![Hitachi EX200-5 to EX270-5 Repair Manual [Excavator]](https://youfixthis.com/wp-content/uploads/2014/12/2019-12-01_15-43-27-300x300.jpg)
Part of the Hitachi Repair Manuals.
Both factory books in one bundle: the Technical Manual T137E-00 (pages 1-426) and the Workshop Manual W137E-00 (pages 427-1008). The Technical volume carries specifications, hydraulic and electrical system theory, the full operational performance tests and Dr.EX troubleshooting. The Workshop volume is the wrench side: cab, counterweight, main frame, pump device, swing bearing, travel device, front attachment cylinders, and the ISUZU 6BD1TPJ engine with its torque charts and angular bolt tightening method. Numbers straight off the spec pages: main relief 34.3 MPa, overload relief 36.3 MPa, 99.3 kW at 2050 rpm. Full electric wiring, engine harness and cab harness diagrams are included. Covers both the EX200-3 and the long-crawler EX200LC-3.
What's Inside This Hitachi EX200-3, EX200LC-3 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Manual, Introduction | 1-2 | How the Technical Manual Is Organised, Page Numbering and Section Codes, How to Use the Operational Performance Tests |
| Technical Manual, SAFETY | 3-10 | Safety Precautions Before Testing, Working Around a Running Machine, Decal Locations |
| Technical Manual, Section 01 Specifications | 11-36 | Foreword, Specifications, Working Ranges·Transportation, Shoe Types and Appliations, Weight |
| Technical Manual, Section 02 Upperstructure | 37-93 | Layout, Layout of Upperstructure, Tank, Hydraulic Oil Tank, Fuel Tank |
| Technical Manual, Section 03 Undercarriage | 94-115 | Component Location, Travel Device, Travel Reduction Gears, Travel Motor |
| Technical Manual, Section 04 Electrical SYSTEM | 116-189 | Component Location, Relays, Monitor and Switch Panel, Characteristics of the Electrical System |
| Technical Manual, Section 05 Hydraulic SYSTEM | 190-217 | General, Hydraulic Circuit, Main Circuit, Pilot Circuit, Control System |
| Technical Manual, Section 06 Operational Performance TEST | 218-295 | Purpose, Terminology, Preparation for Performance Tests, Engine Test |
| Technical Manual, Section 07 Troubleshooting | 296-423 | Diagnosing Procedure, Dr.EX, Dr.EX Start-Up Procedure, Clearing Self-Diagnosing Function, Retrial "a" |
| All Diagram | 424-426 | Electric Wiring Diagram, Engine Harness Diagram, Cab Harness Diagram |
| Workshop Manual, Introduction | 427-428 | How the Workshop Manual Is Organised, Tightening Torque Conventions, Adjustment of Differential Pressure |
| Workshop Manual, SAFETY | 429-436 | Safety Precautions Before Disassembly, Lifting and Supporting Components, Hydraulic Pressure Release |
| Workshop Manual, Section 01 General Information | 437-448 | Precautions for Disassembly and Assembly, Precautions for Disasembling and Assembling, Tightening Torque, Tightening Torque Specifications, Torque Chart |
| Workshop Manual, Section 02 Upperstructure, Group 01 Cab | 449-456 | Remove and Install Cab, Dimensions of the Cab Glass |
| Workshop Manual, Section 02 Upperstructure, Group 02 Counterweight | 457-458 | Counterweight, Remove and Install Counterweight |
| Workshop Manual, Section 02 Upperstructure, Troubleshooting, Specifications & Disassembly | 459-652 | Main Frame, Remove and Install Main Frame, Pump Device, Remove and Install Pump Device, Disassemble Pump Device, Assemble Pump Device |
| Workshop Manual, Section 03 Undercarriage | 653-778 | Swing Bearing, Remove and Install Swing Bearing, Disassemble Swing Bearing, Assemble Swing Bearing, Travel Device |
| Workshop Manual, Section 04 FRONT Attachment | 779-816 | Front Attachment, Remove and Install Front Attachment, Maintenance Stanards, Cylinders |
| Workshop Manual, Section 06 ENGINE and Accessory | 817-1008 | Notes on the Format of Engine Section, Main Data & Specificatons, Desing Features & General Outline, Tightening Torque Specifications, Angular Nut and Bolt Tightening Method |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Operating weight | 18,500 kg (40,800 lb) — EX200-3; 19,000 kg (41,900 lb) — EX200LC-3 | p. 14 |
| Engine output | 99 kW (135 PS) at 2050 rpm | p. 14 |
| Bucket capacity (heaped) | PCSA 0.8 m³ (1.05 yd³), CECE 0.7 m³ | p. 14 |
| Arm digging force | 89 kN (9100 kgf) | p. 14 |
| Bucket digging force | 113 kN (11,500 kgf) | p. 14 |
| Ground pressure | 41 kPa (0.42 kgf/cm², 6.0 psi) — EX200-3; 39 kPa (0.40 kgf/cm², 5.7 psi) — EX200LC-3 | p. 14 |
| Travel speed (fast/medium/slow) | 5.7 / 3.7 / 2.2 km/h | p. 14 |
| Main relief pressure | 34.3 MPa | p. 34 |
| Overload relief pressure | 36.3 MPa | p. 34 |
| Maximum engine torque | 461 N·m (47 kgf·m) at 1600 rpm | p. 32 |
Hitachi EX200-3, EX200LC-3 Common Problems This Manual Covers
Weak digging force and slow cycle times
Before condemning the pump, run the checks in Section 06 Operational Performance Test and verify main relief at 34.3 MPa and overload relief at 36.3 MPa. The section covers preparation, terminology and the engine test so you compare against factory figures, not guesswork.
Manual Section: Technical Manual, Section 06 Operational Performance Test p. 190Machine mistracks or one track drags on straight travel
Start with the Travel Device coverage in Technical Manual Section 03 Undercarriage, which lays out the travel motor and travel reduction gears, then follow Workshop Manual Section 03 to pull and rebuild the travel device once you have isolated the weak side.
Manual Section: Technical Manual Section 03 / Workshop Manual Section 03 Undercarriage p. 653Boom or arm drifts down under load, rod seals weeping
Workshop Manual Section 04 Front Attachment covers removal, installation and maintenance standards for the cylinders. Rod diameters are in the book: boom 85 mm, arm 95 mm, bucket 75 mm, so you can order the right seal kits before opening anything up.
Manual Section: Workshop Manual, Section 04 Front Attachment p. 779Electrical gremlins: dead relays, monitor panel acting up, harness damage
Chase it with the ALL DIAGRAM set, the full electric wiring diagram plus separate engine harness and cab harness diagrams, cross-checked against component and relay locations in Technical Manual Section 04 Electrical System, then work faults methodically with the Section 07 diagnosing procedure.
Manual Section: ALL DIAGRAM / Technical Manual Section 04 Electrical System p. 190Frequently Asked Questions
Is this actually both volumes, or just one book like most listings?
Both. You get the Technical Manual T137E-00 (specifications, systems, performance tests, troubleshooting) and the Workshop Manual W137E-00 (disassembly and assembly), 1008 pages total. Plenty of sellers split these; here the diagnosis book and the repair book are in the same download. p. 427
My machine feels weak and slow. Does this give real test procedures with factory numbers?
Yes. Section 06 Operational Performance Test in the Technical volume walks through preparation, terminology and the engine test, and the hydraulic coverage gives you the settings to check against: main relief 34.3 MPa, overload relief 36.3 MPa. That is how you separate a worn pump from a misadjusted relief valve. p. 218
Does troubleshooting need a modern code reader plugged into the machine?
No, this excavator predates OBD-style scanners. Section 07 is built around the period Hitachi Dr.EX diagnostic tool, with its start-up procedure, clearing the self-diagnosing function and the Retrial A routine, plus symptom-based diagnosing procedures you can work through with a multimeter and gauges. p. 296
Is the engine covered, or do I need a separate ISUZU book?
Workshop Section 06 Engine and Accessory covers the ISUZU 6BD1TPJ: main data and specifications, design features, tightening torque specifications and the angular nut and bolt tightening method. Rated output is 99.3 kW at 2050 rpm. For most in-frame engine work you will not need another manual. p. 31
I have the LC version. Is the EX200LC-3 really covered?
Yes, both machines run through the whole set. Section 01 Specifications carries working ranges, transportation data, shoe types and applications, and weights, which is where the standard and LC undercarriages differ most, and the undercarriage sections apply to both. p. 14
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