Comprehensive Hitachi EX200-5, EX200LC-5, EX220-5, EX220LC-5, EX230LC-5, EX270-5 and EX270LC-5 Excavator Technical and Workshop Manual 1995-1998

Hitachi EX200-5 - EX270LC-5 Excavator: Professional Technical & Workshop Manual 1995-1998

Maximize the uptime and performance of your Hitachi EX-5 series fleet with this comprehensive, multi-volume service resource. This is not a simplified owner’s guide; it is the definitive technical documentation used by factory-trained technicians to diagnose, maintain, and overhaul Hitachi’s legendary mid-to-large excavators.

Complete Model Coverage

This manual provides specific technical data and service procedures for the following Hitachi EX-5 series machines:

• Hitachi EX200-5 / EX200LC-5
• Hitachi EX220-5 / EX220LC-5
• Hitachi EX230LC-5
• Hitachi EX270-5 / Hitachi EX270LC-5

Professional Three-Tier Structure

To provide a complete repair ecosystem, this manual is organized into three specialized sections, allowing you to move from basic operational understanding to complex structural repairs:

1. Technical Manual (Operational Principle): Deep-dive into the "how" and "why" of your machine. Master the activation sequences of all hydraulic and electrical systems.
2. Technical Manual (Troubleshooting): Precision diagnostics to eliminate guesswork. Includes detailed performance tests to identify issues before they lead to catastrophic failure.
3. Workshop Manual: The heavy-lifting section. Contains maintenance standards, specialized tool requirements, and exhaustive step-by-step disassembly/assembly instructions.

Targeted Technical Insights & Serial Number Specifics

Accuracy is critical in heavy machinery repair. This manual provides the granular detail necessary for professional-grade service:

• Serial Number Specificity: Includes distinct procedures for Travel Pilot Valves. Specifically covers EX200-5/200LC-5 units up to Serial Number 83346 and separate instructions for units from Serial Number 83347 onwards.
• Precision Torque Specifications: Detailed torque charts for every critical junction, including:
  • Engine Cushion Mounting (M16/M18 bolts)
  • Swing Device Mounting (M20/M22 bolts)
  • Track Shoe Bolts (M18/M20 bolts)
  • Sprocket and Roller Mounting data
• Hydraulic Safety & Mastery: Step-by-step air-bleeding protocols for the main pump, travel motors, and swing motors to protect your high-pressure components from air-lock damage.
• Rigging & Safety Data: Exact component weights for safe shop operations, such as the Cab (approx. 551 lb / 250 kg), Selector Head (66 lb / 30 kg), and Counterweights (ranging from 9,050 lb to 12,600 lb depending on model).

Clear Benefits for the Owner & Technician

By utilizing this factory-level manual, you gain a clear competitive advantage:

• Reduce Downtime: Diagnostic charts help you find and fix the root cause of mechanical issues faster than generic guides.
• Protect Your Investment: Following Hitachi’s exact maintenance standards ensures that your machine operates within its engineered tolerances, extending the life of pumps, motors, and structural pins.
• Safety First: Detailed warnings regarding pressurized fluids, battery safety, and proper lifting techniques protect you and your crew in the shop.
• Fleet Versatility: One comprehensive resource covers multiple models in the EX-5 lineup, making it ideal for large-scale operations and mixed fleets.

Ensure your Hitachi equipment stays on the job site and out of the scrap yard. This manual is the essential tool for anyone serious about the longevity and safety of their heavy equipment investment.