Hitachi Zaxis 200 Instruction manual

Manual No. : KM-178E

Vol. No. : W178-E-02

Workshop Manual

Excavator

PRINTED IN SINGAPORE (PS) 2004.10

200·225USR·225US·230·270 Excavator Workshop Manual

200

225USR

225US

230·270

Service Manual (Manual No. KM-178E) consists of the following three separate volumes;

Technical Manual (Operational Principle) :Vol. No. TO178E

Technical Manual (Troubleshooting) :Vol. No. TT178E

Workshop Manual :Vol. No. W178E

Zaxis200/225/230/270-WSM 13/10/04, 12:261

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INTRODUCTION

IN-01

TO THE READER

• This manual is written for an experienced technician

to provide technical information needed to maintain

and repair this machine.

• Be sure to thoroughly read this manual for cor-

rect product information and service procedures.

• If you have any questions or comments, at if you

found any errors regarding the contents of this

manual, please contact using “Service Manual

Revision Request Form” at the end of this man-

ual.

(Note: Do not tear off the form. Copy it for us-

age.):

Publications Marketing & Product Support

Hitachi Construction Machinery Co. Ltd.

TEL: 81-298-32-7173

FAX: 81-298-31-1162

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this manual.

• The Operator’s Manual

• The Parts Catalog

• Operation Manual of the Engine

• Parts Catalog of the Engine

• Hitachi Training Material

MANUAL COMPOSITION

• This manual consists of two portions:

the Technical Manual and the Workshop Manual.

Use the manuals according to purpose.

• Information included in the Technical Manual:

technical information needed for redelivery and

delivery, operation and activation of all devices

and systems, operational performance tests, and

troubleshooting procedures.

• Information included in the Workshop Manual:

technical information needed for maintenance

and repair of the machine, tools and devices

needed for maintenance and repair, maintenance

standards, and removal/installation and assem-

ble/disassemble procedures.

PAGE NUMBER

• Each page has a number, located on the center

lower part of the page, and each number contains

the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number

Section Number

T: Technical Manual W: Workshop Manual

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INTRODUCTION

IN-02

SAFETY ALERT SYMBOL AND HEADLINE

NOTATIONS

In this manual, the following safety alert symbol and

signal words are used to alert the reader to the

potential for personal injury of machine damage.

This is the safety alert symbol. When you see this

symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed

along with the safety alert symbol.

The safety alert symbol is also used to draw attention

to component/part weights.

To avoid injury and damage, be sure to use appropri-

ate lifting techniques and equipment when lifting

heavy parts.

• CAUTION:

Indicated potentially hazardous situation which

could, if not avoided, result in personal injury or

death.

• IMPORTANT:

Indicates a situation which, if not conformed to the

instructions, could result in damage to the machine.

• NOTE:

Indicates supplementary technical information or

know-how.

UNITS USED

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

this manual.

MKSA system units and English units are also

indicated in parenthheses just behind SI units.

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

A table for conversion from SI units to other system

units is shown below for reference purposees.

Quantity To Convert

From Into Multiply By

MPa kgf/cm210.197Pressure

MPa psi 145.0

kW PS 1.360Power

kW HP 1.341

Temperature °C °F °C×1.8+32

km/h mph 0.6214Velocity

min-1 rpm 1.0

Flow rate L/min US gpm 0.2642

mL/rev cc/rev 1.0

Quantity To Convert

From Into Multiply By

mm in 0.03937Length

mm ft 0.003281

L US gal 0.2642

L US qt 1.057

Volume

m3yd31.308

Weight kg lb 2.205

N kgf 0.10197Force

N lbf 0.2248

N⋅m kgf⋅m 1.0197Torque

N⋅m lbf⋅ft 0.7375

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SAFETY

SA-1

RECOGNIZE SAFETY INFORMATION

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

this manual, be alert to the potential for personal

injury.

• Follow recommended precautions and safe

operating practices.

001-E01A-0688

SA-688

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

the degree or level of hazard - DANGER,

WARNING, or CAUTION - are used with the safety

alert symbol.

• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death

or serious injury.

• WARNING indicates a potentially hazardous

situation which, if not avoided, could result in

death or serious injury.

• CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in

minor or moderate injury.

DANGER or WARNING safety signs are

located near specific hazards. General

precautions are listed on CAUTION safety

signs.

• Some safety signs don’t use any of the

designated signal words above after the safety

alert symbol are occasionally used on this

machine.

• CAUTION also calls attention to safety messages in

this manual.

• To avoid confusing machine protection with

personal safety messages, a signal word

IMPORTANT indicates a situation which, if not

avoided, could result in damage to the machine.

• NOTE indicates an additional explanation for an

element of information.

002-E01C-1223

SA-1223

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SAFETY

SA-2

FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the

machine and all safety messages in this manual.

• Safety signs should be installed, maintained and

replaced when necessary.

• If a safety sign or this manual is damaged or

missing, order a replacement from your author-

ized dealer in the same way you order other

replacement parts (be sure to state machine

model and serial number when ordering).

• Learn how to operate the machine and its controls

correctly and safely.

• Allow only trained, qualified, authorized personnel

to operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-

chine life.

• 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 au-

thorized dealer before operating or performing

maintenance work on the machine.

003-E01B-0003

SA-003

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SAFETY

SA-3

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label at-

tached 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, ambu-

lance service, hospital, and fire department

posted near your telephone.

004-E01A-0437

SA-437

WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

A hard hat

Safety shoes

Safety glasses, goggles, or face shield

Heavy gloves

Hearing protection

Reflective clothing

Wet weather gear

Respirator or filter mask.

Be sure to wear the correct equipment and clothing

for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other

parts of the machine.

• Operating equipment safely requires the full

attention of the operator. Do not wear radio or

music headphones while operating the machine.

005-E01A-0438

SA-438

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SAFETY

SA-4

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

impairment or loss of hearing.

• Wear a suitable hearing protective device such

as earmuffs or earplugs to protect against

objectionable or uncomfortably loud noises.

006-E01A-0434

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 “PRE-START

INSPECTION” chapter in the operator’s manual.

S007-E01A-0435

SA-435

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SAFETY

SA-5

GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all

dirt and/or oil from the soles of your work boots. If

any controls such as a pedal is operated while

with dirt and/or oil on the soles of the operator’s

work boots the operator’s foot may slip off the

pedal, possibly resulting in a personal accident.

• Don’t leave parts and/or tools lying around the

operator’s seat. Store them in their specified lo-

cations.

• Avoid storing transparent bottles in the cab. Don’t

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 extin-

guish the match and/or tobacco.

• Don’t leave cigarette lighters in the cab. When

the temperature in the cab increases, the lighter

may explode.

524-E01A-0000

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SAFETY

SA-6

USE HANDHOLDS AND STEPS

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

• When you mounting and dismounting the ma-

chine, 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 mounting and dis-

mounting the machine.

008-E01B-0439

SA-439

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator

leading to misoperations.

• The seat should be adjusted whenever changing

the operator for the machine.

• The operator should be able to fully depress the

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.

009-E01A-0378

SA-378

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