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Part of the Hitachi Repair Manuals.
All 843 pages of this Hitachi EX 200-2 technical manual PDF cover one job: putting your hydraulic excavator back to factory spec, from the upperstructure pump device down to the last track bushing. You get full hydraulic schematics with circuit routing, wiring diagrams for the 24-volt electrical system, and a thick troubleshooting section built on performance checks instead of guesswork. Step-by-step procedures walk you through pump disassembly, control valve spool work, swing motor rebuilds, travel device teardown, and track link replacement, backed by tightening torque tables. When the oil pressure lamp comes on, pressure has fallen below 0.4 kgf/cm2 (5.7 psi); once coolant passes 101 C (213.8 F), the overheat buzzer sounds, and the diagnostic charts tell you why. An idle excavator earns nothing. Bookmarked and keyword-searchable: pull it up on your phone in the shop and start wrenching.
What's Inside This Hitachi EX200-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Manual Hitachi Ex 200-2 | 1-235 | Introduction, Safety, Technical Manual Ex200-2 |
| Performance Check and Troubleshooting Hitachi Ex 200-2 | 236-459 | Technical Manual Ex200-2 |
| Specifications | 460-468 | Tightening Torque, Painting Standards |
| Upperstructure - Cab, Counterweight, Main Frame | 469-481 | Cab Removal, Counterweight Removal, Main Frame Installation |
| Upperstructure - Pump Device | 482-518 | Pump Device Disassembly, Pilot Gear Pump, Pump Assembly |
| Upperstructure - Control Valve | 519-564 | Control Valve Removal, Spool Assembly, Relief Valve Adjustment |
| Upperstructure - Swing Device and Dampener Valve | 565-712 | Swing Device Removal, Swing Motor, Swing Dampener Valve, Relief Valve |
| Undercarriage - Swing Bearing, Travel Device, Center Joint | 713-797 | Swing Bearing, Travel Device Disassembly, Travel Motor, Center Joint |
| Undercarriage - Track Adjuster, Front Idler, Rollers | 798-835 | Track Adjuster, Front Idler, Upper Roller, Lower Roller |
| Undercarriage - Track Link | 836-843 | Track Link Removal, Master Pin, Track Bushing, Grouser Shoe |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fuse 11-20 | 20A | p. 133 |
| Battery voltage | 24 volts | p. 161 |
| Engine oil pressure | 0.4kgf/cm2 (5.7psi) | p. 172 |
| Overheat indicator coolant temperature | 101°C (213.8°F) | p. 172 |
| Swing speed | 11 min-1 | p. 17 |
| Travel speed (fast) | 5.5 km/h | p. 17 |
Hitachi EX200-2 Common Problems This Manual Covers
Hitachi EX200-2 engine cranks slowly or won't start, fuel filters recently replaced, batteries seem good
Test the batteries under load first; the two 12V units must deliver a combined 24 volts to the starter circuit, detailed on page 161. Replace both fuel filters and bleed air from the lines at the injection pump. If cranking stays weak, trace the starter and relay circuit using the wiring diagram.
Manual Section: Electrical System TroubleshootingHydraulic pressure drops under load, boom and arm move slow with weak digging force
Warm the hydraulic oil to 50°C (122°F) before testing, as page 367 requires. Check main pump delivery pressure at neutral; the chart on page 240 calls for 42 ± 6 kgf/cm². Verify system relief for boom, arm, and bucket reaches 350 +20 -0 kgf/cm². If it won't build, inspect hoses for leaks and replace clogged filters.
Manual Section: Hydraulic Component TestEngine overheats during normal digging, coolant temperature alarm and buzzer come on mid-shift
Check coolant level cold, then inspect the radiator core for packed debris and blow it out from the fan side. Verify the thermostat opens during warm-up; the overheat switch trips the alarm at 101°C (213.8°F), so a buzzer at normal working loads points to blocked airflow or a stuck thermostat, not a bad sender.
Manual Section: Monitor System TroubleshootingMachine mistracks or travels slow in fast range, one track lags behind the other
Measure travel speed on flat ground in fast range; the specification on page 17 is 5.5 km/h for both models. If one track lags, swap the travel lines at the center joint to isolate motor from valve: if the slow side follows the hoses, the motor is fine. Verify travel relief holds 350 +20 -0 kgf/cm² per page 240 before pulling the travel motor.
Manual Section: Travel Device TroubleshootingPilot controls feel sluggish, levers slow to respond, attachments hesitate before moving
Test pilot pressure at the pilot valve inlet; page 383 calls for 52 +10/-0 kgf/cm² (739 +142/-0 psi). If it reads low, check the pilot gear pump and clean the pilot line filter. Confirm the hydraulic oil sits no more than 48mm (1 7/8in) below the L mark on the tank sight gauge, covered on page 173.
Manual Section: Hydraulic Component TestFrequently Asked Questions
What are the torque specifications for the engine cushion rubber mounting bolts?
The engine cushion rubber mounting bolts require a tightening torque of 392.28 N·m (400 kgf·m, 289.32 lbf·ft). p. 462
How do I adjust the A-sensor position to the correct voltage?
After installing the A-sensor, connect a digital-type volt meter to the output voltage measurement harness and adjust the sensor position until the reading is 4.40 ± 0.03V. Tighten the mounting bolts to 1 to 1.5 kgf·m (7.2 to 10.9 lbf·ft). p. 206
What is the service interval for replacing the fuel filter element?
The fuel filter element should be replaced every 500 hours of operation. p. 24
What is the capacity of the hydraulic oil tank?
The hydraulic oil tank has a capacity of 130 liters (34.3 US gal, 28.6 Imp gal). p. 21
What is the tightening torque for the swing motor mounting bolts?
The swing motor mounting bolts should be tightened to 88.26 N·m (9.0 kgf·m, 65.10 lbf·ft). p. 462
What do I get after purchasing this Hitachi EX 200-2 manual?
Immediate download of the complete 843-page searchable Technical Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Can I print specific sections of this Hitachi EX 200-2 manual?
Zero restrictions. The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
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