S01NE0310382

Operator’s Manual

80-GI

ZX80-GI 000001 ONWARDS

 INTRODUCTION
Read this manual carefully to learn how to operate
and service your machine correctly. Failure to do so
could result in personal injury or machine damage.
This standard specification machine can be
operated under the following conditions without
being modified. Atmospheric Temperature: –20 °C to
40 °C (–4 °F to 104 °F) Altitude: 0 m to 1500 m (0 ft to
4900 ft)
In case the machine is used under conditions other
than described above, consult your nearest Tata
Hitachi dealer.
This manual should be considered a permanent
part of your machine and should remain with the
machine when you sell it.
This machine is of metric design. Measurements in
this manual are metric. Use only metric hardware and
tools as specified.
Right-hand and left-hand sides are determined by
facing in the direction of forward travel.
Write product identification numbers in the
Machine Numbers section. Accurately record all the
numbers to help in tracing the machine should it be
stolen. Your dealer also needs these numbers when
you order parts. If this manual is kept on the machine,
also file the identification numbers in a secure place
off the machine.
Be sure to use fuel that complies with your local
standard. Also use of fuel that complies with solid
contamination level of class 18/16/13 of ISO4406-
1999 (solid contamination includes dust) is
recommended. If the fuel specified above is not used,
a problem may arise on the engine. Consult your
nearest Tata Hitachi dealer.
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.
Warranty is provided as a part of Tata Hitachi’s
support program for customers who operate and
maintain their equipment as described in this manual.
The warranty is explained on the warranty certificate
which you should have received from your dealer.
This warranty provides you the assurance that Tata
Hitachi will back its products where defects appear
within the warranty period. In some circumstances,
Tata Hitachi also provides field improvements, often
without charge to the customer, even if the product is
out of warranty.
Should the equipment be abused, or modified to
change its performance beyond the original
factory specifications, the warranty will become
void and field improvements may be denied.
Setting fuel delivery above specifications or
otherwise overpowering machines will result in such
action.
Only qualified, experienced operators officially
licensed (according to local law) should be allowed to
operate the machine. Moreover, only officially
licensed personnel should be allowed to inspect and
service the machine.
PRIOR TO OPERATING THIS MACHINE, INCLUDING
SATELLITE COMMUNICATION SYSTEM, IN A
COUNTRY OTHER THAN A COUNTRY OF ITS
INTENDED USE, IT MAY BE NECESSARY TO MAKE
MODIFICATIONS TO IT SO THAT IT COMPLIES WITH
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
(INCLUDING SAFETY STANDARDS) AND LEGAL
REQUIREMENTS OF THAT PARTICULAR COUNTRY.
PLEASE DO NOT EXPORT OR OPERATE THIS
MACHINE OUTSIDE OF THE COUNTRY OF ITS
INTENDED USE UNTIL SUCH COMPLIANCE HAS
BEEN CONFIRMED. PLEASE CONTACT TATA
HITACHI CONSTRUCTION MACHINERY CO., LTD. OR
ANY OF OUR AUTHORIZED DISTRIBUTOR OR
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
SAFETY .......................................................................... S-1
Recognize Safety Information ....................................................S-1
Understand Signal Words .............................................................S-1
Follow Safety Instructions ............................................................S-2
Prepare for Emergencies ...............................................................S-3
Wear Protective Clothing..............................................................S-3
Protect Against Noise ....................................................................S-4
Inspect Machine ..............................................................................S-4
General Precautions for Cab ........................................................S-5
Use Handholds and Steps ............................................................S-6
Adjust the Operator's Seat ...........................................................S-6
Ensure Safety Before Rising from or Leaving
Operator’s Seat ...........................................................................S-7
Fasten Your Seat Belt ......................................................................S-7
Move and Operate Machine Safely ...........................................S-8
Operate Only from Operator's Seat ..........................................S-8
Jump Starting ...................................................................................S-9
Keep Riders off Machine ...............................................................S-9
Precautions for Operations .......................................................S-10
Investigate Job Site Beforehand .............................................S-11
Protect Against Falling Stones and Debris ..........................S-12
Provide Signals for Jobs Involving Multiple Machines....S-13
Confirm Direction of Machine to Be Driven ........................S-13
Drive Machine Safely ...................................................................S-14
Avoid Injury from Rollaway Accidents ..................................S-16
Avoid Injury from Back-Over and Swing Accidents .........S-17
Keep Person Clear from Working Area ..................................S-18
Never Position Bucket Over Anyone .....................................S-18
Avoid Undercutting .....................................................................S-19
Avoid Tipping .................................................................................S-19
Never Undercut a High Bank ....................................................S-20
Dig with Caution ...........................................................................S-20
Operate with Caution .................................................................S-20
Avoid Power Lines ........................................................................S-21
Precautions for Lightning ..........................................................S-21
Danger Zone ....................................................................................S-21
Object Handling ........................................................................... S-22
Protect Against Flying Debris .................................................. S-22
Park Machine Safely .....................................................................S-23
Handle Fluids Safely−Avoid Fires............................................S-23
Transport Safely ............................................................................S-24
Practice Safe Maintenance ........................................................S-25
Warn Others of Service Work ...................................................S-26
Support Machine Properly ........................................................S-26
Stay Clear of Moving Parts ........................................................S-27
Prevent Parts from Flying ..........................................................S-27
Store Attachments Safely ..........................................................S-28
Prevent Burns .................................................................................S-28
Replace Rubber Hoses Periodically ........................................S-29
Avoid High-Pressure Fluids .......................................................S-29
Prevent Fires ...................................................................................S-30
Evacuating in Case of Fire ..........................................................S-32
Beware of Exhaust Fumes..........................................................S-32
Precautions for Welding and Grinding .................................S-33
Avoid Heating Near Pressurized Fluid Lines .......................S-34
Avoid Applying Heat to Lines Containing Flammable
Fluids ...........................................................................................S-34
Precautions for Handling Accumulator and
Gas Damper ..............................................................................S-34
Remove Paint Before Welding or Heating ...........................S-35
Beware of Asbestos and Silicon Dust and Other
Contamination .........................................................................S-35
Prevent Battery Explosions .......................................................S-36
Service Air Conditioning System Safely ...............................S-36
Handle Chemical Products Safely ...........................................S-37
Dispose of Waste Properly .........................................................S-37
Never Ride Attachment ..............................................................S-38
Precautions for Communication Terminal ...........................S-38
Precautions for Communication Terminal
Equipment ........................................................................................S-39
SAFETY SIGNS ............................................................. S-41
COMPONENTS NAME ....................................................1-1
Components Name ........................................................................1-1
GETTING ON/OFF THE MACHINE ................................. 1-2
OPERATOR’S STATION .................................................. 1-3
Cab Features ......................................................................................1-3
Monitor Panel ...................................................................................1-4
Coolant Temperature Gauge .................................................1-5
Fuel Gauge ...................................................................................1-5
Auto-Idle Indicator ....................................................................1-5
ECO Mode Indicator ..................................................................1-5
PWR Mode Indicator .................................................................1-5
Remaining Fuel Indicator ........................................................1-6
Air Filter Restriction Indicator ................................................1-6
Overheat Indicator ....................................................................1-6
Low Engine Oil Pressure Indicator .......................................1-6
Alternator Indicator ...................................................................1-6
Preheat Indicator ........................................................................1-6
Engine Trouble Indicator .........................................................1-7
Pilot Control Shut-Off Lever Indicator ................................1-7
Liquid Crystal Display (LCD) ...................................................1-8
Hour Meter ...................................................................................1-8
Switch Panel ......................................................................................1-9
Auto-Idle Switch ......................................................................1-10
Power Mode Switch ...............................................................1-11
Travel Mode Switch ................................................................1-11
Work Light Switch ........................................................................1-12
Wiper/Washer Switch ............................................................1-13
Key Switch .......................................................................................1-14
Horn Switch ....................................................................................1-14
Cigar Lighter ...................................................................................1-15
Using Cigar Lighter .................................................................1-15
Using Cigar Lighter Port as External Power Source ....1-15
Cab Light .........................................................................................1-16
Pilot Control Shut-Off Lever .....................................................1-17
Engine Stop Switch ......................................................................1-17
Fuse Box ...........................................................................................1-18
 CONTENTS
Auto Air Conditioner (Optional) ..............................................1-19
Features: .....................................................................................1-19
Components Name ................................................................1-20
Controller Part Name and Function .................................1-21
Cab Heater Operation ...........................................................1-23
Cooling Operation ..................................................................1-24
Defroster Operation ...............................................................1-25
Cool Head/Warm Feet Operation ......................................1-25
Tips for Optimal Air Conditioner Usage ...............................1-26
For Rapid Cooling ...................................................................1-26
When Windows Become Clouded ....................................1-26
Off-Season Air Conditioner Maintenance ......................1-26
AM/FM Radio Operation (Optional) .......................................1-27
Controls on the radio .............................................................1-27
Station Presetting Procedure ..............................................1-28
Digital Clock Setting Procedure .........................................1-29
Time Adjustment ....................................................................1-29
Sound Adjustment .................................................................1-30
Cab Door Release Lever .............................................................1-31
Opening/Closing and Removing Cab Inside Window ....1-32
Opening Upper Front Window ................................................1-33
Opening Upper Front Window ..........................................1-33
Removing and Storing Lower Front Window .....................1-34
Removing and Storing Lower Front Window ...............1-34
Opening Side and Rear Windows ...........................................1-35
Opening/Closing Overhead Window ....................................1-36
Emergency Exit .............................................................................1-37
Installation and Adjustment of Mirrors ................................1-38
Seat Belt ...........................................................................................1-39
Seat Belt......................................................................................1-39
BREAK-IN ....................................................................... 2-1
Observe Engine Operation Closely ...........................................2-1
Every 8 Hours or Daily ....................................................................2-1
After the First 50 Hours .................................................................2-1
After the First 100 Hours ...............................................................2-1
OPERATING THE ENGINE .............................................. 3-1
Inspect Machine Daily Before Starting ....................................3-1
Before Starting Engine ..................................................................3-2
Starting the Engine .........................................................................3-3
Check Instruments After Starting ..............................................3-5
Using Booster Batteries .................................................................3-6
Stopping the Engine ......................................................................3-8
DRIVING THE MACHINE ................................................ 4-1
Travel Levers and Pedals ...............................................................4-1
Travel Mode Switch ........................................................................4-3
Traveling .............................................................................................4-4
Operating on Soft Ground ...........................................................4-5
Raise One Track Using Boom and Arm ....................................4-5
Towing Machine a Short Distance .............................................4-6
Operating in Water or Mud ..........................................................4-7
Precautions for Traveling on Slopes ..........................................4-8
Parking the Machine on Slopes ..................................................4-9
Parking the Machine ......................................................................4-9
OPERATING THE MACHINE ...........................................5-1
Control Lever (ISO Pattern) .........................................................5-1
Attachment Pedal (Hydraulic Breaker) (Optional) ...............5-2
Blade Lever ........................................................................................5-3
Precautions for Blade Operation ................................................5-3
Pilot Control Shut-Off Lever ........................................................5-4
Warming Up Operation .................................................................5-5
Engine Speed Control ....................................................................5-6
Auto-Idle .............................................................................................5-7
Auto-Idle ON/OFF ......................................................................5-8
Power Mode ......................................................................................5-9
Operating Backhoe ......................................................................5-10
Shovel ...............................................................................................5-11
Grading Operation .......................................................................5-12
Do Not Strike the Ground with Bucket Teeth .....................5-13
Avoid Hammer Work ...................................................................5-13
Avoid Abusive Operation ..........................................................5-14
Avoid Side Load the Bucket ......................................................5-14
Avoid Hitting Blade With Front-End Attachment .............5-15
Avoid Hitting Blade With Bucket .............................................5-15
Avoid Striking the Blade Into a Rock .....................................5-15
Hydraulic Breaker and Hydraulic Crusher (Optional) ......5-16
Precautions for Breaker Operation .........................................5-17
Change Hydraulic Oil and Replace Full-Flow Filter
Element ......................................................................................5-21
Precautions for Crusher Operation ........................................5-22
Attachment .....................................................................................5-25
Allowable Weight Limits of Installed Attachment ......5-25
Precaution For Arm Roll-In/Bucket Roll-In Combined
Operation ...................................................................................5-27
Shackle Hole Usage .....................................................................5-27
Emergency Boom Lowering Procedure ...............................5-28
Precautions for After Operations ............................................5-29
TRANSPORTING ............................................................ 6-1
Transporting by Road ....................................................................6-1
Loading/Unloading on a Trailer .................................................6-2
Transporting Machine with Blade ........................................6-2
Loading/Unloading ...................................................................6-3
Loading ..........................................................................................6-3
Fastening Machine for Transporting ........................................6-5
Unloading ..........................................................................................6-5
Lifting Machine ................................................................................6-7
MAINTENANCE ..............................................................7-1
Correct Maintenance and Inspection Procedures ...............7-1
Check the Hour Meter Regularly ................................................7-3
Layout ..................................................................................................7-4
Maintenance Guide Table .......................................................7-5
Preparations for Inspection and Maintenance .....................7-7
Hood and Access Covers ...............................................................7-8
Recommended Oil & Lubricants ................................................7-9
Brand Names of Recommended Engine Oil ....................7-9
Brand Names of Recommended Gear Oil ........................ 7-9
Brand Names of Recommended Hydraulic Oil................7-9
Miscellaneous ................................................................................7-13
Periodic Replacement of Parts ................................................7-14
Recommended Oil Viscosity .....................................................7-15
A. Greasing ......................................................................................7-16
 CONTENTS
Front Joint Pins ........................................................................7-17 Measure Engine Compression Pressure..........................7-80
Swing Bearing ..........................................................................7-18 Check Starter and Alternator ..............................................7-80
Swing Internal Gear................................................................7-19 Check Crankcase Breather ...................................................7-80
Blade Joint Pins ........................................................................7-20 Check Gas Damper .................................................................7-81
B. Engine ..........................................................................................7-21 Tightening and Retightening Torque of Nuts and
Engine Oil Level .......................................................................7-21 Bolts ........................................................................................7-81
Change Engine Oil ..................................................................7-22
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
Replace Engine Oil Filter .......................................................7-22
CONDITIONS ................................................................. 9-1
C. Transmission ..............................................................................7-24
Travel Reduction Gear ...........................................................7-24 Maintenance Under Special Environmental Conditions ...9-1
D. Hydraulic System .....................................................................7-26 STORAGE ..................................................................... 10-1
Inspection and Maintenance of Hydraulic Equipment ...7-26 Storing the Machine ....................................................................10-1
Replacement of Hydraulic Oil and Filter ..............................7-28
Check Hydraulic Oil Level ....................................................7-29 TROUBLESHOOTING ...................................................11-1
Drain Hydraulic Tank Sump .................................................7-30 Troubleshooting ...........................................................................11-1
Change Hydraulic Oil .............................................................7-31 SPECIFICATIONS ......................................................... 12-1
Suction Filter Cleaning ..........................................................7-33 Specifications .................................................................................12-1
Replace Full-Flow Filter .........................................................7-34 ZX80-GI .......................................................................................12-1
Replace Pilot Oil Filter............................................................7-35 Working Ranges (Grouser shoe)..............................................12-2
Replace Swing Drain Filter Element .................................7-36 ZX80-GI .......................................................................................12-2
Replace Air Breather Element .............................................7-37 Bucket Types and Applications ...............................................12-3
Check Hoses and Lines .........................................................7-38 ZX80-GI .......................................................................................12-3
E. Fuel System ................................................................................7-42
Recommended Fuel ...............................................................7-42 INDEX ...........................................................................14-1
Drain Fuel Tank Sump ...........................................................7-44
Check Water Separator .........................................................7-45
Replace Fuel Cartridge Filter ...............................................7-47
Check Fuel Hoses ....................................................................7-48
F. Air Cleaner ...................................................................................7-49
Clean and Replace Air Cleaner Element .........................7-49
G. Cooling System ........................................................................7-51
Check Coolant Level ..............................................................7-52
Check and Adjust Fan Belt Tension ...................................7-53
Change Coolant .......................................................................7-54
Clean Radiator and Oil Cooler Core ..................................7-55
Clean Oil Cooler Front Screen.............................................7-56
Clean Air Conditioner Condenser .....................................7-56
H. Electrical System ......................................................................7-57
Battery .........................................................................................7-58
Replacing Fuses .......................................................................7-63
I. Miscellaneous .............................................................................7-65
Check and Replace Bucket Teeth ......................................7-65
Change Bucket .........................................................................7-67
Convert Bucket Connection Into Face Shovel ..............7-68
Adjust the Bucket Linkage ...................................................7-69
Remove Travel Levers ............................................................7-70
Check and Replace Seat Belt ...............................................7-70
Check Windshield Fluid Level .............................................7-71
Check Track Sag .......................................................................7-72
Clean and Replace Air Conditioner Filter .......................7-75
Check Air Conditioner ...........................................................7-77
Clean Cab Floor........................................................................7-79
Check Injection Nozzle .........................................................7-80
Retighten Cylinder Head Bolt .............................................7-80
Inspect and Adjust Valve Clearance .................................7-80
Check Injection Timing .........................................................7-80
 CONTENTS

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
 MACHINE NUMBERS
Travel Motor

TYPE :

MFG. NO. :

M1CD-01-005

Swing Motor

TYPE :

MFG. NO. :

M1CD-07-004

Hydraulic Pump

TYPE :

MFG. NO. :

MDEK-00-003

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.

To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could result SA-1223

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 SA-003
correctly and safely.
Allow only trained, qualified, authorized personnel to
operate the machine.
Keep your machine in proper working condition.
Unauthorized modifications of the machine may
impair its function and/or safety and affect machine
life.
Do not modify any machine parts without
authorization. Failure to do so may deteriorate the
part safety, function, and/or service life. In addition,
personal accident, machine trouble, and/or damage
to material caused by unauthorized modifications
will void 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 of dropping the elements. Failure to
do so may affect the exhaust gas purifying device,
possibly damaging it or fowering 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 TATA-
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 SA-437

your telephone.

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.

You may need :

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing 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. SA-439

Never get on and off the machine with tools in

your hands.

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. SA-378

Adjust the rear view mirror position so that the

best rear visibility is obtained from the operator’s
seat. If the mirror is broken, immediately replace
it with a new one.

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 minimize the chance of injury
from an accident.
SA-237
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 operable before operating the machine. If any
faulty illumination is present, immediately repair it.
Ensure the cab door, windows, doors and covers
are securely locked.
Check the mirrors and the monitor in the CAB for
problems.
SA-426
If there is, replace the problem part(s) or clean the
mirror, camera and the monitor.
Refer to Rear View Monitor section on the cleaning
of the camera and the monitor.

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.
SA-444
Before starting the engine, confirm the safety
around the machine and sound the horn to alert
bystanders.

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 BEFORE HAND

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 SA-380
edges of excavations and road shoulders.
When working on an incline or on a road shoulder,
employ a signal person as required.
Confirm that your machine is equipped with a FOPS
cab before working in areas where the possibility of
falling stones or debris exist.
When the footing is weak, reinforce the ground before
starting work.
When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing becomes
loose and slippery.
Beware the possibility of fire when operating the
machine near flammable objects such as dry grass.

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 machine tipping over from occurring.
When operating on rough terrain or on slopes:
M104-05-016
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 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
SA-658
stop.
Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover.
If the direction must be changed, move the
machine to level ground, then, change the direction
to ensure safe operation.

SA-441

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 M104-05-008
may not be obtained.
Use a signal person when moving, swinging or
operating 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 M178-03-001

of the side frame to indicate the machine front

direction.
Select a travel route that is as flat as possible.
Steer the machine as straight as possible, making
small gradual changes in direction.
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.
SA-011
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.
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 ECO.
Run the engine at slow idle speed without load for SA-391

5 minutes to cool down the engine.

Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK
position.
Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
Position the machine to prevent rolling.
Park 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
SA-383
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
No machine motions shall be made unless signals
are clearly understood by both signalman and
operator.
SA-384
Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
Keep windows, mirrors, and lights clean and in
good condition.
Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
Read and understand all operating instructions in
the operator’s manual.

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. SA-012

Keep the bucket low to the ground and close to

the machine.
Reduce operating speeds to avoid tipping or
slipping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is
unavoidable.
Reduce swing speed as necessary when swinging
loads.
Be careful when working on frozen ground.
SA-440
Temperature increases will cause the ground to
become soft and make ground travel unstable.

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.
SA-382
Contact your local “diggers hot line” if available in
your area, and/or the utility companies directly.
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

The machine is vulnerable to lightning strikes.
In the event of an electrical storm, immediately stop
operation, and lower the bucket to the ground.
Evacuate to a safe place far away from the machine.
After the electrical storm has passed, check all of
the machine safety devices for any failure. If any
failed safety devices are found, operate the machine
only after repairing them.

SA-1088

DANGER ZONE
The circular area is the swing area of the machine, It is
dangerous for bystanders and field personnel to stand or
work in this area when machine is running.
Field personnel must also be warned not to stand or work
behind the machine since the machine may travel in the
reverse direction any time, causing serious injury or death.

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-432

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
SA-014
operating the machine.

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 and power mode switch
ECO.
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, possi-
bly 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 SA-018

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
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 SA-395
support the machine weight.
3. Turn auto-idle switch OFF and turn mode switch
to ECO position.
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” SA-527

chapter of this manual.

Keep all parts in good condition and properly
installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
When cleaning parts, always use nonflammable
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 SA-527
supported solely by a jack.

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 SA-344
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 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-039

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. SA-225

The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.
Hot fluids and surfaces :
Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
Wait for the oil and components to cool before
starting any maintenance or inspection work.

SA-034

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
SA-019
attachment to fall on a 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 SA-031
protection.
If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the 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. SA-019

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.

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 Flammables :
Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the
machine daily, and by removing adhered oil or
accumulated flammables 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 flammables 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
flammables such as dead leaves from entering.
However, flammables which have passed through
the wire screen may cause fires. Check and clean
the machine every day and immediately remove
accumulated flammables.

Check Key Switch :

Short circuits can cause fires.
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

Check for Oil Leaks :
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 SA-393

Emergency Evacuation Method.

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 SA-818
starting grinding.
After finishing welding and grinding, recheck that there
are no abnormalities such as the area surrounding
the welded area still smoldering.

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, SA-030
soldering, etc..

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
SA-029
with 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
SA-029
air.
When operating the machine in a work site where
asbestos fibers, silicon dust or other contamination
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 SA-032
tighten all terminals.
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.
See your authorized dealer for MSDS’s (available
SA-309
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.
Use leakproof containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
Battery contains hajardous lead and acid; do not
SA-226
dispose off after use. Please return the Battery to
central board of pollution control authorised
recyclers / dealers for disposal.
Do not pour waste onto the ground, down a drain,
or into 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 ON ATTACHMENT

Never allow anyone to ride on 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 SA-2302

above 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 TATA-
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.

1 4
RIGHT WINDOW

3
6

14 7

2 5 15

10

8
10

11 12

9
13

SS-3449

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

Sign indicates a burn hazard from spurting hot water or B

oil if radiator or hydraulic tank is uncapped while hot. SS4459928

Allow radiator or hydraulic 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.

SS4467096

S-47
 SAFETY SIGNS

18.

19.
WARNING
IT CONTAINS NITROGEN UNDER HIGH PRESSURE.
DON’T ALLOW FIRE OR HEAT NEAR IT. DON’T TRY TO
DISASSEMBLE IT.
WEAR EYE PROTECTION AHD CAREFULLY DRILL A
HOLE AT THE POINT MARKED x 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

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 ।

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।

1 4
RIGHT WINDOW

3
6

14 7

2 5 15

10

8
10

11 12

9
13

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
 SAFETY SIGNS

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

S-49
 COMPONENTS NAME

Components Name
1- Bucket
2- Bucket Cylinder
4
3- Arm
3
4- Arm Cylinder
5- Boom Cylinder
2
6- Boom 6
7- Fuel Tank
8- Hydraulic Oil Tank
9- Engine
5
10- Counterweight
11- Track 7
8
12- Blade 1

13- Blade Cylinder

16
14- Front Idler
9
15- Travel Device
16- Cab
10

11

15

12

13

14
MDEK-01-012

1-1
 GETTING ON/OFF THE MACHINE

Getting ON/OFF the Machine

1
Foot holds and handrails 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:
Never attach a wire on the foot holds to lift the cab
or main body or while transporting the machine on a
truck or trailer as it is dangerous.
MDEK-01-001
The door knob (1) is not a handrail. Do not use the
door knob (1) as a handrail when getting on and off
the machine.
Do not hold the control levers or control shut-off
lever when getting on and off the machine.

MDEK-01-002

1-2
 OPERATOR'S STATION

Cab Features 1 2 3 4 5 6

1- Left Control Lever/Horn Switch

7
2- Left Travel Pedal
3- Left Travel Lever
16
4- Right Travel Lever 8

5- Right Travel Pedal 15 9

6- Right Control Lever 10
14
7- Monitor Panel 11
8- Blade lever
12
9- Switch Panel
10- Key Switch
11- Radio (for Optional Equipments)
12- Air Conditioner Panel (for Optional Equipments)
13- Operator's Seat 13
MDEK-01-003
14- Ash Tray
15- Cab Door Release Lever 17
19
16- Pilot Control Shut-Off Lever 18
17- Glove Compartment (Hot and Cool Box)
18- Cigar Lighter
19- Fuse Box
20- Engine Stop Switch

MDEK-01-013

MDEK-01-004
20

1-3
 OPERATOR'S STATION

Monitor Panel
1 2
1- Coolant Temperature Gauge
2- Fuel Gauge
3- Liquid Crystal Display (LCD) (Hour Meter)
4- Digging Mode Indicator
5- Air Filter Restriction Indicator
6- Remaining Fuel Indicator
7- Pilot Control Shut-Off Lever Indicator
8- Preheat Indicator 3
15
9- Engine Trouble Indicator
14
4
10- Alternator Indicator
13
11- Overheat Indicator
12- Low Engine Oil Pressure Indicator 12 5
13- Auto-Idle Indicator
11 6
14- ECO Mode Indicator
15- PWR Mode Indicator 10

9 7

MDEK-01-005
8

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

Remaining Fuel Indicator

When the remaining fuel indicator lights ON at a flat
ground, remaining fuel level is approximately 19 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,
run the engine at slow idle speed and lower the coolant M178-01-036
temperature.
When the engine runs at slow idle speed, the buzzer stops.

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
the engine, check the engine oil system and oil level. M178-01-037

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

1-6
 OPERATOR'S STATION

Engine Trouble Indicator

Engine or engine related parts are abnormal. Consult your
authorized Tata 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 Tata Hitachi dealer when the indicator lights ON
in red.
MDCR-01-012

1-7
 OPERATOR'S STATION

Liquid Crystal Display (LCD)

"Hour Meter" can be displayed on LCD (3) as the standard
mode.

MDEK-01-005

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

1-8
 OPERATOR'S STATION

Switch Panel
1- Engine Control Dial
2- Auto-Idle Switch 1
3- Power Mode Switch
4- Travel Mode Switch
2
5- Work Light Switch
6- Wiper/Washer Switch 3

MDEK-01-006

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

M1U1-01-033

1-9
 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.

MDEK-01-005

1-10
 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

1-11
 OPERATOR'S STATION

Work Light Switch

Work light switch has the following positions:

1 Position
Work light (1) on the base machine will light. Also,
the instrument panel illumination will light. (The LCD
operates at a low brightness.) MDCR-01-025
2 Position
Work light (2) will light in addition. Also, the instrument
panel illumination will light. (The LCD operates at a low
2
brightness.)
OFF Position
Work lights (1) and (2) and the instrument panel
illumination will turn off. (The LCD operates at normal
brightness.)
1

M1CD-01-010

1-12
 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 Position: 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.

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
M1U1-01-018
operated with the washer fluid tank empty. Monitor
the washer fluid squirting time and the fluid level in
the washer reservoir.

1-13
 OPERATOR'S STATION

Key Switch
1
1- OFF (Engine Off ) 2
2- ACC (Horn, Radio etc.)
3- ON (Engine ON) 3

4- START (Engine Start)

4

MDAA-01-313
Horn Switch
Horn switch (5) is located on the top of the left control lever.
The horn continuously sounds as long as the switch is pushed.

MDAA-01-345

1-14
 OPERATOR'S STATION

Cigar Lighter
Using Cigar Lighter
1
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 Tata Hitachi dealer.

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

MDAA-01-313
2. Press and release the lighter knob.
3. The cigar lighter knob will return to the original position
when the lighter becomes usable. Pull the 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.
Cigar Lighter MDEK-01-007
IMPORTANT: Only 24 V electric power is available from
the cigar lighter port on this machine.
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.

1-15
 OPERATOR'S STATION

Cab Light
Turn the cab light ON or OFF by using switch (1).

MDEK-01-008

MDEK-01-009

1-16
 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

Engine Stop Switch

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

MDEK-01-004
2

1-17
 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
5A 10 A MDEK-01-010
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

1-18
 OPERATOR'S STATION

Auto Air Conditioner (Optional)

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.

Highest and Lowest Temperature Control

Using the temperature control switch, when the
temperature is set at 32.0 °C or at 18.0 °C, the maximum
heating or cooling performance is selected, 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.

1-19
 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
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.

4 MDEK-01-003

6 7 8

13 12 11 10 9
MDCR-01-023

1-20
 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).

1-21
 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

1-22
 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.

1-23
 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 MDCR-01-020

1-24
 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). 1

Control air flow direction by adjusting the louvers at the

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
MDCR-01-020
vents and feet vents respectively. 3

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).

1-25
 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

1-26
 OPERATOR'S STATION

AM/FM Radio Operation (Optional)

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).

1-27
 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.

1-28
 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.

1-29
 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.

1-30
 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).

1-31
 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, rear 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.

MPORTANT: Protect cab electrical components from bad

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

1-32
 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

1-33
 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.

MDAA-01-298

1-34
 OPERATOR'S STATION

Opening Side and Rear Windows 1

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

Side Window M178-01-061

Rear Window MDEK-01-014

1-35
 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.

M1CC-01-027
2

3
2

M1CC-01-028

1-36
 OPERATOR'S STATION

Emergency Exit
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
1
machine and the outside situation.

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

MDEK-01-008
2. If the cab door should be difficult to open or use, open
the upper front window. Escape through the window.

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 3 2
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. If upper front window should be difficult to open, check

the decal (3) affixed to the window glass. M1CC-01-032

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 3 2
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.

MDEK-01-011

1-37
 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

1-38
 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

1-39
 OPERATOR'S STATION

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

1-40
 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
 BREAK-IN

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

2-2
 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
intercooler
5. Looseness and missing of mounting bolts and nuts
1. Fuel level, leaks and contamination of fuel in tank
Working Device
4. Looseness and missing of mounting bolts and nuts
1. Check cylinders, pipe lines and hoses for oil leaks and
damages.
2. Wear and damage of the bucket
3. Check bucket teeth for looseness, wear and missing
4. Lubrication state of the 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 2 seconds and
then turn OFF. Indicators and warning lights that did not
light within the period are blown out.
However, alternator indicator (3) and low engine oil
pressure indicator (4) will continue to stay lit. MDCR-01-020
LOCK position

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 2
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.
Besides, if alternator indicator (3) light was off after
indicators' blowout check, the machine is abnormal.
Immediately consult your authorized Tata Hitachi
dealer. MDAA-01-313

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.

MDEK-01-005

3-2
 OPERATING THE ENGINE

Starting the Engine 1

Starting the Engine in Ordinary Temperature

1. Pull the pilot control shut-off lever (1) up to the LOCK
position.
2. Turn key switch (2) 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. Key switch (2) will automatically return to ON
position.

MDAA-01-313

Slow Idle

3
M1U1-01-033

3-3
 OPERATING THE ENGINE
Starting In Cold Weather
1
Preheating
1. Pull the pilot control shut-off lever (1) up to the LOCK
position.
2. Turn engine control dial (2) to around the middle
between the L and H position.
3. Turn key switch (3) 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, MDCR-01-020
LOCK Position
preheating is not required.

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

switch (3) to "START" position to rotate the starter.
Release key switch (3) immediately after the engine has 3
started.
IMPORTANT: Never operate the starter for more than 10
seconds at a time. If engine fails to start, return key Slow Idle
switch to “OFF”.Wait for more than 30 seconds, then
try again.
Failure to do so may cause damage to the starter and/
or discharging the batteries. 2 M1U1-03-003 MDAA-01-313

6. Release key switch (3) immediately after the engine has

started. Key switch (3) will automatically return to ON
position.

MDEK-01-005
4

3-4
 OPERATING THE ENGINE

Check Instruments After Starting

Checking instruments through monitor functions
After starting the engine, check the following points
through the monitor functions.

1. Check that alternator alarm indicator (1) is OFF. In case

alternator alarm indicator (1) stays ON, immediately stop
the engine. Inspect the alternator and battery system for
any abnormality.
2. Check that engine oil pressure indicator (2) is OFF and
the alarm buzzer does not sound. In case engine oil
pressure indicator (2) stays ON and the buzzer sounds,
immediately stop the engine. Inspect the engine oil
pressure system and the oil level. 2
IMPORTANT: In case any abnormality is found on the
monitor unit, immediately stop the engine. Inspect the
cause of the trouble. 1

Check engine noise and exhaust gas color:

Check that the engine noise and exhaust gas color is
normal. MDEK-01-005

NOTE: Check the exhaust gas color as follows. (After warm

up operation, run the engine with no loads.)
Clear :Normal (Perfect combustion)
Black :Abnormal (Imperfect combustion, abnormal fuel
system)
White :Abnormal (Oil is leaking into the combustion
chamber, abnormal fuel system)

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 (1) to LOCK position.
3. Turn engine control dial (2) to the slow idle position and
run the engine for 5 minutes to cool the engine. SA-390
1
4. Turn key switch (3) OFF to stop the engine.

If the engine does not stop with the key switch turned in
the OFF position
In case the engine does not stop even if the key switch is
turned OFF due to failure of the machine, move engine stop
switch (4) located at the front-left side of the seat stand
downward to stop the engine.
After operating switch (4), be sure to return the switch back
to the upward position.
MDCR-01-020

Slow Idle

M1U1-01-033

MDAA-01-313

4 MDEK-01-004

3-8
 DRIVING THE MACHINE

Travel Levers and Pedals Front

Travel operation can be performed with either the levers or

pedals.

WARNING: In the standard travel position, the front

idlers are positioned at the front of the machine and Front Idler
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 Left Right
traveling.

NOTE:
An arrow-mark seal is stuck on the inside surface of the side
frame to indicate the machine front direction.
Travel Motor
Travel lever dampers are provided for smooth control. In
extremely cold weather (lower than -20 °C (-68 °F)), the Rear M104-01-038
travel lever (or pedal) will become heavy to operate. This is
caused by increase in oil viscosity which is not abnormal.

Forward/Reverse Travel
Move both levers (or pedals) forward together to travel
forward.
Pull the levers (or pedals) back together to travel in
reverse. The travel speed can be controlled by adjusting
the lever (or pedal) operating stroke.

Ascending/Descending Slopes
The machine gradeability is 30 ° (58 %). Slowly operate Arrow-mark
M178-03-001
the travel levers (or pedals) when descending a slope.
When the travel levers are placed in neutral, the travel
brakes are automatically applied to stop the machine.

M104-04-009
Forward and Reverse
M104-04-003

4-1
 DRIVING THE MACHINE
Pivot Turn
Steer the machine by driving only one side crawler.
Operate either of the travel levers (or pedals).

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

Spin Turn
Steer the machine in a position by driving both side
crawlers in opposite directions each other. Push one lever
(or pedal) forward and pull the other back at the same
time.

WARNING: During pivot or spin turn machine

operations, the base machine may shake. When
turning the machine in a tight area, slowly operate the
machine while taking care not to allow the machine to
come in contact with the surrounding objects.

M104-04-011
Spin Turn M104-04-007

4-2
 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

4-3
 DRIVING THE MACHINE

Traveling

CAUTION: Use a signal person when moving,

swinging or operating 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.
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
machine as straight as possible, making small gradual
changes in direction. Travel Motor
Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary. M104-05-008
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.
When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
Arrow-mark M178-03-001
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.

SA-011

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 M1CC-04-001
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.
90~110 °
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.
M1CC-04-002

Place blocks under machine frame to support the machine.

IMPORTANT: When the machine is modified as a face

shovel by installing the hoe bucket in reverse, avoid
raising the machine above the ground using the front 90~110 °
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 M1CC-04-003
of the pins.

MZX5-04-003

4-5
 DRIVING THE MACHINE

Towing Machine a Short Distance

Soft Protector

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
To prevent the wire ropes from being damaged, place some for towing
protective material between the track frame and the wire lightweight
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
on page 5-27 for using the center shackle hole Shackle
appropriately.
MZX5-04-004

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
IMPORTANT: If the swing bearing, swing gears and center
ZX80-GI 560 mm (22 in)
joint are submerged in water or mud by mistake,
premature wearing on parts such as the swing bearing
may result. Grease must be changed or overhauling
will be required immediately. Stop operating the
machine as soon as possible, and contact your
authorized dealer.
Lubricate swing bearing. (See Maintenance Guide, 500 hours)

4-7
 DRIVING THE MACHINE

Precautions for Traveling on Slopes

CAUTION: Avoid possible injury from traveling

on slopes. Tipping over or skidding down of the
machine may result. Thoroughly read and understand
precautions below and be sure to travel at slow speed
on slopes. Never attempt to travel on slopes with the
bucket loaded or any load suspended by the bucket. A

Never attempt to ascend or descend 30 degrees or

steeper slopes.
Be sure to fasten the seat belt.
Keep the bucket pointed in the direction of travel, SA-657
approximately 200 to 300 mm (8 to 12 in) (A) above
the ground. If the machine starts to skid or becomes
unstable, lower the bucket immediately.
Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.
Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow A
speed.
If the engine stalls on a slope, immediately lower the SA-658
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
obtained.

SA-441

MZX5-04-002

4-8
 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 and the blade to the ground.
Slow Idle
3. Turn the auto-idle switch off.

4. Turn engine control dial (1) counterclockwise to the stop

(the slow idle position). Run the engine approximately 5
minutes to cool the engine.
M1U1-01-033
5. Turn the key switch to OFF. Remove the key from the key
switch. 2

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

4-9
 DRIVING THE MACHINE

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

4-10
 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
lever is accidentally bumped or otherwise engaged. 1 5
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.

1- Arm Roll-Out MDEK-01-003

2- Arm Roll-In
3- Swing Right 3
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

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. Move pedal lock (2) forward to the UNLOCK position. MDAA-05-007

2. Push down on attachment pedal (1) to operate the
breaker.
1
Loosen stopper bolt (3) until stopper bolt (3) comes in
contact with the bracket in attachment pedal (1) neutral
to prevent attachment pedal (1) from being stepped
backward. 2
3. Remove foot from attachment pedal (1) to stop the
breaker.
4. 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

5-2
 OPERATING THE MACHINE

Blade Lever
Use blade lever (1) on the operator’s right to raise and lower
the blade.
4
When the lever is released, it automatically returns to neutral,
keeping the blade in its position until the lever is operated
again.
3
1- Blade Lever
1
2- Blade Raise 2

3- Neutral
4- Blade Lower

MDEK-01-003

4
M1CC-07-016

Precautions for Blade Operation

This blade is designed as a light service attachment for the
hydraulic excavator. Please keep the following points in mind:

This blade is designed to be used for dozing work only. Do

not attempt to dig deeply with the blade. Doing so will
damage not only the blade but the undercarriage as well.
Do not apply intensive or uneven loads. Never apply high-
speed impact to the blade by running the machine into a
load.
Jacking up the machine with this blade, the surface beneath
the blade comes under high pressure, increasing the risk of
surface collapse.
Always be sure that the surface is strong enough to support
the weight of the machine during operation.
Avoid dangerously uneven distribution of weight on the
blade by maintaining even contact between the blade and
the ground.
Never use this blade as an outrigger.
Avoid contact between the bucket and the blade while
digging.

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.

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.
MDEK-01-005
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 10 seconds and
stay ON later.

MDEK-01-005

MDCR-04-001

5-8
 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.

MDEK-01-006

5-9
 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.
When operating the machine with the blade (if
equipped) positioned towards the front, the bucket
teeth may come in contact with the blade if you are
not careful.

5-10
 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!
IMPORTANT: If a bucket hook is mounted, take care (Take care not
not to hit the arm with the hook when rolling in the to hit the cab
bucket. with bucket)

MZX5-05-003
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 °

M1CC-05-002

5-11
 OPERATING THE MACHINE

Grading Operation
Use the blade for soil refilling and general grading operations
after excavation.
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.
M1CC-05-003
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 the maintain
a 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.

5-12
 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.

MZX5-05-004

5-13
 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.

MZX5-05-005

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.

MZX5-05-006

5-14
 OPERATING THE MACHINE

Avoid Hitting Blade With Front-End Attachment

When operating the machine with the blade positioned
towards the front, the bucket or boom cylinder may come into
contact with the blade if you are not careful. Be sure to prevent
this from happening.

MDED-05-003

MDED-05-004
Avoid Hitting Blade With Bucket
When crowding the arm into a traveling or transporting
position, be careful not to let the bucket hit the blade.

Avoid Striking the Blade Into a Rock MDED-05-004

Do not attempt to strike large rocks with the blade, as doing

so will damage the blade and the blade cylinders, shortening
their operating lives.

MDED-05-005

5-15
 OPERATING THE MACHINE

Hydraulic Breaker and Hydraulic Crusher

(Optional)
Selecting a Breaker or Crusher
Select a breaker or crusher that is the correct size and
weight for your machine, considering the stability of the
machine, hydraulic oil pressure and flow rate of the breaker
or crusher. See your authorized dealer for correct breaker
information.

Precautions for Operation

Carefully study the operation manuals of the breaker and
crusher. To avoid damaging the machine, hydraulic breaker
or crusher, 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 or crusher with the bucket. When the
breaker or crusher 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 or crusher 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.

5-16
 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 MZX5-13-019
broken before starting breaker operation.

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.

Avoid operating breaker at cylinder stroke end

MZX5-13-020
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.

MZX5-13-021

5-17
 OPERATING THE MACHINE
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
through the broken seal, damage to the hydraulic system
may result. Rod

MZX5-13-017

Do not use breaker for lifting operation.

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

MZX5-13-022

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

MZX5-13-023

5-18
 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

MZX5-13-024

Do not operate breaker with the arm positioned

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

MZX5-13-006

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.

MZX5-13-007

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

5-19
 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

5-20
 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.

5-21
 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
MZX5-13-008
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.

MZX5-13-009

5-22
 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

MZX5-13-010

When operating the crusher up high with the boom fully

raised, be careful of falling objects.

MZX5-13-011

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.

MZX5-13-012

5-23
 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.

5-24
 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)
Specification Std. Model

Base Machine Breaker Crusher/Pulverizer

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

ZX80-GI Std. 650 800 850 1050

5-25
 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.
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.

5-26
 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
Watch Out!
which is longer than that of the bucket, is installed, the Take care not to
attachment may come in contact with the cab and/or 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
the boom while rolling in the front attachment. MZX5-13-010

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
ZX80-GI 19610 N (2000 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.

5-27
 OPERATING THE MACHINE

Emergency Boom Lowering Procedure

WARNING: Prevent personal injury. Confirm that no

FRONT
one is under the front attachment before starting the
procedure below.

In case the engine suddenly stops and the engine cannot

restart, lower the boom in the following procedures.

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.

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. Emergency Valve
T1CD-05-04-002

Lock Nut (1)

Tool :13 mm
Torque:13 N·m (1.3 kgf·m)
Screw (2)
Tool :4 mm (Hexagonal wrench)
Torque:7.0 N·m (0.7 kgf·m)

Emergency Valve

T1CD-05-04-001

5-28
 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.
(Refer to the group for “PARKING THE MACHINE” in the
DRIVING THE MACHINE section.)
Fill the fuel tank with fuel.
Clean the machine.
If anti-freeze or long life coolant is not used in cold
weather, be sure to drain coolant from the radiator and
the engine jacket. Also, be sure to put a “No Water in
Radiator” tag in a visible place if the coolant has been
drained.

M1CG-05-003

5-29
 OPERATING THE MACHINE

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

5-30
 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
M1P1-06-001
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.

Transporting Machine with Blade

When the machine is equipped with the long arm and
blade, position the blade in the opposite direction from
the front attachment. If the blade is positioned in the
same direction with the front attachment, the bucket
will come in contact with the blade.

M1CC-07-022

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.

MDEK-06-001

15 ° or less

M1CC-05-008

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 °. 90 ° to 100 °

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
place around 180 °. M1CC-05-007

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.
M1CC-05-009
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.
2. Fasten each corner of the machine and front attachment M1P1-06-001
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 90 ° to 100 °
over it.

IMPORTANT: Make sure that the angle of the boom and

the arm is kept between 90 to 110 ° when unloading
the unit. M1CC-05-010
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.

M1CC-05-011

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
Support Bar
the boom until the bucket comes in contact with the
ground. Center of
Gravity
2. Pull the pilot control shut-off lever to the LOCK position.
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
that they do not come in contact with the machine while
lifting.
M1CD-06-002
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
maintenance.
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 necessary 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 authorized dealer.

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 to the right side of the cab
(outside). Refer to the page 7-5.

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

4 7

35

3 34
8 9 10
2
11
12
1

37 36
13
33
14
15
32 16
17
18

31
30
29
28 19
27
26
25 20
22
21
24 23

MDEK-01-012

1- Bucket 11- Control Valve 21- Shoe 31- Travel Device

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

7-4
 MAINTENANCE
Maintenance Guide Table
The maintenance guide table is affixed to the right side
of the cab (outside). 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, Swing Drain Filter, Hydraulic
Gear) Oil Tank Filter, Suction Filter)

Gear Oil
Air Cleaner Element
(Travel Reduction Device)

Coolant
Engine Oil
(Long-Life Coolant)

Fuel Filter
Engine Oil Filter
(Fuel Filter Cartridge)

Hydraulic Oil

7-5
 MAINTENANCE
Maintenance Guide Table

Lubrication Interval
10 8 (hours)

11
14
13 1
9 2

7 12

5 3 4
MDEK-07-001

Item Page Item Page

1 Engine Oil 7-22 8 Hydraulic Oil Filter (Full Flow) 7-36
2 Coolant (Long-Life Coolant) 7-56 9 Hydraulic Oil Filter (Pilot) 7-41
3 Grease 7-19 10 Hydraulic Oil Filter (Air Breather) 7-42
4 Grease 7-17 11 Engine Oil Filter 7-22
5 Hydraulic Oil 7-33 12 Fuel Filter (Fuel Cartridge Filter) 7-51
6 Gear Oil ( Travel Device) 7-27 13 Swing Drain Filter 7-25
7 Hydraulic Oil Filter (Suction) 7-35 14 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 and the blade to the ground.
M1CC-07-002
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 3
WARNING: 2
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.
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.
When the engine access cover is opened, raise the cover
until stay (1) is secured with catch (2).
Engine Cover
NOTE: Work on the engine only after providing a safe M1CD-01-011
footing such as a stepladder. In case working on the engine
is required, remove stay (1) from catch (2). While raising the 5
engine access cover, insert stay (1) into holder (3) to secure the
engine access cover.
Be sure to close the engine access cover only after inserting
stay (1) into catch (2).
4
After opening the right and/or left access cover, be sure to
secure the cover by inserting rod (4) into frame lock hole (5).

Right Cover
M1CD-07-036

5
Left Cover
M1CD-01-006

7-8
 MAINTENANCE

RECOMMENDED OIL & LUBRICANTS - ZX80GI

Change
Application Where to use Grade Brand Name
Interval
TATA-HITACHI HN 46U/ TATA-
5000Hrs.** ISO VG 46 HITACHI SUPER EX 46HN (Factory
Hydraulic Hydraulic System & Filled)
Oil Steering System
2500Hrs.** ISO VG 46 TATA-HITACHI Supreme 46P
1500Hrs.** ISO VG 46 TATA-HITACHI Super 46S
SAE 15W40
Engine Oil FIP, Engine Crank case 500Hrs. TATA-HITACHI Engine Plus
CH4

Swing Device (Internal self lubricated Device ) External Lubrication not required
Gear Oil
Travel Device 2000Hrs SAE-90 TATA-HITACHI Gear Oil
Swing Gear, Swing
Grease 500Hrs.
Bearing etc.
NLGI-2 TATA-HITACHI Heavy Duty Grease
Pivot Points, Pins &
8Hrs.
Bushes
One year TATA-HITACHI Super Cool
Coolant Radiator or JIS K2242 (Premixed coolant. Don't mix water-
2000 hrs. fill directly in Radiator)

**For Rockbreaker application Hydraulic Oil change interval will be 1000Hrs. irrespective of grade of oil used.

For Rockbreaker application Hydraulic Oil Filter should get replaced at 250Hrs.
For Bucket application Hydraulic Oil Filter should get replaced at 1000Hrs.

Pilot Oil filter should get replace at every 1000Hrs.

Engine Oil filter should get replaced at every 500Hrs.

Fuel filter should get replaced at every 250hrs.

Never mix two different brands of oil.

7-9
 MAINTENANCE

Maintenance Guide
A. GREASING

Interval (hours)
Parts Qty Page
8 50 100 250 500 1000 2000
Bucket and Link Pins 8 7-17
1. Front Joint Pins
Others 9 7-17
2. Swing Bearing 2 7-19
3. Swing Internal Gear 1 7-20
4. Blade Joint Pins 4 7-21
: In case excavations are performed in water, grease the pin after operation is complete.
Maintenance also required when operating under extremely severe condition.
: Check and add grease if necessary.

B. ENGINE

Interval (hours)
Parts Qty Page
8 50 100 250 500 1000 2000
1. Engine Oil Check Oil Level 1 7-22
2. Engine Oil (Oil Pan) 10.5L Change 11.5 L 7-23
(Oil Filter) 1L
3. Engine Oil Filter Replace 1 7-23

C. TRANSMISSION
Interval (hours)
Parts Qty Page
8 50 100 250 500 1000 2000
Check Oil Level 2 7-25
1. Travel Reduction Gear
Change 2.5 L×2 7-26

Note : Swing Device fitted in this machine is internal self lubricated device. External lubrication not required.

7-10
 MAINTENANCE
D. HYDRAULIC SYSTEM
Interval (hours)
Parts Qty Page
8 50 100 250 500 1000 1500 2500 5000
1. Check Hydraulic Oil Level 1 7-30
2. Drain Hydraulic Oil Tank Sump 1 7-31
3. Change Hydraulic Oil 100 L @
7-32
4. Suction Filter Cleaning 1 When changing hydraulic oil 7-34
5. Replace Full-Flow Filter 1 # 7-35
6. Replace Pilot Oil Filter 1 7-36
7. Replace Swing Drain Filter 1 7-37
8. Replace Air Breather Element 1 7-38
Check Hoses for leaks, loose - 7-39
9.
and Lines for cracks, bend, etc. - 7-39
:
Changing interval differs according to the brand of hydraulic oil used.
@ :
Factory filled oil.
:
For Rock Breaker application.
# :
For Bucket application only.
Refer to the “changing intervals of hydraulic oil and full flow filter element. See recommended oil chart.
E. FUEL SYSTEM
Tank capacity 135 L
Interval (hours)
Parts Qty Page
8 50 100 250 500 1000 2000
1. Drain Fuel Tank Sump 1 7-45
2. Check & Drain Water Separator 1 7-46
3. Replace Fuel Cartridge Filter 1 7-48
for leaks, cracks - 7-49
4. Check Fuel Hoses
for cracks, bend, etc. - 7-49

F. AIR CLEANER

Interval (hours)
Parts Qty Page
8 50 100 250 500 1000 2000
Air Cleaner Outer Element Replace 1 Outer element should be replaced after 1000 hrs 7-50
or after cleaning 6 times which ever is earlier.
Air cleaner Inner element Replace 1 Inner element should be replaced along with 7-51
outer element.

: Do not clean Inner filter element.

: Shorten the interval in a dusty work site.

7-11
 MAINTENANCE
G. COOLING SYSTEM

Interval (hours)
Parts Qty Page
8 50 100 250 500 1000 2000
1. Check Coolant Level 1 7-53
2. Check and Adjust Fan Belt Tension 1 7-54
3. Change Coolant 12 L Once in a year or 2000 hrs whichever is earlier.* 7-55
Outside 1 7-56
4. Clean Radiator and Oil Cooler Core
Inside 1 Once a year 7-56
5. Clean Oil Cooler Front Screen 1 7-57
6. Clean Air Conditioner Condenser (Opt) 1 7-57
: Maintenance required only during first time check.
: Shorten the maintenance interval when the machine is operated in dusty areas.

* : When genuine Tata Hitachi Long-Life Coolant is used, change in a year or 2000 operating hours,
whichever comes first.

H. ELECTRICAL SYSTEM

Interval (hours)
Parts Qty Page
8 50 100 250 500 1000 2000
Check Electrolyte Level 2 Every month 7-60
1. Battery Check electrolyte specific Every month
2 7-64
gravity
2. Replacing Fuses Replace - As required 7-65

7-12
 MAINTENANCE
I. MISCELLANEOUS

Interval (hours)
Parts Qty Page
8 50 100 250 500 1000 1500
1. Check and Replace Bucket Teeth - 7-66
2. Change Bucket - As required 7-68
3. Convert Bucket Connection Into Face Shovel - As required 7-69
4. Adjust Bucket Linkage 1 As required 7-70
5. Remove Travel Levers 2 As required 7-71
6. Check and Replace Seat Belt 1 Every 3 years 7-71
7. Check Windshield Fluid Level 1 As required 7-72
8. Check Track Sag 2 7-73
Circulating Air Clean 1 7-76
Clean and Replace Air Filter Replace 1 After cleaning 6 times or so 7-76
9.
Conditioner Filter (Opt) Clean 1 7-76
Fresh Air Filter
Replace 1 After cleaning 6 times or so 7-76
10. Check Air Conditioner (Opt) - 7-78
11. Clean Cab Floor - As required 7-80
12. Check Injection Nozzle - * 7-81
13. Retighten Cylinder Head Bolt - *As required 7-81
14. Inspect and Adjust Valve Clearance - * 7-81
15. Check Injection Timing - *As required 7-81
16. Measure Engine Compression Pressure - * 7-81
17. Check Starter and Alternator - * 7-81
18. Check Crankcase Breather - * 7-81
19. Check Gas Damper - *As required 7-82
20. Tightening and Retightening Torque of Nuts and Bolts - 7-82
: Maintenance required only during first time check.
NOTE: * Contact your nearest Tata Hitachi dealer for maintenance.

7-13
 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

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
Every 2 years or 4000 hours whichever comes first
Best Machine

Pump delivery hose Every 2 years or 4000 hours whichever comes first
Swing hose Every 2 years or 4000 hours whichever comes first
Hydraulic System

Travel high pressure hose Every 2 years or 4000 hours whichever comes first
Attachment Line Hose Every 2 years or 4000 hours whichever comes first
Working Device

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 Every 3 years
NOTE: Be sure to replace seals, such as O-rings and gaskets,
when replacing hoses.

7-14
 MAINTENANCE
Recommended Oil Viscosity

Oil Recommendation for Atmospheric

Parts Kind of Oil Temperature (°C)
-30 -20 -10 0 10 20 30 40
Super Wide DH-1 10W30
Engine Oil Pan Engine Oil
Super Wide DH-1 15W40
Travel Device Gear Oil Hitachi Gear Oil GL-4_90
Hydraulic System
Hydraulic Oil New Randy HN
(Hydraulic Oil Tank)
JIS Special Class 1
JIS Class 1
Fuel Tank Diesel Oil JIS Class 2
JIS Class 3
JIS Special Class 3
Grease Nipple Lithium Grease SEP Grease
Radiator Coolant Tata Hitachi Long-Life Coolant

7-15
 MAINTENANCE

A. Greasing
Front Joint Pins
Bucket and Link Pins --- every 8 hours
Lubricate all fittings shown in the figure.

M1CD-07-002

MDED-07-032

Others --- every 8 hours

Lubricate all fittings shown in the figure.
Boom Foot

M1CD-07-004

Boom Cylinder Bottom

M1CD-01-003

7-16
 MAINTENANCE
Boom and Arm Joint Pin, Arm Cylinder Rod Pin and Bucket
Cylinder Bottom Pin

M1CG-07-007

Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin

(Centralized greasing system)

M1CD-07-006

7-17
 MAINTENANCE
Swing Bearing
--- every 500 hours

CAUTION: Lubricating both the swing bearing and

gear and rotating the upperstructure must be done by
one person. Before you lubricate the swing bearing,
clear the area of all persons.
Each time you leave the cab
Lower the bucket and the blade to the ground.
Stop the engine.
Pull the pilot control shut-off lever to the LOCK
position.
Use handrails.

1. Park the machine on a level surface. M1CD-07-007

2. Lower the bucket and the blade to the ground.

3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for five
minutes.
5. Turn the key switch OFF. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK position.
7. With the upperstructure stationary, apply grease via the
two grease fittings.
8. Start the engine. Raise the bucket several inches off the
ground and rotate the upperstructure 45° (1/8 turn).
9. Lower the bucket to the ground.
10. Repeat the procedure three times, beginning with step
3.
11. Apply grease to the swing bearing until grease can be
seen escaping from the swing bearing seals.
Grease capacity: 0.20 L
12. Take care not to supply excessive grease.

7-18
 MAINTENANCE
Swing Internal Gear
--- every 500 hours
1
CAUTION: Adding or changing swing internal gear
grease and rotating the upperstructure must be done
by one person. Before you start, clear the area of all
persons.
Each time you leave the cab
Lower the bucket and the blade to the ground.
Stop the engine.
Pull the pilot control shut-off lever to the LOCK
position.
Use handrails.
M1CD-01-002

1. Park the machine on a level surface.

2. Lower the bucket and the blade to the ground. 2

3. Turn the auto-idle switch off.

4. Run the engine at slow idle speed without load for five
minutes.
5. Turn the key switch OFF. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK position.
7. Open the tool box cover on the upperstructure and
remove cover (1).
8. Grease must be to the top of all internal gear teeth of the M157-07-161
swing bearing and be free of contamination.
Add approximately 0.5 kg of grease, if required. If the
grease is contaminated, remove grease and change with
clean grease.
IMPORTANT: If water or mud is found in the swing gear
area, see Operating in Water or Mud in the "Driving the
Machine" section.

9. Install the cover (1).

10. If grease shows any sign of water or mud, change all the
grease on the internal gear.
Remove cover (2) from the bottom of the swing gear
housing, located near the center joint.
Grease capacity: 4.4 L

7-19
 MAINTENANCE
Blade Joint Pins
--- every 500 hours
Lubricate all fittings shown in the figure.
Blade joint pins
Blade cylinder rod/bottom pins

M1CC-00-001

M1CC-07-021

7-20
 MAINTENANCE

B. Engine
Engine Oil Level 2

--- check daily (Before starting the engine)

IMPORTANT: An incorrect engine oil level may cause

trouble on the engine (The oil level should be between
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.
MDEK-07-002
1
Check oil level before starting the engine.
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.

CAUTION: Do not spill oil while changing oil. Spilled M178-07-011

fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.

MDEK-07-003

7-21
 MAINTENANCE
Change Engine Oil
— every 500 hours
2
Replace Engine Oil Filter
— every 500 hours

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 MDEK-07-002
spilled oil. Spilled fuel and oil, and trash, grease,
debris, accumulated coal dust, and other flammables
may cause fires. 3

1. Arrange a container to receive the drain oil (20 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).
Tightening Torque: 78±5 N·m (8±0.5 kgf·m) 4 MDEK-07-003
Wrench size: 30 mm

Oil Pan

Clean Cloth

Container

M104-07-010

7-22
 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. Pour a clean oil in the new cartridge, not letting it
overflow. 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

9. Tighten the filter 3/4 to 1 turn more using the filter

MDEK-07-003
wrench. Be careful not to overly tighten the cartridge
element. Deformation of the cartridge may result.
10. Fill the engine with recommended oil through the oil
filler.
11. Check that the oil level is between the minimum and
maximum level scales on the dipstick. Then, start the
engine.
12. After starting the engine, check no oil is leaking from the
sealing surface.
13. 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
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.

7-23
 MAINTENANCE

C. Transmission
Air Release Plug 1
Travel Reduction Gear (Oil Supply Plug)

Check Oil Level --- every 250 hours Oil Level Check
Plug 2
1. Park the machine on a level surface.
Horizontal Oil Level
2. Rotate the travel motor until the imaginary line through
air release plug (1) and drain plug (3) is vertical.
3. Lower the bucket and the blade to the ground. Drain Plug 3

4. Turn the auto-idle switch off. MDAA-07-047

5. Run the engine at slow idle speed without load for five
minutes.
6. Stop the engine. Remove the key from the key switch.
1
7. Pull the pilot control shut-off lever to the LOCK position.

WARNING: Keep body and face away from the air 2

release plug (1). Gear oil is hot. Wait for gear oil to cool
and then gradually loosen the air release plug (1) to
release pressure.

8. After gear oil has cooled, slowly loosen air release plug
(1) to release pressure. 3
9. Remove air release plug (1) and oil level check plug (2).
Oil must be up to the bottom of hole. M1CC-07-019

10. If necessary, add oil until oil flows out of the oil level
check plug (2) hole. (See gear oil chart)
11. Wrap the plug threads with sealing-type tape. Install air
release plug (1) and oil level check plug (2).
Tighten plugs (1) and (2) to 50 N·m (5 kgf·m).
12. Check the gear oil level in the other travel reduction
gear.

7-24
 MAINTENANCE
Change Gear Oil --- every 2000 hours
1. Park the machine on a level surface.
1
2. Rotate the travel motor until the imaginary line through
air release plug (1) and drain plug (3) is vertical.
2
3. Lower the bucket and the blade to the ground.
4. Turn the auto-idle switch off.
5. Run the engine at slow idle speed without load for five
minutes.
6. Stop the engine. Remove the key from the key switch.
3
7. Pull the pilot control shut-off lever to the LOCK position.
M1CC-07-019
WARNING: Keep body and face away from the air
release plug (1). Gear oil is hot. Wait for gear oil to cool
and then gradually loosen the air release plug (1) to
release pressure.

8. After gear oil has cooled, slowly loosen air release plug
(1) to release pressure, and temporarily retighten plug
(1).
9. Remove drain plug (3) and plug (1), in that order, to drain
oil.
10. Clean drain plug (3). Wrap the threads of the drain plug
(3) with sealing-type tape. Install the drain plug (3).
Tighten the drain plug (3) to 50 N·m (5 kgf·m).
11. Remove oil level check plug (2).
12. Add oil until oil flows out of the oil level check plug hole.
(See gear oil chart)
13. Clean air release plug (1) and oil level check plug (2).
Wrap the threads of oil level check plug (2) and air
release plug (1) with sealing-type tape. Reinstall the
plugs.
Tighten the plugs (1) and (2) to 50 N·m (5 kgf·m).
14. Repeat steps 8. to 13. for the other travel reduction gear.

7-25
 MAINTENANCE

D. Hydraulic System
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 and the blade 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.
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.

7-26
 MAINTENANCE
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.
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.
The mew machine is filled with hydraulic oil of Super
EX 46HN (change interval: every 5000 hours). When
adding or changing the hydraulic oil, continue to use
the Super EX 46HN.
Never run the engine without oil in the hydraulic oil
tank.

7-27
 MAINTENANCE

Replacement of Hydraulic Oil and Filter

Change Hydraulic Oil and Replace Hydraulic Oil Tank Filter
Hydraulic breaker operation subjects the hydraulic system to
become contaminated faster and to quickly deteriorate the
hydraulic oil. For this reason, hydraulic oil must be changed
and the hydraulic oil tank filter must be replaced more often
than the machine equipped with a bucket. Failure to do so
may result in damage to the breaker, hydraulic oil
pump, and other related hydraulic system components.
Recommended changing intervals are shown below.
For filter replacement and oil changing intervals
are shown below. (For filter replacement and oil
changing procedures, refer to “Hydraulic System in the
“MAINTENANCE” Section.)

Changing intervals (Hours)

Attachments Availability ÌHydraulic Oil Full Flow Filter Element Element Type
1500
Bucket 100% 2500 1000 High Performance Element
5000
Hydraulic Breaker 100% 1000 250 High Performance Element

: Replacement intervals differ depending on the brand of hydraulic oil used. Refer to the Hydraulic System
in the MAINTENANCE section.

Replacement Intervals (Hours) of Hydraulic Oil and Full Flow Filter Element
Hours to Replace Hours to Replace
Element Hydraulic Oil
100

: When using high performance

element (micro-glass)
Replacement Interval when using : When using filter-paper element
80 1500-hour life time hydraulic oil

Replacement Interval when using

Average 2500-hour life time hydraulic oil
Breaker 60
Operating
Availability
(%) Replacement Interval when using
5000-hour life time hydraulic oil

40

20

0
0 1000 2000 3000 4000 5000
Excavator Operating Hours M1U1-05-006

7-28
 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 and the blade on the ground
as shown to the right. Stop the engine.
2. Check oil level with level gauge (1) at the side of the M1CC-07-002
hydraulic oil tank. When the oil level is correct, it can be
seen between marks on level gauge (1).

MDEK-07-004

7-29
 MAINTENANCE
Drain Hydraulic Tank Sump
--- every 250 hours
IMPORTANT: Never run the engine without oil in
hydraulic oil tank.

1. Park the machine on a level surface with the

upperstructure rotated 90° for easier access. M1CC-07-006

2. Lower the bucket and the blade to the ground.

3. Turn the auto-idle switch off. 1
4. Run the engine at slow idle speed without load for five
minutes.
5. Turn the key switch OFF. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK position.

CAUTION: The hydraulic oil tank is pressurized. Push

the pressure release button (1) on the air breather to
release pressure.

7. Push the pressure release button (1) on the air breather

to release pressure. M1CD-01-008

CAUTION: Do not loosen the drain plug (2) until oil

is cool. Hydraulic oil may be hot, potentially causing
serious injury.

8. After oil is cool, loosen drain plug (2) to drain water and
sediment. Do not remove the plug completely, only
loosen it enough to drain water and sediment.
9. After draining water and sediment, retighten the drain
plug (2).

2
M1CD-07-011

7-30
 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. M1CC-07-006

IMPORTANT: Changing interval differs according to the

brand of hydraulic oil used, or average attachment 2 1
operating availability. (Refer to 7-28)

Change Hydraulic Oil

Level Gauge
1. Park the machine on solid and level ground. Swing
the upperstructure to make a work space under the
hydraulic oil tank. Fully extend the bucket cylinder and
Upperand
fully retract the arm cylinder. Lower the bucket and the Lower Marks
blade on the ground. Stop the engine.
2. Push air bleed valve (1) to bleed air from the hydraulic oil
tank.
3. Remove filler port cover (2) from the top of the hydraulic M1CD-07-012
oil tank.
4. Arrange a container with the hydraulic oil capacity.
Remove oil by using a suction pump. 1
5. Slowly remove drain plug (3) on the bottom of the fuel
2
tank to drain remaining oil from the fuel tank.
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) M1CD-01-008

IMPORTANT: When changing hydraulic oil, take care not

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

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

procedures shown next page.

3
M1CD-07-011

7-31
 MAINTENANCE
Air Bleeding Procedures
IMPORTANT: If the hydraulic pump is not filled with oil, it
will be damaged when the engine is started.

The machine is equipped with two main pumps. Bleed air from
these pumps after changing hydraulic oil.

1. Remove air bleed plugs (4) on each pumps.

2. Fill the pump with oil through air bleed plugs (4) port on
each pumps until oil flows out of air bleed plug (4) hole.
4 MDEK-07-005
3. Temporarily tighten air bleed plugs (4) on each pumps,
start the engine and run at slow idle. Loosen one of air
bleed plugs (4) slightly until oil flows from plug port to
release trapped air completely. Tighten air bleed plug (4).
Repeat this step for the rest of plugs.
4. Purge air from the hydraulic system by running the
engines at slow idle and operating the control levers
slowly and smoothly for 15 minutes.
5. Position the machine as illustrated in the oil level
checking procedure.
6. Lower the bucket and the blade to the ground.
7. Turn the auto-idle switch off.
8. Stop the engines. Remove the key from the key switches.
9. Pull the pilot control shut-off lever to the LOCK position
10. Check the hydraulic oil tank gauge. Remove cover to add
oil if necessary.

7-32
 MAINTENANCE
Suction Filter Cleaning 1
--- each time when hydraulic oil is changed
The suction filter is located on the bottom of the hydraulic oil
tank.
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).
3
Wrench size: 17 mm
Tightening Torque: 50 N·m (5 kgf·m)
5. Bleed air from the hydraulic system.
(Refer to the descriptions for “ Bleed air from the M1CD-07-014
hydraulic system”)

762 mm

20 mm

2 Rod assembly

M107-07-070

7-33
 MAINTENANCE
Replace Full-Flow Filter
— every 1000 hours (Bucket Application)
— every 250 hours (Rock 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 M1CC-07-002
before starting any maintenance work.

Procedures:
1. Park the machine on a level surface.
1 2 3
2. Lower the bucket and the blade to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for five
minutes.
4
5. Stop the engine. Remove the key from the key switch.
6. Pull the pilot control shut-off lever to the LOCK position.
5
CAUTION: The hydraulic oil tank is pressurized. Push
the pressure release button on the air breather before
removing the air breather.

7. Push the pressure release button on the hydraulic oil

tank to release pressure. 6

8. Hold down filter cover (2) against light spring load when
removing the last two bolts (1). Remove filter cover (2).
9. Remove spring (4), valve (5) and element (6).

NOTE: Remove the element and inspect for metal particles

and debris in the bottom of the filter can. Excessive amounts
of brass and steel particles can indicate a failed hydraulic
pump, motor, valve or an impending failure. A rubber type of
material can indicate cylinder packing failure.
10. Discard element (6) and O-ring (3).
11. Install a new element (6), valve (5) and spring (4).
12. Install filter cover (2) with a new O-ring (3).
13. Install and tighten bolts (1) to 50 N·m (5 kgf·m).
14. Bleed air from the hydraulic system and check the
hydraulic oil level after replacing the element.
(Refer to the descriptions for “ Bleed air from the M178-07-069
hydraulic system”)
If the machine is operated with air mixed in the circuit,
damage to the pump may result.

NOTE: Replace element at the regular interval to keep

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

7-34
 MAINTENANCE
Replace Pilot Oil Filter
— every 1000 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. M1CC-07-002

1. Park the machine on a level surface.

2. Lower the bucket and the blade to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for five
minutes.
5. Stop the engine. Remove the key from the key switch.
6. Pull the pilot control shut-off lever to the LOCK position.

CAUTION: The hydraulic oil tank is pressurized. Push

the pressure release button on the air breather before
removing the air breather. Pilot Oil Filter MDEK-07-009

7. Use a wrench to remove filter case (4) from filter head (1)
by turning it counterclockwise.
8. Remove filter element (2) by turning it.
9. Remove and discard O-ring (3) and filter element (2).
10. Clean filter head (1) O-ring (3) and the element area.
11. Apply a thin film of clean oil to a new O-ring (3) and 1
install it in filter head (1). Be sure O-ring (3) is correctly
positioned.
2
12. Apply a thin film of clean oil to the ring of new filter
element (2), that fits into filter head (1). Slowly install 3
filter element (2) by turning it.
13. Clean filter case (4).
4
14. Install filter case (4) onto filter head (1) by turning it
clockwise. Tighten case 40 N·m (4 kgf·m).
(Refer to the descriptions for “ Bleed air from the
hydraulic system”)
MDEK-07-031
If the machine is operated with air mixed in the circuit,
damage to the pump may result.

NOTE: Replace element at the regular interval to keep

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

7-35
 MAINTENANCE
Replace Swing Drain Filter 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. M1CC-07-002

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

bucket cylinder fully extended, the arm cylinder fully
retracted, and the bucket and the blade lowered to the
ground as illustrated to the right. Stop the engine.
2. Be sure to bleed air from the hydraulic oil tank by
pressing the air vent valve on the top of the hydraulic oil
tank before replacing the element.
3. Using a filter wrench, turn cartridge type element (1)
(swing drain filter) counterclockwise to remove the
element.
4. Coat a new cartridge gasket with hydraulic oil. Turn the
cartridge clockwise until the gasket comes in contact 1 MDEK-07-009
with the sealing surface.
5. Tighten the cartridge further by 1-1/4 turns using
the filter wrench. Take care not to overly tighten the
cartridge.
Tightening Torque: 8.0 to 10.0 N·m (0.8 to 1 kgf·m)
6. Always beware not to allow water and/or dust to enter
the filter.
7. Bleed air from the hydraulic system and check the
hydraulic oil level after replacing the element.
(Refer to the descriptions for “ Bleed air from the
hydraulic system”)
If the machine is operated with air mixed in the circuit,
damage to the pump may result.

NOTE: Replace element at the regular interval to keep

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

7-36
 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. M1CC-07-002

Replacement Procedures
1. Park the machine on solid and level ground. Fully extend
the bucket cylinder, fully retract the arm cylinder, and
lower the bucket to the ground as illustrated to 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. Turn cover (2) clockwise about 1/4 turn. Turn cap (1)
counterclockwise to remove it.
4. Turn cover (2) counterclockwise to remove it. Then,
M1CD-01-008
remove element (3).
5. Install new element (3). Tighten to install cover (2) until
cover (2) comes in contact with the element. Then,
further tighten the cover (2) 1/4 turn.
6. Securely tighten cap (1) clockwise by hand. While 1
holding cap (1) by hand so that cap (1) does not rotate,
securely tighten cover (2) by rotating counterclockwise 5
to 10° by hand.
2
7. Take care never to allow water and/or contaminant to
stay between cover (2) and body (4) (air breathing port).
3
NOTE: Replace element at the regular interval to keep
hydraulic oil clean and to extend the service life of the
hydraulic components.
4

M1G6-07-001

7-37
 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 Check Hose covers Leak (1) Replace 1 1
2 2
Hose ends Leak (2) Replace
3 3
Fittings Leak (3) Retighten or replace
hose or O-ring M137-07-008 M115-07-145

7-38
 MAINTENANCE
7
4
Interval Check Points Abnormalities Remedies 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 9

8
Hose Bend (8), Collapse (9) Replace
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 flange Leak (11) Replace 11
Check joints
Bolts Loose or leak (11) Retighten or M137-07-001 M137-07-007
replace O-ring
Welded surfaces on flange Leak (12) Replace
joints
Every 250 Flange joint neck Crack (13) Replace
hours Welded surfaces on flange Crack (12) Replace
joints
Clamps Missing or deformation Replace or
Loose bolts retighten

Hoses and Lines

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

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

15 MDEK-07-006

7-39
 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)

7-40
 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
to the torque values shown below.
Wrench size (mm) 17, 19
Tightening N·m 35
torque (kgf·m) (3.5)

11
MDEK-07-007

7-41
 MAINTENANCE

E. Fuel System

CAUTION: Beware of fire.

Fuel is flammable. Keep fuel away from fire hazards.

IMPORTANT: Always fill the fuel tank with the specified

diesel fuel. Failure to do so may cause engine trouble
and also making it difficult for the engine to start.

Recommended Fuel
Use high quality DIESEL FUEL only (JIS K-22204) (ASTM 2-D).
Kerosene must NOT be used. For rough indication on the
limit of ambient temperature to use the fuel, refer to the
table below.
Specification of diesel oil varies depending on the season
and area, thus fuel may freeze even if it is in the specified
range given below.
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.

7-42
 MAINTENANCE
Refueling 1

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

and the blade 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. To avoid condensation, fill the tank at the end of each
day's operation. Fuel tank capacity is 135 liters.
Do not fill the tank more than specified. Stop filling when
a yellow mark on fuel level gauge (3) becomes visible.
Position the oil filler gun so that the gun will not
encumber the movement of the level gauge (3) float.
3. Immediately after fueling, install and lock filler cap (2) to
prevent vandalism and loss.
IMPORTANT:
Take care not to allow dirt and/or water to enter the
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 (3) becomes visible. MDEK-01-005

M1CD-01-008

Yellow Mark

M157-07-060

7-43
 MAINTENANCE
Drain Fuel Tank Sump
--- daily
1. Park the machine on a level surface with the
upperstructure rotated 90 ° for easier access.
2. Lower the bucket and the blade to the ground.
3. Turn the auto-idle off. 1
4. Run the engine at slow idle speed without load for five
minutes.
5. Turn the key switch OFF. Remove the key from the key
switch.
6. Pull the pilot control shut-off lever to the LOCK position.
M1CD-07-018
7. Open drain cock (1) for several seconds to drain water
and sediment. Close the drain cock.

7-44
 MAINTENANCE
Check Water Separator
— every 8 hours 2
Water separator (1) is a device designed to separate water from
the fuel. There is a float inside the case which buoys when
water accumulates.
When the float rises to the water draining level, drain water.

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. Loosen plug (2) at upper part of water separator (1). 3 1 MDEK-07-008
Loosen drain plug (3) at lower part of the case to drain
water.
3. After draining water, securely tighten drain plug (2) and
plug (3).

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.

7-45
 MAINTENANCE
Bleed Air from the Fuel System
Air in the fuel system may make the engine hard to start or 2 5
make it run irregularly.
After draining water and sediment from the water separator,
replacing the fuel filter, cleaning the fuel solenoid pump 4
strainer or running the fuel tank dry, be sure to bleed the air
from the fuel system.

Main Points to Bleed Air

1. Make sure that the plug on top of the water separator
and the drain plug are closed. 3 MDEK-07-008
3. Loosen air bleed plug (4) of the fuel filter. Move feed
pump (5) up and down until no bubble comes out.
4
NOTE: Do not loosen plug (2) on top of water separator (3)
when bleeding air.
If plug (3) is loosened, air can not be bled.

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

Move feed pump (5) up and down until its operation
force gets heavier, tighten the air bleed plug.
5. Start the engine. Check the fuel supply system for fuel
leaks.
MDEK-07-032

7-46
 MAINTENANCE
Replace Fuel Cartridge Filter
— 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
1 MDEK-07-008
Hitachi dealer for the details.

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".)

7-47
 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

7-48
 MAINTENANCE

F. Air Cleaner
1 Clean and Replace Air Cleaner Element 2
Clean — when air cleaner element is clogged or
when the restriction indicator comes on.

Replace — after cleaning 6 times or after 1000 hrs.

which ever comes first
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 is equipped, do not remove the
inner element. MDEK-07-010

CAUTION : When using compressed air pressure (less 1

than 0.2 Mpa (2 kgf/cm2), wear safety glasses
or goggles.)

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. MDEK-07-011

3. In case the air cleaner restriction indicator lights soon after

cleaning outer element (1) even if the cleaning 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.

7-49
 MAINTENANCE
Replace Air Cleaner Inner Element
Air Filter Restriction Switch
IMPORTANT: Do not reuse the inner element. Always 1 2
replace the 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
Replace the inner element along with the outer M157-07-061
element.

Please don’t clean the inner element.

7-50
 MAINTENANCE

G. Cooling System
Coolant — Always use TATA-HITACHI long life coolant only.

Antifreeze Mixing Ratio

Air Temperature Mixing Ratio Antifreeze Soft water

[° C] [%] [L] [L]
-1 30 3.6 8.4
-15 35 4.2 7.8
-20 40 4.8 7.2
-25 45 5.4 6.6
-30 50 6.0 6.0

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.

7-51
 MAINTENANCE
Check Coolant Level
1
--- daily
Check that the coolant level is between the FULL and LOW
marks on coolant reservoir (2). If the coolant level is below the
low mark, remove the reservoir cap and add coolant to coolant
reservoir (2).

CAUTION: Do not loosen radiator cap (1) unless

the system is cool. Loosen the cap slowly to the stop.
Release all pressure before removing the cap.
MDEK-07-012
If coolant reservoir (2) is empty, add coolant through radiator
cap (1).
2
When refilling a long life coolant (LLC), use the same
brand product and the same mixture ratio as already
used in the machine.

If only water is refilled, the mixture ratio in the long life

coolant (LLC) is diluted so that anti-rust and antifreeze
effect in the coolant will become deteriorated.

FULL

LOW

MDEK-07-013

7-52
 MAINTENANCE
Check and Adjust Fan Belt Tension
— every 250 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 Alternator Pulley
with a depressing force of approximately 98 N (10 kgf ).
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 bolt (1) at the top of alternator (3), and lock
bolt (2) at the bottom of alternator(3).
2. Adjust belt tension by moving alternator (3) forward or 3 1
backward.
3. Securely tighten lock nut (1) and (2).
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.

2 MDEK-07-014

7-53
 MAINTENANCE
Change Coolant
— once in a year or 2000 hrs.

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

change interval is once every two years or every 2000
hours 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 1
bucket and the blade 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
of the temperature gauge reaches the green zone, run
the engine for about ten more minutes.
M1CD-07-023
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.
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 2 MDEK-07-015
if necessary.

7-54
 MAINTENANCE
Clean Radiator and Oil Cooler Core
Outside --- every 500 hours
Inside --- once a year

CAUTION: Use reduced compressed air pressure

(Less than 0.2 MPa, 2 kgf/cm2) 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.

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 MDEK-07-033
(2 kgf/cm2)) or tap water. It will prevent a reduction in cooling
system performance.
Air Conditioner Condenser Oil Cooler

Radiator

MDEK-07-016

7-55
 MAINTENANCE
Clean Oil Cooler Front Screen
Condenser Front Screen
--- every 500 hours

IMPORTANT: Check the screen daily and replace it if

necessary when the machine is operated in dusty
areas.

Clean Air Conditioner Condenser

--- every 500 hours

IMPORTANT: Check the screen daily and replace it if

necessary when the machine is operated in dusty
areas.

M1CD-07-024

7-56
 MAINTENANCE

H. Electrical System
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.

7-57
 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 flammables 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. SA-032
Do not continue to use or charge the battery when
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.

MDEK-07-033
Battery Location

7-58
 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.

7-59
 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.

7-60
 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

7-61
 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.

7-62
 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
9- BACK UP 19- HORN MDEK-07-017
10 A 10 A
8- ECF 18- - Spare Fuses
5A
7- ROOM LAMP 17- POWER ON 10 20
5A 5A 9 19
6- OPTION2 16- GLOW RELAY 8 18
20 A 5A 7 17
5- OPTION1 15- AUXILIARY 6 16
5A 10 A 5 15
4- SOLENOID 14- MONITOR 4 14
10 A 5A 3 13
3- HEATER 13- LIGHTER 2 12
20 A 10 A 1 11

2- WIPER 12- RADIO

10 A 5A
Tool
1- LAMP 11- EC MOTOR
M1GR-01-003
20 A 10 A

7-63
 MAINTENANCE
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. Replace it if blown.
21- + Side (Red)
45 A
22- – Side (Black)
65 A

22 21 MDEK-07-018

7-64
 MAINTENANCE

I. Miscellaneous 1 4 5
Check and Replace Bucket Teeth — daily
Fig. shown here are vertical lock type bucket.
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
New Limit of Use A
156 80 M104-07-056

Replace
2
CAUTION:
Guard against injury from flying pieces of metal. 3

Wear goggles or safety glasses, and safety

equipment appropriate to the job.

1. Use hammer (2) and drift (3) to drive out locking pin (5).
Take care not to damage lock rubber (4).
2. Check lock pin (5) and lock rubber (4). Short locking pins
and damaged rubber pin locks must be replaced with M104-07-116
new ones.

RIGHT WRONG
5

Flush one end of the locking pin

to evaluate. In this instance, the
locking pin is too short.
M104-07-118 M104-07-058

WRONG

Crack on the rubber. The steel ball dents

The steel ball may when pushing the
come out. ball.
M104-07-059

7-65
 MAINTENANCE
3. Clean shank (6) surface.
4. Install rubber pin lock (4) into shank (6) hole as shown.

RIGHT WRONG

6 4
M104-07-060
5. Position new tooth (1) over shank (6).

RIGHT WRONG
6 1

6. Drive locking pin (5) fully into the hole as shown. M104-07-061

RIGHT WRONG

1 5

M104-07-062

7-66
 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.

7-67
 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

7-68
 MAINTENANCE

Adjust the 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. Park the machine on a level surface. Lower the bucket

to the ground with the flat side down so that the bucket
will not roll.
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.

NOTE: Bolt (1) does not need to be removed to remove

shims. Shims are of a split type that can be easily pushed off
with a screwdriver after bolts (1) have been loosened.
Clearance
Adjust Part
4. Slightly loosen three (M10) bolts (1) using a 8 mm
wrench. Remove all shims (2) from clearance (c) between
plate (3) and bucket.
5. Push and hold bolts (1) to remove all clearance (a)
between arm and boss (4). Holding boss (4) against
M503-07-056
arm increases clearance (b). Measure distance (b) using
a feeler gauge. This distance should not be adjusted
below 0.5 mm (0.02 in).
6. Install as many shims (2) into clearance (b) as possible. II
Bucket Pin Arm 4
Bucket
NOTE: Remaining shims (2) must be installed in clearance (c) d
to prevent arm end face or bolt damage. 2
3
7. Install remaining shims (2) into clearance (c) and tighten
bolts (1) to 50 N·m (5 kgf·m).

1
NOTE: The total number of shims (2) used is A.
A : 12 (6 pairs) a
b c
8. Replace boss (4) if measurement (d) is 5 mm (0.2 in) or II
less.

SECTION II
M1CD-07-037

7-69
 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)

and buckle (6). 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

7-70
 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

MDEK-07-033

7-71
 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
support the machine. M1CC-07-014

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 --- 210 to 235 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.

7-72
 MAINTENANCE
Loosen the Track

CAUTION: The pressure inside the cylinder of the

track adjuster is high. Do not loosen valve (1) quickly
or loosen it too much as valve (1) may fly out or high
pressure grease in the adjusting cylinder may spout
out. Slowly loosen valve (1) while keeping body parts
and face away from valve (1). Never loosen grease
fitting (2).

IMPORTANT: When gravel or mud is packed between M107-07-075

sprockets and track links, remove it before loosening.

1. To loosen the track, slowly turn valve (1)

counterclockwise using long socket 19; grease will
escape from the grease outlet. 1
2. Between 1 to 1.5 turns of valve (1) is sufficient to loosen 2
the track.
3. If grease does not drain smoothly, slowly rotate the
raised track.

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.

4. When proper track sag is obtained, turn valve (1) Grease Outlet
clockwise and tighten to 147 N·m (15 kgf·m).
M104-07-119

7-73
 MAINTENANCE
Tighten the Track

CAUTION: It is abnormal if the track remains tight

after turning valve (1) counterclockwise or if the track 2
is still loose after charging grease to fitting (2). In such
cases, NEVER ATTEMPT TO DISASSEMBLE the track or
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.

M104-07-119

7-74
 MAINTENANCE
2 1
Clean and Replace Air Conditioner Filter

Clean Filter
Circulating Air Filter --- every 500 hours
Fresh Air Filter --- every 500 hours

Replace Filter
Circulating Air Filter --- After cleaning 6 times or so
Fresh Air Filter --- After cleaning 6 times or so

Removing Fresh Air Filter

M1CD-07-027
1. From the cab outside, pull the upper section of filter
cover (1) located at the rear of the cab to remove the
cover (1). 2
2. Pull the grip on fresh air filter (2) through the opening for
filter cover (1) to remove fresh air filter (2).

Removing Circulating Air Filter (Outside)

1. Circulating air filter (outside) (3) is located beside the
seat stand.
2. Remove screw (4). While pulling toward the cab front,
unlatch air filter (outside) (3) from the seat stand to
remove air filter (outside) (3). M1CD-07-028

3
4

M1CC-07-011

7-75
 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.

7-76
 MAINTENANCE

Check Air Conditioner

Check pipe connections for refrigerant gas leakage

If oil seepage is found around pipe connections, it indicates
possible gas leakage.

Check Refrigerant
Start the engine and run at approximately 1500 min-1
(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 MDEK-07-019

machine
Detail
Type Amount Oil Seepage

HFC134a 0.80±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. MDEK-07-020

7-77
 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 compressor pulley 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
is seated correctly.

1 2 3 Air Compressor Pulley

MDEK-07-021

7-78
 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.

7-79
 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 500 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.

Check Crankcase Breather

--- every 1500 hours
See your authorized dealer.

7-80
 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.

7-81
 MAINTENANCE

Bolt Dia Wrench Size Torque

No. Descriptions Q’ty
mm (mm) N·m (kgf·m)
1 Engine cushion rubber mounting bolt 16 4 24 210 (21)
2 Engine bracket mounting bolt 12 8 19 90 (9)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21)
4 Fuel tank mounting bolt 16 4 24 270 (27)
— — 17 25 (2.5)
— — 19 30 (3)
— — 22 40 (4)
5 ORS fittings for hydraulic hoses and piping — — 27 95 (9.5)
— — 32 140 (14)
— — 36 180 (18)
— — 41 210 (21)
6 Pump mounting bolt 18 2 27 300 (30)
7 Control valve mounting bolt 14 3 22 180 (18)
8 Control valve bracket mounting bolt 12 4 19 90 (9)
9 Swing device mounting bolt 16 10 24 210 (21)
10 Swing motor mounting bolt 14 8 12 180 (18)
11 Battery mounting nut 10 4 17 50 (5)
12 Cab mounting nut 16 4 24 210 (21)
Swing bearing mounting bolt to upperstructure 16 24 24 270 (27)
13
Swing bearing mounting bolt to undercarriage 16 24 24 270 (27)
Travel device mounting bolt 16 20 24 300 (30)
14
Travel reduction device cover mounting bolt 14 8 22 140 (14)
15 Sprocket mounting bolt 16 24 24 270 (27)
16 Upper roller mounting bolt 14 2 22 140 (14)
17 Lower roller mounting bolt 14 40 22 245 (24.5)
18 Track shoe bolt 14 304 22 245 (24.5)
6 — 10 10 (1)
19 Cover mounting bolt 10 — 17 50 (5)
12 — 19 90 (9)
Flexible master coupling of piping 8 3 sets 13 10.3 to 12.4 (1.05 to 1.26)
20 Jubilee clamp of low pressure piping — — 9.5 4.4 (0.45)
T-bolt clamp of low pressure piping — — 11 5.9 (0.6)

7-82
 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) 17 50 (5.0) 8
12 110 (11) 90 (9) 35 (3.5) 19 90 (9) 10
14 180 (18) 140 (14) 55 (5.5) 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) 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.

7-83
 MAINTENANCE
1. Retighten the engine cushion rubber mounting bolts.

MDEK-07-022

2. Retighten the engine bracket mounting bolts. MDEK-07-023

MDEK-07-024

MDEK-07-025

7-84
 MAINTENANCE
3. Retighten the hydraulic oil tank mounting bolts.

MDEK-07-026

4. Retighten the fuel tank mounting bolts.

MDEK-07-027

5. Retighten the ORS fitting hydraulic hoses and piping.

M1CD-07-004

7-85
 MAINTENANCE
6. Retighten the pump mounting bolts.

MDEK-07-029
7. Retighten the control valve mounting bolts.

8. Retighten the control valve bracket mounting bolts.

M1CD-07-032

9. Retighten the swing device mounting bolts.

M1CD-07-032

M1CD-07-004

7-86
 MAINTENANCE
10. Retighten the swing motor mounting bolts.

11. Retighten the battery mounting nuts. M1CD-07-004

MDEK-07-033

7-87
 MAINTENANCE
12. Retighten the cab mounting nuts.

M1U1-07-026
13. Retighten the swing bearing mounting bolts to the
upperstructure.

M1CD-07-007

Retighten the swing bearing mounting bolts to the

undercarriage.

M1CD-07-035

7-88
 MAINTENANCE
14. Retighten the travel device mounting bolts.

M1CD-01-005

Retighten the travel reduction device cover mounting

bolts.

MDEK-07-030

15. Retighten the sprocket mounting bolts.

M1CC-07-019

16. Retighten the upper roller mounting bolts.

M152-07-046

7-89
 MAINTENANCE
17. Retighten the lower roller mounting bolts.

M104-07-090
18. Retighten the shoe mounting bolts.

M104-07-091
19. Retighten the cover mounting bolts.

M1CD-01-008

7-90
 MAINTENANCE
20. Retighten flexible master coupling.

M1G6-07-008

M1CD-07-034

Retighten coupling and T-bolt clump.

MDEK-00-003

7-91
 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 Tata 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
 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

9-2
 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
 STORAGE

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

10-2
 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

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
Starter does not rotate or is not

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
Poor contact in connector * Repair or replace
Damaged wire harness * Repair
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
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)
Faulty controller (MC) * 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
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.

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
ZX80-GI
A
G

E
M P
D N
K O J
I
H
L MDEK-12-001

Model ZX80-GI
Front-End Attachment 1.62 m Arm
Standard Bucket Capacity (Heaped) PCSA 0.30 m3, CECE 0.26 m3
Operating Weight 7300 kg
Basic Machine Weight 5650 kg
Engine MITSUBISHI S4S 40kW/2000 min-1 (54 PS/2000 rpm)
A: Overall Width 2260 mm
B: Cab Height 2600 mm
C: Rear End Swing Radius 1750 mm
D: Minimum Ground Clearance *360 mm
E: Counterweight Clearance *760 mm
F: Engine Cover Height *1760 mm
G: Overall Width of Upperstructure 2260 mm
H: Undercarriage Length 2765 mm
I: Undercarriage Width 2150 mm
J: Sprocket Center to Idle Center 2140 mm
K: Track Shoe Width 450 mm (Grouser Shoe)
L: Blade Width 2200 mm
M: Blade Height 435 mm
N: Blade Bottom Highest Position
*400 mm
(above ground level)
O: Blade Bottom Lowest Position
*280 mm
(above ground level)
P: Maximum Approach Angle 26.2 degree (tan θ=0.49)
Ground Pressure 32 kPa (0.32 kgf/cm2)
Swing Speed 10.1 min-1 (rpm)
Travel Speed 5.0/3.4 km/h
Gradeability 30 degree (58 %)

NOTE: * The dimensions do not include the height of the shoe lug.

12-1
 SPECIFICATIONS

Working Ranges (Grouser shoe)

ZX80-GI
A
G

H
D

F
MDEK-12-002
Backhoe

Model ZX80-GI
Category 1.62 m Arm
Item Backhoe
A: Maximum Digging Reach (mm) 6320
B: Maximum Digging Depth (mm) *4170
C: Maximum Cutting Height (mm) *7150
D: Maximum Dumping Height (mm) *5060
E: Overall Height (mm) 2600
F: Overall Length (mm) 6080
G: Minimum Swing Radius (mm) 1720
H: Minimum Swing Radius Height (mm) 5530
NOTE: *The dimensions do not include height of the shoe lug.

12-2
 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.

ZX80-GI

Bucket Capacity
Bucket Width (mm) Front-End Attachment
(m3)
Bucket
PCSA CECE With Side Without side 1.62 m
Heaped Heaped Cutter cutter Arm
Hoe Bucket 0.30 0.26 800 700 ?
Reinforced Hoe Bucket 0.30 0.26 - 670 U

NOTE:
: For general excavating (digging and loading operation of sand, gravel, clay, ordinary earth and so on.)
: For heavy duty excavating (digging and loading operation of mountain gravels, blasted rock, hard clay, soft rock and so
on.)

12-3
 SPECIFICATIONS

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

12-4
 INDEX
A Change Hydraulic Oil and Replace Full-Flow Filter
Adjust the Bucket Linkage ........................................................7-69
Adjust the Operator’s Seat ...........................................................S-6
After the First 100 Hours ...............................................................2-1
After the First 50 Hours .................................................................2-1
Air Cleaner ......................................................................................7-49
Air Filter Restriction Indicator .....................................................1-6
Allowable Weight Limits of Installed Attachment ............5-25
Alternator Indicator ........................................................................1-6
AM/FM Radio Operation (Optional) .......................................1-27
Attachment .....................................................................................5-25
Attachment Pedal (Hydraulic Breaker) (Optional) ...............5-2
Auto Air Conditioner (Optional) ..............................................1-19
Auto-Idle .............................................................................................5-7
Auto-Idle Indicator ..........................................................................1-5
Auto-Idle ON/OFF............................................................................5-8
Auto-Idle Switch ...........................................................................1-10
Avoid Abusive Operation ..........................................................5-14
Avoid Applying Heat to Lines Containing Flammable
Fluids ...........................................................................................S-34
Avoid Hammer Work ...................................................................5-13
Avoid Heating Near Pressurized Fluid Lines .......................S-34
Avoid High-Pressure Fluids .......................................................S-29
Avoid Hitting Blade With Bucket .............................................5-15
Avoid Hitting Blade With Front-End Attachment .............5-15
Avoid Injury from Back-Over and Swing Accidents .........S-17
Avoid Injury from Rollaway Accidents ..................................S-16
Avoid Power Lines ........................................................................S-21
Avoid Side Load the Bucket ......................................................5-14
Avoid Striking the Blade Into a Rock .....................................5-15
Avoid Tipping .................................................................................S-19
Avoid Undercutting .....................................................................S-19
B Cool Head/Warm Feet Operation ...........................................1-25
Battery ..............................................................................................7-58
Before Starting Engine ..................................................................3-2
Beware of Asbestos and Silicon Dust and Other
Contamination .........................................................................S-35
Beware of Exhaust Fumes..........................................................S-32
Blade Joint Pins .............................................................................7-20
Blade Lever ........................................................................................5-3
Brand Names of Recommended Engine Oil ....................... 7-9
Brand Names of Recommended Gear Oil ............................ 7-9
Brand Names of Recommended Hydraulic Oil .................. 7-9
BREAK-IN .............................................................................................2-1
Bucket Types and Applications ...............................................12-3
ZX80-GI .......................................................................................12-3
C DRIVING THE MACHINE .................................................................4-1
Cab Door Release Lever .............................................................1-31
Cab Features ......................................................................................1-3
Cab Heater Operation .................................................................1-23
Cab Light .........................................................................................1-16
Change Bucket ..............................................................................7-67
Change Coolant ............................................................................7-54
Change Engine Oil .......................................................................7-22
Change Hydraulic Oil ..................................................................7-31
14-1
Element ......................................................................................5-21
Check Air Conditioner.................................................................7-77
Check and Adjust Fan Belt Tension ........................................7-53
Check and Replace Bucket Teeth ............................................7-65
Check and Replace Seat Belt ....................................................7-70
Check Coolant Level ....................................................................7-52
Check Crankcase Breather .........................................................7-80
Check Fuel Hoses ..........................................................................7-48
Check Gas Damper ......................................................................7-81
Check Hoses and Lines ...............................................................7-38
Check Hydraulic Oil Level ..........................................................7-29
Check Injection Nozzle ...............................................................7-80
Check Injection Timing ...............................................................7-80
Check Instruments After Starting ..............................................3-5
Check Starter and Alternator ...................................................7-80
Check the Hour Meter Regularly ................................................7-3
Check Track Sag ............................................................................7-72
Check Water Separator ...............................................................7-45
Check Windshield Fluid Level ..................................................7-71
Cigar Lighter ...................................................................................1-15
Clean Air Conditioner Condenser ...........................................7-56
Clean and Replace Air Cleaner Element ...............................7-49
Clean and Replace Air Conditioner Filter .............................7-75
Clean Cab Floor .............................................................................7-79
Clean Oil Cooler Front Screen ..................................................7-56
Clean Radiator and Oil Cooler Core .......................................7-55
Components Name .............................................................1-1, 1-20
Confirm Direction of Machine to Be Driven ........................S-13
Control Lever (ISO Pattern) .........................................................5-1
Controller Part Name and Function .......................................1-21
Controls on the radio ..................................................................1-27
Convert Bucket Connection Into Face Shovel ....................7-68
Coolant Temperature Gauge .......................................................1-5
Cooling Operation .......................................................................1-24
Cooling System .............................................................................7-51
Correct Maintenance and Inspection Procedures ...............7-1
D
Defroster Operation ....................................................................1-25
Dig with Caution ...........................................................................S-20
Digital Clock Setting Procedure ..............................................1-29
Dispose of Waste Properly .........................................................S-37
Do Not Strike the Ground with Bucket Teeth .....................5-13
Drain Fuel Tank Sump ................................................................7-44
Drain Hydraulic Tank Sump ......................................................7-30
Drive Machine Safely ...................................................................S-14
E
ECO Mode Indicator .......................................................................1-5
Electrical System ...........................................................................7-57
Emergency Boom Lowering Procedure ...............................5-28
Emergency Exit .............................................................................1-37
Engine ...............................................................................................7-21
Engine Oil Level ............................................................................7-21
 INDEX
Engine Speed Control ....................................................................5-6
Engine Stop Switch ......................................................................1-17
Engine Trouble Indicator ..............................................................1-7
Ensure Safety Before Rising from or Leaving
Operator’s Seat ...........................................................................S-7
Evacuating in Case of Fire ..........................................................S-32
Every 8 Hours or Daily ....................................................................2-1
F Miscellaneous ................................................................................7-65
Fasten Your Seat Belt ......................................................................S-7
Fastening Machine for Transporting ........................................6-5
Features: ..........................................................................................1-19
Follow Safety Instructions ............................................................S-2
For Rapid Cooling .........................................................................1-26
Front Joint Pins ..............................................................................7-16
Fuel Gauge .........................................................................................1-5
Fuel System .....................................................................................7-42
Fuse Box ...........................................................................................1-18
G Off-Season Air Conditioner Maintenance ...........................1-26
General Precautions for Cab ........................................................S-5
GETTING ON/OFF THE MACHINE ...............................................1-2
Grading Operation .......................................................................5-12
Greasing ...........................................................................................7-16
H Operate Only from Operator’s Seat ..........................................S-8
Handle Chemical Products Safely ...........................................S-37
Handle Fluids Safely-Avoid Fires............................................ S-23
Hood and Access Covers ..............................................................7-8
Horn Switch ....................................................................................1-14
Hour Meter .........................................................................................1-8
Hydraulic Breaker and Hydraulic Crusher (Optional) ......5-16
Hydraulic System ..........................................................................7-26
I
Inspect and Adjust Valve Clearance .......................................7-80
Inspect Machine ..............................................................................S-4
Inspect Machine Daily Before Starting ....................................3-1
Inspection and Maintenance of Hydraulic Equipment ...7-26
Installation and Adjustment of Mirrors ................................1-38
Investigate Job Site Beforehand .............................................S-11
J Power Mode ......................................................................................5-9
Jump Starting ...................................................................................S-9
K
Keep Person Clear from Working Area..................................S-18
Keep Riders off Machine ...............................................................S-9
Key Switch .......................................................................................1-14
Kind of Oils ...................................................................................... 7-9
L Precautions for Communication Terminal ...........................S-38
Layout ..................................................................................................7-4
Lifting Machine ................................................................................6-7
Liquid Crystal Display (LCD) .........................................................1-8
Loading ...............................................................................................6-3
Loading/Unloading ........................................................................6-3
Loading/Unloading on a Trailer .................................................6-2
Low Engine Oil Pressure Indicator .............................................1-6
14-2
M
MACHINE NUMBERS ...........................................................................1
MAINTENANCE .................................................................................7-1
Maintenance Guide .................................................................... 7-10
Maintenance Guide Table .............................................................7-5
Maintenance Under Special Environmental Conditions ...9-1
Measure Engine Compression Pressure ...............................7-80
Monitor Panel ...................................................................................1-4
Move and Operate Machine Safely ...........................................S-8
N
Never Position Bucket Over Anyone .....................................S-18
Never Ride Attachment ..............................................................S-38
Never Undercut a High Bank ....................................................S-20
O
Object Handling ........................................................................... S-22
Observe Engine Operation Closely ...........................................2-1
Opening Side and Rear Windows ...........................................1-35
Opening Upper Front Window ................................................1-33
Opening/Closing and Removing Cab Inside Window ....1-32
Opening/Closing Overhead Window ....................................1-36
Operate with Caution .................................................................S-20
Operating Backhoe ......................................................................5-10
Operating in Water or Mud ..........................................................4-7
Operating on Soft Ground ...........................................................4-5
OPERATING THE ENGINE ...............................................................3-1
OPERATING THE MACHINE ...........................................................5-1
OPERATOR’S STATION ....................................................................1-3
Overheat Indicator ..........................................................................1-6
P
Park Machine Safely .....................................................................S-23
Parking the Machine ......................................................................4-9
Parking the Machine on Slopes ..................................................4-9
Periodic Replacement of Parts .................................................7-14
Pilot Control Shut-Off Lever .............................................1-17, 5-4
Pilot Control Shut-Off Lever Indicator .....................................1-7
Power Mode Switch .....................................................................1-11
Practice Safe Maintenance ........................................................S-25
Precaution For Arm Roll-In/Bucket Roll-In Combined
Operation ...................................................................................5-27
Precautions for After Operations ............................................5-29
Precautions for Blade Operation ................................................5-3
Precautions for Breaker Operation .........................................5-17
Precautions for Crusher Operation ........................................5-22
Precautions for Handling Accumulator and
Gas Damper ..............................................................................S-34
Precautions for Lightning ..........................................................S-21
Precautions for Operations .......................................................S-10
Precautions for Traveling on Slopes ..........................................4-8
Precautions for Welding and Grinding .................................S-33
 INDEX
Preheat Indicator .............................................................................1-6 T
Preparations for Inspection and Maintenance .....................7-7 Tightening and Retightening Torque of Nuts and
Prepare for Emergencies ...............................................................S-3 Bolts .............................................................................................7-81
Prevent Battery Explosions .......................................................S-36 Time Adjustment ..........................................................................1-29
Prevent Burns .................................................................................S-28 Tips for Optimal Air Conditioner Usage ...............................1-26
Prevent Fires ...................................................................................S-30 Towing Machine a Short Distance .............................................4-6
Prevent Parts from Flying ..........................................................S-27 Transmission ..................................................................................7-24
Protect Against Falling Stones and Debris ..........................S-12 Transport Safely ............................................................................S-24
Protect Against Flying Debris .................................................. S-22 TRANSPORTING ................................................................................6-1
Protect Against Noise ....................................................................S-4 Transporting by Road ....................................................................6-1
Provide Signals for Jobs Involving Multiple Machines....S-13 Transporting Machine with Blade .............................................6-2
PWR Mode Indicator.......................................................................1-5 Travel Levers and Pedals ...............................................................4-1
R Travel Mode Switch .............................................................1-11, 4-3
Travel Reduction Gear ................................................................7-24
Raise One Track Using Boom and Arm ....................................4-5
Traveling .............................................................................................4-4
Recognize Safety Information ....................................................S-1
Troubleshooting ...........................................................................11-1
Recommended Fuel ....................................................................7-42
Remaining Fuel Indicator .............................................................1-6 U
Remove Paint Before Welding or Heating ...........................S-35 Understand Signal Words .............................................................S-1
Remove Travel Levers ..................................................................7-70 Unloading ..........................................................................................6-5
Removing and Storing Lower Front Window .....................1-34 Use Handholds and Steps ............................................................S-6
Replace Air Breather Element ..................................................7-37 Using Booster Batteries .................................................................3-6
Replace Engine Oil Filter ............................................................7-22 Using Cigar Lighter ......................................................................1-15
Replace Fuel Cartridge Filter ....................................................7-47 Using Cigar Lighter Port as External Power Source..........1-15
Replace Full-Flow Filter ..............................................................7-34
Replace Pilot Oil Filter .................................................................7-35 W
Replace Rubber Hoses Periodically ........................................S-29 Warming Up Operation .................................................................5-5
Replace Swing Drain Filter Element .......................................7-36 Warn Others of Service Work ...................................................S-26
Replacement of Hydraulic Oil and Filter ..............................7-28 Wear Protective Clothing..............................................................S-3
Replacing Fuses ............................................................................7-63 When Windows Become Clouded ..........................................1-26
Retighten Cylinder Head Bolt ..................................................7-80 Wiper/Washer Switch ..................................................................1-13
Work Light Switch ........................................................................1-12
S Working Ranges (Grouser shoe)..............................................12-2
SAFETY ................................................................................................S-1 ZX80-GI .......................................................................................12-2
SAFETY SIGNS ................................................................................S-39
Seat Belt ...........................................................................................1-39
Service Air Conditioning System Safely ...............................S-36
Shackle Hole Usage .....................................................................5-27
Shovel ...............................................................................................5-11
Sound Adjustment .......................................................................1-30
Specifications .................................................................................12-1
ZX80-GI .......................................................................................12-1
Starting the Engine .........................................................................3-3
Station Presetting Procedure ...................................................1-28
Stay Clear of Moving Parts ........................................................S-27
Stopping the Engine ......................................................................3-8
STORAGE ..........................................................................................10-1
Store Attachments Safely ..........................................................S-28
Storing the Machine ....................................................................10-1
Suction Filter Cleaning ...............................................................7-33
Support Machine Properly ........................................................S-26
Swing Bearing ................................................................................7-18
Swing Internal Gear .....................................................................7-19
Switch Panel ......................................................................................1-9

14-3
 INDEX

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

14-4
 INDEX

MEMO
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................
....................................................................... ..........................................................................................................................

14-5 Master Manual Ref. No. ENMDEKL0-1-1, Corrected on 2nd-May-2