Description

Fiat-hitachi EX200 Workshop Manual

You’ve got a Fiat-hitachi EX200 Workshop Manual in your hands. Good. Because if you’re cracking open a pump or digging into the control valve on an EX200 without factory specs, you’re wasting time and risking a come-back. I’ve torqued enough head bolts to know: one wrong value and you’re pulling it all apart again. This 392-page document is what Hitachi put together for their own techs. It’s not a reprint or a third-party knockoff. It’s the real thing.

Safety First: What Page IN-01 Tells You

The manual opens with a safety alert symbol and headache notations. Page IN-01 explains exactly how heavy a component is – so you don’t guess and drop a counterweight on your foot. The manual stresses using proper lifting techniques and equipment. That’s not fluff; that’s a warning from Hitachi that saves your back and your career. Aftermarket manuals often skip this section or write generic warnings. This one gives you the specific weight ratings and lifting procedures for this machine.

Tightening Torque Specifications – Where to Find Them

Section 1, Group 2 is dedicated to tightening torque. You get a torque chart, piping joint specs, and values for every fastener group. Page IN-02 shows the unit conversion – SI, MKS, and English – so you can torque in ft-lbs if you need. Don’t use a generic chart from the internet for hydraulic fittings. The OEM chart accounts for thread size, grade, and lubrication condition. I’ve seen stripped threads and blown seals because someone used a standard bolt torque on a pipe joint. This manual’s torque data is the only reference you should trust. For matching part numbers, grab the HITACHI EX200 EX200LC Parts Catalog alongside.

Does This Manual Cover the Pump Device Rebuild?

Yes. Section 2, Group 4 dives into the pump device – remove and install, disassemble, assemble, plus disassembly and assembly of the regulator and pilot pump. Each step is laid out for an experienced technician, with maintenance standards at the end of the group. You’re not left guessing which shim goes where. The manual tells you the sequence and the torque for each bolt. If you’re rebuilding a control valve, there are five separate control valve sections (1 through 5) with their own disassembly and assembly procedures. That level of detail is why this workshop manual is worth having on the bench. Pair it with the HITACHI EX200 EX200LC Hydraulic Excavator Parts Catalog for part cross-referencing.

6 Groups in Undercarriage Section

Section 3 covers the undercarriage with six groups: Swing Bearing, Travel Device, Center Joint, Track Adjuster, Front Idler, Upper and Lower Roller, and Track. Each group has removal, disassembly, assembly, and maintenance standards. For example, the Travel Device includes disassembly and assembly of the travel motor and brake valve, plus a maintenance standard table. You get the factory spec for roller clearance, track tension, and bolt torque. This is not a service summary – it’s the full rebuild procedure. If you’re doing track work, you need the Hitachi EX200 Operation Principle Manual to understand the hydraulic theory behind the travel motor, but the workshop manual gives you the hands-on steps.

Get the Right Torque Values for Piping Joints

The torque chart in Section 1, Group 2 includes a dedicated subsection for piping joints. Hydraulic leaks often trace back to over- or under-torqued fittings. The manual lists the exact torque for each joint type. Don’t assume SAE values translate to metric hydraulic fittings – they don’t. I’ve had to re-flare lines because someone used a generic spec. The OEM manual removes that guesswork. For comparison, rebuilding a Manual Transmission requires the same discipline – use the factory spec or it’ll whine. The EX200’s hydraulic system is no different.

Source Authenticity: OEM vs. Aftermarket

This is an original Hitachi workshop manual, not a compilation from unknown sources. The OCR excerpt shows the publisher’s contact information and manual composition structure. It lists the Technical Manual (Operational Principle), Technical Manual (Troubleshooting), and Workshop Manual as separate documents. This is the workshop portion – the one that covers maintenance and repair, tools, devices, and assembly/disassembly procedures. Aftermarket manuals often merge information from multiple sources and introduce errors. With this factory document, you get the exact specs Hitachi used on the assembly line. The same applies when rebuilding a Manual Transmission – use the OEM manual or risk gear noise.

Frequently Asked Questions

Can I use this manual for the EX200-5 with serial number after 83347?

Yes. The manual covers those variations – specifically for the travel pilot valve assembly. Check the relevant group for your serial number.

What torque values are given for the swing motor?

Torque specs are in Section 1 Group 2 but also referenced in each assembly procedure. For swing motor, the maintenance standard includes bolt torque. You must use the values from this manual, not from a chart found online. I’ve seen guys strip threads because they used a generic value for a metric fine thread. The manual gives the exact grade and torque for each application. Don’t shortcut this.

Is the manual in English?

Yes, the original OCR excerpt shows English. It includes SI units and conversions to English units.

How many pages?

392 pages. Covers introduction through section 4. It’s the full workshop manual, not an excerpt.

If you’re serious about keeping your EX200 in the dirt and not in the shop, this is the documentation you need. Don’t rely on aftermarket copies that might have wrong specs. Access the Factory Manual from AutoRepairManuals and have it on your tablet or print it for the bench.