Hitachi EX200-5 EX220-5 EX230LC-5 EX270-5 Excavator Operational Principle Technical Manual

Description

Hitachi EX200-5 EX220-5 EX230LC-5 EX270-5 Excavator Operational Principle Technical Manual

This Hitachi EX200-5, EX220-5, EX230LC-5, EX270-5 Excavator Operational Principle Technical Manual (document number TO157E02) is a 160-page factory-format reference covering the EX200-5, EX200LC-5, EX220-5, EX220LC-5, EX230LC-5, EX270-5, and EX270LC-5 hydraulic excavators. It is written for an experienced technician and explains how every device and system on these machines is built and how it works, rather than covering removal, disassembly, or repair procedures.

• Manual type: Technical Manual (Operational Principle)
• Brand/models: Hitachi EX200-5, EX200LC-5, EX220-5, EX220LC-5, EX230LC-5, EX270-5, EX270LC-5 hydraulic excavators
• Language: English
• Page count: 160 pages
• File format: PDF
• Document number: TO157E02

Chapters Covered

• Introduction — to the reader, additional references, manual composition, page numbering, safety alert symbols, units used
• Section 1 General
  • Group 1 Specification — Specifications; Working Ranges and Machine Dimensions for Transportation
  • Group 2 Component Layout — How to See Component Layout Pages; Main Components; Electrical System (Overall System, Relays, Monitor and Switch Panels); Pump and Related Parts; Other Components

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• Section 2 System
  • Group 1 Control System — Outline; Engine Control; Pump Control; Valve Control; Other Control Function
  • Group 02 Hydraulic System — Main Circuit; Pilot Circuit; Neutral Circuit; Single Actuator Operation; Combined Operation
  • Group 03 Electrical System — Outline; Electric Power Circuit; Bulb Check Circuit; Preheat Circuit; Starting Circuit; Charging Circuit; Surge Voltage Prevention Circuit; Accessory Circuit; Engine Stop Circuit
• Section 3 Component Operation
  • Group 1 Pump Device — Outline; Main Pump; Regulator; Pilot Pump; N Sensor (Engine Speed Sensor); Pump Pressure Sensor
  • Group 2 Swing Device — Outline; Swing Motor; Valve Unit; Swing Parking Brake; Swing Reduction Gear
  • Group 3 Control Valve — Outline; Hydraulic Circuit; Flow Combiner Valve; Pump Control Valve; Main Relief Valve; Overload Relief Valve (With Make-Up Function); Arm Regenerative Valve; Boom Anti-Drift Valve; Arm Anti-Drift Valve; Bucket Flow Control Valve; Travel Flow Control Valve; Travel/Boom Lower Selector Valve; Boom Regenerative Valve
  • Group 4 Pilot Valve — Outline; Operation
  • Group 5 Travel Device — Outline; Travel Reduction Gear; Travel Motor; Travel Brake Valve; Parking Brake
  • Group 6 Others (Upperstructure) — Pilot Shut-Off Valve; Shockless Valve; Solenoid Valve Unit; Pilot Relief Valve; EC Motor
  • Group 7 Others (Undercarriage) — Swing Bearing; Center Joint; Track Adjuster

Together, these chapters take a technician from the machine’s dimensions and component locations, through the microcomputer-based control logic that governs the engine, pump, and valves, into the internal construction and function of every major hydraulic component on the EX200-5, EX220-5, EX230LC-5, and EX270-5 range.

What This Excavator Manual Covers

The Component Specifications pages give full technical data for each model: the EX200-5/EX200LC-5 uses an Isuzu A-6BG1T 6-cylinder diesel (99.3 kW/1950 min⁻¹), while the EX220-5, EX220LC-5, EX230LC-5, EX270-5, and EX270LC-5 use the Hino H07C-TD engine in different output tunes up to 132 kW/2050 min⁻¹. Main pump model (HPV102FW), pilot pump, control valve (KVMG-200H) relief pressures, swing motor, travel motor, cylinder bore/stroke dimensions, battery, alternator, and air conditioner data are listed model-by-model, along with full operating weight, working range, and transport dimension tables and diagrams for the backhoe and face-shovel (reversed bucket) front-end configurations.

The System section explains, with block diagrams and circuit drawings, how the machine’s onboard controller (MC) reads sensor and switch signals — engine control dial, pressure switches, pilot pressure sensors, auto-idle switch, learning switch, HP mode switch — and issues output signals for engine control, pump control (including power boost and travel motor swash angle control), and valve control (speed sensing, arm regenerative control). It also walks through Auto-Idle Control and Engine Learning Control operation, the main/pilot/neutral hydraulic circuits, and the electrical system’s power, bulb-check, preheat, starting, charging, surge-voltage-prevention, accessory, and engine-stop circuits, with several circuits described separately for the EX200-5/200LC-5 versus the EX220-5/220LC-5/230LC-5/270-5/270LC-5 group.

The Component Operation section is the technical core of this Hitachi excavator manual, breaking down the pump device (main pump, regulator, pilot pump, N sensor, pump pressure sensor), swing device (swing motor, valve unit, swing parking brake, swing reduction gear), control valve assembly (hydraulic circuit routing, flow combiner valve, pump control valve, main and overload relief valves with make-up function, arm and boom regenerative valves, boom and arm anti-drift valves, bucket and travel flow control valves, travel/boom lower selector valve), pilot valve, travel device (travel reduction gear, travel motor, travel brake valve, parking brake), and upperstructure/undercarriage components such as the pilot shut-off valve, shockless valve, solenoid valve unit, pilot relief valve, EC motor, swing bearing, center joint, and track adjuster — each illustrated with cutaway and schematic drawings showing internal oil flow.

Why Technicians Need This EX200-5 EX220-5 EX230LC-5 EX270-5 Technical Manual

Correctly diagnosing a hydraulic or electrical fault on the EX200-5, EX220-5, EX230LC-5, or EX270-5 depends on first understanding how the system is supposed to behave. This Operational Principle Technical Manual gives a technician that foundation: the exact relief pressures, flow rates, and control logic Hitachi engineered into each model, and how the pump, valve, and electrical circuits interact under normal, boosted, and auto-idle operation. Having the correct operating principle for the specific model in front of you — rather than guessing from a generic excavator guide — reduces diagnostic time and prevents unnecessary parts replacement.

This Hitachi EX200-5, EX220-5, EX230LC-5, EX270-5 Excavator Operational Principle Technical Manual is delivered as an instant PDF download — no shipping, no waiting. Open it on a phone, tablet, laptop, or shop PC, or print the pages you need for the bay. Payment is processed securely and the download link is available immediately after checkout.