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Part of the Hitachi Repair Manuals.
Wrenching on an EX200-5 or EX200LC-5? This 398-page Hitachi EX200-5, EX200LC-5 technical manual PDF (OEM #TO160E-00) walks you through the whole hydraulic excavator: pump device, swing device, control valve, travel device, and the full control system. You get hydraulic circuit diagrams covering main, pilot, and combined-operation circuits, plus wiring for the starting, charging, preheat, and engine stop circuits. The troubleshooting coverage runs page after page: diagnosing procedures, fault code lists, electrical system inspection, and harness checks. Set main relief pressure at 34.3 MPa (36.3 MPa on power boost), and torque the swing motor drain hose to 39 N-m. Your excavator is dead in the mud, and forum guesses won't restart it. This bookmarked PDF opens on any laptop, tablet, or phone; download it and bring the factory numbers straight to the cab.
What's Inside This Hitachi EX200-5, EX200LC-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 4-23 | Specification (Specifications, Working Ranges and Machine Dimensions for Transportation, Engine, Engine Accessories, Hydraulic Devices, Electrical Equipment) |
| Upperstructure | 24-83 | Pump Device, Swing Device, Control Valve, Pilot Valve, Others |
| Undercarriage | 84-105 | Travel Device, Others |
| Electrical Circuit | 106-123 | Electric Power Circuit, Preheat Circuit, Starting Circuit, Charging Circuit, Surge Voltage Prevention Circuit, Accessory Circuit, Engine Stop Circuit |
| Hydraulic Circuits | 124-129 | Main Circuit, Pilot Circuit, Neutral Circuit, Single Actuator Operation, Combined Operation |
| Control System | 130-155 | Engine Control, Work Mode Control, HP Mode Control, E Mode Control, Auto-Idle Control, Auto-Warming Up Control, Engine Learning Control, Pump Control |
| Troubleshooting | 156-392 | Diagnosing Procedure, Fault Code List, Troubleshooting a, Troubleshooting B, Troubleshooting C, Electrical System Inspection, Harness Check |
| Electrical Circuit Diagrams | 393-398 | Cab Harness, Engine Harness, Electrical Circuit Diagram, Relay Harness, Connector Diagrams, Air Conditioner Harness |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main relief pressure (Normal) | 34.3 MPa | p. 13 |
| Main relief pressure (Power boost) | 36.3 MPa | p. 13 |
| Minimum pump flow rate adjustment | 6.47 cm³/rev | p. 227 |
| Maximum pump flow rate adjustment | 5.39 cm³/rev | p. 227 |
| Swing motor drain hose torque | 39 N·m | p. 228 |
| Glow plug resistance | 10 Ω or less | p. 310 |
| Glow plug voltage | 20 to 24 V | p. 310 |
| Tightening Torque (1) | 7 N·m (0.7 kgf·m) | p. 331 |
| Specified Output Voltage | 2.50 ± 0.05 V | p. 347 |
| Engine Rated Output | 99.3 kW | p. 10 |
| Main Relief Valve Pressure (Normal) | 34.3 MPa | p. 13 |
| Main Relief Valve Pressure (Power Boost) | 36.3 MPa | p. 13 |
Hitachi EX200-5, EX200LC-5 Common Problems This Manual Covers
Hitachi EX200-5 hydraulic pump whining under load, boom slow, digging power gone
Check hydraulic oil level and inspect the suction side for air leaks; a pump sucking air howls long before it fails. Test main relief pressure against the 34.3 MPa (350 kgf/cm2, 4977 psi) normal spec on page 13. If flow tests low, note that a quarter turn of the minimum flow screw on page 227 changes delivery 6.47 cm3/rev.
Manual Section: Troubleshooting B (Symptoms) p. 13Bucket and arm sluggish, machine feels gutless in the cut, relief squeals early
Test each circuit at the pump port before blaming the pump. Set boom, arm, and bucket relief to 350+20/-5 kgf/cm2 per the table on page 235; swing gets 330+20/-5. Verify power boost reaches 36.3 MPa (380 kgf/cm2, 5261 psi). If a valve will not hold setting, pull it and inspect the seat for scoring.
Manual Section: Troubleshooting B (Symptoms) p. 235Engine rpm stuck, throttle dial does nothing, engine speed will not change
Check the EC sensor output first: back-probe the connector and confirm 2.50 plus or minus 0.05 V per the adjustment procedure on page 347. Off spec, adjust or replace the EC motor. If the reading is good, work the harness between the main controller and EC motor with a lamp kit before condemning the engine controller.
Manual Section: Troubleshooting B p. 347Engine cranks slow and starts hard on cold mornings, rough idle after start
Load-test both batteries against the 96 Ah (5 hour rate) capacity spec before touching the starter. Measure glow plug resistance, 10 ohms or less, and confirm 20 to 24 V at the plugs during preheat as shown on page 310. Verify charging at 24 V 40 A, then clean every ground strap; corroded grounds mimic a dying starter.
Manual Section: Electrical System Inspection p. 310Oil weeping from swing motor drain hose fitting, wet film over the slew area
Clean the fitting dry, run the swing both directions, and watch where oil actually appears before pulling parts. Torque the swing motor drain hose fitting to 39 N·m (4 kgf·m, 29 lbf·ft) as specified on page 228. If it still weeps, replace the seal; a crushed O-ring on a drain line drips again within a shift.
Manual Section: Troubleshooting p. 228Frequently Asked Questions
How do I reset the buzzer on a Hitachi EX200-5 excavator?
The buzzer can be silenced by pressing the buzzer stop switch located on the monitor panel. This is typically used to stop the alarm when the engine oil pressure or overheat indicators are active. p. 19
What are the error code meanings on a Hitachi EX200-5?
Error codes indicate specific component failures. For example, code 01 is an EEPROM failure, code 05 is an N Sensor failure, and code 06 is an EC Sensor failure. Corrective actions usually involve performing 'Retrial B', checking the harness, or replacing the specific sensor. p. 247
What are the torque specifications for the swing relief valve?
The swing relief valve adjusting screw lock nut should be tightened to 177 N·m (18 kgf·m, 130 lbf·ft). p. 220
What is the standard valve clearance for the engine?
The standard valve clearance for both the intake and exhaust valves is 0.40 mm (0.0157 in) when the engine is cold. p. 193
What is the standard injection pressure for the nozzle?
The standard injection pressure for the nozzle is 18.1 MPa (185 kgf/cm², 2631 psi). p. 195
How will I receive this Hitachi EX200-5 Technical Manual?
This is a 398-page scanned PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print specific sections of this Hitachi EX200-5 Technical 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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