Hitachi ZX200-5G Manuel d'instructions

WDCD-EN-00ZX200-5G •200LC-5G •210H-5G •210LCH-5G •210K-5G •210LCK-5G HYDRAULIC EXCAVATOR WORKSHOP MANUAL

PRINTED IN JAPAN (K) 2012, 02

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

200-5G

200LC-5G

210H-5G

210LCH-5G

210K-5G

210LCK-5G

Service Manual consists of the following separate Part No.

Technical Manual (Operational Principle) : Vol. No.TODCD-EN

Technical Manual (Troubleshooting) : Vol. No.TTDCD-EN

Workshop Manual : Vol. No.WDCD-EN

Engine Manual : Vol. No.EDCD-EN

WDCD-EN-00

PART NO.

Hydraulic Excavator

Workshop Manual

INTRODUCTION

IN-01

To The Reader

Additional References

Manual Composition

Page Number

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 correct

product information and service procedures.

Please refer to the other materials (operator’s manual,

parts catalog, engine technical material and Hitachi

training material etc.) in addition to this manual.

This manual consists the Technical Manual, the Workshop

Manual and the Engine Manual.

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.

Each page has a number, located on the center lower part

of the page, and each number contains the following

information:

Example:

Technical Manual: T 1-3-5

T Technical Manual

1 Section Number

3 Group Number

5 Consecutive Page Number for Each Group

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 manual. (Note: Do not tear off

the form. Copy it for usage.):

Publications Marketing & Product Support Hitachi

Construction Machinery Co. Ltd.

TEL: 81-29-832-7084

FAX: 81-29-831-1162

E-mail: [email protected]

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 assemble / disassemble

procedures.

Information included in the Engine Manual:

Technical information needed for redelivery and delivery

and maintenance and repair of the machine, operation

and activation of all devices and systems, troubleshooting

and assemble / disassemble procedures.

Workshop Manual: W 1-3-2-5

W Workshop Manual

1 Section Number

3 Group Number

2 Sub Group Number

5 Consecutive Page Number for Each Group

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.

dThis 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 appropriate

lifting techniques and equipment when lifting heavy

parts.

dCAUTION:

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.

fNOTE:

Indicates supplementary technical information or know-

how.

Units Used

Quantity To Convert From Into Multiply By

Length mm in 0.03937

mm ft 0.003281

Volume L US gal 0.2642

L US qt 1.057

m3yd31.308

Weight kg lb 2.205

Force N kgf 0.10197

N lbf 0.2248

Torque N·m kgf·m 0.10197

Pressure MPa kgf/cm210.197

MPa psi 145.0

Power kW PS 1.360

kW HP 1.341

Temperature °C °F °C×1.8+32

Velocity km/h mph 0.6214

min-1 rpm 1.0

Flow rate L/min US gpm 0.2642

mL/rev cc/rev 1.0

fNOTE: The numerical value in this manual might be

different from the above-mentioned table.

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

manual. MKSA system units and English units are also

indicated in parentheses 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 purposes.

SYMBOL AND ABBREVIATION

SY-1

Symbol /

Abbreviation

Name Explanation

TO Technical manual (Operational principle) Technical manual (Operational Principle).

TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).

T/M Technical manual Technical manual.

W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly

and Assembly).

MC Main Controller Main controller. MC controls the engine, pump, and valve

according to the machine operating condition.

ECF Engine Controller Engine controller. ECF controls EC motor according to the

machine operating condition.

GSM Global System for Mobile communications

controller

Communication controller. GSM is a type of wireless

communication system, is used in more than on 100

countries around Europe and Asia, and becomes the factual

global standards of the mobile telephone.

GPS Global Positioning System Global positioning system.

CAN Controller Area Network CAN communication. CAN is a serial communications

protocol internationally-standardized by ISO (International

Organization for Standardization).

A/C Air Conditioner Air conditioner.

OP, OPT Option Optional component.

MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and

adjustment.

A/I Auto-Idle Auto-idle.

WU Warming-Up Warming-up.

Li Low (Slow) Idle Slow idle engine speed.

ATT Attachment Attachment. Attachment is optional parts such as breaker,

crusher, and pulverizer in this manual.

HI, Hi High Travel fast position.

LO, Lo Low Travel slow position.

SYMBOL AND ABBREVIATION

SY-2

(Blank)

Recognize Safety Information

These are the SAFETY ALERT SYMBOLS.

When you see these symbols on your machine or in this

manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating

practices.

Understand Signal Words

On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or CAUTION

- are used with the safety alert symbol.

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious

injury.

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate

injury.

DANGER or WARNING safety signs are located near

specific hazards. General precautions are listed on

CAUTION safety signs.

Some safety signs do not use any of the designated signal

words above after the safety alert symbol are occasionally

used on this machine.

To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates a

situation which, if not avoided, could result in damage to

the machine.

NOTE: indicates an additional explanation for an

element of information.

SA-1

SAFETY

SA-688

SA-1223

Follow Safety Instructions

Carefully read and follow all safety signs on the machine

and all safety messages in this manual.

Safety signs should be installed, maintained and replaced

when necessary.

If a safety sign or this manual is damaged or missing,

order a replacement from your authorized dealer in the

same way you order other replacement parts (be sure to

state machine model and serial number when ordering).

Learn how to operate the machine and its controls correctly

and safely.

Allow only trained, qualified, authorized personnel to

operate the machine.

Keep your machine in proper working condition.

Unauthorized modifications of the machine may impair

its function and/or safety and affect machine life.

Do not modify any machine parts without authorization.

Failure to do so may deteriorate the part safety, function,

and/or service life. In addition, personal accident,

machine trouble, and/or damage to material caused by

unauthorized modifications will void Hitachi Warranty

Policy.

Never attempt to modify or disassemble the inlet/exhaust

parts and the muffler filter. Avoid giving shocks on the

muffler filter by striking elements with other objects or

dropping the elements. Failure to do so may affect the

exhaust gas purifying device, possibly damaging it or

lowering its performance.

Do not use attachments and/or optional parts or

equipment not authorized by Hitachi. Failure to do so

may deteriorate the safety, function, and/or service life

of the machine. In addition, personal accident, machine

trouble, and/or damage to material caused by using

unauthorized attachments and/or optional parts or

equipment will void Hitachi Warranty Policy.

The safety messages in this SAFETY chapter are intended

to illustrate basic safety procedures of machines. However

it is impossible for these safety messages to cover every

hazardous situation you may encounter. If you have any

questions, you should first consult your supervisor and/

or your authorized dealer before operating or performing

maintenance work on the machine.

SAFETY

SA-2

SA-003

Prepare for Emergencies

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

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

Thoroughly read and understand the label attached on

the fire extinguisher to use it properly.

To ensure that a fire extinguisher can be always used

when necessary, check and service the fire extinguisher

at the recommended intervals as specified in the fire

extinguisher manual.

Establish emergency procedure guidelines to cope with

fires and accidents.

Keep emergency numbers for doctors, ambulance

service, hospital, and fire department posted near your

telephone.

Wear Protective Clothing

Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

A hard hat

Safety shoes

Safety glasses, goggles, or face shield

Heavy gloves

Hearing protection

Reflective clothing

Wet weather gear

Respirator or filter mask.

Be sure to wear the correct equipment and clothing for the

job. Do not take any chances.

Avoid wearing loose clothing, jewelry, or other items that

can catch on control levers or other parts of the machine.

Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones while

operating the machine.

SAFETY

SA-3

SA-437

SA-438

Protect Against Noise

Prolonged exposure to loud noise can cause impairment or

loss of hearing.

Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or

uncomfortably loud noises.

Inspect Machine

Inspect your machine carefully each day or shift by walking

around it before you start it to avoid personal injury.

In the walk-around inspection be sure to cover all points

described in the "Inspect Machine Daily Before Starting"

section in the operator’s manual.

SA-434

SAFETY

SA-4

SA-435

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