Hitachi EX1200-5C Excavator Technical Manual (Troubleshooting) TT18EE – PDF Service Guide

Description

Hitachi EX1200-5C Excavator Technical Manual (Troubleshooting) – Vol. TT18EE

This is the complete Troubleshooting volume of the Hitachi EX1200-5C Excavator service documentation – the companion book to the Operational Principle volume (TO18EE) and the Workshop Manual that together make up Service Manual No. KM-18EE. Where the Operational Principle manual explains how each system is built and how it works, and the Workshop Manual covers removal, installation and repair, this volume tells you what to measure, what the readings should be, and what to do when the machine does not behave as it should. It is written for the experienced technician working on the EX1200-5C in the field or in the workshop.

File Details

• Manual type: Technical Manual (Troubleshooting)
• Brand: Hitachi
• Model: EX1200-5C Excavator
• Language: English
• Page count: 353
• File format: PDF
• Volume number: TT18EE
• Service manual number: KM-18EE
• Companion volumes: Technical Manual (Operational Principle) TO18EE; Workshop Manual

Chapters Covered

• Section 4 – Operational Performance Test
  • Group 1 – Introduction
  • Group 2 – Standard
  • Group 3 – Engine Test
  • Group 4 – Excavator Test (travel speed, track revolution speed, mistrack, travel parking function, swing speed, swing function drift, swing motor leakage, maximum swingable slant angle, swing bearing play, hydraulic cylinder cycle time, cylinder drift, control lever operating force, control lever stroke, boom raise/swing combined operation check)
  • Group 5 – Component Test (primary and secondary pilot pressure, solenoid valve set pressure, main pump delivery pressure, main relief valve set pressure, overload relief valve set pressure, main pump flow rate, oil cooler fan motor drive pump flow rate, swing motor drainage, travel motor drainage)
• Section 5 – Troubleshooting
  • Group 1 – General (diagnosing procedure, built-in diagnosing system operation, display list, binary number bit list, main controller fault code list)
  • Group 2 – Cross Reference Table (electrical circuit diagram, hydraulic circuit diagrams for Backhoe and Loading Shovel)
  • Group 3 – Component Layout (main components, electrical system components, on and around pumps, main control valve, swing control valve, signal control valve, others)
  • Group 4 – Troubleshooting A (main controller fault codes 01-25 and 31-37)
  • Group 5 – Troubleshooting B (correlation between trouble symptoms and part failures, engine system, all-actuator system, front attachment, swing, travel, other systems)
  • Group 6 – Troubleshooting C (monitor diagnosis – gauges, indicators, LCD, buzzer, hourmeter)
  • Group 7 – Troubleshooting D (engine diagnosis via flashing pattern of indicator lights)
  • Group 8 – Electrical System Inspection (fuses, fusible links, battery, alternator, voltage checks, continuity checks)

Between them, these two sections give a technician a complete, closed diagnostic loop. Section 4 lays out the measurement procedures and the standard values those measurements should produce on a healthy EX1200-5C – engine speeds, travel and swing cycle times, cylinder cycle times, drift limits, pilot and relief pressures, pump flow rates and motor drain rates, all referenced at a controlled hydraulic oil temperature of 50 ± 5 °C. Section 5 then takes that same data and turns it into diagnosis: fault codes from the main controller and ECM, symptom-by-symptom flow charts for the engine, all-actuator, front attachment, swing, travel and auxiliary systems, monitor and indicator troubleshooting, and the electrical inspection groundwork – fuse and fusible link checks, voltage tables and continuity methods – that everything else depends on.

Performance Testing and Standard Values

The operational performance test section is built around the Operational Performance Standard table, which lists the EX1200-5C reference values for fast idle, slow idle, auto-idle and quick idle engine speeds; fast and slow travel times over 20 m; track revolution times; permissible mistrack; swing speed and swing function drift; maximum swingable slant angle; swing bearing play and its allowable limit; cylinder cycle times for boom, arm, bucket and bucket dump cylinders in both Backhoe and Loading Shovel configuration; dig function drift limits; control lever operating forces; and lever strokes. Each test is presented with its own preparation steps, measurement method and evaluation criteria, so the same procedure can be repeated identically across a fleet or across service intervals.

Troubleshooting A, B, C and D

Fault-code diagnosis (Troubleshooting A) covers the main controller A and main controller B code lists, including abnormal EEPROM, RAM and A/D conversion, engine speed faults, reception faults between controllers, sensor voltage faults, front and travel pilot pressure faults, engine control dial angle faults, pump delivery pressure faults, exhaust gas temperature faults and oil temperature sensor faults. Symptom-based diagnosis (Troubleshooting B) works from the other direction – starting with what the operator reports, such as slow travel, mistracking, sluggish boom raise, unresponsive auto-idle or a grease pump that will not stop, and following a flow chart to the probable failed component. Monitor troubleshooting (Troubleshooting C) handles gauges, indicator lights and the LCD, and Troubleshooting D reads engine faults from the flashing pattern of the engine warning indicator.

Built-In Diagnosing System

The manual documents the machine’s built-in diagnosing system in detail: how to activate it, how to switch between main controller A and main controller B displays, and the full display list of monitored items – hourmeter, trips, actual engine speed, hydraulic oil temperature, fault codes, pump pressures, front and travel operation pressures, exhaust gas temperature, EC angle, digital inputs and outputs, proportional valve outputs, and output currents for the hydraulic oil cooling and power increase circuits. Hexadecimal and binary conversion tables are included so that bit-level input and output states can be interpreted correctly.

Electrical System Inspection

The electrical inspection group sets out the precautions for working on the harness – disconnecting the negative battery terminals first, correct handling of water-resistant connectors, the wire colour coding scheme – and then the practical checks: fuse box 1 and fuse box 2 layouts with fuse ratings and connected circuits, fusible link inspection, battery voltage and alternator checks, a full 24-volt circuit voltage table, and single-line, multi-line, continuity and short-circuit test methods.

Who This Manual Is For

This is a technical document aimed at the experienced technician rather than the casual reader. It assumes access to the machine, to test instruments such as pressure gauges, hydraulic testers, a spring scale and a dial gauge, and to the other two volumes of Service Manual No. KM-18EE when a repair procedure rather than a diagnostic procedure is required. Coverage spans both Backhoe and Loading Shovel configurations of the EX1200-5C, and several procedures note different reference values depending on machine serial number.

IMAGES PREVIEW

Used properly, the Hitachi EX1200-5C Excavator Technical Manual (Troubleshooting) lets you test a machine to a known standard, interpret the built-in diagnosing system correctly, follow a fault to the failed component instead of guessing, and confirm a repair by re-measuring against the same reference values. Getting the diagnosis right the first time matters on a machine of this size – wrong assumptions about pump, regulator, control valve or sensor behaviour cost downtime, parts and labour. The manual is supplied as an instant-download PDF: no shipping, no waiting, readable on a laptop, tablet or phone in the cab or the workshop, and printable if you prefer a paper copy on the bench.