Table of Contents
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URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (K) 2012, 02
PART NO.
WDCD-EN-00
Workshop Manual
ZX
200
-5G
200LC
-5G
210H
-5G
210LCH
-5G
210K
-5G
210LCK
-5G
Hydraulic Excavator
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
Engine Manual
: Vol. No.TODCD-EN
: Vol. No.TTDCD-EN
: Vol. No.WDCD-EN
: Vol. No.EDCD-EN
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Chapters
Table of Contents
Related Manuals for Hitachi ZX200LC-5G
Summarization of Contents
Introduction to the Hitachi Hydraulic Excavator Workshop Manual
To The Reader
Information for technicians on maintaining and repairing the machine, emphasizing thorough reading of the manual.
Additional References
Lists other Hitachi materials like operator's manual and parts catalog for supplementary information.
Manual Composition
Details the content of the Technical Manual, Workshop Manual, and Engine Manual.
Page Numbering System
Explains the structure of page numbers in the manual (Section-Group-Page).
Safety Alert Symbols and Headline Notations
Explains safety alert symbols (Danger, Warning, Caution) and their meanings for hazard indication.
Units Used in the Manual
Details SI units and provides a conversion table for various quantities.
Symbols and Abbreviations Used in the Manual
Symbol and Abbreviation Definitions
Lists and explains common symbols and abbreviations used throughout the manual.
General Safety Information and Precautions
Recognize Safety Information
Guides readers on identifying and understanding safety alert symbols.
Understand Signal Words
Explains the meaning of signal words like DANGER, WARNING, CAUTION, and IMPORTANT.
Follow Safety Instructions
Provides essential guidelines for safe operation and maintenance of the machine.
Prepare for Emergencies
Outlines steps to prepare for potential emergencies like fire or accidents.
Wear Protective Clothing
Recommends necessary safety equipment and clothing for operating the machine.
Protect Against Noise
Advises on protecting hearing from prolonged exposure to loud noise.
Inspect Machine Daily
Emphasizes the importance of daily walk-around inspections to avoid personal injury.
General Precautions for Cab
Lists safety precautions related to the machine's operator cab.
Use Handholds and Steps Safely
Provides guidance on safe practices for mounting and dismounting the machine.
Adjust the Operator's Seat
Explains how to adjust the operator's seat for proper operation and visibility.
Ensure Safety Before Rising from or Leaving Operator’s Seat
Details safety procedures before moving from or leaving the operator's seat.
Fasten Your Seat Belt
Highlights the importance of wearing a seat belt to minimize injury in case of accidents.
Move and Operate Machine Safely
Provides instructions for safely moving and operating the machine on the job site.
Operate Only from Operator's Seat
Stresses the necessity of operating the machine only from the designated operator's seat.
Jump Starting Precautions
Details safety procedures and warnings related to jump starting the engine.
Keep Riders off Machine
Warns against allowing unauthorized persons to ride on the machine due to injury risks.
Precautions for Operations
General safety measures to follow during machine operations.
Investigate Job Site Beforehand
Emphasizes pre-operation checks of the job site conditions to prevent tipping or collapse.
Install OPG Guard
Advises on equipping the machine with an OPG guard for protection against falling objects.
Provide Signals for Jobs Involving Multiple Machines
Guidelines for using signals and a signal person when operating multiple machines.
Confirm Direction of Machine to Be Driven
Ensures correct operation of travel pedals/levers by confirming undercarriage position.
Drive Machine Safely
Provides instructions for safe driving on various terrains, including slopes.
Avoid Injury from Rollaway Accidents
Details procedures to avoid machine rollaways, especially when parking on grades.
Avoid Injury from Back-Over and Swing Accidents
Offers precautions to prevent injuries from backing up or swinging the machine.
Keep Person Clear from Working Area
Stresses the importance of maintaining a clear working area to prevent accidents.
Never Position Bucket Over Anyone
Warns against lifting or swinging the bucket over people or vehicle cabs.
Avoid Undercutting
Advises on safe excavation practices to prevent collapse and machine tipping.
Avoid Tipping
Provides instructions on how to avoid machine tipping, especially on grades.
Never Undercut a High Bank
Warns about the dangers of undercutting high banks due to potential collapse.
Dig with Caution
Highlights precautions to take when digging near underground cables or gas lines.
Operate with Caution
Advises caution when operating the machine near overhead obstacles.
Avoid Power Lines
Details safety procedures for operating near electric lines to prevent electrocution.
Precautions for Lightning
Provides safety measures to take during electrical storms.
Object Handling Safety
Safety guidelines for lifting and handling loads to prevent injury or death.
Protect Against Flying Debris
Advises on wearing eye protection and closing cab windows to prevent debris injury.
Park Machine Safely
Lists steps for safely parking the machine to prevent accidents.
Handle Fluids Safely - Avoid Fires
Provides safety instructions for handling flammable fluids to prevent fires and explosions.
Transport Safely
Offers precautions for safely loading and unloading the machine onto trucks or trailers.
Practice Safe Maintenance
Outlines safe procedures and precautions to follow before and during maintenance work.
Warn Others of Service Work
Instructs on using 'Do Not Operate' tags to prevent accidental machine movement during service.
Support Machine Properly
Emphasizes the importance of securely supporting the machine before working on it.
Stay Clear of Moving Parts
Warns about entanglement hazards with rotating parts and advises on protective measures.
Prevent Parts from Flying
Details safety precautions when working with high-pressure grease or travel reduction gears.
Store Attachments Safely
Provides guidance on safely storing attachments to prevent falling hazards.
Prevent Burns
Warns about hazards associated with hot spraying fluids and hot surfaces.
Replace Rubber Hoses Periodically
Recommends periodic replacement of rubber hoses to prevent failures.
Avoid High-Pressure Fluids
Advises on precautions to prevent injury from high-pressure fluid injection.
Prevent Fires
Offers checks for oil leaks and short circuits that can lead to fires.
Clean up Flammables
Instructions on cleaning up flammable materials to prevent fires.
Check Key Switch Function
Ensures proper functioning of the key switch for fire prevention.
Check Heat Shields
Highlights the importance of checking heat shields to prevent fires.
Evacuating in Case of Fire
Provides procedures for safely evacuating the machine in case of a fire.
Beware of Exhaust Fumes
Warns about the hazards of exhaust fumes and recommends ventilation.
Precautions for Welding and Grinding
Safety measures to take when performing welding or grinding operations.
Avoid Heating Near Pressurized Fluid Lines
Advises against heating near pressurized fluid lines to prevent flammable spray.
Avoid Applying Heat to Lines Containing Flammable Fluids
Warns against welding or flame cutting pipes containing flammable fluids.
Precautions for Handling Accumulator and Gas Damper
Details safety instructions for handling accumulators and gas dampers due to explosion risk.
Remove Paint Before Welding or Heating
Instructs on removing paint before welding or heating to avoid hazardous fumes.
Beware of Asbestos and Silicon Dust and Other Contamination
Advises on precautions for inhaling dust, asbestos fibers, or silicon dust.
Prevent Battery Explosions
Provides safety guidelines to prevent battery gas explosions.
Service Air Conditioning System Safely
Offers safety instructions for handling refrigerant and servicing the air conditioning system.
Handle Chemical Products Safely
Emphasizes safe handling of chemicals and refers to MSDS for details.
Dispose of Waste Properly
Provides guidelines on environmentally responsible disposal of machine waste.
Never Ride Attachment
Strictly prohibits riding on attachments or loads due to extreme danger.
Precautions for Communication Terminal Equipment
Warns about potential malfunction of medical devices due to electrical waves from the terminal.
Precaution for Communication Terminal Equipment
Details specific absorption rate (SAR) values and precautions for communication terminals.
Before Returning the Machine to the Customer
Confirms proper functioning of safety systems and replacement of worn parts after maintenance.
Section 1: General Information
Group 1 Precautions for Disassembling and Assembling
Covers essential safety precautions for disassembling and assembling components.
Group 2 Tightening
Details specifications and procedures for proper bolt and nut tightening.
Group 3 Painting
Specifies painting colors and standards for various machine parts.
Group 4 Bleeding Air
Provides procedures for bleeding air from the hydraulic oil tank, system, and fuel system.
Group 5 Pressure Release Procedure
Explains how to safely release remaining pressure in the hydraulic circuit.
Group 6 Preparation
Outlines necessary preparations before performing inspection and maintenance procedures.
Section 2: Maintenance Standard
Group 1 Upperstructure
Covers maintenance standards for upperstructure components like pump device and swing motor.
Group 2 Undercarriage
Details maintenance standards for undercarriage components such as travel motor and track.
Group 3 Front Attachment
Specifies maintenance standards for front attachment components like pins, bushings, and cylinders.
Section 3: Upperstructure
Group 1 Cab
Details removal, installation, and dimensions of cab components, including glass.
Group 2 Counterweight
Provides procedures for the removal and installation of the counterweight.
Group 3 Main Frame
Outlines the steps for removal and installation of the main frame.
Group 4 Engine
Details the procedures for the removal and installation of the engine.
Group 5 Radiator Assembly
Provides instructions for replacing the radiator, oil cooler, and intercooler.
Group 6 Hydraulic Oil Tank
Covers the removal and installation procedures for the hydraulic oil tank.
Group 7 Fuel Tank
Details the removal and installation procedures for the fuel tank.
Group 8 Pump Device
Includes removal, installation, disassembly, and assembly procedures for the pump device.
Group 9 Control Valve
Covers removal, installation, disassembly, and assembly of control valves and related components.
Group 10 Swing Device
Provides procedures for removal, installation, disassembly, and assembly of the swing device.
Group 11 Pilot Valve
Details removal, installation, disassembly, and assembly procedures for left, right, and travel pilot valves.
Group 12 Solenoid Valve
Covers removal, installation, disassembly, and assembly of solenoid valves.
Group 13 Signal Control Valve
Provides procedures for removal, installation, disassembly, and assembly of the signal control valve.
Section 4: Undercarriage
Group 1 Swing Bearing
Covers removal, installation, disassembly, and assembly of the swing bearing.
Group 2 Travel Device
Details removal, installation, disassembly, and assembly for travel devices, motors, and brake valves.
Group 3 Center Joint
Provides procedures for removal, installation, disassembly, assembly, and replacement of center joint parts.
Group 4 Track Adjuster
Covers removal, installation, disassembly, assembly, and precautions for floating seals of the track adjuster.
Group 5 Upper and Lower Rollers
Details removal, installation, disassembly, assembly, and precautions for floating seals of upper and lower rollers.
Group 6 Track
Provides procedures for the removal and installation of the track system.
Section 5: Front Attachment
Group 1 Front Attachment
Covers removal and installation procedures for the entire front attachment assembly.
Group 2 Cylinder
Details removal, installation, disassembly, and assembly of Boom, Arm, and Bucket cylinders.
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