Hitachi EX200 LC-2 Excavator: Common Issues and Maintenance Tips

[MikePhua]

The Hitachi EX200 LC-2 is a versatile and reliable excavator known for its robust performance in construction, excavation, and mining projects. Despite its durability, like all heavy machinery, it can face a range of issues, especially with wear and tear over time. Understanding the machine’s common problems, maintenance practices, and troubleshooting techniques can help operators and technicians extend the lifespan of the equipment and keep it running efficiently.
Overview of the Hitachi EX200 LC-2
The Hitachi EX200 LC-2 is part of the EX series of hydraulic excavators, which are well-regarded for their power, speed, and fuel efficiency. With a powerful engine and a hydraulic system designed for maximum productivity, the EX200 LC-2 is used in a wide range of industries, from construction to agriculture. It has an operating weight of around 20 tons, with a digging depth of over 6 meters, making it a versatile choice for various tasks.
Common Problems with the Hitachi EX200 LC-2
While the EX200 LC-2 is a highly capable machine, it can experience issues, especially in older models or those subjected to heavy workloads. Here are some common problems that users may encounter:
1. Hydraulic System Issues
The hydraulic system is one of the most critical components of an excavator. If the hydraulic system experiences issues, it can affect the entire machine’s performance.
Symptoms: Slow boom and arm movements, erratic bucket operation, or a lack of lifting power.
Possible Causes:

• Low Hydraulic Fluid: The hydraulic fluid may have leaked or evaporated, causing the system to lose pressure.
  
• Worn Hydraulic Pumps: Over time, the hydraulic pumps can wear out, causing a decrease in efficiency.
  
• Clogged Filters: A clogged hydraulic filter can restrict fluid flow, leading to poor performance.
  

Solution: Regularly check the hydraulic fluid levels and top up when necessary. Replace worn-out filters and hydraulic components according to the manufacturer’s recommendations. Conduct periodic inspections of the hydraulic lines for any signs of leaks.
2. Electrical Problems
Electrical issues are another common problem in the EX200 LC-2. These can range from faulty wiring to sensor malfunctions.
Symptoms: Dashboard warning lights staying on, engine not starting, or the excavator’s functions becoming unresponsive.
Possible Causes:

• Faulty Sensors: The sensors that monitor engine temperature, oil pressure, and other key systems may malfunction, triggering warning lights.
  
• Loose or Corroded Wiring: Over time, wiring can become loose or corroded, preventing signals from reaching the correct components.
  
• Blown Fuses: A blown fuse can cause certain electrical systems to fail, such as the cabin lights or the hydraulic controls.
  

Solution: Inspect the electrical wiring for any signs of wear or corrosion, and ensure that all connections are secure. Test sensors to verify their functionality and replace any faulty ones. Replace any blown fuses and ensure that the electrical system is properly grounded.
3. Engine Performance Issues
The engine of the EX200 LC-2 powers the entire machine, and any issues here can have a significant impact on performance.
Symptoms: The engine may struggle to start, run roughly, or consume excessive fuel.
Possible Causes:

• Clogged Fuel Filters: A clogged fuel filter can restrict fuel flow to the engine, causing performance problems.
  
• Faulty Fuel Injectors: Over time, fuel injectors can become clogged or wear out, leading to poor combustion and engine hesitation.
  
• Low Compression: Low compression due to worn piston rings or valves can cause engine misfires.
  

Solution: Regularly replace the fuel filters and inspect the fuel injectors for any signs of clogging or wear. Test the engine's compression to ensure it is within specifications and replace components as needed. Additionally, ensure that the fuel system is clean and free from contaminants.
4. Undercarriage Wear
The undercarriage of the EX200 LC-2 is subjected to constant wear from operating on rough terrain, especially when the excavator is used for digging and moving materials.
Symptoms: Excessive vibration, uneven wear on tracks, or difficulty in moving the excavator.
Possible Causes:

• Track Tension: If the track tension is not adjusted properly, the tracks may wear unevenly or become too loose, affecting performance.
  
• Worn Track Rollers: Over time, track rollers can wear out, causing the tracks to become misaligned.
  
• Damaged Track Shoes: Track shoes can become worn or cracked, reducing the excavator’s stability.
  

Solution: Inspect the tracks and rollers regularly for signs of wear and tear. Adjust the track tension as necessary and replace worn or damaged components. Perform routine undercarriage maintenance to ensure smooth and efficient operation.
5. Overheating Issues
Overheating is a common issue in heavy machinery, especially if the cooling system is not functioning properly.
Symptoms: The engine temperature gauge rises too high, or the machine shuts down unexpectedly due to overheating.
Possible Causes:

• Clogged Radiator: Dirt, debris, or coolant build-up can block airflow to the radiator, causing the engine to overheat.
  
• Faulty Thermostat: A faulty thermostat may cause the engine to run too hot or too cold.
  
• Low Coolant: Low coolant levels can reduce the engine’s ability to regulate temperature.
  

Solution: Regularly check coolant levels and ensure that the radiator is clean and free from debris. Replace the thermostat if it is faulty, and ensure that the cooling system is functioning efficiently. Clean the cooling system periodically to maintain optimal performance.
Maintenance Tips for the Hitachi EX200 LC-2
To extend the lifespan and maintain the performance of the Hitachi EX200 LC-2, regular maintenance is essential. Here are some maintenance tips to keep the excavator running smoothly:

1. Regular Inspections: Conduct regular visual and functional inspections of the machine to catch any issues before they become major problems.
   
2. Clean the Air Filters: Regularly clean or replace the air filters to ensure optimal engine performance and prevent dust and debris from entering the engine.
   
3. Lubricate Moving Parts: Ensure that all moving parts, such as the boom, arm, and bucket, are well-lubricated to prevent wear and tear.
   
4. Hydraulic System Maintenance: Inspect the hydraulic fluid, hoses, and filters regularly to prevent leaks and ensure smooth operation.
   
5. Monitor Fluid Levels: Keep an eye on the oil, fuel, and coolant levels to ensure that the engine and hydraulic system run efficiently.
   

Conclusion
The Hitachi EX200 LC-2 excavator is a powerful and reliable machine for a variety of construction and excavation tasks. While it is built to last, understanding common issues and performing regular maintenance can significantly improve its lifespan and performance. By addressing problems like hydraulic issues, electrical malfunctions, engine performance, undercarriage wear, and overheating promptly, operators can keep the EX200 LC-2 running at its best. Always refer to the manufacturer's guidelines and use the wiring schematic to aid in troubleshooting and repairs for a smooth, efficient operation.