1995–1998 Hitachi EX200-5, EX200LC-5, EX220-5, EX220LC-5, EX230LC-5, EX270-5 and EX270LC-5 Excavator Service Manual (P/N 157W-1-1)

The 1995–1998 Hitachi EX200-5, EX200LC-5, EX220-5, EX220LC-5, EX230LC-5, EX270-5, and EX270LC-5 service documentation combines the Workshop Manual with the Technical Manuals for Troubleshooting and Operational Principle.

• Hydraulic pumps and valves: Pump device, regulator, pilot pump, and control valve disassembly and assembly, with inspection standards and hydraulic-system bleeding procedures.

• Swing and travel drives: Reduction gear and motor overhaul, brake valve service, center joint repair, and component wear inspections.

• Undercarriage and front attachment: Swing bearing, track adjuster, idler, roller, and track service, plus attachment removal, cylinder rebuilding, and pin-and-bushing inspection.

• Engine repair: Cylinder-head and bottom-end overhaul, timing-gear assembly, lubrication and cooling-system repairs, injection-timing checks, and compression testing.

• Machine diagnosis: Dr.EX fault-code diagnosis, live monitoring, service-mode adjustments, engine learning, and hydraulic performance tests with model-specific standards.

• Electrical troubleshooting: Wiring diagrams, harness and connector drawings, continuity and voltage checks, and diagnostic charts for gauges, warning indicators, and control circuits.

This documentation is written for experienced technicians maintaining and repairing these excavators.

Hydraulic Assembly and Pilot-Valve Variants

Pump overhaul covers drive-disc splines, gear backlash, plunger clearances, center-shaft alignment, servo mechanisms, and bearing preload. The assembly procedures identify special tools ST 3058 and ST 3070 for bearing-preload work.

Separate procedures cover the pilot shut-off, shockless, proportional solenoid, and pilot relief valves. The EX270-5/EX270LC-5 material also includes the swing parking-brake release valve.

Travel pilot-valve identification: The EX200-5/EX200LC-5 workshop instructions and operational-principle diagrams use different serial-number breakpoints, as listed above. Comparing the installed valve with the corresponding component illustration helps identify the appropriate rebuild procedure.

Air-bleeding instructions address trapped air that can damage the hydraulic pump, with additional guidance for swing and travel motors. Floating-seal illustrations explain how incorrect O-ring seating can cause leakage or seal damage.

Isuzu and Hino Engine Repair

The machine-specific specifications identify the Isuzu A-6BG1T for EX200-5/EX200LC-5 and the Hino H07C-TD for the larger listed models. Supporting engine-family material also discusses other configurations, so engine identification matters when selecting specifications.

Internal repair coverage includes cylinder heads, liners, pistons, connecting rods, crankshafts, and timing gears. Oil-pump, oil-cooler, water-pump, and thermostat sections extend the coverage beyond basic engine removal and installation.

Fuel-system scope: The Isuzu material includes nozzle inspection, injection timing, and pump calibration sheets. It directs injection-pump adjustment and repair to an authorized ZEXEL or Bosch service outlet.

The Hino portion includes engine electrical circuits and turbocharger overhaul. Its separately listed injection-pump, governor, generator, starter, and air-compressor overhaul chapters are not included in this PDF.

Dr.EX Diagnosis and Performance Testing

Dr.EX coverage explains fault-code retrieval, monitoring of controller inputs and outputs, and service-mode adjustments. Engine-speed adjustment and engine learning are documented for work involving the engine control mechanism or replacement of the main controller.

Fault-code charts distinguish EC-sensor, pump-pressure-sensor, arm roll-in pressure-sensor, and engine-control-dial faults. Symptom-based troubleshooting addresses weak or slow attachment functions, swing problems, travel faults, and engine complaints.

Performance tests cover pump delivery pressure and flow, relief-valve settings, motor drainage, swing-bearing play, cylinder cycle times, and attachment drift. Model-specific standard tables provide the comparison data for evaluating those measurements.

Main Pump P-Q diagrams, the EX200-5 Electrical Circuit and Connectors sheets, and EX220-5/EX270-5 Hydraulic Circuit Diagrams support fault tracing. Separate monitor-system charts address fuel and coolant gauges, warning lights, the buzzer, and the hour meter.

Structural Repairs and Assembly References

Removal and installation procedures cover the cab, counterweight, main frame, and front attachment. Cab assembly layouts and glass dimensional drawings accompany the structural work, while attachment tables document pin, bushing, arm, and bucket connections.

Torque charts distinguish bolt grades and applications. Piping-joint illustrations cover 30° and 37° union connections and O-ring seal joints, alongside specifications for T-bolt and worm-gear hose clamps.

Follow the manual’s safety precautions for stored hydraulic pressure and heavy component lifts, and consult a qualified technician if a procedure exceeds your training or equipment.

Examples from the Pump Inspection Standards

These two examples show a small selection of the dimensional inspection data supplied for the pump device.

Gear backlash has a standard value of 0.68 mm (0.03 in), with an allowable limit of 1.5 mm (0.06 in).

For the main pump, plunger-to-cylinder-block bore clearance has a standard value of 0.043 mm (0.002 in) and an allowable limit of 0.08 mm (0.003 in).

PDF Navigation, Diagram Detail, and Included Sections

Text search and drawing detail: PDF text search and embedded bookmarks are not available. Use the printed contents and section numbering for navigation. Some small wire and terminal labels in the full-page electrical diagrams remain difficult to read even when enlarged.

The download is one printable, English-language, 1,159-page PDF: Workshop Manual material, 741 pages; Troubleshooting and Operational Performance Test material, 258 pages; and Operational Principle material, 160 pages. These totals already include 58 introduction and safety pages and 54 pages marked blank.