Hitachi EX200-5 Series Hydraulic Excavator Workshop Manual (P/N 157W)

Hitachi EX200-5 Series Hydraulic Excavator Workshop Manual

• Covers 1997–2000s Hitachi EX200-5 through EX270-5 excavators (including LC variants)
• Original OEM publication (workshop manual series 157W, 1997 edition)
• Features over 50 detailed exploded-view diagrams and specific torque-specification tables
• Available as an instant download directly to your device without expiration
• Fully searchable PDF file to quickly locate any part number or specification
• Formatted for standard US Letter and A4 printing

Technical Coverage and Contents Breakdown

This factory-authorized manual provides the foundational service data required to maintain the Dash-5 excavator series. It details the precise tools, maintenance standards, and step-by-step procedures necessary for disassembly and reassembly.

Content is logically organized by machine section. You will find dedicated groups breaking down the cab, counterweight, main frame, and pump device. Sections covering the upperstructure specify exact parameters for cab removal, including critical glass dimensions. Because working on heavy machinery inherently involves high-pressure hydraulic components and heavy lifting, always secure the equipment and observe proper shop safety protocols before initiating any service work.

The documentation goes deep into the hydraulic system. It provides precise instructions for bleeding air from the pump housing, travel motors, and swing motors to prevent trapped air from causing component failure. Mechanics will also find critical details on handling floating seals, pipe thread connections, and managing proper hose routing to avoid operational wear.

Specification Highlights

Fastener integrity is critical in heavy equipment. This manual provides comprehensive torque tables for standard hardware—like hexagon T-bolts, H-bolts, and socket bolts—along with specialized piping joint tightening values. For example, the documentation specifies that swing device mounting bolts require 490–640 Nm, depending on the exact machine configuration.

Beyond hardware, the hydraulic system section clearly outlines hard service limits. This includes the 0.68 mm gear backlash standard and exact tolerance charts for pump components such as sleeve diameters and plunger clearances. It also lists intake and exhaust tolerances to ensure your rebuilds align perfectly with original manufacturer assembly standards.