All-Inclusive Factory Service Technical manual for Hitachi Hydraulic Excavators Models EX1200-7 .

This manuals will assist you in diagnosing, repairing, troubleshooting, operating, assembling, and checking for your hydraulic excavator.
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Covered Models:
   EX1200-7 (FCO Cummins engine)

The manual comprises 22 documents, including four Workshop Manuals, the Troubleshooting Manual, Operational Principle Manual, three Operators Manuals, Wiring Diagram, three Assembly Manuals, and 9 Check Sheets

1. Workshop Manual: Swing Motor (WSDSME17F2)
Format: PDF, 146 pages
Language: English

2. Workshop Manual: Travel Transmission (WSDTDE17F1)
Format: PDF, 166 pages
Language: English

3. Workshop Manual: Main Pump (WSDMPDE17F2)
Format: PDF, 152 pages
Language: English

4. Workshop Manual (WKAA90EN01)
Format: PDF, 948 pages
Language: English
Table of Contents:
   GENERAL
      Precautions for Disassembling and Assembling
      Tightening
      Painting
      Bleeding Air
      Releasing Pressure
      Preparation
   MAINTENANCE STANDARD
      Upperstructure
      Undercarriage
      Front Attachment
      Loader Front Attachment
   UPPERSTRUCTURE
      Cab
      Counterweight
      Main Frame
      Engine
      Radiator Assembly
      Oil Cooler Assembly
      Hydraulic Oil Tank
      Fuel Tank
      Pump Device
      Control Valve
      Swing Device
      Pilot Valve
      Solenoid Valve
      Signal Control Valve
      Muffler
      Fan Valve
      Fan Motor
   UNDERCARRIAGE
      Swing Bearing
      Travel Device
      Center Joint
      Track Adjuster
      Front Idler
      Upper and Lower Rollers
      Track
   FRONT ATTACHMENT
      Front Attachment
      Cylinder
      Gorup 3 Bushing and Point
   LOADER FRONT ATTACHMENT
      Front Attachment
      Cylinder
      Gorup 3 Bushing and Point

5. Troubleshooting Manual (TTKAA90EN01)
Format: PDF, 472 pages
Language: English
Table of Contents:
   OPERATIONAL PERFORMANCE TEST
      Introduction
      Standard
      Engine Test
      Machine Performance Test
      Component Test
   TROUBLESHOOTING
      Diagnosing Procedure
      Monitor
      Cross Reference Table
      Component Layout
      Troubleshooting A
      Troubleshooting B
      Troubleshooting C
      Air Conditioner
      e-Service

6. Operational Principle Manual (TOKAA90EN01)
Format: PDF, 415 pages
Language: English
Table of Contents:
   GENERAL
      Specifications
      Component Layout
      Component Specifications
   SYSTEM
      Controller
      Control System
      Engine System
      Hydraulic System
      Electrical System
      Air Conditioning System
   COMPONENT OPERATION
      Pump Device
      Swing Device
      Control Valve
      Pilot Valve
      Travel Device
      Signal Control Valve
      Others (Upperstructure)
      Others (Undercarriage)
   

7. Operators Manual: Quick Visual Inspection (Loader Front) (PMKAA91ENQV00(LD))
Format: PDF, 248 pages
Language: English
Table of Contents:
   VISUAL INSPECTION EX1200-7 LOADER FRONT
      COMPLETING AND SUBMITTING THE INSPECTION SHEETS
      SAFETY
      Inspection procedure
      Noting the cracks
      0 hour to 250 hours
      251 hours to 500 hours
      501 hours to 750 hours
      751 hours to 1000 hours
      1001 hours to 1250 hours
      1251 hours to 1500 hours
      1501 hours to 1750 hours
      1751 hours to 2000 hours
      2001 hours to 2250 hours
      2251 hours to 2500 hours
      2501 hours to 2750 hours
      2751 hours to 3000 hours
      3001 hours to 3250 hours
      3251 hours to 3500 hours
      3501 hours to 3750 hours
      3751 hours to 4000 hours
      4001 hours to 4250 hours
      4251 hours to 4500 hours
      4501 hours to 4750 hours
      4751 hours to 5000 hours
      5001 hours to 5250 hours
      5251 hours to 5500 hours
      5501 hours to 5750 hours
      5751 hours to 6000 hours
      6001 hours to 6250 hours
      6251 hours to 6500 hours
      6501 hours to 6750 hours
      6751 hours to 7000 hours
      7001 hours to 7250 hours
      7251 hours to 7500 hours
      7501 hours to 7750 hours
      7751 hours to 8000 hours
      8001 hours to 8250 hours
      8251 hours to 8500 hours
      8501 hours to 8750 hours
      8751 hours to 9000 hours
      9001 hours to 9250 hours
      9251 hours to 9500 hours
      9501 hours to 9750 hours
      9751 hours to 10000 hours
   BACK COVER

8. Operators Manual: Quick Visual Inspection (Backhoe Front) (KO58001)
Format: PDF, 248 pages
Language: English
Table of Contents:
   VISUAL INSPECTION EX1200-7
      COMPLETING AND SUBMITTING THE INSPECTION SHEETS
      SAFETY
      Inspection procedure
      Noting the cracks
      0 hour to 250 hours
      251 hours to 500 hours
      501 hours to 750 hours
      751 hours to 1000 hours
      1001 hours to 1250 hours
      1251 hours to 1500 hours
      1501 hours to 1750 hours
      1751 hours to 2000 hours
      2001 hours to 2250 hours
      2251 hours to 2500 hours
      2501 hours to 2750 hours
      2751 hours to 3000 hours
      3001 hours to 3250 hours
      3251 hours to 3500 hours
      3501 hours to 3750 hours
      3751 hours to 4000 hours
      4001 hours to 4250 hours
      4251 hours to 4500 hours
      4501 hours to 4750 hours
      4751 hours to 5000 hours
      5001 hours to 5250 hours
      5251 hours to 5500 hours
      5501 hours to 5750 hours
      5751 hours to 6000 hours
      6001 hours to 6250 hours
      6251 hours to 6500 hours
      6501 hours to 6750 hours
      6751 hours to 7000 hours
      7001 hours to 7250 hours
      7251 hours to 7500 hours
      7501 hours to 7750 hours
      7751 hours to 8000 hours
      8001 hours to 8250 hours
      8251 hours to 8500 hours
      8501 hours to 8750 hours
      8751 hours to 9000 hours
      9001 hours to 9250 hours
      9251 hours to 9500 hours
      9501 hours to 9750 hours
      9751 hours to 10000 hours
   BACK COVER

9. Operators Manual (ENMKAAEN14)
Format: PDF, 478 pages
Language: English
Table of Contents:
   SAFETY
   VISIBILITY MAP
   SAFETY SIGNS
   NAME OF COMPONENTS
   GETTING ON AND OFF THE MACHINE
   OPERATOR'S STATION
   BREAK-IN
   OPERATING THE ENGINE
   DRIVING THE MACHINE
   OPERATING THE MACHINE
   TRANSPORTING
   MAINTENANCE
   HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT
   MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
   STORAGE
   TROUBLESHOOTING
   SPECIFICATIONS
   INDEX

10. Wiring Diagram (TTKAA90EN01CIR)
Format: PDF, 41 pages
Language: English
Table of Contents:
   ELECTRICAL CIRCUIT DIAGRAM (Serial No. 7045 and up)
   ELECTRICAL CIRCUIT DIAGRAM (Serial No. 7002 to 7043)
   AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM
   FLOOR HARNESS
   CAB HARNESS
   MAIN HARNESS
   ENGINE HARNESS
   CONTROL VALVE HARNESS
   PUMP HARNESS
   SPEAKER (L) HARNESS
   MONITOR HARNESS
   WIU HARNESS
   OPTION FUSE HARNESS
   LUBRICATE HARNESS (YAMADA)
   COUNTER-WEIGHT HARNESS
   LUBRICATE HARNESS (LINCOLN)
   RADIATOR HARNESS
   GSM HARNESS
   WIPER HARNESS
   CAB LIGHT 1 HARNESS
   CAB LIGHT 2 HARNESS
   CAB LIGHT 3 HARNESS
   FENDER (R) HARNESS
   FUEL TANK HARNESS
   BOOM LIGHT HARNESS
   SPEAKER (R) HARNESS
   BOOM LIGHT (OPTION) HARNESS
   STEP LIGHT HARNESS
   CSU CAB HATNESS
   CUS MAIN HARNESS
   CSU PUMP HARNESS
   AERIAL ANGLE MAIN HARNESS
   AERIAL ANGLE MONITOR HARNESS
   AERIAL ANGLE SWITCH HARNESS
   SWITCH HARNESS
   RELAY PANEL HARNESS
   OIL TANK HARNESS
   FUEL PUMP SWITCH HARNESS
   HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)
   HYDRAULIC CIRCUIT DIAGRAM(LOADING SHOVEL)
   CONNECTORS

11. Assembly Manual (KO59001)
Format: PDF, 207 pages
Language: English
Table of Contents:
   1. Precautions
   2. Workers plan (Backhoe front)
   3. Parts check
   4. Preparations (Backhoe front)
   5. Machines, apparatus, tools, and materials necessary for assembly
   6. Assembly of upperstructure
   7. Mounting procedures for backhoe front
   8. Checks after completing the assembly
   9. Checking machine performance
   ASSEMBLY CHECK SHEET

12. Assembly Manual (KO60401)
Format: PDF, 223 pages
Language: English
Table of Contents:
   1. Precautions
      1-1 Safety precautions for servicemen
      1-2 How to use a power wrench
      1-3 Work precautions
   2. Workers plan (Backhoe front)
      2-1 Transportation (Backhoe front)
   3. Parts check
      3-1 Check
   4. Preparations (Backhoe front)
   5. Machines, apparatus, tools, and materials necessary for assembly
   6. Assembly of upperstructure
      6-1 Preparations
      6-2 Connection of upperstructure and side frames
      6-3 Connection of travel motor hoses
      6-4 Assembly of cab & handrail, step and ladder etc.
      6-5 Installation of counterweight, muffler, camera and rear lamps
      6-6 Greasing of swing bearing
      6-7 Vacuuming (air purge work) & charging of refrigerant
      6-8 Final check of superstructure
      6-9 Releasing the air from the main pumps
      6-10 Trial operation of superstructure
      6-11 Disassembly procedures for shipment
   7. Mounting procedures for backhoe front
      7-1 Preparation
      7-2 Mounting of backhoe boom
      7-3 Mounting of arm
      7-4 Mounting of bucket
      7-5 Adjustment of track link tension
      7-6 Final trial operation check
      7-7 Disassembly procedures for shipment
   8. Checks after completing the assembly
   9. Checking machine performance

13. Assembly Manual (PMKAA90ENAM03)
Format: PDF, 427 pages
Language: English
Table of Contents:
   1. Workers plan
   2. Parts check
   3. Preparations
   4. Machines, apparatus, tools, and materials necessary for assembly
   5. Assembly of base machine
   6. Mounting procedures for loader front
   6. Mounting procedures for backhoe front
   7. Checks after completing the assembly (LD)
   7. Checks after completing the assembly (BH)
   8. Checking machine performance (LD)
   8. Checking machine performance (BH)
   9. Assembly check sheets (LD)
   9. Assembly check sheets (BH)

14. Check Sheets: UT Inspection (Loader Front) (PMKAA91ENUT00(LD))
Format: PDF, 59 pages
Language: English

15. Check Sheets: Daily Visual Inspection (Backhoe Front) (KO59200)
Format: PDF, 6 pages
Language: English

16. Check Sheets: Visual Inspection (PMKAA91ENVI01)
Format: PDF, 46 pages
Language: English

17. Check Sheets: Weekly Video Inspection (Backhoe Front) (KO58200)
Format: PDF, 12 pages
Language: English
Table of Contents:
   EX1200-7 WEEKLY VISUAL INSPECTION
      Main Frame
      Backhoe BE Boom
      Backhoe Arm

18. Check Sheets: Visual Inspection (Backhoe Front) (KO57900)
Format: PDF, 41 pages
Language: English
Table of Contents:
   EX1200-7 VISUAL INSPECTION BACKHOE FRONT
      INTRODUCTION
      COMPLETING AND SUBMITTING THE INSPECTION SHEETS
      INSPECTION PROCEDURE
      STRUCTURE VISUAL INSPECTIONCHECK REPORT
      Track Frame
      Side Frame
      Main Frame
      Backhoe BE Boom
      Backhoe Arm

19. Check Sheets: UT Inspection (Backhoe Front) (KO57800)
Format: PDF, 52 pages
Language: English
Table of Contents:
   EX1200-7 ULTRA-SONIC INSPECTION
      INTRODUCTION
      DISTRIBUTION OF THE INSPECTION SHEET
      DEFINITION OF THE DEFECT LENGTH IN ULTRA-SONICTESTING
      INSPECTION PROCEDURE
      EVALUATION OF DEFECT HEIGHT (H) BY DISTANCECORRECTION TECHNIQUE AT INTERNAL BULKHEAD
      ULTRA-SONIC EXAMINATIONREPORT FOR THE STRUCTURE
      Track Frame
      BE Boom
      Backhoe Arm

20. Check Sheets: Daily and Weekly Maintenance (PMKAA91ENDW01(LD))
Format: PDF, 5 pages
Language: English
Table of Contents:
   CHECK POINT-1 : HYDRAULIC , ENGINE AND ELECTRIC COMPONENTS
   CHECK POINT-2 : FRONT ATTACHMENT
   DAILY AND WEEKLY CHECK SHEETS FOR EX1200-7

21. Check Sheets: Monthly Maintenance (PMKAA91ENMM00(LD))
Format: PDF, 15 pages
Language: English
Table of Contents:
   REPLACEMENT ITEMS-1
      List of Consumable Parts
   REPLACEMENT ITEMS-2
   CLEANING ITEMS
   VISUAL CHECK ITEMS
   GREASING & DRAINING ITEMS
   CHECK SHEETS FOR Initial 50 HOURS to 2000 HOURS

22. Check Sheets: Parts Visual Check (KO59400)
Format: PDF, 67 pages
Language: English
Table of Contents:
   INTRODUCTION
   INSPECTION PROCEDURE
   PRECAUTIONS FOR INSPECTION
   PRECAUTIONS IN USING THE PARTS VISUAL CHECK SHEET
   PARTS VISUAL CHECK
   PIPING SYSTEM
   ELECTRIC PARTS
   IMPORTANT CHECKS