Hitachi EX200-5 Series Hydraulic Excavator Workshop Manual

Hitachi EX200-5 Series Hydraulic Excavator Workshop Manual

• Covers 1997–2000s Hitachi EX200-5, EX200LC-5, EX220-5, EX220LC-5, EX230LC-5, EX270-5, and EX270LC-5 hydraulic excavators
• Original OEM publication, workshop manual series 157W, 1997 edition
• Contains 50+ detailed exploded-view diagrams and 3 distinct torque-specification tables
• Re-download the file any time, no expiration
• Full-text search finds any part number in seconds
• Accessible from your device as soon as the order is placed
• Laid out for standard letter and A4 printing
• This specific edition is the factory-authorized workshop manual for the Dash-5 series, providing the foundational service data for the EX200-5 through EX270-5 build

Technical Scope and Manual Composition

This Hitachi EX200-5 workshop manual provides technical information for the maintenance and repair of the EX200-5, EX200LC-5, EX220-5, EX220LC-5, EX230LC-5, EX270-5, and EX270LC-5 hydraulic excavators. The publication documents tools and devices needed for maintenance, specific maintenance standards, and removal, installation, disassembly, and assembly procedures. The content is organized by machine section, including dedicated groups for the cab, counterweight, main frame, pump device, and control valve system.

Sections covering the upperstructure detail the removal and installation of the cab, including glass dimensions, and provide specific instructions for handling the hydraulic pump device and control valve. The manual outlines the procedure for bleeding air from the hydraulic system to ensure the pump housing, travel motors, and swing motors operate correctly without trapped air. Expert details are provided on handling floating seals, pipe thread connections, and managing hose routing to prevent rubbing or damage during operation.

Specification Highlights

Detailed torque tables are provided for standard hardware, including hexagon T-bolts, H-bolts, and socket bolts, along with specialized piping joint tightening values. For the Hitachi EX200-5 series, the manual specifies tightening torque for swing device mounting bolts at 490–640 Nm depending on the configuration. The hydraulic system documentation includes service limits, such as the gear backlash standard of 0.68 mm, and tolerance charts for pump components like sleeve diameters and plunger clearances. Intake and exhaust tolerances and clearance data for internal pump components ensure maintenance meets the manufacturer’s assembly standards.

Reference only — always consult a certified technician before performing service on this equipment. An official OEM workshop manual documenting maintenance, removal, and installation procedures for the Hitachi EX200-5 through EX270-5 excavator series, including technical torque specifications and hydraulic system assembly data.