Hitachi Zaxis 200 Instruction manual

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 ’ 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.
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.
1- 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.
1- 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 in the operator ’ s 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 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

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.

W1-1-2
GENERAL/PrecautionsforDisassemblingandAssembling
Precautions for Assembling
• Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace part.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
remove the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and in-
stallation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the mo-
tor mayresult.
If the cylinder is operated with air
trapped in the cylinder tube, dam-
age to the cylinder may result.
Be sure to bleed air before starting
the engine.
Bleeding Air from HydraulicPump
• Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
Bleeding Air from Travel Motor / SwingMotor
• With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.

W1-1-3
GENERAL/PrecautionsforDisassemblingandAssembling
Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil asnecessary.
M104-07-021

W1-1-4
GENERAL/PrecautionsforDisassemblingandAssembling
Floating Seal Precautions
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set
with seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check the slide surface on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.
(3) Check O-ring (B) for tears, breaks,
deformation or hardening.
2. If incorrectly assembled, oil leakage or damage
will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air.
(2) Clean the floating seal and seal mounting
bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.
(3) Check that the O-ring is not twisted, and that it
is installed correctly on the seal ring.
W105-03-05-019
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal
mating face (C) by measuring the distances
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating.
Correct
a
C Incorrect
a
A
B
W105-03-05-020
b
b
a=b a
b
W110-03-05-004
A
B
Correct
Incorrect

W1-1-5
GENERAL/PrecautionsforDisassemblingandAssembling
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings
safely.
• Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 C (212 F). If unavoidably lifting a
load with a temperature of 100 C (212 F) or
more, reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the
lifted load balanced.
• When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing
slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won ’ t dete-
riorate with heat, sun light, or chemicals.
Correct Eyehole
Lifting Method
W102-04-02-016
Incorrect Eyehole
Lifting Method
W105-04-01-008
Bent Sling
W162-01-01-009

178W-2-1
Group 1 Cab
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 6 Swing Device
Remove and Install Cab ..............................W2-1-1
Dimensions of the Cab Glass ....................W2-1-13
Group 2 Counterweight
Remove and Install Counterweight..............W2-2-1
Group 3 Main Frame
Remove and Install Main Frame..................W2-3-1
Group 4 Pump Device
Remove and Install Pump Device................W2-4-1
Disassemble Pump Device..........................W2-4-2
Assemble Pump Device.............................W2-4-10
Disassemble Regulator..............................W2-4-22
Assemble Regulator ..................................W2-4-24
Disassemble Solenoid Valve .....................W2-4-26
Assemble Solenoid Valve ..........................W2-4-28
Disassemble and Assemble Pilot
Pump ........................................................W2-4-30
Maintenance Standard...............................W2-4-32
Group 5 Control Valve
Remove and Install Control Valve................W2-5-1
Disassemble Control Valve
4-Spool Section..........................................W2-5-8
Disassemble Control Valve
5-Spool Section........................................W2-5-14
Disassemble and Assemble
4-Spool and 5-Spool Section ...................W2-5-20
Assemble Control Valve
4-Spool Section........................................W2-5-22
Assemble Control Valve
5-Spool Section........................................W2-5-30
Remove and Install Swing Device............... W2-6-1
Disassemble Swing Device (ZAXIS200,
200-E, 225US, 225USR, 230) ................... W2-6-4
Disassemble Swing Device (ZAXIS270)... W2-6-10
Assemble Swing Device (ZAXIS200,
200-E, 225US, 225USR, 230) ................. W2-6-16
Assemble Swing Device (ZAXIS270)........ W2-6-24
Disassemble Swing Motor (ZAXIS200,
200-E, 225US, 225USR, 230) ................. W2-6-30
Disassemble Swing Motor (ZAXIS270)..... W2-6-34
Assemble Swing Motor (ZAXIS200,
200-E, 225US, 225USR, 230) ................. W2-6-38
Assemble Swing Motor (ZAXIS270).......... W2-6-42
Disassemble and Assemble Parking
Release Valve (ZAXIS270)...................... W2-6-46
Maintenance Standard .............................. W2-6-47
Group 7 Pilot Valve
Remove and Install Right Pilot Valve ..........W2-7-1
Remove and Install Left Pilot Valve............. W2-7-5
Remove and Install Travel
Pilot Valve .................................................. W2-7-8
Disassembe Right and Left
Pilot Valves .............................................. W2-7-10
Assemble Right and Left
Pilot Valves .............................................. W2-7-18
Disassemble Travel Pilot Valve ................. W2-7-26
Assemble Travel Pilot Valve ...................... W2-7-34

178W-2-2
Group 8 Pilot Shut-Off Valve
Remove and Install Pilot Shut-Off Valve......W2-8-1
Disassemble Pilot Shut-Off Valve
(ZAXIS200, 200-E, 225USR, 230, 270).......W2-8-4
Disassemble Pilot Shut-Off Valve
(ZAXIS225US) ...........................................W2-8-6
Assemble Pilot Shut-Off Valve
(ZAXIS200, 200-E, 225USR, 230, 270).....W2-8-8
Assemble Pilot Shut-Off Valve
(ZAXIS225US) .........................................W2-8-10
Group 9 Signal Control Valve
Remove and Install Signal
Control Valve..............................................W2-9-1
Group 10 Solenoid Valve
Remove and Install Solenoid
Valve Unit .................................................W2-10-1
Disassemble Proportional
Solenoid Valve .........................................W2-10-2
Assemble Proportional
Solenoid Valve .........................................W2-10-4

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