Hitachi EX200-2 EX200LC-2 Technical and Workshop Manual – Hydraulic Excavator PDF

Description

Hitachi EX200-2 EX200LC-2 Technical and Workshop Manual – Hydraulic Excavator PDF

This download brings together the Hitachi EX200-2 technical manual and the matching EX200-2 workshop manual in one PDF. The first half explains how the machine is built and how the hydraulic, electrical, and travel systems work. The second half walks through removal, disassembly, inspection, assembly, and maintenance standards for the same components, plus a full engine-and-accessory workshop section for the Isuzu industrial diesel family used on this model. Serial applicability shown in the weight tables starts at 147-60001- for both the standard EX200-2 and long-undercarriage EX200LC-2.

File Details

• Manual type: Technical Manual and Workshop Manual (combined)
• Brand / models: Hitachi EX200-2, EX200LC-2
• Language: English
• Page count: 1151
• File format: PDF
• Internal numbering: T-series technical pages and W-series workshop pages (examples: 107T-01-01, 107W-01-01)

Machines and Configuration Shown in the Manual

The specifications group treats the excavator as three assemblies: front-end attachment, upperstructure, and undercarriage. Standard specification data is written around a backhoe with a 2.91 m (9 ft 7 in.) arm and a 0.8 m³ PCSA/SAE (0.7 m³ CECE/JIS) bucket. Operating weight is listed as 18 500 kg (40 800 lb) for the EX200-2 and 19 000 kg (41 900 lb) for the EX200LC-2. Basic machine weight is 15 000 kg and 15 500 kg respectively. The engine line in the machine specification table is ISUZU 6BD1T, 99 kW (135 ps) at 2050 min⁻¹ (rpm).

Working-range charts cover three arm lengths used on both models: 2.21 m, 2.91 m, and 2.91 m plus a 1.5 m extension. With the 2.91 m arm, maximum digging radius is 9 910 mm and maximum digging depth is 6 670 mm (shoe-lug height excluded). Lifting-capacity tables follow SAE J1097 and are given separately for EX200-2 and EX200LC-2 with the 5.68 m boom, 2.91 m arm, 3900 kg counterweight, 0.8 m³ bucket, and 600 mm shoes. Travel speeds are 2.5 / 3.5 / 5.5 km/h. Swing speed is 11 min⁻¹. Gradeability is 35° (tan θ = 0.70). Ground pressure with 600 mm grouser shoes is 0.41 bar on EX200-2 and 0.39 bar on EX200LC-2.

Service refill figures include a 310 liter fuel tank, 21 liters of engine coolant, 25 liters of engine oil, 8.2 liters in the swing reduction gears, 5.5 liters in each travel reduction gear, 200 liters in the hydraulic system, and 130 liters in the hydraulic oil tank. Recommended fuel is ASTM D 975 No. 2D diesel; kerosene is not permitted. Grease, engine oil, gear oil, hydraulic oil, and coolant recommendations sit in their own group with service-hour intervals from 8 through 2000 hours.

Chapters Covered

Technical Manual

• Section 01 Specifications — general information, working range, lifting capacities, refill capacities, transportation dimensions and weights, fuels and lubricants, interchangeability with EX200 and attachment installation notes
• Section 02 Upperstructure — layout; hydraulic oil and fuel tanks; main pump, regulator, and gear pump; swing motor, brake valve, parking brake, swing dampener valve, and reduction device; main and pilot piping; three-spool and four-spool control valve, system pressure regulator, surge and overload relief, variable pressure compensated valve, shuttle and holding valves; pilot valve; lock valve
• Section 03 Undercarriage — component location, swing bearing, center joint, travel reduction device, travel motor, travel brake valve, parking brake, track adjuster
• Section 04 Electrical System — component location, monitor and switch panels, relays, wiring diagram and connectors; engine control system and EC motor; monitor functions and check procedure; power, preheat, start, charging, accessory, auto-idle, and engine-stop circuits; fuse, fusible-link, A-sensor, and EC-sensor inspection
• Section 05 Hydraulic System — main, suction, delivery, return, drain, and pilot circuits; load sensing, speed sensing, flow dividing, job-mode selector, 3-speed propel, swing parking brake, warm-up, and power-boost control; neutral, swing, arm-in, combined, and relief circuits
• Section 06 Operational Performance Test — performance standards; engine speed and compression tests; travel, swing, cylinder cycle, drift, lever force/stroke, and combined-function checks; pilot, PC, PI, main-pump, regulator, overload-relief, flow, and motor-drain tests; Dr. EX basic performance checks
• Section 07 Troubleshooting — diagnosing procedure and Dr. EX start-up/self-diagnosis; connector maps; EC- and PVC-related fault codes; machine-malfunction cause charts; monitor, gauge, and level-indicator faults; harness continuity and circuit tests on the 24-volt system

Workshop Manual

• Section 01 Specifications — tightening-torque charts and painting standard
• Section 02 Upperstructure — cab, counterweight, and main-frame R&I; pump device; four-section and three-section control valves; swing device and swing motor with maintenance standards; front and travel pilot valves; shut-off valve, shockless valve, accumulator; solenoid, proportional solenoid, relief, and reducing valves; travel and swing/bucket shuttle valves; swing dampener valve
• Section 03 Undercarriage — swing bearing; travel device, travel motor, and brake valve; center joint; track adjuster; front idler; upper and lower rollers; track link — each with R&I, disassembly/assembly, and wear limits where listed
• Section 04 Front-End Attachments — boom/arm/bucket attachment R&I and pin-bushing limits; bucket, arm, and boom cylinder R&I, cylinder overhaul, inspection, and rod maintenance standards
• Section 05 Special Tool — special-tool list and drawings (ST-numbered tools used throughout the tests and overhauls)
• Section 06 Engine and Accessory — general repair rules and main data; maintenance (lube, fuel, cooling, valve clearance, injection timing, compression, turbocharger); engine disassembly; inspection and repair of head, valves, cam, pistons, crank, flywheel, and timing cover; engine assembly and tuning; lubricating, cooling, and fuel systems including injection-pump calibration; turbocharger; air compressor; starter and alternator; engine troubleshooting; engine special tools

Taken as a whole, the Hitachi EX200-2 EX200LC-2 Technical and Workshop Manual – Hydraulic Excavator PDF gives a technician both the system theory needed to interpret a fault and the bench procedures needed to take a pump, valve, motor, travel unit, cylinder, or engine apart and put it back together to the printed limits.

Performance Testing and Dr. EX Diagnostics

Section 06 is written as a measured checkout, not a narrative. Engine tests cover speed (including auto-idle) and compression. Machine tests cover travel speed and track revolution time, mistrack, travel parking, swing speed and drift, swing-motor leakage, swing-bearing play, cylinder cycle times, dig-function drift, lever operating force and stroke, and combined boom-raise/arm-roll-in and boom-raise/swing checks. Hydraulic component tests set and confirm pilot primary and secondary pressure, proportional-solenoid PC pressure, swing-parking-brake release pressure, reducing-valve PI pressure, main-pump delivery pressure, system-pressure-regulator relief, overload-relief settings, main-pump flow against a PQ curve, and swing- and travel-motor drain oil. Several relief-adjustment tables distinguish machines around EX200-2 S/NO. 68710 and EX200LC-2 S/NO. 6649, and notes address 1100-version and later machines and 1200-version Dr. EX power-boost display.

Troubleshooting Section 07 then uses those same numbers. After a six-step diagnosing method and Dr. EX start-up, the book lists EC-related and PVC-related fault codes, maps how electronic failures change machine behavior, and walks harness tests on the battery circuit, sensors, switch panels, EC motor, engine-stop motor, emergency relay, and related 24-volt wiring. Two 12-volt batteries in series supply the system.

Engine Workshop Note

The engine section states that the workshop pages apply to the 4BD1, 4BD1T, 6BB1, 6BD1, and 6BD1T industrial diesel family, with illustrations based on 6BD1 and 6BD1T. The 4BD1T and 6BD1T are turbocharged. For the excavator itself the specification pages and the engine data table mark 6BD1T EX200-2: water-cooled four-cycle vertical in-line OHV, direct injection, dry liners, 6 cylinders, 102.0 × 118.0 mm bore × stroke, 5,785 cm³ displacement, 17.5:1 compression, injection order 1-5-3-6-2-4, Bosch A-type in-line plunger pump with RSV mechanical governor, and injection timing 16° BTDC on 6BD1T. Compression pressure is given as 31 kg/cm² at 200 rpm (warm). Valve clearance (cold) is 0.40 mm intake and exhaust. Where workshop main-data figures and the machine instruction book disagree, the engine pages say the instruction book takes precedence.

Safety Content in the Front Matter

The opening safety pages cover parking and supporting the machine, high-pressure fluid injection, battery explosion and acid burns, exhaust fumes, cooling-system pressure, welding near paint or pressurized lines, moving parts, power lines (keep any part of the machine or load farther than 3 m plus twice the insulator length from the line), and the requirement to attach a “Do Not Operate” tag on the right-side controller lever before service. Those rules sit in front of both the technical and workshop material.

Use This Manual on the Job

With the Hitachi EX200-2 EX200LC-2 Technical and Workshop Manual – Hydraulic Excavator PDF a shop can identify the machine configuration, pick the correct oil and grease, run a full operational performance test, read Dr. EX and harness results, then overhaul the main pump, control valve, swing and travel units, center joint, undercarriage, front cylinders, and the 6BD1T engine to the published maintenance standards and torque charts. Using the printed pressures, cycle times, wear limits, and special-tool list keeps adjustments inside the values the book uses for evaluation instead of guesswork. The file is delivered as an instant PDF after payment — no shipping wait — and can be opened on a computer, tablet, or phone and printed for the bench or the machine.