAINTENANCE
Replace Fuel Pre-Filter Cartridge
— every 250 hours
IMPORTANT:
Use Tata Hitachi genuine cartridge filter. Failure to do
so may deteriorate the engine performance and/
or shorten the engine service life. Please be noted
that all engine failures caused by using other
manufacturers' cartridge filter are excluded from
Tata Hitachi Warranty Policy.

Procedures:
1
1. Close cock (1) on the bottom of the fuel tank
2. Remove cartridge filter (2) by using a tool.
Use leakproof containers when replacing a filter for
safety and to prevent fuel from pouring onto the ground. MDAA-07-007
3. Apply thin film of fuel onto the gasket surface of new
cartridge filter (2).
4. Install cartridge filter (2) by rotating it by hand until the
seal surface contacts with gasket.
5. Tighten the filter 2/3 turns more using a filter wrench.
Be careful not to overly tighten the cartridge element. 3
Deformation of the cartridge may result.
6. Open cock (1) on the bottom of the fuel tank. 2
7. Loosen air bleed plug (3) to drain fuel. When no air
bobbles observed in fuel, tighten air bleed plug (3).
8. Bleed Air from the Fuel System
MDCR-07-008
After replacing the fuel filter element, bleed air from the
fuel supply system.
( Refer to " Bleed Air from the Fuel System".)

7-48
 MAINTENANCE
Replace Fuel Main Filter Cartridge 1
— every 250 hours
IMPORTANT:
Use Tata Hitachi genuine cartridge filter. Failure to do
so may deteriorate the engine performance and/
or shorten the engine service life. Please be noted
that all engine failures caused by using other
manufacturers' cartridge filter are excluded from
Tata Hitachi Warranty Policy.
Change 250 operating hours depending on
environmental conditions. Consult your nearest
Tata Hitachi dealer for the details.
MDCD-07-010

Procedures:
1. Remove cartridge filter (1) by using a tool.
Use leakproof containers when replacing a filter for
safety and to prevent fuel from pouring onto the ground.
2. Apply thin film of fuel onto the gasket surface of new
cartridge filter (1).
3. Install cartridge filter (1) by rotating it by hand until the
seal surface contacts with gasket.
4. Tighten the filter 2/3 turns more using a filter wrench.
Be careful not to overly tighten the cartridge element.
Deformation of the cartridge may result.
5. Bleed Air from the Fuel System
After replacing the fuel filter element, bleed air from the
fuel supply system.
( Refer to " Bleed Air from the Fuel System".)

7-49
 MAINTENANCE
Clean Feed Pump Strainer 4 3 2
--- every 1000 hours

1. Close the cock located at lower part of the fuel tank to

stop feeding fuel.
2. Remove joint bolt (2) at fuel feeding side of water M178-07-102
separator (1). Remove plug (4) and strainer (3) and clean
them with light oil. 2
3. After cleaning, reinstall strainer (3) and plug (4) onto
joint bolt (2). Tighten joint bolt (2).
Joint bolt tightening torque: 1
20 to 25 N·m (2.0 to 2.5 kgf·m)
4. Return the fuel cock to its original position (open).

Bleed Air from the Fuel System

After cleaning the feed pump strainer, bleed air from the
fuel supply system.
(Refer to " Bleed Air from the Fuel System".)
MDCR-07-008

7-50
 MAINTENANCE
Check Fuel Hoses
---daily
--- every 250 hours

CAUTION: Fuel leaks can lead to fires that may result

in serious injury.
Escaping combustible fluid can cause fires. Check for
kinked hoses, hoses that rub against each other, and
any fuel leaks.
Repair or replace any loose or damaged hoses.
Never reinstall bent or damaged hoses.

According to the check points shown below, check hoses for

oil leaks and damage.
If any abnormality is found, replace or retighten as instructed
in the table.

Hose
Interval Check Points Abnormalities Remedies
1
(hours) 2
Daily Hose ends Leak (1) Retighten or replace
Hose covers Wear, crack (2) Replace
Every 250 Hose covers Crack (3) Replace 1
hours Hose ends Crack (4) Replace
M137-07-003
Hose Bend (5), Collapse (6) Replace
3
Hose fittings Corrosion (7) Replace

M137-07-004

M137-07-005

7
M137-07-006

7-51
 MAINTENANCE

F. Air Cleaner
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
CLEAN -- CLEAN EVERY 250HRS. OR WHEN INDICATOR LIT. WHICHEVER IS EARLIER
AIR CLEANER OUTER ELEMENT
REPLACE 1NO. AFTER 6 TIMES OF CLEANING OR 1500 HRS. WHICHEVER IS EARLIER
AIR CLEANER INNER ELEMENT REPLACE 1NO. IT SHOULD NOT BE CLEANED IT SHOULD GET REPLACED ONLY
WHEN OUTER ELEMENT IS REPLACED

Clean and Replace Air Cleaner Element 2

Clean every 250 hours or when the restriction
indicator comes ON
Replace after cleaning 6 times or after 1500 Hrs.

Clean and Replace Air Cleaner Outer Element

Stop the engine before maintaining outer element (1).

1. Before removing outer element (1), unfasten cover

clamp (2). If the inner element (optional) is equipped, do
not remove the inner element.

CAUTION: When using compressed air pressure M1U1-07-027

(less than 0.2 MPa (2 kgf/cm2)), wear safety glasses or
goggles.
1
IMPORTANT: Do not hit or clash outer element (1) against
other object to clean the element.

2. Allow compressed air pressure [less than 0.2 MPa (2 kgf/

cm2)] to blow out of the inside of outer element (1) to
clean the element. After cleaning is complete, be sure to
check outer element (1) for any damage. If any damage
is found, replace the element with new one.
3. In case the air cleaner restriction indicator lights soon
after cleaning outer element (1) even if the cleaning M1U1-07-028
times are less than 6 times, replace both outer and inner
elements with new ones.
IMPORTANT: Do not install element (1) and/or the cover
forcibly when installing the clamps. Failure to do so
may result in deformation of clamps (2), element, and/
or cover.

7-52
 MAINTENANCE
Replace Air Cleaner Inner Element
Air Filter Restriction Switch
IMPORTANT: Do not reuse the inner element. Always 1 2
replace with new one.

1. When removing outer element (1), clean inside of air

cleaner body (2) with compressed air (lower than 0.2 Cover
MPa (2 kgf/cm2) before removing inner element (3).
2. Remove inner element (3) and replace with new element
(3).

3 Valve
M157-07-061

7-53
 MAINTENANCE

G. COOLING SYSTEM
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
LEVEL CHECK --
COOLANT
CHANGE 26L
RADIATOR, OIL COOLER & OUTSIDE
CLEAN
INTERCOOLER CORE INSIDE 1NO. ONCE A YEAR
RADIATOR INTERIOR CLEAN 1NO. WHEN CHANGING COOLANT
RADIATOR, OIL COOLER, INTER COOLER
CLEAN
FRONT SCREEN 1NO.
AIR CONDITIONER CONDENSER CLEAN 1NO.
When genuine TATA-HITACHI long life coolant is used, replace it every 1 year or 2000hrs. Whichever is earlier.
Never mix water in to coolant. Use directly in radiator.

Antifreeze Mixing Ratio

Air Temperature Mixing Ratio Antifreeze Soft water

[° C] [%] [L] [L]
-1 30 7.8 18.2
-15 35 9.1 16.9
-20 40 10.4 15.6
-25 45 11.7 14.3
-30 50 13.0 13.0

Precautions for handling antifreeze

CAUTION: Antifreeze is poisonous.

Antifreeze is poisonous; if ingested, it can cause
serious injury or death. Induce vomiting and get
emergency medical attention immediately.
If antifreeze is accidentally splashed into eyes, flush
with water for 10 to 15 minutes and get emergency
medical attention.
When storing antifreeze, be sure to keep it in a
clearly marked container with a tight lid. Always
keep ANTIFREEZE out of the reach of children.
Use attention to fire hazards. LLC is specified as a
dangerous substance in the fire protection law.
When disposing of LLC, be sure to comply with
all local regulations. When storing or disposing
of antifreeze, be sure to comply with all local
regulations.

7-54
 MAINTENANCE
Check Coolant Level
1
---daily
With the engine cold, the coolant level must be between the
FULL and LOW marks on coolant reservoir (2).
If the coolant level is below the low mark, add coolant to
coolant reservoir (2).
CAUTION: Do not remove cap (1) until the coolant
temperature in the radiator becomes cool. Hot steam
may spout out, possibly causing severe burns. After
the coolant temperature has lowered, slowly loosen
cap (1) to release the inside air pressure before
removing cap (2). M1U1-07-024
2
If coolant reservoir (2) is empty, add coolant to the radiator
and then to coolant reservoir (2).

FULL

LOW

MDCD-07-012

7-55
 MAINTENANCE
Check and Adjust Fan Belt Tension
--- every 100 hours (first time after 50 hours)

IMPORTANT: Loose fan belt may result in insufficient

battery charging, engine overheating, as well as
premature belt wear. Belts that are too tight, however,
can damage both bearings and belts. 2.5 to 3 mm
98 N (10 kgf ) Fan Pulley
Inspect
Check fan belt tension by depressing the midpoint between
the fan pulley and the alternator pulley by your thumb with Alternator Pulley
a depressing force of approximately 98 N (10 kgf, 22 lbf ).
Deflection must be within the value illustrated in the right.
Visually check the belt for wear. Replace if necessary.
Crank Pulley

Adjust Drive Belt Tension M1GR-07-006

1. Loosen lock nut (1) at the top of alternator (3), and lock
nut (4) at the bottom of alternator(3).
1 2
2. Adjust belt tension by moving alternator (3) forward or
backward by using adjustment bolt (2).
3
3. Securely tighten lock nut (1) and (4).
IMPORTANT: When a new belt is installed, be sure to re-
adjust the tension after operating the engine for 3 to 5
minutes at slow idle speed to be sure that the new belt
is seated correctly.

M197-07-072
4

7-56
 MAINTENANCE
Change Coolant
— Once in a year or 2000 Hrs. whichever is earlier.

NOTE: When genuine Tata Hitachi Long-Life Coolant is used,

change interval is once in a year or 2000 Hrs. whichever
comes first.
CAUTION: Do not loosen the radiator cap until the
system has cooled. Hot steam may spout out, possibly
causing severe burns. Loosen the cap slowly to the
stop. Release all pressure before removing the cap.

Procedure:
1. Park the machine on a solid level surface. Lower the
breaker to the ground. Stop the engine.
2. Remove the radiator cap. Open drain cocks (1), (2) on
the radiator and the water jacket to allow the coolant to
drain completely. Remove impurities such as scale at the
same time.
3. Close drain cocks (1), (2). Fill the radiator with tap water
and a radiator cleaner agent. Start the engine and run at
a speed slightly higher than slow idle; when the needle 1
of the temperature gauge reaches the green zone, run
the engine for about ten more minutes. M1U1-07-072

4. Stop the engine and open radiator drain cock (1). Flush
out the cooling system with tap water, until draining
water is clear. This helps remove rust and sediment.
2
5. Close drain cock (1). Fill the radiator with tap water and
LLC at the specified mixing ratio. When adding coolant,
do so slowly to avoid mixing air bubbles in the system.
Run the engine to sufficiently bleed air from the cooling
system.
6. After adding coolant, operate the engine for several
minutes. Check the coolant level again, and add coolant
if necessary.
M178-07-025

7-57
 MAINTENANCE
Clean Radiator/Oil Cooler/Inter Cooler Core
Oil Cooler Air Conditioner Condenser Inter Cooler
Outside --- every 500 hours
Inside --- once a year

CAUTION: Use reduced compressed air pressure

(Less than 0.2 MPa, 2 kgf/cm 2) for cleaning purposes.
Wear personal protection equipment including eye
protection.

IMPORTANT: If air with pressure of higher than 0.2 MPa

(2 kgf/cm2) or tap water with high delivery pressure is
used for cleaning, damage to the radiator/oil cooler/
inter cooler fins may result.
Radiator MDCD-07-011
The radiator, the oil cooler and the inter cooler are arranged in
tandem.
If dirt or dust is accumulated on them, cooling system
performance decreases. Clean the radiator/oil cooler/inter
cooler cores with compressed air pressure (lower than 0.2 MPa
(2 kgf/cm2)) or tap water. It will prevent a reduction in cooling
system performance.

7-58
 MAINTENANCE
Clean Oil Cooler, Radiator and Inter Cooler Front
Screen
--- every 500 hours

IMPORTANT: Check the screen daily and replace it if

necessary when the machine is operated in dusty
areas.

Pull the clip lever on the screen to remove the screen.

Insert the clip into the cover hole and turn over the clip lever
to hold the screen.
MDAA-07-024
The screen can not be held properly if the clip nut is too tight
or loose. Adjust the tightening torque of the clip nut to hold Screen
the screen. Cover
Rubber
For rough indication of the tightening torque, refer to the
below. Nut
Lever
Tightening Torque: 0.5 N·m
or
A: 2.5 to 3.5 mm A

Clean Air Conditioner Condenser

--- every 500 hours

IMPORTANT: Check the screen daily and replace it if MDAA-07-025

necessary when the machine is operated in dusty
areas.

7-59
 MAINTENANCE

H. Electrical System
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
BATTERY ELECTROLYTE LEVEL CHECK --
BATT. ELECTROLYTE SPECFIC GRAVITY CHECK --
LOOSE TERMINALS / CONTACTS CHECK --
BATT. CABLES
HARNESS SHEATH / COVER CHECK --
AND WIRES
HARNESS CLIP CHECK --

Note - TATA-HITACHI recommend to use petrolium jelly to lubricate battery terminals. Grease shouldn’t be used.
Wire Harness should not be in contact with Hydraulic Hoses, Air Conditioner Hoses, Oil, Grease etc.
In no case Harness should lie on the main frame base plate - Oil Spilt on the main frame shall harden the
harness sheath & damage the same.

IMPORTANT:
Improper radio communication equipment and
associated parts, and/or improper installation
of radio communication equipment affects the
machine's electronic parts, causing involuntary
movement of the machine.
Also, improper installation of electrical equipment's
may cause machine failure and/or a fire on the
machine.
Be sure to consult your authorized dealer when
installing radio communication equipment or
additional electrical parts, or when replacing
electrical parts.
Never attempt to disassemble or modify the
electrical/electronic components. If replacement
or modification of such components is required,
contact your authorized dealer.

7-60
 MAINTENANCE

Battery

WARNING:
Battery gas can explode. Keep sparks and flames
away from batteries.
Do not leave cover (1) removed. Do not keep tools,
metals or flammable materials around the battery
or inside the battery room. If a metal tool is placed
across the battery terminal and a vehicle component
such as the engine block, sparks may be created,
possibly resulting in fire and/or explosion.
Do not continue to use or charge the battery when
SA-032
electrolyte level is lower than specified. Explosion of
the battery may result.
Charge the batteries in a well ventilated location.
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into the eyes.
Wearing eye protection and rubber gloves.

IMPORTANT:
If the battery is used with the electrolyte level lower
than the specified lower level, the battery may
deteriorate quickly.
Do not refill electrolyte more than the specified
upper level. Electrolyte may spill, damaging the
painted surfaces and/or corroding other machine
parts.

SA-036
NOTE: In case electrolyte is refilled more than the specified
upper level line or beyond the bottom end of the sleeve,
remove the excess electrolyte until the electrolyte level
is down to the bottom end of the sleeve using a pipette.
After neutralizing the removed electrolyte with sodium
bicarbonate, flush it with plenty of water, otherwise, consult
the battery manufacturer. Or, consult the battery maker.

1 Batteries Location MDCD-07-011

7-61
 MAINTENANCE
Precautions for Handling Batteries
If electrolyte spills on your skin and/or clothes,
immediately flush the skin and/or clothes with water and
then wash further with soap.
If splashed in eyes, flush with water for approximately 15
minutes and seek immediate medical attention.
Avoid using fire hazards such as matches lighters and
tobacco near the batteries. Do not allow sparks to fly.
Check or service the battery only after stopping the
engine, turning the key OFF and removing the battery
caps.
Contact with the battery immediately after operation may
cause personal injury.
Wait for the battery to cool.
When the battery is recharged, inflammable hydrogen
gas is created. Remove the battery from the base
machine. Recharge the battery after removing the caps in
a well ventilated area.
When disconnecting the battery terminals, first
disconnect the ground line [minus (-)] side terminal.
When connecting the battery terminals, connect the
ground line [minus (-)] side terminal last. If a piece of
metal, such as a tool comes in contact with the battery
plus (+) side terminal and the vehicle frame when both
terminals are connected, the electrical system may short-
circuit, possibly creating a dangerous situation.
If a new battery is used along with an old battery, the
service life of the new battery may be shortened. Replace
two batteries at one time. Using old battery together with
new battery may shorten the new battery life time.
Loose terminal may allow sparks to fly. Securely tighten
the terminals.

7-62
 MAINTENANCE
Electrolyte Level Check --- every one month
Check the electrolyte level at least once a month.

1. Park the machine on level ground and stop the engine.

2. Check the electrolyte level.
2.1 When checking the level from the battery side:
Clean around the level check lines with a wet towel.
Do not use a dry towel. Static electricity may be
developed, causing the battery gas to explode. Check U.L (Upper Level)
if the electrolyte level is between U.L (Upper Level) L.L (Lower Level)
and L.L (Lower Level) Do not use a dry towel. Static M146-07-109
electricity may be developed, causing the battery gas Filler Port
to explode.
In case the electrolyte level is lower than the middle
level between the U.L and L.L, immediately refill with Sleeve
distilled water or commercial battery fluid. U.L (Upper Level)
L.L (Lower Level)
After refilling, securely tighten the filler plug. Separator Top
M146-07-110
Be sure to refill with distilled water before recharging
(operating the machine).
2.2 When impossible to check the level from the battery Proper
side or no level check mark is indicated on the side: Since the electrolyte surface touches the bottom end of
the sleeve, the electrolyte surface is raised due to surface
After removing the filler plug from the top of the tension so that the electrode ends are seen curved.
battery. Check the electrolyte level by viewing through M146-07-111
the filler port. It is difficult to judge the accurate
electrolyte level in this case. Therefore, when the
Lower
electrolyte level is flush with the U.L, the level is judged
to be proper. Then, referring to the right illustrations, When the electrolyte surface is lower than the bottom
check the level. When the electrolyte level is lower than end of the sleeve, the electrode ends are seen straight.
the bottom end of the sleeve, refill with distilled water M146-07-112
or commercial battery fluid up to the bottom end of
the sleeve.
After refilling, securely tighten the filler plug.
Be sure to refill with distilled water before recharging
(operating the machine).
2.3 When an indicator is available to check the level, follow
the checking results.

7-63
 MAINTENANCE
3. Always keep around the battery terminals clean to
prevent battery discharge. Check terminals for loose
and/or rust.
Check terminals for loose and/or rust. Coat terminals
with grease or petroleum jelly to prevent corrosion build
up.

M409-07-072

7-64
 MAINTENANCE
Check electrolyte specific gravity--- every one month
The electrolyte specific gravity varies depending on the
electrolyte temperature. The specific gravity should be kept
within the range shown below. Charge the battery if the
specific gravity is below the limit.

Recommended range of specific gravity by electrolyte temperature

40 ° C

20 ° C
Working Range
Fluid temp. 0°C

-20 ° C

-40 ° C
1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32 1.33

Specific gravity of battery fluid

M104-07-054
NOTE: Measure the electrolyte specific gravity when
the electrolyte temperature is equal to the atmospheric
temperature. Do not check the electrolyte specific gravity
immediately after operation as the correct value can not be
obtained.

7-65
 MAINTENANCE
Replacing Fuses
--- as necessary
If any electrical equipment fails to operate, first check the
fuses. Fuse box is located behind the operator's seat.

NOTE:
One each spare fuse for respective fuse capacities is
provided in the fuse box.
A fuse removing jig is provided in the fuse box.

10- CONTROLLER 20- OPTION3

5A 5A MDAA-01-297

9- BACK UP 19- HORN

10 A 10 A Spare Fuses

8- ECF 18- - 10 20
5A
9 19
7- ROOM LAMP 17- POWER ON 8 18
5A 5A
7 17
6- OPTION2 16- GLOW RELAY 6 16
20 A 5A
5 15
5- OPTION1 15- AUXILIARY 4 14
5A 10 A
3 13
4- SOLENOID 14- MONITOR 2 12
10 A 5A 1 11
3- HEATER 13- LIGHTER
20 A 10 A
2- WIPER 12- RADIO Tool
10 A 5A M1GR-01-003

1- LAMP 11- EC MOTOR

20 A 10 A

Fusible Link (Main Fuse)

In case the starter won't rotate even if the key switch is
turned to the START position, fusible link may be the cause
of the trouble. Remove the cover next to the engine coolant
reservoir to check the fuse. Replace it if blown.
21- + Side (Red)
45 A
22- – Side (Black)
65 A

21 22 M1U1-07-023
Battery

7-66
 MAINTENANCE

I. Miscellaneous
INTERVAL (HOURS)
PARTS QTY.
8 50 125 250 500 1000 1500 2000 2500 4000 5000
BUCKET TEETH FOR WEAR & LOOSE CHECK --
BUCKET LINKAGE ADJUST -- AS REQURIED
TRAVEL LEVER REMOVE 2NOS. AS REQURIED
SEAT BELT REMOVE 1NO. EVERY 3 YEARS
TRACK SAG CHECK 2NOS.
CLEAN 1NO. CLEAN AFTER EVERY 250HRS. OR WHEN EXCESSIVELY CHOCKED
AIR CONDITIONER CIRCULATING FILTER
REPLACE 1NO. AFTER CLEANING 6 TIMES
CLEAN 1NO. CLEAN AFTER EVERY 250HRS. OR WHEN EXCESSIVELY CHOCKED
AIR CONDITIONER FRESH AIR FILTER
REPLACE 1NO. AFTER CLEANING 6 TIMES
AIR CONDITIONER GAS QUANTITY CHECK --
COMPRESSOR BELT TENSION CHECK 1NO.
CONDENSER CORE CLEAN 1NO.
INJECTION NOZZLE CHECK
CYLINDER HEAD BOLT TIGHTHESS CHECK *AS REQURIED
INJECTION TIMING CHECK *AS REQURIED
ENGINE COMPRESSION PRESSURE CHECK
STARTER AND ALTERNATOR CHECK
WATER PUMP GREASE REPLACE
GAS DAMPER CHECK *AS REQURIED
TIGHTENING TORQUE OF BOLTS & NUTS CHECK Initial
Contact your nearest TATA-HITACHI dealer for maintenance.

7-67
 MAINTENANCE

Check and Replace Bucket Teeth 1 4

--- daily
Check bucket teeth (1) for wear and looseness.
Replace teeth (1) if tooth wear exceeds the designated service
limit shown below.
Dimension A in mm
A
New Limit of Use MDCR-07-010
230 108
2 3
Replace

CAUTION:
Guard against injury from flying pieces of metal.
Wear goggles or safety glasses, and safety
equipment appropriate to the job.

1. Use hammer (2) and drift (3) to drive out lock pin (4).
Ensure that lock pin (4) is not damaged. If it is damaged,
replace the lock pin with new one.
2. Remove tooth (1). When tooth (1) is removed, washer (5)
may fall off. If washer (5) falls off, install it in the original
place (recessed area at the side of adapter (6)).
MDCR-07-011
Ensure that washer (5) is not damaged. If it is damaged,
replace the washer with new one.
3. Install new tooth (1) into adapter (6). Identify the
orientation of lock pin (4), and carefully tap in lock pin
(4). Ensure that washer (5) is fit in the groove of lock pin
(4).

6 5 MDCR-07-012

5 5

4 6
6

1
1

After Installing the Lock Pin MDCR-07-013

Before Installing the Lock Pin MDCR-07-014

7-68
 MAINTENANCE

Change Bucket

CAUTION: When driving the connecting pins in or

out, guard against injury from flying pieces of metal
or debris. Wear goggles or safety glasses, hard hat and
face shield.

Before starting converting work, keep bystanders clear of the

machine. Slowly move the front attachment. When using a
signal person, coordinate hand signals before starting.

Removal
O-Ring Shift
1. Place the bucket in a stable position.
2. Slide the O-rings out of the way, as shown.
3. Remove bucket pins A and B to separate the arm and
bucket.

Installation Bucket Boss

1. Clean the pins and pin bores. Apply sufficient grease to

the pins and pin bores. Link

2. Place the new bucket in stable position as shown in the

B
figure.
A
3. Fit the arm and alternate bucket. Be sure the bucket will
not roll. Install bucket pins A and B.
4. Install the locking pins and snap rings on pins A and B.
5. Install O-rings to the specified positions.
6. Apply grease to each pin. M104-07-063
7. Start the engine and run at slow idle. Slowly operate the
bucket in both directions to check for any interference in
bucket movement.

7-69
 MAINTENANCE

Convert Bucket Connection Into Face Shovel

O-Ring Shift
CAUTION: When driving the connecting pins in or
out, guard against injury from flying pieces of metal
or debris. Wear goggles or safety glasses, hard hat and
face shield.

Converting the bucket connection allows you to use the Bucket Boss
machine as a face shovel. Before starting converting work,
keep bystanders clear of the machine. Slowly move the front
attachment. When using a signal person, coordinate hand Link
signals before starting. B

Procedure: A
1. Place the bucket in a stable position.
2. Slide the O-rings out of the way, as shown.
3. Remove bucket pins A and B to separate the arm and
bucket.
Clean the pins and pin bores. Apply sufficient grease to
the pins and pin bores.
4. Turn the bucket 180°. Be sure the bucket will not roll.
5. Fit the arm and alternate bucket. Be sure the bucket will
not roll. Install bucket pins A and B.
6. Install the locking pins and snap rings on pins A and B.
7. Install O-rings to the specified positions.
Convert Bucket
8. Apply grease to each pin.
9. Start the engine and run at slow idle. Slowly operate the
bucket in both directions to check for any interference in
bucket movement. Link

M104-07-064

7-70
 MAINTENANCE

Adjust Bucket Linkage

The machine is provided with a bucket adjustment system to

take up play in the linkage. When play in the linkage increases,
remove and install shims as follows:

1. Place the bucket in a stable position. Clearance Adjust Part

2. Run the engine at slow idle. With the bucket on the

ground, slowly swing counterclockwise slightly until the
top of the left bucket boss contacts the arm.
3. Stop the engine. Pull the pilot control shut-off lever to
the LOCK position. M503-07-056

4. Slightly loosen three bolts (1) using a 22 mm wrench.

4
Remove all shims (2) from clearance (c) between plate Bucket Pin Arm Top Boss II Bucket
(3) and bucket. As shim (2) is a dual partitioning type, it d 2
can be easily removed by slightly loosening bolt (1) and
inserting tip of a screw driver into the contact surface of 3
left and right shims (2).
5. Push and hold bolts (1) to remove all clearance (a)
between arm and boss (4). Holding boss (4) against arm
1
increases clearance (b). Install as many shims (2) into
clearance (b) as possible.
a
6. Install remaining shims (2) into clearance (c) and tighten
b c
bolts (1) to 140 N·m (14 kgf·m).
II
NOTE: The total number of shims (2) used in clearance (b)
and (c) are 6¯ 2=12. Remaining shims (2) must be installed in
clearance (c) to prevent arm end face or bolt damage. Replace
boss (4) with new one if measurement (d) is 5 mm (0.2 in) or
less.

SECTION II M1G6-07-010

7-71
 MAINTENANCE

Remove Travel Levers

The travel levers may be removed if desired.

Procedure: 3
4
Remove bolts (1) and (2) to remove travel levers (3) and (4)
from brackets. 2

NOTE: Wrench size: 17 mm

Tightening Torque: 50 N·m (5 kgf·m) 1

Check and Replace Seat Belt

Check --- daily
M178-07-077
Replace --- every 3 years

Prior to operating the machine, thoroughly examine belt (5),

buckle (6) and attaching hardware (7). If any item is damaged
or materially worn, replace the seat belt or component before
operating the machine.
We recommend that the seat belt be replaced every three 5
years regardless of its apparent condition.
6

M1U1-07-008

6 5

M1U1-07-009

7-72
 MAINTENANCE

Check Windshield Fluid Level

Check fluid in windshield washer tank (1). If the fluid level is

low, remove cap (2) and add fluid via the opening. 2

1
MDCR-07-002

7-73
 MAINTENANCE
Check Track Sag
--- every 50 hours

Swing the upperstructure 90 ° and lower the bucket to raise

the track off the ground as shown. Measure distance (A) at the
middle of the track frame from the bottom of the track frame
to the back face of the track shoe.
Each time, be sure to place blocks under the machine frame to
M104-07-067
support the machine.
CAUTION: To prevent accidents, care should be taken
to ensure that hands, feet, and any body parts do not
become entangled when working around the tracks.

Track sag specifications --- 300 to 335 mm

NOTE: Check track sag after thoroughly removing soil stuck

on the track area by washing.

Adjust Track Sag

1. If track sag is not within specifications, loosen or tighten M107-07-068
the track following the procedures shown on the next
page.
2. When adjusting track sag, lower the bucket to the
ground to raise one track off the ground. Repeat this
procedure to raise the other track. Each time, be sure to
place blocks under the machine frame to support the
machine. To prevent accidents, care should be taken
to ensure that hands, feet, and any body parts do not
become entangled when working around the tracks.
3. After adjusting both side track sags, rotate the tracks
backward and forward to equalize both side track sags.
4. Recheck the track sag once more. Readjust as necessary.

7-74
 MAINTENANCE
Loosen the Track

CAUTION: Do not loosen valve (1) quickly or loosen

it too much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (1). Never loosen
grease fitting (2).

IMPORTANT: When gravel or mud is packed between

sprockets and track links, remove it before loosening.

1. To loosen the track, slowly turn valve (1) M107-07-075

counterclockwise using long socket 24; grease will
escape from the grease outlet.
2. Between 1 to 1.5 turns of valve (1) is sufficient to loosen
the track. 2 1

3. If grease does not drain smoothly, slowly rotate the

raised track.
4. When proper track sag is obtained, turn valve (1)
clockwise and tighten to 90 N·m (9.2 kgf·m, 67 lbf·ft).

Tighten the Track

CAUTION: It is abnormal if the track remains tight

after turning valve (1) counterclockwise or if the track Grease Outlet
is still loose after charging grease to fitting (2). In such
cases, NEVER ATTEMPT TO DISASSEMBLE the track or M104-07-119
track adjuster, because of dangerous high-pressure
grease inside the track adjuster. See your authorized
dealer immediately.

To tighten the track, connect a grease gun to grease fitting (2)

and add grease until the sag is within specifications.

7-75
 MAINTENANCE

Clean and Replace Air Conditioner Filter 1

Clean Circulating/Fresh Air Filters

Circulating Air Filter --- every 250 hours
Fresh Air Filter --- every 250 hours

2
Replace Circulating/Fresh Air Filters
Circulating Air Filter --- After cleaning 6 times or so
Fresh Air Filter --- After cleaning 6 times or so

MDAA-07-040

Removing Fresh Air Filter

1. Insert the key into keyhole (2) on left cab side cover (1).
Then, rotate the key counterclockwise to unlock the key.
Open cover (1).
2. While pressing knobs (4) on both sides of fresh air filter 4
(3) inward, horizontally remove the fresh air filter.

3 M1U1-07-011

5
Removing Recirculation Filter
1. Recirculation filter (5) is located under the rear tray.
2. Holding grips (6), pull them toward you to remove.
6

MDAA-07-039

7-76
 MAINTENANCE

WARNING: When using compressed air pressure, wear

safety glasses or goggles.

Cleaning
Clean the circulating and fresh air filters.
Clean both the external and internal filters by blowing
compressed air or washing with water.

Washing procedure with water is as follows:

1. Use tap water.
2. Submerge the filter in water containing a neutral
detergent for about 5 minutes.
3. Clean the filter with water again.
4. Dry the filters.

Installation
When installing the cleaned circulating/fresh air filter or
new filters, follow the reverse order of the Removing Filter
procedures described on the previous page.

7-77
 MAINTENANCE

Check Air Conditioner

Oil Seepage
Check pipe connections for refrigerant gas leakage
If oil seepage is found around pipe connections, it indicates
possible gas leakage.
Detail
Check Refrigerant
Start the engine and run at approximately 1500 min-1 M1CD-07-038
(rpm). Turn the air conditioner switch to ON. Set the blower
switch to HI and set the temperature control switch to the
coolest position (18 °C on the Control Panel). Operate the air
conditioner 2 to 3 minutes. Check if cool air comes out from
the vent in the cab.

Kind of refrigerant and amount when shipping the M157-07-041

machine

Type Amount
HFC134a 0.85±0.05 kg

Check the condenser

If the condenser fins become clogged with dirt or insects,
the cooling effect will be decreased.
Be sure to keep it clean at all times. (Refer to "Clean Radiator
Core" in Maintenance Section.)

Check compressor
After operating the air conditioner for 5 to 10 minutes,
touch both the high pressure pipe and the low pressure
pipe.
If normal, the high-pressure side pipe will be hot, and the
low-pressure side cold.

Check mounting bolts for looseness

Confirm that the compressor mounting bolts and other
mounting/fastening bolts are securely tightened.

7-78
 MAINTENANCE
Inspect belt, check and adjust tension
Alternator Pulley Fan Pulley
--- every 250 hours
Visually check the compressor and fan belts for wear.
Check fan belt tension by depressing the midpoint of the
belt with the thumb. Deflection must be shown in the right 8 to 12 mm
98 N (10 kgf )
figure with a depressing force of approximately 98 N (10
kgf ).
If cool air does not come out, or any other abnormalities are
found in air conditioner system, see your authorized dealer Crank Pulley Air Compressor Pulley
for inspection.
M1G6-07-011

Adjust Compressor Belt Tension

1. Loosen lock nut (2) of tension pulley (1).
2. Move the tension pulley (1) by adjusting bolt (3) under
tension pulley (1) until tension is correct.
3. Securely tighten bolt (2) of tension pulley (1).
IMPORTANT: When a new belt is installed, be sure to re-
adjust the tension after operating the engine for 3 to 5
minutes at slow idle speed to be sure that the new belt 1
is seated correctly. 2
3
Air Compressor Pulley M1G6-07-013

7-79
 MAINTENANCE
Clean Cab Floor
--- as required

IMPORTANT: When cleaning the cab floor with tap

water, spray the floor only. Take care not to splash
the surrounding area. Do not increase water spray
speed by restricting the hose end, and do not use high
pressure steam for cleaning. Be sure to completely
remove any moisture from the surrounding area.

1. Park the machine on solid and level surface. Lower the

bucket to the ground. Before cleaning, stop the engine.
2. Sweep the cab floor clean using a brush, and brush dust
MDAA-07-041
from the cab floor while spraying water.
3. When cleaning the floor mat, sweep dust (water) along
the grooves on the floor mat.
4. When cleaning after removing the floor mat, sweep dust
(water) through one cleaning hole.

7-80
 MAINTENANCE
Check Injection Nozzle
--- every 500 hours
See your authorized dealer.

Retighten Cylinder Head Bolt

--- as required
See your authorized dealer.

Inspect and Adjust Valve Clearance

--- every 1000 hours
See your authorized dealer.

Check Injection Timing

--- as required
See your authorized dealer.

Measure Engine Compression Pressure

--- every 1000 hours
See your authorized dealer.

Check Starter and Alternator

--- every 1000 hours
See your authorized dealer.

Replace Water Pump Grease

--- every 4000 hours
See your authorized dealer.

7-81
 MAINTENANCE
Check Gas Damper
--- as required

CAUTION: The gas damper has been charged with

high-pressure nitrogen gas. Inappropriate handling
may cause explosion, possibly resulting in serious
injury or death.

The gas dampers are used in the tool box and the cab
overhead window. Contact your nearest TATA HITACHI dealer
immediately at any of the following situations.
The cover or window can not be opened with normal
operating force.
The cover or window can not maintain its open position.
Oil or gas leak is found.

Tightening and Retightening Torque of Nuts and

Bolts
--- every 250 hours (first time after 50 hours)

Tighten or retighten nuts and bolts used on this machine in

accordance with the torque values shown in the following
table. Bolts and nuts should be replaced with those of the
same or higher grade.
Check tightness after the first 50 hours then every 250 hours.
For tightening nuts and bolts other than specified in the table
below, refer to the Tightening Torque Chart at the end of this
section.

7-82
 MAINTENANCE

Wrench Torque
No. Descriptions Bolt Dia Quantity
size N·m (kgf·m)
Engine cushion rubber mounting bolts (Pump side) 18 2 27 360 (36)
1. Engine cushion rubber mounting nuts (Pump side) 16 4 24 210 21
Engine cushion rubber mounting nuts (Fan side) 14 4 22 140 14
Engine bracket mounting bolts 10 7 17 50 (5)
2.
Engine bracket mounting nuts (Fan side) 10 1 17 50 (5)
3. Hydraulic oil tank mounting bolts 18 4 27 400 (40)
4. Fuel tank mounting bolts 16 6 24 270 (27)
5. Radiator mounting bolts (Lower side) 16 3 24 270 (27)
6. Pump transmission mounting bolts 10 8 17 65 (6.5)
Control valve mounting bolts 16 4 24 210 (21)
7.
Control valve bracket mounting bolts 16 4 24 270 (27)
8. Swing device mounting bolts 20 14 30 500 (50)
9. Swing motor mounting bolts 12 8 10 90 (9)
- - 17 25 (2.5)
- - 19 30 (3)
- - 22 40 (4)
10. ORS fittings for hydraulic hoses and piping - - 27 95 (9.5)
- - 32 140 (14)
- - 36 180 (18)
- - 41 210 (21)
11. Hycolin tube mounting nuts - - 17 35 (3.5)
12. Battery mounting nuts 10 4 17 50 (5)
Cab mounting nuts 16 4 24 210 (21)
13. Cab mounting anchor bolts (Optional) 22 2 32 550 (55)
Cab cushion rubber mounting bolts 12 8 19 110 (11)
6 - 10 10 (1)
14. Cover mounting bolts 10 - 17 50 (5)
12 - 19 90 (9)
8 13 10.3 to 12.4 (1.05 to 1.26)
Flexible master coupling of low pressure piping 4 sets
1/4-28UNF 11 6 (0.6)
15. - - 7 6 (0.6)
Jubilee clamp of low pressure piping
- - 8 6 (0.6)
T-bolts clamp of low pressure piping - 9 10 6 (0.6)
(Upperstructure) 20 37 30 510 (51)
16. Swing bearing mounting bolts
(Undercarriage) 20 36 30 500 (50)
Travel device mounting bolts 20 28 30 630 (63)
17. Travel reduction device cover mounting bolts 14 12 22 180 (18)
Sprocket mounting bolts 20 36 30 550 (55)
18. Upper roller mounting bolts 16 16 24 270 (27)
19. Lower roller mounting bolts 18 64 27 460 (46)
20. Track shoe mounting bolts 20 392 27 804 (82)
21. Track guard mounting bolts 18 16 27 500 (50)

7-83
 MAINTENANCE
Tightening Torque Chart

Hexagon Wrench Socket Bolt

Bolt Dia.
Wrench size Socket Bolt Wrench size
mm
mm mm
N·m(kgf·m) N·m(kgf·m) N·m(kgf·m) N·m (kgf·m)
3.3 to 4.2 10 5
6
(0.3 to 0.4)
8 30 (3.0) 20 (2.0) 10 (1.0) 13 20 (2.0) 6
10 65 (6.5) 50 (5.0) 20 (2.0) *16, 17 50 (5.0) 8
12 110 (11) 90 (9) 35 (3.5) *18, 19 90 (9) 10
14 180 (18) 140 (14) 55 (5.5) *21, 22 140 (14) 12
16 270 (27) 210 (21) 80 (8.0) 24 210 (21) 14
18 400 (40) 300 (30) 120 (12) 27 300 (30) 14
20 550 (55) 400 (40) 170 (17) 30 400 (40) 17
22 750 (75) 550 (55) 220 (22) *34, 32
24 950 (95) 700 (70) 280 (28) 36
27 1400 (140) 1050 (105) 400 (40) 41
30 1950 (195) 1450 (145) 550 (55) 46
33 2600 (260) 1950 (195) 750 (75) 50
36 3200 (320) 2450 (245) 950 (95) 55

CAUTION: If fixing bolts for counterweight are

loosened, consult your nearest authorized dealer.

IMPORTANT:
Apply lubricant (e. g. white zinc B solved into spindle
oil) to bolts and nuts to stabilize their friction
coefficient.
Remove soil, dust, and/or dirt from the nut and bolt
thread surfaces before tightening.
Tighten nuts and bolts to specifications. If tightened
with excessively low or high torque, missing or
breakage of nuts and/or bolts may result.
NOTE: *Hex size of bolt differs depending on the machine
production plant and bolt procured region.

7-84
 MAINTENANCE
1. Engine cushion rubber mounting bolts and nuts

(Fan Side)
MDCD-07-013

(Pump Side) MDCD-07-014

2. Engine bracket mounting bolts and nuts

(Fan Side)
MDCD-07-013

(Fan Side) MDCD-07-031

7-85
 MAINTENANCE
3. Hydraulic oil tank mounting bolts

MDCR-07-003

4. Fuel tank mounting bolts

MDCR-07-003

5. Radiator mounting bolts

MDCD-07-015

MDCD-07-016

7-86
 MAINTENANCE
6. Pump transmission mounting bolts

M1U1-07-021

7. Control valve mounting bolts

M1U1-07-025

Control valve bracket mounting bolts

M1U1-07-041

8. Swing device mounting bolts

MDCD-07-002

7-87
 MAINTENANCE
9. Swing motor mounting bolts

MDCD-07-002

10. ORS fittings for hydraulic hoses and piping

M104-07-079

11. Hycolin tube mounting nuts

MDCD-07-009

12. Battery mounting nuts

MDCD-07-011

7-88
 MAINTENANCE
13. Cab mounting nuts

M1U1-07-026

14. Cover mounting bolts

M1U1-07-042

7-89
 MAINTENANCE
15. Flexible master coupling of low pressure piping

M1G6-07-008

T-bolt clamp of low pressure piping

MDCD-07-029

16. Swing bearing mounting bolts

Upperstructure side M107-07-088

M107-07-089
Undercarriage side

7-90
 MAINTENANCE
17. Travel device mounting bolts

M164-07-005

Travel reduction device cover mounting bolts

M1G6-07-007

Sprocket mounting bolts

M154-07-050

18. Upper roller mounting bolts

M157-07-224

7-91
 MAINTENANCE
19. Lower roller mounting bolts

M107-07-092

20. Track shoe mounting bolts

M107-07-093

21. Track guard mounting bolts

M107-07-094

7-92
 MAINTENANCE

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7-93
 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

Maintenance Under Special Environmental Conditions

Operating Conditions Precautions for Maintenance

Muddy Soil, Rainy or After Operation : Clean the machine and check for cracks, damaged, loose or missing bolts
Snowy Weather and nuts. Lubricate all necessary parts without delay.
Near the Ocean After Operation : The following salt pollution measures must be taken when the machine is
operated at sea or at coastline.
(1) After completing the work, extend/retract the hydraulic cylinders
several times to form oil film on the rod surface. Store the machine
with cylinders retracted as much as possible.
(2) Thoroughly clean the machine with fresh water to wash off salt.
(3) Perform touch up painting periodically on hose fittings, lubrication
piping and inserting position of cover, where sea water is easily
collected, in order to prevent corrosion.
(4) During storage of the machine, cover the machine by tarps to prevent
sea water from entering into the cab vent. Apply rust prevention oil
(example: ANTIRUST P-1300NP-3 JX Nippon Oil & Energy Corporation)
onto plated part of the cylinder rods.
Dusty Atmosphere Air Cleaner : Clean the element regularly at shorter service intervals.
Radiator : Clean the oil cooler screen to prevent clogging of the radiator core.
Fuel System : Clean the filter element and strainer regularly at shorter service intervals.
Engine, Muffler : Clean earlier than the normal interval to prevent dust from sticking and
accumulating.
Rocky Ground Tracks : Carefully operate while checking for cracks, damage and loose bolts and
nuts. Loosen the tracks a little more than usual.
Front Attachment : Standard attachment may be damaged when digging rocky ground.
Reinforce the bucket before using it, or use a heavy duty bucket.
Falling Stones Cab Head Guard : Provide a cab guard to protect the machine from falling stones. Consult
your nearest Hitachi dealer.

Freezing Weather Fuel/Lubricant : Use high quality and low viscosity fuel and oil.
Engine Coolant : Be sure to use antifreeze.
Battery : Fully charge the batteries at shorter intervals. If not fully charged,
electrolyte may freeze.
Track : Keep the track clean. Park the machine on a hard surface to prevent the
tracks from freezing to the ground.

9-1
 STORAGE

Storing the Machine

In case the machine is to be stored for longer than one month, pay attention to the following points to prepare next
operation.

Precautions for Long-Term Storage

Item Remedy
Machine Cleaning Wash the machine. Remove soil or other debris adhered to the machine.
Lubrication/Greasing Check lubricant's level and contamination. Fill up or change if necessary.
Lubricate all grease points.
Coat grease to exposed metal surfaces which are subject to rust.
(i.e. cylinder rods etc.)
Battery Remove the batteries and store them in a dry protected place after charging fully. If not
removed, disconnect the negative battery cable from the (-) terminal.
Coolant Add anti-rusting agent. If storing in extremely cold areas, either add extra anti-freeze or
drain coolant completely to avoid freezing. In this case, place a sign reading "NO COOLANT".
Protection Against Dust
and Moisture Store the machine in a dry storage area using a protective cover.
Tools Inspect and repair, then store.
Lubrication Operation If oil film on the metal surfaces is lost, rust may begin, possibly causing abnormal wear
of the machine when the machine operation is restarted. If the machine is stored for a
long time, operate hydraulic functions for travel, swing and digging two to three times
for lubrication, at least once a month. Be sure to check the coolant level and lubrication
conditions before operating.
NOTE:
Lubricating operation is a series of warm-up, travel, swing and digging operation carried out repeatedly for a few cycles
at slow speed.
Lubricants will deteriorate during long term storage of the machine. Be sure to carefully check the lubricants before
restarting operation of the machine.

Precautions for Disconnecting or Connecting Batteries

In case the batteries are kept disconnected for more than one month or when the batteries are reconnected, contact
your nearest Tata Hitachi dealer. Resetting of the Information Controller may be required.

10-1
 TROUBLESHOOTING

Troubleshooting
If any machine trouble has occurred, immediately repair it. Make certain the cause of the trouble and take necessary
measures to prevent the reoccurrence of the same trouble.
In case troubleshooting is difficult, or measures marked with * must be taken, consult the nearest Tata Hitachi dealer. Never
attempt to adjust, disassemble, or repair the hydraulic and/or electrical/electronic parts/components.
IMPORTANT: Never attempt to disassemble or modify the electrical/electronic components.

Engine
Consult the nearest Tata Hitachi dealer for the engine troubleshooting.

Engine Auxiliaries

Problem Cause Solution

Batteries will not be charged. Broken battery separator Replace
Faulty regulator * Adjust and replace
Faulty ground line * Repair
Faulty alternator * Repair or replace
Batteries discharges quickly after being Shorted cable * Repair or replace
charged. Shorted battery separator * Repair or replace
Increased sediment in battery * Replace
Coolant temperature is too high. Low coolant level Refill
Insufficient fan belt tension Adjust
Damaged rubber hose * Replace
Faulty thermostat * Replace
Faulty coolant temperature gauge * Replace
Items with * mark: Consult your nearest Tata Hitachi dealer.

11-1
 TROUBLESHOOTING
Impossible to Start the Engine

Problem Cause Solution

Starter does not rotate or is not Discharged battery Charge or replace battery.
powerful Disconnected, loose, or corroded battery After repairing the corroded
terminals area, securely tighten the
connectors.
Lowered pilot control shut-off lever. Pull pilot control shut-off lever
up.
Disconnected, loose, or corroded starter After repairing the corroded
ground line terminals. area, securely tighten the
connectors.
Faulty pilot control shut-off lever electrical Repair
Engine will not start

system
Too high engine oil viscosity Change engine oil with
appropriate viscosity.
Faulty starter and/or electrical system * Repair and adjustment
Starter rotates No fuel After checking that no fuel is
leaking, refill fuel.
Malfunction of EC motor * Repair or replace
Air in the fuel system Bleed air.
Clogged fuel filter After draining water, replace
the element.
Frozen fuel Warm the fuel pump with
hot water or wait until the
atmospheric temperature rises.
Engine stop switch is ON * Repair and adjustment
Faulty preheat system * Repair and adjustment
Even though the engine is started, the Too low idle speed * Repair and adjustment
engine stalls soon Maladjustment of engine control cable * Adjust
Clogged fuel filter After draining water, replace
the element.
Clogged pre-fuel filter Clean or replace the element.
Faulty engine control system * Repair and adjustment
Clogged air cleaner Clean or replace the element.
Faulty injection pump * Repair and adjustment
Engine runs irregularly Faulty fuel system * Repair and adjustment
Water or air in the fuel system Drain water or bleed air.
Faulty engine control system * Repair and replace
Items with *mark: Consult your nearest Tata Hitachi dealer.

11-2
 TROUBLESHOOTING
Control Lever

Problem Cause Solution

Lever is heavy to operate. Rusted joint * Lubricate or repair
Worn pusher * Replace
Does not move smoothly Worn pusher * Repair or replace
Faulty pilot valve * Replace
Does Not Return to Neutral Faulty pilot valve * Replace
The lever is tilted in the neutral position Worn joint * Repair or replace
due to increase in play Faulty pilot valve * Replace
Items with * mark: Consult your nearest Tata Hitachi dealer.

11-3
 TROUBLESHOOTING
Hydraulic System
When the machine is stored without operation, air mixed in hydraulic oil will become separated and will accumulate
in the cylinder upper sections, causing a delay in the response time of the machine movement or weak power
development.
In case these symptoms appear, repeatedly operate all actuators several times.
Problem Cause Solution
No hydraulic Functions Faulty hydraulic pump * Repair or replace
(Noise from pumps) Lack of hydraulic oil Refill
Broken suction pipe and/or hose * Repair or replace
No hydraulic Functions Faulty pilot pump * Replace
(Hydraulic pump noise remains Faulty pilot shut-off solenoid valve * Replace
unchanged.)
Faulty wire harness (pilot shut-off solenoid * Repair or replace
valve) pilot shut-off switch.
The pilot control shut-off lever is in the LOCK Turn the pilot shut-off lever to
position. the UNLOCK position.
All actuators have no power. Malfunction due to worn hydraulic pump * Replace
Decreased main relief valve set pressure in the * Adjust
control valve
Lack of hydraulic oil Refill
Clogged suction strainer in the hydraulic oil Clean
tank
Absorption of air from the oil suction side Retighten
Faulty pressure sensor. * Replace
Faulty solenoid valve * Replace
Only one side lever is inoperable or has Faulty relief valve in the valve * Repair or replace
no power. Broken pipe and/or hose * Repair or replace
Loose pipe line joint Retighten
Broken O-ring at pipe line joint * Replace
Faulty hydraulic pump * Repair or replace
Faulty pilot valve * Replace
Faulty pilot circuit line * Repair or replace
Faulty pilot solenoid valve * Repair or replace
Items with * mark: Consult your nearest Tata Hitachi dealer.

11-4
 TROUBLESHOOTING

Problem Cause Solution

Only one actuator is inoperable. Broken control valve spool * Replace
Embedded foreign matter in valve spool * Repair or replace
Broken pipe and/or hose * Repair or replace
Loose pipe line joint Retighten
Broken O-ring at pipe line joint * Replace
Broken actuator * Repair or replace
Faulty pilot valve * Replace
Faulty pilot circuit line * Repair or replace
Faulty pilot solenoid valve * Repair or replace
Only one cylinder is inoperable or has Broken oil seal in cylinder * Repair or replace
no power. Oil leak due to damage to cylinder rod * Repair or replace
Faulty pilot valve * Replace
Faulty pilot circuit line * Repair or replace
Faulty pilot solenoid valve * Repair or replace
Hydraulic oil temperature increases. Stained oil cooler Clean
Insufficient engine fan belt tension Adjust
Insufficient rotation speed of hydraulically * Repair or replace
driven fan
Oil leak from low pressure hose Loose clamps Retighten
Faulty suction manifold * Repair or replace
Items with * mark: Consult your nearest Tata Hitachi dealer.

11-5
 TROUBLESHOOTING
Drive Function

Problem Cause Solution

One or both side tracks are inoperable. Damaged center joint * Repair or replace
Incompletely released parking brake * Repair or replace
Broken travel motor * Repair or replace
Faulty pilot valve * Replace
Faulty pilot circuit line * Repair or replace
Does not travel smoothly. Overly tensioned or slackened crawler sag Adjust
Lack of lubricant in front idler and/or roller Refill
Deformed track frame * Repair or replace
Embedded foreign matter such as rock Remove
fragments
Dragged parking brake * Repair
Travel speed does not change. Faulty travel speed switch. * Replace
Faulty pressure sensor. * Replace
Pump 1 and 2 delivery pressure sensors
Pumps 1, 2 control pressure sensors
Poor contact in connector * Repair or replace
Damaged wire harness * Repair
Faulty controller (MC) * Replace
Faulty solenoid valve * Repair or replace
Faulty motor * Repair or replace
Items with * mark: Consult your nearest Tata Hitachi dealer.

11-6
 TROUBLESHOOTING
Swing Function

Problem Cause Solution

Upperstructure does not swing Faulty swing parking brake * Repair or replace
Faulty swing parking brake release valve * Repair or replace
Broken swing motor * Repair or replace
Faulty pilot valve * Replace
Faulty pilot circuit line * Repair or replace
Swing is not smooth Worn swing gear * Repair or replace
Damaged swing bearing and bearing balls. * Repair or replace
Lack of grease Refill
Combination valve * Repair or replace
Items with *mark: Consult your nearest Tata Hitachi dealer.

Immediately after the control valve, swing motor relief valve and/or the swing motor is replaced, a noise may be
emitted and/or operation may not be performed smoothly due to air trapped in the hydraulic line.
Slowly continue to operate the machine for approx. 10 minutes to bleed air.
After repair work is complete, be sure to check the oil level in the hydraulic oil tank. Refill hydraulic oil as needed.

11-7
 TROUBLESHOOTING
Engine Speed

Problem Cause Solution

Even if operating the engine control Blown fuse Replace
dial, the engine speed does not Faulty engine control dial * Replace
change.
Poor contact in connector * Repair or replace
Damaged wire harness (between EC dial and * Repair
MC, or MC and ECM)
Faulty controller (MC, ECM) * Replace
Faulty EC motor * Repair or replace
Work mode does not change. Faulty mode switch * Replace
Poor contact in connector * Repair or replace
Damaged wire harness (between MC and * Repair
monitor)
Faulty controller (MC) * Replace
Faulty solenoid valve * Repair or replace
Auto-idle is inoperable or not released. Faulty pressure sensor. * Replace
Poor contact in connector * Repair or replace
Damaged wire harness * Repair
Faulty controller. * Replace
Items with * mark: Consult your nearest Tata Hitachi dealer.

Pump Control

Problem Cause Solution

Front attachment and/or travel speed Blown control fuse Replace
is slow. Poor contact in connector * Repair or replace
Damaged wire harness * Repair
Faulty controller. * Replace
Faulty pump solenoid valve. * Replace
Faulty pressure sensor. * Replace
Items with *mark: Consult your nearest Tata Hitachi dealer.

Others
The machine may have a noise, excessive vibration, and abnormal smell when any trouble occurs.
Always beware of the machine conditions during operation.

11-8
 SPECIFICATIONS

Specifications
ZX220LC-GI

A
G C

B
F

E
D

K J
I H
MDCR-12-001

Model ZX220LC-GI
Type of Front-End Attachment - 2.22 m Arm 2.42 m Arm 2.91 m Arm
Bucket Capacity (Heaped) m3 PCSA 0.90 m (1.18 yd ), CECE 0.80 m3
3 3

Operating Weight kg 21500 21000 21100

Base Machine Weight kg 16900 16500 16500
-1
Engine - ISUZU CC-6BG1T 125 kW/2100 min (170 PS/2100 rpm)
A: Overall Width (Excluding back mirrors) mm 2990
B: Cab Height mm 2940
C: Rear End Swing Radius mm 2910
D: Minimum Ground Clearance mm *450
E: Counterweight Clearance mm *1020
F: Engine Cover Height mm *2240
G: Overall Width of Upperstructure mm 2710
H: Undercarriage Length mm 4460
I: Undercarriage Width mm 2990
J: Sprocket Center to Idle Center mm 3660
K: Track Shoe Width 600
mm
(Grouser shoe)
Ground Pressure kPa(kgf/cm2) 44(0.45) 43(0.44) 44(0.45)
Swing Speed min-1(rpm) 12.6 (12.6)
Travel Speed (fast/slow) km/h 5.5/3.5
Gradeability Degree (%) 35(70)
*The dimensions do not include the height of the shoe lug.

12-1
 SPECIFICATIONS

Working Ranges (Grouser shoe)

ZX220LC-GI
A

F
MDCD-12-002

Backhoe

Model ZX220LC-GI
Category 2.22 m Arm 2.42 m Arm 2.91 m Arm
Item Backhoe Backhoe Backhoe
A: Maximum Digging Reach (mm) 9230 9450 9940
B: Maximum Digging Depth (mm) 5880 6120 6620
C: Maximum Cutting Height (mm) 9230 9360 9710
D: Maximum Dumping
(mm) 6490 6510 6840
Height
E: Overall Height (mm) 3130 3200 3010
F: Overall Length (mm) 9770 9760 9670
G: Minimum Swing Radius (mm) 3530 3530 3500
NOTE: The dimensions do not include height of the shoe lug (except Item E).

12-2
 SPECIFICATIONS

Shoe Types and Applications

ZX220LC-GI
2.22 m Arm
Grouser Shoe
Shoe Width 600
500
(Reinforced)
For Ordinary Ground For Ordinary Ground
Application
(Standard) (Option)
Operating Weight (kg) 21500 21000
Base Machine Weight (kg) 16900 16400
Cab Height (mm) 2940 2940
Base Machine Minimum Ground Clearance (mm) *450 *450
Specifications Undercarriage Length (mm) 4460 4460
Undercarriage Width (mm) 2990 2890
kPa 44 52
Ground Pressure
(kgf/cm2) (0.45) (0.53)

2.42 m Arm
Grouser Shoe
Shoe Width 600
600 500
(Reinforced)
For Ordinary Ground For Ordinary Ground For Ordinary Ground
Application
(Standard) (Option) (Option)
Operating Weight (kg) 21000 21300 20700
Base Machine Weight (kg) 16500 16700 16200
Cab Height (mm) 2940 2940 2940
Base Machine Minimum Ground Clearance (mm) *450 *450 *450
Specifications Undercarriage Length (mm) 4460 4460 4460
Undercarriage Width (mm) 2990 2990 2890
kPa 43 44 52
Ground Pressure
(kgf/cm2) (0.44) (0.45) (0.53)

2.91 m Arm
Grouser Shoe
Shoe Width 600
600 500
(Reinforced)
For Ordinary Ground For Ordinary Ground For Ordinary Ground
Application
(Standard) (Option) (Option)
Operating Weight (kg) 21100 21400 20800
Base Machine Weight (kg) 16500 16700 16200
Cab Height (mm) 2940 2940 2940
Base Machine Minimum Ground Clearance (mm) *450 *450 *450
Specifications Undercarriage Length (mm) 4460 4460 4460
Undercarriage Width (mm) 2990 2990 2890
kPa 44 44 52
Ground Pressure
(kgf/cm2) (0.45) (0.45) (0.53)
NOTE: *The dimensions do not include the height of the shoe lug.

12-3
 SPECIFICATIONS

Bucket Types and Applications

Use a bucket and arm in combination shown in the below table. If a mass excavation bucket or extreme service
excavations bucket which are not described in the table is used, machine stability will not be ensured and strong force
may apply to the main body, front attachment and cylinders, resulting in damage to the machine.
Use the bucket and the arm in combination only described in the below table.

ZX220LC-GI

Bucket Capacity
Bucket Width (mm) Front-End Attachment
(m3)
Bucket
With Side Without side 2.22 m 2.42 m 2.91 m
Heaped CECE
Cutter cutter Arm Arm Arm
0.90 (GP) 0.80 1240 1130
Hoe Bucket
1.00 0.90 1340 1230
0.90 (HD) 0.80 - 1010 ¯ ¯
Reinforced Hoe Bucket
0.90 (GR) 0.80 - 1010 ¯ ¯

NOTE:
GP: General purpose
HD: Heavy duty
GR: Granite
: General excavating
: Light duty excavating
: Heavy duty excavating
¯ : Not applicable (not warrantable)

Hoe bucket is applicable to the following types of work.

For general excavating (digging and loading operation of sand, gravel, clay, ordinary earth and so on.)
For light duty excavating (digging and loading operation of dry, loosened earth, sand, mud and so on. The bulk density
shall be less than 1600 kg/m3 as a standard.)
For heavy duty excavating (digging and loading operation of mountain gravels, blasted rock, hard clay, soft rock and so
on.)

12-4
 INDEX
A Change Hydraulic Oil and Replace Full-Flow Filter
Adjust Bucket Linkage ................................................................7-71 Element ......................................................................................5-24
Adjust the Operator’s Seat ...........................................................S-6 Check Air Conditioner................................................................. 7-68
Adjusting Operator’s Seat (Optional) ....................................1-45 Check and Adjust Fan Belt Tension ........................................7-56
Adjusting the Seat ........................................................................1-43 Check and Replace Bucket Teeth ............................................7-68
After the First 100 Hours ...............................................................2-1 Check and Replace Seat Belt ....................................................7-72
After the First 50 Hours .................................................................2-1 Check Coolant Level ....................................................................7-55
Air Cleaner ......................................................................................7-52 Check Fuel Hoses ..........................................................................7-51
Air Filter Restriction Indicator .....................................................1-6 Check Gas Damper ......................................................................7-81
Allowable Weight Limits of Installed Attachment ............5-28 Check Hoses and Lines ...............................................................7-39
Alternator Indicator ........................................................................1-7 Check Hydraulic Oil Level ..........................................................7-29
AM/FM Radio Operation ............................................................1-31 Check Injection Nozzle ...............................................................7-81
Armrest Adjustment .........................................................1-44, 1-46 Check Injection Timing ...............................................................7-81
Attachment .....................................................................................5-28 Check Instruments After Starting ..............................................3-5
Attachment Indicator.....................................................................1-6 Check Starter and Alternator ...................................................7-81
Attachment Pedal (Hydraulic Breaker) (Optional) ...............5-3 Check the Hour Meter Regularly ................................................7-3
Auto Air Conditioner ...................................................................1-23 Check Track Sag ............................................................................7-74
Auto-Idle .............................................................................................5-7 Check Water Separator ...............................................................7-49
Auto-Idle Indicator ..........................................................................1-5 Check Windshield Fluid Level ..................................................7-73
Auto-Idle ON/OFF............................................................................5-8 Cigar Lighter ...................................................................................1-18
Auto-Idle Switch ...........................................................................1-11 Clean Air Conditioner Condenser ...........................................7-59
Avoid Abusive Operation ..........................................................5-15 Clean and Replace Air Cleaner Element ...............................7-52
Avoid Applying Heat to Lines Containing Flammable Clean and Replace Air Conditioner Filter .............................7-76
Fluids ...........................................................................................S-34 Clean Cab Floor .............................................................................7-80
Avoid Hammer Work ...................................................................5-14 Clean Feed Pump Strainer .........................................................7-50
Avoid Heating Near Pressurized Fluid Lines .......................S-34 Clean Oil Cooler, Radiator and Inter Cooler Front
Avoid High-Pressure Fluids .......................................................S-29 Screen .........................................................................................7-61
Avoid Injury from Back-Over and Swing Accidents .........S-17 Clean Radiator/Oil Cooler/Inter Cooler Core ......................7-60
Avoid Injury from Rollaway Accidents ..................................S-16 Components Name .............................................................1-1, 1-24
Avoid Power Lines ........................................................................S-21 Confirm Direction of Machine to Be Driven ........................S-13
Avoid Side Load the Bucket ......................................................5-15 Console and Seat Fore-aft Adjustment .....................1-43, 1-45
Avoid Tipping .................................................................................S-19 Control Lever (HITACHI Pattern) (Optional) ............................5-2
Avoid Undercutting .....................................................................S-19 Control Lever (ISO Pattern) .........................................................5-1
Controller Part Name and Function .......................................1-25
B Controls on the radio ..................................................................1-31
BREAK-IN .............................................................................................2-1 Convert Bucket Connection Into Face Shovel ....................7-72
Backrest Adjustment ........................................................1-43, 1-46 Cool Head/Warm Feet Operation ...........................................1-29
Battery ..............................................................................................7-61 Coolant Temperature Gauge .......................................................1-5
Before Starting Engine ..................................................................3-2 Cooling Operation .......................................................................1-28
Beware of Asbestos and Silicon Dust and Other Cooling System .............................................................................7-56
Contamination .........................................................................S-35 Correct Maintenance and Inspection Procedures ...............7-1
Beware of Exhaust Fumes.......................................................... S-32
Brand Names of Recommended Engine Oil .......................7-12 D
Bucket Types and Applications ...............................................12-4 DRIVING THE MACHINE .................................................................4-1
ZX220LC-GI................................................................................ 12-4 Defroster Operation ....................................................................1-29
Dig with Caution ...........................................................................S-20
C Digging Indicator ............................................................................1-6
COMPONENTS NAME .....................................................................1-1 Digital Clock Setting Procedure ..............................................1-33
Cab Door Release Lever .............................................................1-35 Display Selector ...............................................................................1-9
Cab Features ......................................................................................1-3 Dispose of Waste Properly .........................................................S-37
Cab Heater Operation .................................................................1-27 Do not strike the ground with bucket teeth ......................5-14
Cab Light Switch ...........................................................................1-19 Do not use wide track shoes on rough ground. ................5-16
Change Bucket ..............................................................................7-69 Drain Fuel Tank Sump .................................................................7-47
Change Coolant ............................................................................7-57 Drive Machine Safely ...................................................................S-14
Change Engine Oil, Replace Engine Oil Filter .....................7-20 Drive the Machine Carefully ........................................................4-1
Change Hydraulic Oil ..................................................................7-29

14-1
 INDEX
E K
ECO Mode Indicator .......................................................................1-5 Keep Person Clear from Working Area.................................. S-18
Electrical System ...........................................................................7-62 Keep Riders off Machine ...............................................................S-9
Emergency Exit .............................................................................1-41 Key Switch .......................................................................................1-17
Engine ...............................................................................................7-19 Kind of Oils ......................................................................................7-12
Engine Oil Level ............................................................................7-19
L
Engine Speed Control ....................................................................5-6
Engine Stop Switch ......................................................................1-21 Layout ..................................................................................................7-4
Engine Trouble Indicator ..............................................................1-8 LCD .......................................................................................................1-9
Ensure Safety Before Rising from or Leaving Operator’s Lifting Machine ................................................................................6-7
Seat .................................................................................................S-7 Loading/Unloading on a Trailer .................................................6-2
Evacuating in Case of Fire ..........................................................S-32 Low Engine Oil Pressure Indicator .............................................1-7
Every 8 Hours or Daily ....................................................................2-1 M
F MACHINE NUMBERS ...........................................................................1
Fasten Your Seat Belt ......................................................................S-7 MAINTENANCE .................................................................................7-1
Fastening Machine for Transporting ........................................6-5 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
Features: ..........................................................................................1-23 CONDITIONS ................................................................................9-1
Follow Safety Instructions ............................................................S-2 Maintenance Guide ........................................................................7-9
For Rapid Cooling .........................................................................1-30 Maintenance Guide Table .............................................................7-5
Front Joint Pins ..............................................................................7-15 Maintenance Under Special Environmental Conditions ...9-1
Fuel Gauge .........................................................................................1-5 Measure Engine Compression Pressure ...............................7-83
Fuel System .....................................................................................7-45 Miscellaneous ................................................................................7-70
Fuse Box ...........................................................................................1-22 Monitor Panel ...................................................................................1-4
Move and Operate Machine Safely ...........................................S-8
G
N
GETTING ON/OFF THE MACHINE ...............................................1-2
General Precautions for Cab ........................................................S-5 Never Position Bucket Over Anyone .....................................S-18
Grading Operation .......................................................................5-13 Never Ride Attachment ..............................................................S-38
Greasing ...........................................................................................7-15 Never Undercut a High Bank ....................................................S-20

H O
Handle (Emergency engine stop) ...........................................1-21 OPERATING THE ENGINE ...............................................................3-1
Handle Chemical Products Safely ...........................................S-37 OPERATING THE MACHINE ...........................................................5-1
Handle Fluids Safely-Avoid Fires ............................................ S-23 OPERATOR’S STATION ....................................................................1-3
Hood and Access Covers ...............................................................7-8 Object Handling ........................................................................... S-22
Horn Switch ....................................................................................1-17 Observe Engine Operation Closely ...........................................2-1
Hour Meter .........................................................................................1-9 Off-Season Air Conditioner Maintenance ...........................1-30
How to Lower Boom In Case of Emergency and Opening Side Windows ..............................................................1-39
When Engine Stops ................................................................5-31 Opening Upper Front Window ................................................1-37
Hydraulic Breaker, Hydraulic Crusher and Opening/Closing and Removing Cab Inside Window ....1-36
Quick Coupler........................................................................... 5-17 Opening/Closing Overhead Window ....................................1-40
Hydraulic Filter Indicator (Optional) .........................................1-7 Operate Only from Operator’s Seat ..........................................S-8
Hydraulic System ..........................................................................7-26 Operate with Caution .................................................................S-20
Operating Backhoe ......................................................................5-11
I Operating in Water or Mud ..........................................................4-7
Inspect and Adjust Valve Clearance .......................................7-83 Operating on Soft Ground ...........................................................4-5
Inspect Machine ..............................................................................S-4 Operational procedures for stop valves and selection
Inspect Machine Daily Before Starting ....................................3-1 valve. ............................................................................................5-18
Inspection and Maintenance of Hydraulic Equipment ...7-26 Overheat Indicator ..........................................................................1-6
Install OPG Guard .........................................................................S-12
P
Installation and Adjustment of Mirrors ................................1-47
Investigate Job Site Beforehand .............................................S-11 PWR Mode Indicator.......................................................................1-5
Park Machine Safely .....................................................................S-23
J Parking the Machine ......................................................................4-8
Jump Starting ...................................................................................S-9 Parking the Machine on Slopes ..................................................4-8
Periodic Replacement of Parts .................................................7-11
Pilot Control Shut-Off Lever .............................................1-20, 5-4

14-2
 INDEX
Pilot Control Shut-Off Lever Indicator .....................................1-8 Service Air Conditioning System Safely ...............................S-36
Piping for Breaker and Crusher (Optional) ..........................5-18 Shackle Hole Usage .....................................................................5-30
Power Boost Switch .............................................................1-17, 5-9 Shoe Types and Applications ...................................................12-3
Power Mode ...................................................................................5-10 ZX220LC-GI................................................................................ 12-3
Power Mode Switch .....................................................................1-12 Shovel ...............................................................................................5-12
Practice Safe Maintenance ........................................................S-25 Sound Adjustment .......................................................................1-34
Precaution For Arm Roll-In/Bucket Roll-In Combined Specifications .................................................................................12-1
Operation ...................................................................................5-30 ZX220LC-GI................................................................................ 12-1
Precaution for Communication Terminal Equipment .....S-39 Starting the Engine .........................................................................3-3
Precautions for After Operations ............................................5-32 Station Presetting Procedure ...................................................1-32
Precautions for Breaker Operation .........................................5-20 Stay Clear of Moving Parts ........................................................S-27
Precautions for Communication Terminal ...........................S-38 Steering the Machine Using Levers ..........................................4-3
Precautions for Crusher Operation ........................................5-25 Steering the Machine Using Pedals ..........................................4-2
Precautions for Handling Accumulator and Stopping the Engine ......................................................................3-8
Gas Damper ..............................................................................S-34 Store Attachments Safely ..........................................................S-28
Precautions for Lightning ..........................................................S-21 Storing the Machine ....................................................................10-1
Precautions for Operations .......................................................S-10 Suction Filter Cleaning ...............................................................7-33
Precautions for Welding and Grinding .................................S-33 Support Machine Properly ........................................................S-26
Preheat Indicator .............................................................................1-7 Suspension Adjustment .............................................................1-45
Preparations for Inspection and Maintenance .....................7-7 Swing Alarm Deactivation Switch (Optional) .....................1-16
Prepare for Emergencies ...............................................................S-3 Swing Bearing ................................................................................7-17
Prevent Battery Explosions .......................................................S-36 Swing Device .................................................................................7-23
Prevent Burns .................................................................................S-28 Swing Internal Gear .....................................................................7-18
Prevent Fires ...................................................................................S-30 Switch Panel ...................................................................................1-10
Prevent Parts from Flying ..........................................................S-27 Switch Panel (for Optional Equipments) ..............................1-16
Protect Against Flying Debris .................................................. S-22
T
Protect Against Noise ....................................................................S-4
Provide Signals for Jobs Involving Multiple Machines.... S-13 TRANSPORTING ................................................................................6-1
Pump Transmission ......................................................................7-22 TROUBLESHOOTING ....................................................................11-1
Tightening and Retightening Torque of Nuts and
R Bolts .............................................................................................7-84
Raise One Track Using Boom and Arm ....................................4-5 Time Adjustment ..........................................................................1-33
Recognize Safety Information ....................................................S-1 Tips for Optimal Air Conditioner Usage ...............................1-30
Recommended Fuel ....................................................................7-45 Towing Machine a Short Distance .............................................4-6
Remaining Fuel Indicator .............................................................1-6 Transmission ..................................................................................7-22
Remove Paint Before Welding or Heating ...........................S-35 Transport Safely ............................................................................S-24
Remove Travel Levers ..................................................................7-74 Transporting by Road ....................................................................6-1
Removing and Storing Lower Front Window .....................1-38 Travel Alarm Deactivation Switch (Optional) .....................1-16
Replace Air Breather Element ..................................................7-40 Travel Mode Switch .............................................................1-12, 4-4
Replace Fuel Main Filter Cartridge .........................................7-51 Travel Reduction Gear ................................................................7-24
Replace Fuel Pre-Filter Cartridge ............................................7-50 Troubleshooting ...........................................................................11-1
Replace Pilot Oil Filter .................................................................7-39
U
Replace Rubber Hoses Periodically ........................................S-29
Replace Water Pump Grease ....................................................7-83 Understand Signal Words .............................................................S-1
Replacement of Full-Flow Filter ...............................................7-34 Unloading ..........................................................................................6-5
Replacing Fuses ............................................................................7-68 Use Handholds and Steps ............................................................S-6
Retighten Cylinder Head Bolt ..................................................7-83 Using Booster Batteries .................................................................3-6
Using Cigar Lighter ......................................................................1-18
S Using Cigar Lighter Port as External Power Source.......... 1-18
SAFETY ................................................................................................S-1
W
SAFETY SIGNS ................................................................................S-41
SPECIFICATIONS ............................................................................12-1 Warming Up Operation .................................................................5-5
STORAGE ..........................................................................................10-1 Warn Others of Service Work ...................................................S-26
Seat Belt ...........................................................................................1-48 Wear Protective Clothing..............................................................S-3
Seat Fore-Aft Adjustment ...............................................1-43, 1-45 When Windows Become Clouded ..........................................1-30
Seat Height and Angle Adjustment ............................1-43, 1-45 Wiper/Washer Switch ..................................................................1-15
Secondary Relief Pressure Adjustment ................................5-19 Work Light Switch ........................................................................1-14

14-3
 INDEX
Work Mode ........................................................................................5-9
Work Mode Switch .......................................................................1-13
Working Ranges (Grouser shoe).............................................. 12-2
ZX220LC-GI................................................................................ 12-2

14-4
 Printed at Jamshedpur, India

Master Manual ED-ZX220LC GI(OM)-1/August 2014 corrected by Designer & Technical Support team.