Hitachi EX200-2 Excavator 1984–1992 Technical Manual (P/N 108I-01 / T107-01–01-001)

This 843-page OEM technical manual (Reference: 108I-01 / T107-01–01-001) delivers the foundational engineering data required for accurate diagnostics, routine maintenance, and major component rebuilds.

Technical Specifications and Data

• Utilize the fully indexed PDF directly on your diagnostic tablet to instantly cross-reference hydraulic pressure values right at the machine during active testing.
• Covers base-model excavators across the entire 147-series serial number range, including standard, long-reach, and high-lift configurations.
• Provides comprehensive specifications for the Hitachi EX200-2, EX200LC-2, ISUZU 6BD1T engine, track frame, center joint, swing bearing, travel device, and accumulator.
• Delivers component-level flow analysis for the shockless valve, pilot valves, pump displacement solenoid valve, swing dampener valve, overload relief valve, N-sensor, and A-sensor.
• Includes 47 exploded-view assembly diagrams, 14 hydraulic circuit schematics, cross-section drawings, lifting capacity charts, working range charts, component location views, and piping schematics for fast component identification.
• Features 5 detailed lubrication/maintenance schedules alongside 4 specialized pressure and tolerance data tables.

Component and System Documentation

When you are tearing down complex upperstructure components, precision is mandatory. This documentation provides deep-dive breakdowns of the main pump device, clearly mapping out both the variable displacement piston pump assembly and the fixed displacement pilot gear pump. Furthermore, flow routes for the arm regenerative valve and holding valves are thoroughly explained to ensure smooth operational logic.

Troubleshooting the control valve? The manual lays out both three-spool and four-spool configurations, accurately identifying relief valve operations, surge suppression mechanisms, and variable pressure compensation logic.

Instead of outsourcing complex system calibrations to a heavy equipment dealership, this manual outlines the specific step-by-step procedures needed to test DP-sensor output voltages, safely bleed nitrogen gas from the accumulator, and accurately adjust the auxiliary spool speed for custom attachments. This direct access to factory repair data enables your technicians to confidently complete major overhauls in-house.

Hydraulic and Operational Specifications

Working on heavy machinery hydraulic systems involves extreme pressure. Always relieve system pressure to prevent severe fluid injection injuries, and verify the specified load-sensing control values before initiating diagnostic tests to ensure absolute shop safety and prevent equipment damage.

Having the correct numbers on hand speeds up any overhaul. This publication details exact service refill capacities for the main hydraulic system, swing reduction gears, and engine cooling systems. Hydraulic pressure monitoring is thoroughly documented via the P-sensor and DP-sensor, providing precise output reference values.

If you are doing a deep engine teardown, the rebuild specs list critical tolerances like the 0.03–0.12 mm piston-to-cylinder clearance for the engine block. You will also find highly specific operational baselines, including the swing dampener relief setting at 25.5 bar (370 psi) for neutral conditions and the exact coolant anti-rust agent volume (420 cc per mix).