Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hitachi Ex200 Service Manual – PDF DOWNLOAD
Original price was: $59.95.$29.95Current price is: $29.95.
Hitachi Ex200 Service Manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hitachi Ex200 Service Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:1031
DOWNLOADABLE:YES
FILE TYPE:PDF
HITACHI EX200 SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Hitachi Ex200 Service Manual
1. SAFETY ALERT SYMBOL AND HEADLINE OF NOTATION
In this manual, the following safety alert symbol and the headline of notation are used to arouse importance in safety and technology.
1.1 SAFETY ALERT SYMBOL
This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol.
1.2 HEADLINE OF NOTATION .
‘ The word “NOTE” is headlined to supplement an additional technical information or know-how.
2. T0 UPDATE THE CONTENTS OF THE SERVICE MANUAL
The each service manual is serially numbered and its number is recorded by us with the name of the person who received the service manual. And they are referred when the delivered service manuals are required to be revised by upato-date information as such information must be supplied quickly and correctly. Please, advise us the name of person who keeps the service manual and is in responsible to keep it up-to—date by sending back to us the slip of the shipping information sheet enclosed in the service manual.
‘ In case that the personal administration change is made, please inform us of the name of the person who is newly appointed to maintain the serivce manual.
3. TO KEEP CONFIDENTIAL
Please, keep the technical informations and know-how contained in the sen/ice manual confidential to the outsiders.
TABLE OF CONTENTS:
Hitachi Ex200 Service Manual
EX200 HYDRAULIC EXCAVATOR SERVICE MANUAL..................................................................... 0 SECTION 01 HOW TO USE.................................................................................... 1 Group 01 Section & Group Contents.................................................................... 2 Group 02 Introduction................................................................................ 5 Introduction .................................................................................... 5 Care of the Handling............................................................................. 5 Group 03 Features of This Manual..................................................................... 6 Construction..................................................................................... 6 Tab ............................................................................................. 7 Page............................................................................................. 7 Contents......................................................................................... 7 Group 04 Safty Informations ......................................................................... 8 SECTION 02 SPECIFICATIONS................................................................................ 11 Group 01 General Specifications...................................................................... 13 Dimensions....................................................................................... 13 Weights and Ground Pressure...................................................................... 14 Capability....................................................................................... 14 Backhoe Buckets.................................................................................. 14 Other Attachments................................................................................ 14 Working Ranges................................................................................... 15 Lifting Capacities............................................................................... 16 Group 02 Components Specifications................................................................... 18 Engine........................................................................................... 18 Main Pump........................................................................................ 22 Pilot Pump ...................................................................................... 23 Control Valve.................................................................................... 24 Swing Motor...................................................................................... 24 Travel Motor .................................................................................... 25 Center Joint..................................................................................... 25 Pilot Valve (for Travel)......................................................................... 25 Pilot Valve (for Swing,Boom,Arm,Bucket).......................................................... 26 Control Neutralizer Valve........................................................................ 26 Shockless Valve.................................................................................. 26 Accumulator...................................................................................... 26 Hydraulic Tank................................................................................... 26 Suction Filter................................................................................... 27 Full-Flow Filter................................................................................. 27 Air Breezer...................................................................................... 27 Bypass Check Valve............................................................................... 27 Pilot Filter..................................................................................... 27 Oil Cooler....................................................................................... 27 Restriction Valve................................................................................ 27 Solenoid Valve................................................................................... 28 Mode Selection Cylinder.......................................................................... 28 Boom Cylinder.................................................................................... 28 Arm Cylinder..................................................................................... 28 Bucket Cylinder.................................................................................. 28 Group 03 Torque Reference............................................................................ 29 Group 04 Others...................................................................................... 34 maintenance Intervals............................................................................ 34 Group 05 Conversion Table............................................................................ 36 SECTION 03 GENENAL....................................................................................... 42 Group 01 Introduction................................................................................ 43 Introduction.................................................................................... 43 Group 02 Construction................................................................................ 44 Construction..................................................................................... 44 Group 03 Hydraulic System............................................................................ 47 Hydraulic System................................................................................. 47 Main Hydraulic Circuit........................................................................... 48 Pilot Hydraulic Circuit.......................................................................... 52 Group 04 Electric System............................................................................. 56 Main Circuit..................................................................................... 56 Control System................................................................................... 57 Monitor System................................................................................... 57 Group 05 Maintenance................................................................................. 58 Removal and Instrallation (Cab,Front Attachment,Superstructure) ................................. 58 Maintenance...................................................................................... 71 Name Plate....................................................................................... 87 SECTION 04 SUPERSTRUCTURE................................................................................ 90 Group 01 Superstructure.............................................................................. 92 Main Frame and Counter-Weight.................................................................... 92 Engine........................................................................................... 94 Hydraulic Oil Tank............................................................................... 107 Fuel Tank........................................................................................ 111 Swing Device..................................................................................... 113 Electric Parts................................................................................... 118 Cab Heater....................................................................................... 121 Engine Control Lever............................................................................. 123 Main Piping ..................................................................................... 124 Oil Cooler Piping................................................................................ 126 Cover............................................................................................ 131 Pump Device...................................................................................... 135 Control Box...................................................................................... 142 Cab Group........................................................................................ 150 Pilot Piping..................................................................................... 157 Control Lever.................................................................................... 164 Group 02 Hydraulic Pump Device....................................................................... 168 O/P, Hydraulic Pump.............................................................................. 168 Outline...................................................................................... 168 Function..................................................................................... 170 Operation.................................................................................... 175 D/A, Main Pump .................................................................................. 189 Disassembry.................................................................................. 189 Inspection................................................................................... 195 Assembly..................................................................................... 198 Special Tools................................................................................ 207 Parts List................................................................................... 209 D/A,RH23A.25B.26A.28A Regulator.................................................................. 211 Disassembly.................................................................................. 211 Assembly..................................................................................... 217 Special Tool................................................................................. 222 Parts List................................................................................... 223 D/A,Pump Transmission............................................................................ 225 Disassembly.................................................................................. 225 Inspection................................................................................... 230 Assembly..................................................................................... 231 Special Tool................................................................................. 236 Parts List................................................................................... 236 D/A.HY-ZFS Gear Pump............................................................................. 238 Disassembly.................................................................................. 238 Inspection................................................................................... 241 Assembly..................................................................................... 243 Special Tool................................................................................. 245 Group 03 Control Valve............................................................................... 247 O/P, KVMG-270-HC Control Valve................................................................... 247 General...................................................................................... 247 Construction and Function.................................................................... 251 D/A, O/P, KVMG-270-HC Control Valve.............................................................. 267 Dissasembly.................................................................................. 267 Inspection................................................................................... 281 Assembly..................................................................................... 282 Group 04 Swing Device................................................................................ 303 O/P, MX173 Cab Swing Motor ...................................................................... 303 Outline...................................................................................... 303 Function..................................................................................... 305 D/A, O/P, MX173 Cab Swing Motor ................................................................. 312 Disassembly.................................................................................. 312 Inspection................................................................................... 321 Assembly..................................................................................... 323 Special Tools................................................................................ 333 O/P.M2X170.210 Cab Motor......................................................................... 337 Outline...................................................................................... 337 Function..................................................................................... 339 D/A.M2X170.210 Cab Motor......................................................................... 346 Disassembly.................................................................................. 346 Inspection................................................................................... 351 Assembly..................................................................................... 353 D/A, Swing Reduction Device...................................................................... 364 Disassembly.................................................................................. 364 Assembly..................................................................................... 369 Special Tools................................................................................ 375 Group 05 Pilot Valve................................................................................. 378 O/P, Pilot Valve................................................................................. 378 Outline...................................................................................... 378 Function..................................................................................... 380 D/A, HV Type Pilot Valve (Front-End Attachment) ................................................. 385 Disassembly.................................................................................. 385 Assembly..................................................................................... 391 Special Tools................................................................................ 397 D/A, HV Type Pilot Valve (Travel)................................................................ 399 Disassembly.................................................................................. 399 Assembly..................................................................................... 405 Special Tools................................................................................ 411 Group 06 Control Neutralizer Valve................................................................... 413 O/P, Control Neutralizer Valve .................................................................. 413 Outline...................................................................................... 413 D/A, Control Neutralizer Valve................................................................... 415 Disassembly.................................................................................. 415 Assembly..................................................................................... 417 Group 07 Shockless Valve............................................................................. 420 O/P, Shockless Valve............................................................................. 420 Outline...................................................................................... 420 Function..................................................................................... 421 D/A, Shockless Valve............................................................................. 425 Disassembly.................................................................................. 425 Inspection................................................................................... 428 Assembly..................................................................................... 429 Group 08 Accumulator................................................................................. 434 O/P, Accumulator................................................................................. 434 Outline...................................................................................... 434 Function..................................................................................... 435 Group 09 Solenoid Valve.............................................................................. 436 O/P, Solenoid Valve............................................................................. 436 Outline...................................................................................... 436 Function..................................................................................... 437 D/A, Solenoid Valve............................................................................. 441 Disassembly.................................................................................. 441 Inspection................................................................................... 445 Assembly..................................................................................... 446 Group 10 Mode Selection Cylinder..................................................................... 451 D/A, Mode Selection Cylinder..................................................................... 451 Disassembly.................................................................................. 451 Assembly..................................................................................... 452 SECTION 05 UNDERCARRIAGE................................................................................. 455 Group 01 Undercarriage............................................................................... 456 Track Frame...................................................................................... 456 Swing Bearing ................................................................................... 458 Travrl Device and Piping......................................................................... 465 Front Idler..................................................................................... 475 Adjuster......................................................................................... 482 Upper Roller and Lower Roller.................................................................... 494 Track Link....................................................................................... 508 Center Joint..................................................................................... 518 Group 02 Travel Devece............................................................................... 525 O/P, Travel Motor................................................................................ 525 Outline...................................................................................... 525 Travel....................................................................................... 525 Brake Valve Assembly......................................................................... 529 D/A, Travel Motor and Travel Device.............................................................. 532 Disassemble Travel Motor..................................................................... 532 Inspect Travel Motor......................................................................... 539 Assemble Travel Motor........................................................................ 541 Special Tools................................................................................ 551 D/A, Travel Motor and Travel Divice.............................................................. 570 Disassemble.................................................................................. 570 Assemble..................................................................................... 577 Special Tools................................................................................ 587 Group 03 Center Joint................................................................................ 592 O/P, Center Joint................................................................................ 592 Outline...................................................................................... 592 D/A, Center Joint ............................................................................... 593 Disassembly.................................................................................. 593 Assembly..................................................................................... 596 Special Tools................................................................................ 599 SECTION 06 FRONT-END ATTACHMENT ......................................................................... 601 Group 01 FRONT-END ATTACHMENT ....................................................................... 602 Boom Assembly.................................................................................... 602 Arm Assembly.................................................................................... 604 Bucket Assembly................................................................................. 607 Front Pipings.................................................................................... 620 Group 02 Hydraulic Cylinder.......................................................................... 635 Operational Principle............................................................................ 634 Disassembly and Assembly........................................................................ 635 Group 03 Pin and Bushing............................................................................. 647 Specifications................................................................................... 647 Group 04 Point and Side Cutter....................................................................... 649 Maintenance...................................................................................... 649 SECTION 07 HYDRAULIC SYSTEM.............................................................................. 651 Group 01 Outline..................................................................................... 653 Outline.......................................................................................... 653 Group 02 Main Hydraulic Circuit...................................................................... 654 Suction Circuit and Delivery Circuit............................................................. 654 Return Circuit................................................................................... 658 Drain Circuit.................................................................................... 660 Group 03 Pilot Circuit............................................................................... 663 Suction,Delivery and Return Circuit.............................................................. 664 Accumulator...................................................................................... 666 Control Neutralizer Valve........................................................................ 666 Pump Displacement Control Circuit................................................................ 668 Relief pressure Change Circuit .................................................................. 671 Switch Valve Circuit............................................................................. 671 Heat-Run Circuit................................................................................. 672 Swing Parking Brake ............................................................................. 674 Group 04 Single Operation............................................................................ 676 Boom Raise Circuit Operation..................................................................... 676 Boom Lower Circuit Operation .................................................................... 677 Arm Roll-In Circuit Operation.................................................................... 678 ArmRoll-Out Circuit Operation.................................................................... 679 Bucket Circuit Operation......................................................................... 680 Swing Circuit Operation.......................................................................... 681 Swing Operation.................................................................................. 683 Travel Circuit Operation......................................................................... 684 Travel Forward and Reverse Operation............................................................. 685 Group 05 Combined Operation.......................................................................... 686 Outline.......................................................................................... 686 Combined Swing and Boom Operation................................................................ 687 Combined Swing and Arm Operation................................................................. 688 Combined Swing and Bucket Operation.............................................................. 689 Combined Swing, Boom, Arm and Buket Operation.................................................... 690 Combined Swing and Travel Operation.............................................................. 691 Combined Boom and Travel Operation .............................................................. 692 Combined Arm and Travel Operation ............................................................... 693 Combined Bucket and Travel Operation ............................................................ 694 Group 06 Extra Control Circuit....................................................................... 695 Outline ......................................................................................... 695 Single Operation................................................................................. 697 Combined Extra and Arm Roll-In Operation......................................................... 698 Combined Extra and Arm Roll-Out Operation........................................................ 699 SECTION 09 ELECTRICAL SYSTEM............................................................................. 700 Group 01 Safety Precautions.......................................................................... 701 Safety Precautions............................................................................... 701 Group 02 Specifications ............................................................................. 702 Battery, Starter, Safety, Relay, Alternator, Regulator, Headlight, Wiper Motor, Speaker, Fuse.... 702 Group 03 Construction and Function................................................................... 704 Construction of Electrical System................................................................ 704 Monitor.......................................................................................... 706 Control (E-P Control) System..................................................................... 715 Function of Seneors and Relays................................................................... 724 Group 04 Circuit Operations.......................................................................... 729 Characteristics of Electrical Circuit............................................................ 729 Electrical Circuit............................................................................... 730 Battery Circuit.................................................................................. 731 Preheat Circuit.................................................................................. 732 Starting Circuit................................................................................. 733 Charging Circuit................................................................................. 735 Safety Circuit................................................................................... 739 Accessory Circuit................................................................................ 740 Gauge Panel Circuit.............................................................................. 741 Control Circuit.................................................................................. 742 Group 05 Maintenance................................................................................. 743 Gauge Panel ..................................................................................... 743 Assembly and Adjustment of Auto-idle Device...................................................... 751 SECTION 10 TROUBLESHOOTING............................................................................... 753 Group 01 Introduction................................................................................ 755 General Infomation............................................................................... 755 Notes on Performance Measurement................................................................. 757 Group 02 Diagnose Malfunctions....................................................................... 760 Malfunctions Phenomena........................................................................... 760 Hydraulic System................................................................................. 762 Electric System.................................................................................. 776 Group 03 Excavator Performance Test.................................................................. 806 introduction..................................................................................... 806 Engine Performance Measurement................................................................... 806 Travel Performance Measurement................................................................... 809 Swing Performance Measurement.................................................................... 815 Front-end Attachment............................................................................. 819 Control Lever Performance Measurement............................................................ 823 Group 04 Components Performance Standard............................................................. 827 introduction..................................................................................... 827 Pilot Relief Valve............................................................................... 827 Main Relief Valve................................................................................ 829 Overload Relief Valve............................................................................ 832 Swing Crossover Relief Valve..................................................................... 834 Travel Crossover Relief Valve.................................................................... 835 Main Hydraulic Pump.............................................................................. 837 Travel Motor..................................................................................... 844 Swing Motor...................................................................................... 845 Group 05 Electrical System Test...................................................................... 847 Common Circuit Test.............................................................................. 847 Articles Necessary For Electrical Circuit Test................................................... 849 Measurement Procedures........................................................................... 850 Mesurement Standard.............................................................................. 851 SECTION 11 ENGINE........................................................................................ 860 Group 01 General Information......................................................................... 863 General Repair Instructions...................................................................... 863 Notes on the Format of this Manual............................................................... 863 Main Data and Specifications..................................................................... 867 Design Features and General Outline.............................................................. 871 Tightening Torque Specifications................................................................. 874 Anglular Nut and Bolt Tightening Method.......................................................... 875 Major Parts Fixing Nuts and Bolts................................................................ 877 Identifications.................................................................................. 888 Group 02 Maintenance................................................................................. 889 Lubricating System............................................................................... 889 Fuel System...................................................................................... 890 Cooling System................................................................................... 894 Valve Clearance Adjustment....................................................................... 894 Injection Timing................................................................................. 896 Compression Pressure Measurement................................................................. 902 Turbocharger Inspection.......................................................................... 903 Engine Repair Kit................................................................................ 904 Recommended Lubricants........................................................................... 906 Engine Oil Viscosity Chart....................................................................... 906 Group 03 Engine Disassembly.......................................................................... 907 External Parts................................................................................... 907 Major Components................................................................................. 915 Rocker Arm and Rocker Arm Shaft.................................................................. 917 Cylinder Head.................................................................................... 918 Piston and Connection Rod........................................................................ 919 Group 04 Inspection and Repair....................................................................... 921 Cylinder Head.................................................................................... 921 Valve Guide...................................................................................... 922 Valve Spring..................................................................................... 925 Tappet........................................................................................... 926 Push Rod......................................................................................... 927 Rocker Arm Shaft and Rocker Arm.................................................................. 927 Idler Gear and Idler Gear Shaft.................................................................. 928 Cam Shaft........................................................................................ 929 Cylinder Body and Liner.......................................................................... 930 Piston and Piston Ring........................................................................... 935 Piston Pin....................................................................................... 936 Connecting Rod................................................................................... 937 Crank Shaft...................................................................................... 939 Fly Wheel and Fly Wheel Housing.................................................................. 947 Timing Gear Case Cover........................................................................... 948 Group 05 Engine Assembly............................................................................. 949 Piston and Connecting Rod........................................................................ 949 Cylinder Head.................................................................................... 951 Rocker Arm and Rocker Arm Shaft.................................................................. 955 Major Components................................................................................. 956 External Parts................................................................................... 966 Engine Tuning Operation.......................................................................... 973 Engine Section View.............................................................................. 975 Group 06 Lubricating System.......................................................................... 976 General Description.............................................................................. 976 Oil Pump......................................................................................... 977 Main Oil Filter.................................................................................. 979 Oil Cooler....................................................................................... 981 Group 07 Cooling System.............................................................................. 983 General Description.............................................................................. 983 Water Pump....................................................................................... 984 Thermostat....................................................................................... 989 Group 08 Fuel System................................................................................. 990 General Descrintion.............................................................................. 990 Fuel Filter...................................................................................... 991 Injection Nozzle................................................................................. 993 Group 09 Turbo Charger............................................................................... 998 General Description.............................................................................. 998 Identification................................................................................... 999 Roter Shaft Play Inspection......................................................................1000 Group 10 Engine Electricals..........................................................................1001 Starter Motor....................................................................................1001 Alternator.......................................................................................1004 Group 11 Troubleshooting.............................................................................1008 Hard Staeting....................................................................................1008 Unstable Low Idring..............................................................................1012 Insufficient Power...............................................................................1015 Excessive Fuel Consumption.......................................................................1018 Overheating......................................................................................1021 White Exhaust Smoke..............................................................................1023 Darkish Exhaust Smoke............................................................................1024 Not Rising Oil Pressure..........................................................................1025 Abnormal Engine Noise............................................................................1027 Group 12 Special Tool List...........................................................................1030 Special Tool List................................................................................1030
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
1 review for Hitachi Ex200 Service Manual – PDF DOWNLOAD
Add a review
Sincere Jedidiah –