1984–1992 Hitachi EX200-2 / EX200LC-2 Excavator Technical & Workshop Manual (P/N 108I-01 / T107-01–01-001)

This Hitachi technical and workshop manual covers EX200-2 and EX200LC-2 excavators, with system descriptions, performance tests, troubleshooting charts, and repair procedures for hydraulic and undercarriage assemblies.

• Hydraulic pump repair: Main pump and pilot gear pump removal, disassembly, inspection, and reassembly, with pump-flow testing and related control adjustments.

• Control valves: Main control valve, pilot valves, shockless valve, and overload relief valve service, including arm regeneration and holding-valve operation.

• Electronic diagnosis: Dr.EX monitoring, EC/PVC fault codes, sensor checks, A-sensor adjustment, and engine-control motor positioning.

• Swing and travel drives: Swing motor, travel motor, reduction gear, and brake inspection, with leakage tests and component wear standards.

• Undercarriage repair: Swing bearing and center joint work, plus track adjuster, idler, roller, and track link disassembly and assembly.

• Service data: Lubrication and maintenance schedules, fluid capacities, tightening torques, lifting capacities, and working-range data for the listed configurations.

Suited to experienced heavy-equipment technicians with hydraulic test equipment, electrical diagnostic tools, and lifting equipment for major assemblies.

Pump, Valve and Accumulator Service

The pump sections distinguish the HPV091DW variable-displacement main pump from the HY/ZFS11/16.8L fixed-displacement pilot gear pump. Pump Device Drawing for Assembly accompanies the repair material; installation notes warn that shaft splines can damage the pump seal lips.

Valve operation and adjustment: The main control valve combines a three-spool block and a four-spool block in one assembly. Coverage includes unload-valve operation, boom and arm holding valves, the pump displacement solenoid, swing dampener, and auxiliary-spool speed adjustment.

Main Hydraulic Circuit and Combined Boom/Swing diagrams trace oil paths during individual and combined movements.

Accumulator material covers operation, replacement, and nitrogen-gas release for disposal. Service precautions address stored hydraulic pressure, suspended equipment, and spring-loaded assemblies.

Dr.EX, EC/PVC and Harness Fault Diagnosis

Troubleshooting separates controller fault codes, hydraulic/mechanical symptoms without codes, and monitor-panel faults. This distinction helps technicians investigate weak or uneven functions even when no fault code is present.

P/Q performance curves distinguish PVC versions through 0600, 0800/1100/1101, and 1103/1200. Dr.EX reference charts relate P-, DP-, N-, A-, and temperature-sensor signals to pump control and engine response.

Electric Wiring Diagram and Table of Connectors Terminal Positions support harness continuity and voltage checks. The electrical section identifies the Hitachi Lamp Harness Test Kit, P/N 4283595, and includes starting, charging, auto-idle, and monitor circuits.

Swing Drives, Travel Units and Track Components

Swing Motor Drawing for Assembly accompanies motor and reduction-gear repairs. Travel-unit procedures cover the planetary reduction gears, spring-applied hydraulic-release brakes, and motor inspection.

Center joint repair includes seal replacement and leakage testing; assembly precautions explain how housing-to-spindle misalignment can damage seals. Track adjuster work calls for the ST-4920 spring holder, while track-link service identifies the ST-1970 master-pin tool.

Isuzu 6BD1T Tests and Front-Attachment Scope

Engine content provides speed and compression tests, lubrication requirements, and cooling-system maintenance. It does not include a full internal Isuzu 6BD1T engine overhaul.

Working-range and lifting-capacity charts distinguish the documented front configurations. Coverage of the Type 15 super long front and high lift front is limited to interchangeability data.

Sample Sensor, Wear and Coolant Specifications

This small selection illustrates the manual’s sensor references, component wear limits, and coolant guidance. The DP-sensor operating description gives 4.5 V with the engine running and the control valves in neutral.

Swing motor inspection data specify a standard piston-to-cylinder clearance of 0.039 mm and a maximum allowable wear clearance of 0.052 mm.

For a cooling system filled with water, the manual lists approximately 420 cc of anti-rust agent; this addition is not required when antifreeze is used.

PDF Bookmarks, Diagram Detail and Page Breakdown

Bookmarks and diagram detail: Embedded PDF bookmarks span the technical, performance-testing/troubleshooting, and workshop material. Technical page text is not searchable. Small wire labels, connector numbers, and pin details need enlargement.

Supplied as one printable, English-language 843-page PDF: 235 pages of technical information, introduction and safety; 224 pages of performance testing and troubleshooting; and 384 workshop pages. The total already includes 13 introductory and safety pages and two title pages.