Part of the Hitachi Repair Manuals.
Boom speed drops off, the upperstructure jerks when you stop a swing on a cold morning, or the monitor shows EC code 13 while the dealer tech is booked out for two weeks. This Hitachi EX200-3 and EX200LC-3 repair manual is for that moment.
It combines Technical Manual T137E-00 for circuits, performance tests and troubleshooting with Workshop Manual W137E-00 for teardown and rebuild. It covers the HPV091EW main pump, control valves and pilot circuit, plus the swing device, travel motors, track adjuster and cylinders. It also covers the Isuzu 6BD1TPJ engine. If you are on your own with the machine and nobody to call, the Dr.EX fault code lists and relief pressure specs tell you what to check next.
Print the sections you need and take them to the bench. A few hydraulic oil prints on the pages just means the book is earning its keep.
What's Inside This Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Manual: Safety & Specifications | 1-36 | Specifications, Working Ranges, Fuels and Lubricants, Refill Capacities, Machine Numbers, Component Specs |
| Technical Manual: Upperstructure Components | 37-93 | Main Pump, Pilot Pump, Swing Device, Control Valve, Relief Valves, Pilot Valve, Solenoid Valves |
| Technical Manual: Undercarriage Components | 94-115 | Travel Reduction Gears, Travel Motor, Travel Brake Valve, Parking Brake, Center Joint, Track Adjuster |
| Technical Manual: Electrical System | 116-189 | Main Circuits, Engine Start and Charging, EC/PVC Control System, Monitor, Fuses, Connectors, Fault Code Lists |
| Technical Manual: Hydraulic System | 190-217 | Hydraulic Circuit, Main and Pilot Circuits, Pump Control, Valve Control, Combined Operation |
| Technical Manual: Operational Performance Test | 218-295 | Engine Speed and Compression, Travel and Swing Tests, Drift Checks, Relief Pressure Settings, Pump Flow Test, Performance Standards |
| Technical Manual: Troubleshooting | 296-423 | Dr.EX Diagnosis, EC and PVC Fault Codes, Machine Malfunctions, Monitor and Indicator Faults, Harness Checks |
| Electric Wiring & Harness Diagrams | 424-426 | Electric Wiring Diagram, Engine Harness Diagram, Cab Harness Diagram |
| Workshop Manual: General, Cab, Counterweight & Main Frame | 427-462 | Disassembly Precautions, Tightening Torque Chart, Cab Removal, Counterweight, Main Frame |
| Workshop Manual: Pump Device Repair | 463-492 | Remove/Install Pump Device, Main Pump and Pilot Pump Disassembly/Assembly |
| Workshop Manual: Control Valve Repair | 493-532 | Four-Section and Three-Section Control Valve Disassembly/Assembly |
| Workshop Manual: Swing Device Repair | 533-570 | Swing Reduction Gear, Swing Motor, Maintenance Standard |
| Workshop Manual: Pilot Valves, Shut-Off, Shockless Valve & Accumulator | 571-610 | Left/Right and Travel Pilot Valves, Pilot Shut-Off Valve, Shockless Valve, Accumulator |
| Workshop Manual: Solenoid, Shuttle & Swing Dampener Valves | 611-652 | Solenoid Valve Unit, Proportional Solenoid Valve, Relief and Reducing Valves, Shuttle Valve, Swing Dampener Valve |
| Workshop Manual: Undercarriage Repair | 653-778 | Swing Bearing, Travel Device and Motor, Brake Valve, Center Joint, Track Adjuster, Idler, Rollers, Track Link |
| Workshop Manual: Front Attachment & Cylinders | 779-816 | Front Attachment Removal, Cylinder Disassembly/Assembly, Maintenance Standards |
| Engine: General Information & Specifications | 817-844 | Isuzu Engine Main Data, Tightening Torques, Angular Tightening Method, Identification |
| Engine: Maintenance & Disassembly | 845-876 | Lubrication, Fuel and Cooling Service, Valve Clearance, Injection Timing, Compression Test, Disassembly |
| Engine: Inspection & Repair | 877-904 | Cylinder Head, Valve Guides, Camshaft, Cylinder Liner, Pistons, Connecting Rod, Crankshaft, Flywheel |
| Engine: Reassembly & Tuning | 905-932 | Piston and Rod Reassembly, Cylinder Head, Major Components, Engine Tuning Operation |
| Engine: Lubricating, Cooling & Fuel Systems | 933-962 | Oil Pump, Oil Filter, Oil Cooler, Water Pump, Thermostat, Injection Nozzle, Injection Pump Calibration |
| Engine: Turbocharger, Air Compressor, Electricals & Troubleshooting | 963-1008 | Turbocharger, Air Compressor, Starter Motor, Alternator, Engine Troubleshooting, Special Tools |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine model | ISUZU 6BD1TPJ | p. 31 |
| Engine rated output | 99.3 kW / 2 050 min-1 (135 PS / 2 050 rpm) | p. 31 |
| Engine displacement | 5 785 cm3 | p. 31 |
| Firing order | 1-5-3-6-2-4 | p. 31 |
| Operating weight | 18 500 kg (40 800 lb) EX200-3; 19 000 kg (41 900 lb) EX200LC-3 | p. 14 |
| Bucket capacity (heaped) | PCSA 0.8 m3 (1.05 yd3), CECE 0.7 m3 | p. 14 |
| Fuel tank capacity | 310 L (82 US gal) | p. 19 |
| Engine oil capacity | 25 L (6.6 US gal) | p. 19 |
| Engine coolant capacity | 21 L (5.5 US gal) | p. 19 |
| Hydraulic system capacity | 200 L (52.8 US gal); hydraulic oil tank 130 L (34.3 US gal) | p. 19 |
| Main pump | HPV091EW, max. flow 187 L (49.4 US gal) x2 | p. 34 |
| Main relief pressure | 34.3 MPa (350 kgf/cm2, 4 977 psi) at 80 L/min | p. 34 |
| Overload relief pressure | 36.3 MPa (370 kgf/cm2, 5 261 psi) at 50 L/min | p. 34 |
| Swing speed | 11.0 min-1 (rpm) | p. 14 |
| Travel speed (fast/medium/slow) | 5.7/3.7/2.2 km/h (3.5/2.3/1.4 mph) | p. 14 |
