Target Audience:
Technicians, equipment owners, and DIY enthusiasts seeking comprehensive service information for Hitachi EX200 hydraulic excavators.
Market Segment:
Medium-sized hydraulic excavators used in construction, earthmoving, and general contracting.
Advantage:
These manuals provide detailed, factory-level information covering all major systems, enabling accurate diagnostics and repairs, which helps maintain machine reliability and performance.
Comprehensive Coverage:
Three manuals covering workshop repair, operation and maintenance, and engine service.
Detailed Procedures:
Step-by-step instructions with specifications and diagrams for troubleshooting, disassembly, and assembly.
Coverage Areas:
Workshop manual covers all major systems; operation and maintenance manual for daily care; engine manual for engine overhaul.
Page Count:
Total pages vary; the workshop manual alone typically over 600 pages, operation manual around 100, engine manual around 200.
Manual Type:
Service and repair manuals
Delivery Method:
Instant digital download
Engine:
Complete engine overhaul procedures, including disassembly, inspection, and reassembly.
Fuel System:
Injection pump timing, injector service, fuel tank and lines.
Electrical System:
Wiring diagrams, starter and alternator service, sensor troubleshooting.
Hydraulic System:
Main pump, control valves, cylinders, swing and travel motors.
Undercarriage:
Track adjustment, idlers, rollers, sprockets.
Power Train:
Transmission, final drives, drive shafts.
Swing System:
Swing gear, swing bearing, swing brake.
Cab and Air Conditioning:
Heater, air conditioner, controls, and cab components.
Safety Equipment:
Horn, backup alarm, mirrors, and warning systems.
Hydraulic Schematics:
Detailed diagrams for hydraulic circuits.
Electrical Schematics:
Full wiring diagrams.
Troubleshooting:
Systematic diagnostic charts for common faults.
Specifications:
Torque specs, clearances, capacities.
Preventive Maintenance:
Scheduled maintenance tables.
Operation Instructions:
Controls, gauges, and operational guidance.
Lubrication:
Grease points, oil types, and interval charts.
Attachments:
Installation and service for buckets and other front attachments.
Boom and Arm:
Inspection and repair procedures.
Cylinder Rebuild:
Hydraulic cylinder disassembly and packing replacement.
Final Drive Service:
Track motor and gear reduction service.
Compatibility:
Works on any device with a PDF reader (Windows, Mac, iOS, Android).
Requirements:
No special software needed; a PDF reader is required.
Searchability:
Digitally searchable with bookmarks for easy navigation.
Print Quality:
High-resolution pages suitable for clear printing.
Binding Type:
Digital (no physical binding)
Paper Type:
N/A - digital only
Engine Make:
Isuzu (typically)
Engine Model:
6BB1 or 6BD1 depending on variant
Engine Type:
Diesel, water-cooled, 6-cylinder
Displacement:
Approximately 5.8 L (6BB1) or 6.5 L (6BD1)
Power Output:
Roughly 110 - 130 hp (varies by variant and RPM)
Injection:
Direct injection (varies)
Type:
Hydraulic drive with travel motors
Speeds:
Two-speed travel drive
Type:
None - hydrostatic transmission is standard
Travel Drive:
Hydrostatic transmission with independent track control
Braking:
Spring-applied, hydraulically released parking brake
Crash Test Information:
N/A - off-road equipment; no crash ratings.
Warning Systems:
Horn, backup alarm, travel alarm (if equipped).
Operator Controls:
Safety lever shut-off, neutral start protection.
Rollover Protection:
ROPS/FOPS cab available as option.
Seatbelt:
Operator seat belt standard.
Engine Oil:
Every 250 hours or per manual schedule.
Hydraulic Oil:
Typically every 1000 hours (check manual).
Greasing:
Daily or every 8 hours for pivot points.
Engine Oil Type:
CF-4 or higher, 15W-40 recommended for most climates.
Hydraulic Oil Type:
ISO VG 46 or 68 anti-wear hydraulic oil (refer to manual).
Known Issues and Wear Items
Common Wear Items:
Bucket teeth, cutting edges, track links, and pins.
Known Issue:
Hydraulic pump wear can cause slow operation; regular oil sampling recommended.
Manufacturer:
Hitachi Construction Machinery Co., Ltd.
Reputation:
Known for durable and reliable hydraulic excavators.
Series:
EX200 series evolved through dash numbers (-1 to -5) with improvements.
Plant:
Manufactured in Japan, later also in other locations.
