Hitachi EX200 Series 2: A Comprehensive Overview and Troubleshooting Guide

[MikePhua]

The Hitachi EX200 Series 2 is a widely recognized hydraulic excavator known for its robustness and performance in various applications, including construction, mining, and forestry. As with many older models, operators often encounter issues that require troubleshooting and maintenance to ensure the machine runs efficiently. In this article, we will take a closer look at the EX200 Series 2, highlighting common issues, troubleshooting methods, and useful tips for extending the life of the equipment.
Overview of the Hitachi EX200 Series 2
The Hitachi EX200 Series 2 is part of the company's well-established line of hydraulic excavators, designed for medium to heavy-duty operations. Its reputation stems from its powerful engine, efficient hydraulics, and durable construction, making it a popular choice for operators in various sectors of the construction industry.

• Engine and Power: The EX200 Series 2 is equipped with a Isuzu 4BG1T turbocharged diesel engine, offering a balance of power and fuel efficiency. This engine allows the machine to perform demanding tasks while maintaining reasonable operational costs.
  
• Hydraulic System: The hydraulic system in the EX200 Series 2 is designed for precise control, making it ideal for tasks like digging, lifting, and grading. Its high-efficiency pumps and components enable it to maintain performance even under heavy workloads.
  
• Cab and Comfort: The cab of the EX200 Series 2 is ergonomically designed to reduce operator fatigue. Features include adjustable seating, easy-to-reach controls, and good visibility, ensuring operators can work long hours comfortably.
  

Common Issues with Hitachi EX200 Series 2
Despite its reputation for reliability, like any older piece of machinery, the Hitachi EX200 Series 2 is not immune to issues. Some of the most commonly encountered problems include:
1. Hydraulic System Failures
Hydraulic system problems are one of the most common issues faced by EX200 Series 2 owners. These problems can manifest in various ways, such as a loss of power, erratic movements, or slow operation. Some possible causes include:

• Worn-out Hydraulic Pump: The hydraulic pump can wear out over time, especially if the machine has been subjected to heavy loads for extended periods.
  
• Hydraulic Hose Leaks: Over time, hydraulic hoses can crack or develop leaks, leading to a loss of pressure and performance. Routine inspections of the hydraulic hoses and connections are crucial.
  
• Clogged Filters: A clogged hydraulic filter can reduce the flow of hydraulic fluid, leading to overheating and inefficient operation.
  

2. Electrical Issues
Electrical problems are another area that can affect the performance of the Hitachi EX200 Series 2. These include:

• Faulty Sensors: The excavator's sensors monitor various functions, including engine performance and hydraulic pressure. If these sensors malfunction, the machine may give inaccurate readings or fail to operate as expected.
  
• Battery or Charging Issues: If the battery or charging system is not working correctly, the excavator may fail to start or experience intermittent power loss during operation.
  
• Wiring Problems: Over time, the wiring in the excavator's electrical system can become corroded or damaged, causing electrical failures.
  

3. Undercarriage and Track Issues
Another common area of concern is the undercarriage. The EX200 Series 2, like other tracked excavators, is prone to undercarriage wear, particularly in harsh working conditions.

• Track Wear: Excessive wear on the tracks can cause slipping and inefficient operation. Over-tightening of the tracks can also lead to premature wear on both the tracks and the drive motor.
  
• Roller and Sprocket Damage: The rollers and sprockets help support the tracks. If they are damaged or worn out, it can result in poor track tension and uneven movement of the excavator.
  

4. Engine Overheating
The Isuzu 4BG1T engine in the EX200 Series 2 is known for its reliability, but engine overheating can still occur, particularly in hot climates or when the machine is working under heavy loads. Common causes of overheating include:

• Radiator Blockage: Dirt, debris, or sludge buildup in the radiator can obstruct airflow, leading to overheating.
  
• Low Coolant Levels: Insufficient coolant in the system can cause the engine to overheat. Regularly checking the coolant levels and maintaining the radiator is essential for proper engine operation.
  
• Malfunctioning Thermostat: A faulty thermostat can cause the engine to run at too high or low a temperature, affecting overall engine efficiency.
  

Troubleshooting and Fixing Common Issues
When troubleshooting issues with the Hitachi EX200 Series 2, it’s essential to approach each problem methodically. Below are some troubleshooting steps for the most common issues:
Hydraulic Issues

• Loss of Power: Check the hydraulic fluid levels first. Low fluid levels can cause a loss of power. If the levels are fine, inspect the hydraulic filter and pump for any signs of wear or blockage.
  
• Erratic Movements: This could be caused by air trapped in the hydraulic system or a leak. Bleed the system to remove any trapped air and check for leaks in the hoses and fittings.
  
• Slow Operation: If the hydraulic system is slow to respond, check for clogged filters and clean or replace them as needed. Also, ensure the hydraulic fluid is the correct type and free from contaminants.
  

Electrical Problems

• Faulty Sensors: If a sensor is malfunctioning, the system may need recalibration or replacement. Use a diagnostic tool to check the sensor's readings and determine if it needs replacing.
  
• Battery or Charging Issues: Check the battery voltage using a multimeter. If the voltage is low, test the alternator and charging circuit to ensure the battery is being charged correctly. Replace any damaged components.
  
• Wiring Issues: Inspect the wiring harness for visible signs of damage or corrosion. Use a multimeter to check for continuity in the circuits and repair or replace damaged wires as needed.
  

Undercarriage and Track Maintenance

• Track Slippage: Check the track tension to ensure it is neither too tight nor too loose. Adjust the track tension according to the manufacturer's specifications. Also, inspect the tracks for excessive wear and replace them if necessary.
  
• Roller and Sprocket Issues: Inspect the rollers and sprockets for signs of damage. If they are worn out, replace them to prevent further damage to the undercarriage.
  

Engine Overheating

• Radiator Check: Regularly clean the radiator fins to ensure proper airflow. If the radiator is clogged, clean it with a pressure washer or replace it if necessary.
  
• Coolant Levels: Ensure the coolant levels are within the recommended range. Top up the coolant as needed and inspect for any leaks in the system.
  
• Thermostat Replacement: If the engine is overheating despite proper coolant levels, the thermostat may need replacing. Test the thermostat by placing it in hot water and checking its opening temperature.
  

Extending the Life of Your Hitachi EX200 Series 2
To get the most out of your Hitachi EX200 Series 2, regular maintenance is key. Below are some tips to keep your excavator in optimal working condition:

• Frequent Oil Changes: Regularly changing the engine oil and hydraulic fluid helps maintain engine performance and extends the life of the machine's components.
  
• Regular Inspections: Conduct routine inspections of the undercarriage, hydraulic system, and electrical components to catch problems early before they become serious.
  
• Proper Storage: When the machine is not in use, store it in a dry, clean environment to prevent rust and corrosion. Protecting the machine from the elements can significantly increase its lifespan.
  
• Training for Operators: Proper training of operators on how to use the machine efficiently and safely can help reduce unnecessary wear and tear on the equipment.
  

Conclusion
The Hitachi EX200 Series 2 is a reliable and durable excavator, but like all heavy equipment, it requires regular maintenance and occasional troubleshooting to keep it performing at its best. By understanding common issues such as hydraulic problems, electrical faults, and engine overheating, operators can address them promptly and keep their equipment running smoothly. Routine inspections and proper maintenance practices are essential to ensure that the EX200 Series 2 continues to deliver the high level of performance that has made it a favorite in the industry for years.