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Part of the Hitachi Repair Manuals.
Factory repair manual for the Hitachi -5 series: EX200-5, EX200LC-5, EX220-5, EX220LC-5, EX230LC-5, EX270-5 and EX270LC-5 hydraulic excavators. This is the workshop-level book, not the operator handbook. It covers system operation and component function for the hydraulic and electrical circuits, performance testing with fault diagnosis and adjustment procedures, then full teardown coverage of the upperstructure (swing device, main pump, control valve), undercarriage (travel device, track components, track adjuster), front attachment (boom, arm, bucket linkage) and the Isuzu engine with cooling, lubrication and fuel systems. If you are chasing a sluggish boom, a stuck engine RPM or a fault code 07, this is the same reference a Hitachi dealer tech would open before touching the machine.
What's Inside This Hitachi EX200-5 to EX270-5 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| System Operation & Component Function | 44-201 | Overall Machine System, Component Operation, Hydraulic and Electrical Circuits |
| Performance Testing & Troubleshooting | 202-446 | Operational Performance Tests, Fault Diagnosis, Adjustment Procedures |
| Upperstructure | 461-646 | Swing Device, Main Pump and Control Valve, Cab and Counterweight |
| Undercarriage | 647-756 | Travel Device, Track and Rollers, Track Adjuster |
| Front Attachment | 757-810 | Boom, Arm, Bucket and Linkage |
| Engine & Accessories | 811-1288 | Engine Overhaul (EX200-5 to EX270-5), Cooling and Lubrication, Fuel and Accessories |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Barometric pressure | 100 kPa | p. 1022 |
| Water vapour pressure | 1.0 kPa | p. 1022 |
| Starter | 24V, 4.5 kW | p. 1023 |
Hitachi EX200-5 to EX270-5 Common Problems This Manual Covers
Engine stuck at one RPM, fault code 07 displayed
The Performance Testing and Troubleshooting section traces code 07 through the harness first: test for an open or short between main controller terminal D21 and engine controller terminal 6 before condemning the engine controller itself.
Manual Section: Performance Testing & TroubleshootingBoom lifts slowly or settles under load
Follow the boom circuit checks in the Troubleshooting section: measure cylinder drift, then inspect the boom I valve and boom crush II valve for leakage, and confirm the pilot oil pipe to the hammer pilot circuit is actually connected on hammer-equipped machines.
Manual Section: Performance Testing & TroubleshootingAll hydraulic functions sluggish, slow cycle times
Run the operational performance tests to compare cycle times against factory spec, then use the System Operation section on the main pump and control valve to isolate low oil level, pump wear or internal leakage through worn seals and hoses.
Manual Section: System Operation & Component FunctionEngine overheating with black or blue exhaust smoke
The Engine and Accessories section covers the cooling and lubrication systems plus fuel delivery diagnosis, so you can separate a restricted radiator or bad thermostat from injection faults or oil finding its way into the combustion chambers.
Manual Section: Engine & AccessoriesFrequently Asked Questions
My EX200-5 engine speed will not change no matter where I set the dial. Does this manual cover that?
Yes, this is a known -5 series fault and the Troubleshooting section walks it step by step. Fault code 07 points to the engine controller, but before you buy an ECU the manual has you check the wiring between main controller terminal D21 and engine controller terminal 6 for an open or short. Plenty of machines got a new controller when a corroded connector was the real problem.
Boom lift has been getting slower over the months. Pump, or something else?
Usually not the pump. The manual's boom circuit diagnosis covers leakage past the boom I valve and boom crush II valve, and a common trap on hammer-piped machines: a pilot oil pipe left disconnected from the hammer pilot circuit will bleed the boom down. The Performance Testing section gives you cylinder drift and cycle time checks so you can prove where the oil is going before you pull anything apart.
Does it cover the engine, or just the excavator side?
Both. The Engine and Accessories section covers overhaul of the Isuzu diesel across the EX200-5 through EX270-5 range, plus cooling, lubrication, fuel system and accessories. If yours is overheating or blowing black or blue smoke, the fault diagnosis procedures help you separate fuel delivery problems from oil contamination before you commit to a rebuild.
Can I set track sag and swing bearing play with this, or is that dealer-only?
It is all in here. The Undercarriage section covers the travel device, rollers, idlers and the track adjuster with the measurement and adjustment procedures, and the Upperstructure section covers the swing device. These are jobs a competent owner-operator can do with basic shop tools and a grease gun for the adjuster.
Which models exactly does this one file cover?
Seven machines: EX200-5, EX200LC-5, EX220-5, EX220LC-5, EX230LC-5, EX270-5 and EX270LC-5. The LC variants share systems with their standard counterparts, so one manual covers the family. If you run a mixed fleet of -5 series diggers this is the one book to keep on the laptop.
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