Hitachi EX220-2 / EX220LC-2 Excavator Manual Set (1990–1998)

Use the Technical Manual to follow how the machine’s systems work, then the Workshop Manual for component removal, disassembly, and assembly.

The Technical Manual includes EX220LC-2 specifications; the workshop procedures are labeled EX220-2. Internal HINO H06CT-T engine overhaul is outside this set’s upperstructure and undercarriage repair scope.

Bookmarked PDF and Diagram Readability

Search and diagram access: Manual content does not support text search. Embedded bookmarks cover both publications and their sections. Small wiring labels require zooming, and some component drawings have faint lines.

One printable, English-language PDF contains 616 pages. The publication totals above include 13 introductory and safety pages and two manual divider pages.

Hydraulic Assemblies, Electrical Controls, and Undercarriage Repair

These selected coverage highlights focus on repair and system reference. Other topics include attachment interchangeability and coolant selection.

• Pump repair: Step-by-step removal, disassembly, and assembly of the main pump and pilot gear pump, including bearing-preload adjustment.

• Control valves: Three- and four-spool control-valve service, main and overload relief-valve adjustments, and arm regenerative-valve construction.

• Swing assemblies: Swing reduction-device and motor overhaul, wet multiple-disc parking-brake inspection, swing dampener-valve service, and maintenance standards.

• Pilot controls: Front and travel pilot-valve rebuilds, shut-off and shockless-valve service, proportional-solenoid valve procedures, and accumulator replacement.

• Undercarriage: Travel reduction-device and motor repair, brake-valve overhaul, swing-bearing and center-joint service, and track, idler, and roller work.

• Electrical adjustments: Fuse and fusible-link checks, A-sensor installation and adjustment, EC-sensor positioning, engine-control motor installation, and engine-stop solenoid linkage adjustment.

• Structural removal: Cab, counterweight, and main-frame removal and installation, with lifting arrangements and component-specific tightening instructions.

Suited to experienced excavator mechanics with hydraulic and electrical diagnostic skills and access to presses, pullers, and lifting equipment.

Load Sensing and Hydraulic Component Repair

This documentation breaks down the upperstructure layout and the construction of the HPV091DW variable-displacement main pump and pilot gear pump. Main and Pilot Pipings diagrams trace circuit paths for the arm regenerative valve, surge relief mechanisms, and variable pressure compensated valves (VPCV).

The DP-sensor, shuttle-valve, and PVC explanations connect load-pressure signals to pump-flow control. That gives you a way to trace the control path behind a hydraulic complaint before consulting the relevant component repair procedure.

The Swing Motor Drawing for Disassembly identifies the brake piston, friction plates, and rotating group. The pump assembly section warns that drive-disk spline teeth can damage new oil-seal lips during installation.

The nitrogen accumulator coverage includes gas-pressure checks and discharge precautions. Observe the manual’s pressure-release and lifting precautions when servicing hydraulic assemblies.

Engine Controls, Wiring, and Electrical Checks

The Electric Wiring Diagram and connector terminal-position views are backed by engine and cab harness tables with circuit numbers and wire colors. Starting, charging, preheat, and engine-stop circuits are explained separately, with voltage checks for fault tracing.

The Solenoid Valve Input Signal System Chart links hydraulic-temperature and swing-pressure inputs with the PVC and EC controllers. The solenoid service instructions distinguish the valve parts from the solenoid unit itself, which is not intended for internal teardown.

Wear Limits and Workshop Tooling

Maintenance standards cover swing and travel motor clearances, center-joint wear, idler and roller bushings, track links, and master bushings. Tool illustrations identify bearing installers and pullers; the torque section distinguishes general fastener values from component-specific instructions.

Track-adjuster work requires the spring compression fixture described in the workshop section because of the stored spring force.

Selected Pilot-Pressure, Swing-Control, and Working-Range Data

Pilot-pump circuit pressure is specified as 49 bar (50 kgf/cm², 711 psi). The swing dampener circuit is inactive below a hydraulic oil temperature of 20°C (68°F), a condition to distinguish from a valve fault.

For the EX220-2 and EX220LC-2 with a 3.61 m arm, the working-range table lists a maximum vertical wall digging depth of 6,740 mm (22 ft 1 in.). Shorter-arm configurations have separate entries.