Part of the Hitachi Repair Manuals.
Need factory data for your Hitachi EX200-5 or EX120-5? This 914-page Hitachi EX200-5, EX120-5 Technical Manual PDF (OEM #TT155E-02) covers both hydraulic excavators from the swing bearing to the injection pump. You get complete electrical circuit diagrams with connector and harness layouts, hydraulic schematics for the pump device, control valve, and travel system, plus a massive troubleshooting section that walks each fault from symptom to root cause. Engine work is covered too: cylinder head, crankshaft, turbocharger, and injection pump calibration data. Set valve clearance at 0.40 mm cold, then torque the rocker arm lock nuts to 25.5 N-m; cylinder head bolts go to 7.0 to 9.0 kg-m followed by an angular tightening of 90-120 degrees. No more chasing electrical gremlins with a test light and a hunch. Bookmarked with a full text layer: search any spec, jump to any system, and get back on the machine.
Other editions of this manual
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Electrical Circuit Diagrams and Harnesses | 1-10 | Wiring Diagrams, Connector Layouts, engine/cab/relay and A/C Harnesses, Key Switches, Controllers, Sensors and Relays |
| Technical Manual Introduction | 11-13 | Operational Principle, Troubleshooting Method, How to Use the Workshop Manual |
| Safety | 14-39 | Emergency Procedures, Protective Equipment, Safe Operation and Maintenance Practices |
| General | 40-55 | Specifications, Working Ranges, Machine Dimensions, Component Weights |
| System Operation | 56-89 | Control System, Hydraulic System and Electrical System Operation |
| Component Operation | 90-165 | Pump Device, Swing Device, Control Valve, Pilot Valve and Travel Component Operation |
| Operational Performance Test | 166-221 | Engine Test, Excavator Test, Component Test and Performance Standards |
| Troubleshooting | 222-707 | Diagnosing Procedures, Symptom-Based Troubleshooting, Electrical and Hydraulic Fault Finding |
| Engine General and Maintenance | 708-757 | Engine Repair Instructions, Main Data and Specifications, lubricating/fuel/cooling Maintenance |
| Engine Assembly | 758-828 | External Parts and Major Component Disassembly and Reassembly Steps |
| Engine Subsystems | 829-862 | Lubricating System, Cooling System, Fuel System and Turbocharger Service |
| Engine Electricals and Accessories | 863-902 | Air Compressor, Starter Motor and Engine Electrical Components |
| Reference | 903-914 | Special Tool List and Unit Conversion Tables |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Valve clearance (inlet/exhaust) | 0.4/0.4 mm | p. 45 |
| Intake valve clearance | 0.40 mm (0.0157 in) | p. 174 |
| Rocker arm adjusting screw lock nut torque | 25.5±4.9 N⋅m (2.6±0.5 kgf⋅m, 18.8±3.6 lbf⋅ft) | p. 174 |
| Cylinder head bolt torque | 7.0-9.0 kg·m (50.6-65.1 lb.ft) | p. 730 |
| Valve Clearance (Intake/Exhaust) | 0.40 mm | p. 174 |
| Swing Device Gear Oil Capacity | 6.4 L | p. 508 |
| Travel Device Gear Oil Capacity | 3.5 L | p. 598 |
| Lower Roller Weight | 20 kg | p. 656 |
| EX120-5 | ||
| Engine Rated Output | 63 kW | p. 42 |
| Swing Speed | 12.7 rpm | p. 42 |
| Main Relief Pressure | 34.3 MPa | p. 47 |
| A-4BG1PG | ||
| Engine Oil Capacity | 13.2 L | p. 47 |
