Hitachi Zaxis 200 Gebrauchsanweisung

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.

1- 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 moderateinjury.

DANGER or WARNING safety signs are

located near specific hazards. General

precautions are listed on CAUTION safety

signs.

•

Some

safety

signs

don

’

use

any

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.

1- E01C-1223

SA-1223

SA-2

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 whennecessary.

•

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 andsafely.

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.

E01B-0003

SA-003

SA-3

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 at-

tached on the fire extinguisher to use itproperly.

•

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.

1- 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.

1- E01A-0438

SA-438

SA-4

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.

E01A-0434

SA-434

INSPECT MACHINE

Inspect your machine carefully each day or shift by

walking around it before you start it to avoid

personalinjury.

•

In the walk-around inspection be sure to cover all

points described in the

“

PRE-START

INSPECTIO

N”

chapter

the

operator

’

manual.

S007-E01A-0435

SA-435

SA-5

SAFETY

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

the

soles

the

operator

’

work

boots

the

operator

’

foot

may

slip

off

the

pedal, possibly resulting in a personal accident.

•

Don

’

leave

parts

and/or

tools

lying

around

the

operator

’

seat.

Store

them

their

specified

lo-

cations.

•

Avoid

storing

transparent

bottles

the

cab.

Don

’

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

’

leave

cigarette

lighters

the

cab.

When

the temperature in the cab increases, the lighter

may explode.

524-E01A-0000

SECTION AND GROUP

CONTENTS

WORKSHOP MANUAL

SECTION 1 GENERAL INFORMATION

SECTION 2 UPPERSTRUCTURE

SECTION 3 UNDERCARRIAGE

SECTION 4 FRONT ATTACHMENT

Group 1 Front Attachment

Group 2 Cylinder

SECTION 5 ENGINE

Group 1 Precautions for disassembling

and Assembling

Group 2 Tightening Torque

Group 3 Painting

Group 4 Bleeding Air from Hydraulic Oil

Tank

Group 1 Cab

Group 2 Counterweight

Group 3 Main Frame

Group 4 Pump Device

Group 5 Control Valve

Group 6 Swing Device

Group 7 Pilot Valve

Group 8 Pilot Shut-Off Valve

Group 9 Signal Control Valve

Group 10 Solenoid Valve

Group 1 Swing Bearing

Group 2 Travel Device

Group 3 Center Joint

Group 4 Track Adjuster

Group 5 Front Idler

Group 6 Upper and Lower Roller

Group 7 Track

TECHNICAL MANUAL (Operational Principle)

SECTION 1 GENERAL

Group 1 Specification

Group 2 Component Layout

Group 3 Component Specifications

SECTION 2 SYSTEM

Group 1 Control System

Group 2 Hydraulic System

Group 3 Electrical System

SECTION 3 COMPONENT OPERATION

Group 1 Pump Device

Group 2 Swing Device

Group 3 Control Valve

Group 4 Pilot Valve

Group 5 Travel Device

Group 6 Signal Control Valve

Group 7 Others (Upperstructure)

Group 8 Others (Undercarriage)

TECHNICAL MANUAL (Troubleshooting)

SECTION 4 OPERATIONAL PER-

FORMANCE TEST

Group 1 Introduction

Group 2 Standard

Group 3 Engine Test

Group 4 Excavator Test

Group 5 Component Test

Group 6 Adjustment

SECTION 5 TROUBLESHOOTING

Group 1 General

Group 2 Component Layout

Group 3 Troubleshooting A

Group 4 Troubleshooting B

Group 5 Troubleshooting C

Group 6 Electrical System Inspection

Group 7 ICX

SECTION 1

GENERAL INFORMATION

CONTENTS

Group 1 Precautions for Disassembling

and Assembling

Precautions for Disassembling and

Assembling ............................................ W1-1-1

Maintenance Standard Terminology ......... W1-1-7

Group 2 Tightening Torque

Tightening Torque Specification ............... W1-2-1

Torque Chart ............................................ W1-2-4

Piping Joint .............................................. W1-2-7

Periodic Replacement of Parts............... W1-2-11

Group 3 Painting

Painting.................................................... W1-3-1

Group 4 Bleeding Air

Bleed Air from Hydraulic Oil Tank............. W1-4-1

178W-1-1

GENERAL/PrecautionsforDisassemblingandAssembling

W1-1-1

PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING

Precautions for Disassembling and Assembling

Clean the Machine

Thoroughly wash the machine before bringing it into

the shop. Bringing a dirty machine into the shop

may cause machine components to be

contaminated during disassembling/assembling,

resulting in damage to machine components, as

well as decreased efficiency in service work.

Inspect the Machine

Be sure to thoroughly understand all disassem-

bling/assembling procedures beforehand, to help

avoid incorrect disassembling of components as

well as personal injury.

Check and record the items listed below to prevent

problems from occurring in the future.

•

The machine model, machine serial number, and

hour meter reading.

•

Reason for disassembly (symptoms, failed parts,

and causes).

•

Clogging of filters and oil, water or air leaks, if

any.

•

Capacities and condition of lubricants.

•

Loose or damaged parts.

Prepare and Clean Tools and DisassemblyArea

Prepare the necessary tools to be used and the

area for disassembling work.

Precautions for Disassembling

•

To prevent dirt from entering, cap or plug the

removed pipes.

•

Before disassembling, clean the exterior of the

components and place on a work bench.

•

Before disassembling, drain gear oil from the

reduction gear.

•

Be sure to provide appropriate containers for

draining fluids.

•

Use matching marks for easier reassembling.

•

Be sure to use the specified special tools, when

instructed.

•

If a part or component cannot be removed after

removing its securing nuts and bolts, do not

attempt to remove it forcibly. Find the cause(s),

then take the appropriate measures to remove it.

•

Orderly arrange disassembled parts. Mark and

tag them asnecessary.

•

Store common parts, such as bolts and nuts with

reference to where they are to be used and in a

manner that will prevent loss.

•

Inspect the contact or sliding surfaces of

disassembled parts for abnormal wear, sticking,

or other damage.

•

Measure and record the degree of wear and

clearances.

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