All-Inclusive Factory Service Technical manual for Hitachi Hydraulic Excavators Models EX1200-5C .

This manuals will assist you in diagnosing, repairing, troubleshooting, repairing engine, maintaining, operating, assembling, and checking for your hydraulic excavator.
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Covered Models:
   EX1200-5C (S6R Engine)

The manual comprises 20 documents, including five Workshop Manuals, the Troubleshooting Manual, Engine Technical Manual, Maintenance Manual, Operational Principle Manual, Wiring Diagram, Assembly Manual, Training Text, and 8 Check Sheets

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

2. Workshop Manual: Pump Transmission (WSDPDE17F1)
Format: PDF, 122 pages
Language: English

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

4. Workshop Manual (W183E00)
Format: PDF, 467 pages
Language: English
Table of Contents:
   GENERAL INFORMATION
      Precautions for Disassembling and Assembling
      Tightening
   UPPERSTRUCTURE
      Cab
      Counterweight
      Pump Device
      Control Valve
      Swing Device
      Pilot Valve
      Pilot Shut-off Valve
      Shockless Valve
      Solenoid Valve
      Signal Control Valve
      Oil Cooler Fan Motor
   UNDERCARRIAGE
      Swing Bearing
      Travel Device
      Center Joint
      Track Adjuster
      Front Idler
      Upper And Lower Roller
      Track
   FRONT ATTACHMENT
      Front Attachment
      Cylinder
      Bushing and Point

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

6. Troubleshooting Manual (TT18EE00)
Format: PDF, 350 pages
Language: English
Table of Contents:
   OPERATIONAL PERFORMANCE TEST
      INTRODUCTION
      STANDARD
      ENGINE TEST
      EXCAVATOR TEST
      COMPONENT TEST
   TROUBLESHOOTING
      GENERAL
      CROSS REFERENCE TABLE
      COMPONENT LAYOUT
      TROUBLESHOOTING A
      TROUBLESHOOTING B
      TROUBLESHOOTING C
      TROUBLESHOOTING D
      ELECTRICAL SYSTEM INSPECTION
   

7. Engine Technical Manual (KM926E03)
Format: PDF, 302 pages
Language: English
Table of Contents:
   COVER
   INTRODUCTION
      How to Use This Manual
      Safety Cautions
   GENERAL CONTENTS
   GENERAL
      1. Outline
      2. Main specification
      3. Tips on Disassembly and Reassembly
   MAINTENANCE STANDARDS
      1. Maintenance Standards Table
      2. Tightening Torque Table
      3. Sealants and Lubricants Table
   BASIC AND SPECIAL TOOLS
      1. Commercially-available Tools
      2. Special Tools
   OVERHAUL INSTRUCTIONS
      1. Determination of Overhaul Timing
      2. Testing Compression Pressure
   DISASSEMBLY OF ENGINE MAIN PARTS
      1. Disassembly of cylinder heads and valve mechanisms
      2. Disassembly of flywheel, timing gear, camshaft, oil pan and oil strainer
      3. Disassembly of damper and pulleys
      4. Disassembly of cylinder liner, piston and connecting rod
      5. Disassembly of crankcase, crankshaft and main bearings
   INSPECTION AND REPAIR OF ENGINE PARTS
      1. Cylinder head and valve mechanism
      2. Cylinder Liner, Piston and Connecting Rod
      3. Damper and crankshaft pulley
      4. Flywheel, timing gear and camshaft
      5. Crankcase, crankshaft and main bearing
   REASSEMBLY OF ENGINE MAIN PARTS
      1. Reassmbly of Crankcase, Crankshaft and Main Bearing
      2. Reassmbly of Cylinder Liner, Piston and Connecting Rod
      3. Reassmbly of Damper
      4. Reassmbly of Flywheel, Timing Gear and Camshaft
      5. Reassmbly of Cylinder Head and Valve Mechanism
   FUEL SYSTEM
      1. Disassembling of the fuel system
      2. Disassembling, inspection and assembling of the fuel system
      3. Assembling the fuel system
   LUBRICATION SYSTEM
      1. Removal of lubrication system
      2. Disassembly and inspection of lubrication system
      3. Installation of lubrication system
   COOLING SYSTEM
      1. Removal of Cooling System
      2. Disassembly, Inspection and Reassembly of Cooling System
      3. Reinstallation of Cooling System
   INLET AND EXHAUST SYSTEMS
      1. Exhaust Manifold
      2. Turbocharger
      3. Air Heater
   ELECTRICAL SYSTEM
      1. Removal of electrical system
      2. Disassembly, Inspection and Reassembly of Electrical System
      3. Installation of electrical system
   ADJUSTMENT BREAK-IN OPERATION AND PERFORMANCE TESTS
      1. Adjustment of engine
      2. Adjustment of actuator control linkage
      3. Break-In Operation
      4. Performance Tests
      5. Inspection procedure of dismounted engine
   OTHERS
      1. Dissassembly and Reassembly of General parts
   ADJUSTING PROCEDURE OF ELECTRONIC GOVERNOR CONTROLS
      1. Introduction
      2. Preparation for adjustment
      3. Connection of Personal Computer and Actuator Controller
      4. Service program start-up
      5. Controller setting item chart
      6. Checks before parts and/or controller setting change
      7. Parts change
      8. Adjustment of control link and controller
      9. Resetting of protection
      10. Disconnection of PC and actuator controller
      11. Confirmation of stop solenoid
      12. Confirmation of engine stop
      13. Personal Computer Set-up (How the check when computer program does not start)
      14. Malfunction display
      15. Tunable Value List
   SERVICE MANUAL REVISION REQUEST FORM

8. Maintenance Manual: Recomended Service Program (KO27600)
Format: PDF, 42 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      MAJOR COMPONENTS PREVENTIVE SERVICE SCHEDULE
      HITACHE SCHEDULED DIAGNOSTIC SERVICE
      CHECK LISTS FOR PERFORMANCE AND COMPONENTS
      RECOMMENDATION OF PREVENTIVE SERVICE TO CUSTOMER
      RECOMMENDED PARTS CATALOG FOR PREVENTIVE SERVICE

9. Operational Principle Manual (TO18EE-00)
Format: PDF, 246 pages
Language: English
Table of Contents:
   GENERAL
      SPECIFICATIONS
      COMPONENT LAYOUT
   SYSTEM
      CONTROL SYSTEM
      HYDRAULIC SYSTEM
      ELECTRICAL SYSTEM
   COMPONENT OPERATION
      PUMP DEVICE
      SWING DEVICE
      CONTROL VALVE
      PILOT VALVE
      TRAVEL DEVICE
      SIGNAL CONTROL VALVE
      OTHERS(UPPERSTRUCTURE)
      OTHERS(UNDERCARRIAGE)

10. Wiring Diagram (TT183E00CIR)
Format: PDF, 4 pages
Language: English

11. Assembly Manual (KO26900_POD)
Format: PDF, 192 pages
Language: English
Table of Contents:
   COVER
   Foreword
      1. Precautions
      2. Workers plan (Loader front)
      2'. Workers plan (Backhoe front)
      3. Parts check
      4. Preparations (Loader front)
      5. Preparations (Backhoe front)
      6. Machines, apparatus, tools, and materials necessary for assembly
      ASSEMBLY OF UPPERSTRUCTURE
      MOUNTING PROCEDURE FOR LOADER FRONT-END ATTACHMENT
      MOUNTING PROCEDURE FOR BACKHOE FRONT-END ATTACHMENT
      CHECKS & PERFORMANCE STANDARDS
      10. Check after completing of assembly
      11. Checking machine performance
   BACK COVER

12. Training Text: EX1200-5-5c Tech ILT (EX1200-5-5c_Tech_ILT)
Format: PDF, 289 pages
Language: English

13. Check Sheets: UT Inspection (Backhoe Front) (KO274BE00)
Format: PDF, 52 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      DISTRIBUTION OF THE INSPECTION SHEET
      DEFINITION OF THE DEFECT LENGTH IN ULTRA-SONIC
      INSPECTION PROCEDURE
      EVALUATION OF DEFECT HEIGHT (H)BY DISTANCE CORRECTION TECHNIQUE AT INTERNAL BULKHEAD
      ULTRA-SONIC EXAMINATION REPORT FOR THE STRUCTURE
      Track Frame
      Loader Boom
      Loader Arm

14. Check Sheets: UT Inspection (Loader Front) (ko274l00)
Format: PDF, 58 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      DISTRIBUTION OF THE INSPECTION SHEET
      DEFINITION OF THE DEFECT LENGTH IN ULTRA-SONIC TESTING
      INSPECTION PROCEDURE
      EVALUATION OF DEFECT HEIGHT(H)BY DISTANCE CORRECTION TECHNIQUE AT INTERNAL BULKHEAD
      ULTRA-SONIC EXAMINATION REPORT FOR THE STRUCTURE
      Track Frame
      Loader Boom
      Loader Arm

15. Check Sheets: Visual Inspection (Loader Front) (KO275L00)
Format: PDF, 38 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      COMPLETING AND SUBMITTING THE INSPECTION SHEETS
      INSPECTION PROCEDURE
      STRUCTURE VISUAL INSPECTION CHECK REPORT
      Track Frame
      Side Frame
      Main Frame
      Loader Boom
      Loader Arm

16. Check Sheets: Completed Assembly (KO27000)
Format: PDF, 25 pages
Language: English
Table of Contents:
   COVER
   FOREWORD
      COMPLETED ASSEMBLY CHECK REPORT FOR THE EX1200-5
      UNDERCARRIAGE/SUPERSTRUCTURE
      FRONT-END ATTACHEMNT
      ELECTRICAL SYSTEM FUNCTION CHECK SHEETS
      IMPLEMENT SPEED CHECK SHEETS

17. Check Sheets: Daily and Weekly Maintenance (KO27100)
Format: PDF, 5 pages
Language: English

18. Check Sheets: Monthly Maintenance (KO27200)
Format: PDF, 55 pages
Language: English
Table of Contents:
   COVER
      1. 50 TO 1250 HOURS
      2. 1500 TO 2500 HOURS
      3. 2750 TO 3750 HOURS
      4. 4000 TO 5000 HOURS
      5. 5250 TO 6250 HOURS
      6. 6500 TO 7500 HOURS
      7. 7750 TO 8750 HOURS
      8. 9000 TO 10000 HOURS
      9. 10250 TO 11250 HOURS
      10. 11500 TO 12500 HOURS
      11. 12750 TO 13750 HOURS
      12. 14000 TO 15000 HOURS
      13. 15250 TO 16250 HOURS
      14. 16500 TO 17500 HOURS
      15. 17750 TO 18750 HOURS
      16. 19000 TO 20000 HOURS

19. Check Sheets: Parts Visual Check (ko27300)
Format: PDF, 41 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      INSPECTION PROCEDURE
      PRECAUTIONS FOR INSPECTION
      PRECAUTIONS IN USING THE PARTS VISUAL CHECK SHEET
      PIPING SYSTEM
      ELECTRIC PARTS
      IMPORTANT CHECKS

20. Check Sheets: Visual Inspection (Bachkhoe Front) (KO275BE00)
Format: PDF, 40 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      COMPLETING AND SUBMITTING THE INSPECTION SHEETS
      INSPECTION PROCEDURE
      STRUCTURE VISUAL INSPECTION CHECK REPORT
      Track Frame
      Side Frame
      Main Frame
      Backhoe BE Boom
      Backhoe Arm