Hitachi EX1200-6 Excavator Performance Test & Troubleshooting Manual – PDF

Description

Hitachi EX1200-6 Excavator Performance Test & Troubleshooting Manual

This Hitachi EX1200-6 Excavator Performance Test & Troubleshooting Manual is a comprehensive training text covering operational performance testing and troubleshooting procedures for the EX1200-6 excavator. Whether you are diagnosing a fault code, measuring pump flow rates, testing hydraulic cylinder cycle times, or working through the CAN harness continuity checks, this manual provides the procedures, specifications, and diagnostic flow charts needed to keep the machine running to standard.

File Details

• Manual Type: Performance Test & Troubleshooting Training Text
• Brand: Hitachi
• Model: EX1200-6
• Language: English
• File Format: PDF
• Page Count: 441 pages
• Document Reference: 18JT Series (18JT-4-2, 18JT-5-4)
• Configurations: Backhoe (BH), Loading Shovel (LD), BE

Chapters Covered

• Section 4: Operational Performance Test
  • Group 1: Introduction — Preparation for Performance Tests
  • Group 2: Standard — Performance Standards, Main Pump P-Q Diagram, Fan Pump P-Q Diagram, Fan Pump I-Q Diagram
  • Group 3: Engine Test — Engine Speed
  • Group 4: Excavator Test — Travel Speed, Track Revolution Speed, Mistrack, Travel Parking Leakage, Swing Speed, Swing Function Drift, Swing Motor Leakage, Maximum Swingable Slant Angle, Swing Bearing Play, Hydraulic Cylinder Cycle Time, Dig Function Drift Check, Control Lever Operating Force, Control Lever Stroke, Combined Operation of Boom Raise/Swing Function Check
  • Group 5: Component Test — Primary Pilot Pressure, Secondary Pilot Pressure, 4-Spool Solenoid Valve Unit Set Pressure, Main Pump Delivery Pressure, Fan Pump Delivery Pressure, Main Relief Set Pressure, Overload Relief Valve Set Pressure, Main Pump Flow Rate Measurement, Fan Pump Flow Rate Measurement, Swing Motor Drainage, Travel Motor Drainage
• Group 5: Troubleshooting A (Fault Code Diagnosis)
  • MC (Main) Fault Code List, MC (Sub) Fault Code List, ICF Fault Code List, Monitor Unit Fault Code List, DLu2 Fault Code List
  • Detailed fault code procedures for codes 11000 through 20062, MC (Sub) codes 15979 through 15999, ICF codes 14000-14008, Monitor Unit codes 13303-13311, and DLu2 codes
• Group 6: Troubleshooting B (Symptom-Based Diagnosis)
  • Correlation between Trouble Symptoms and Part Failures
  • Engine System Troubleshooting (E-1 through E-10)
  • All Actuator System Troubleshooting (A-1 through A-9)
  • Front Attachment System Troubleshooting (F-1 through F-8)
  • Swing System Troubleshooting (S-1, S-2)
  • Travel System Troubleshooting (T-1 through T-4)
  • Other System Troubleshooting (O-1 through O-6)
  • Work After Replacing Components, Charge Air Conditioner with Refrigerant, Warm-Up Operation, Inspection
• Group 7: Troubleshooting C (Engine Diagnosis)
  • How to Read Engine Fault Codes, Engine Fault Code List (SPN/FMI codes)
• Group 8: Electrical System Inspection
  • Precautions for Inspection and Maintenance, Instructions for Disconnecting Connectors, Fuse Inspection, Fusible Link Inspection, Battery Voltage Check, How to Check Alternator, Continuity Check, Voltage and Current Measurement, Check by False Signal, Test Harness
• Monitor Unit and Dr. ZX Diagnostics
  • Monitor Unit screens, service menu, fault code display, password functions, alarm displays
  • Dr. ZX connection and operation — Self-Diagnostic Results, Select Controller, MCF Main, MCF Sub, ICF, Monitor Unit, parameter change, attachment parameter change
• Component Layout
  • Main Component Layout, Pump Device, Control Valve, Swing Control Valve, Utility Box, Inside of Cab, Multifunction Monitor, Switch Panel, Fuse Box, Electrical Equipment Box, Battery Box, Engine, Radiator

This Hitachi EX1200-6 performance test and troubleshooting manual goes far beyond a simple fault code list. It gives you the actual test procedures, the standard values to compare against, and the diagnostic logic to isolate the root cause — whether that is a failed sensor, a sticking valve spool, a worn pump regulator, or a broken wire in the CAN harness. The performance test section alone covers travel speed, track revolution, swing speed and drift, cylinder cycle times, control lever forces and strokes, and pump flow rate measurements, with the performance standards tables right there to tell you what the numbers should be.

What This Manual Helps You Do

With the Hitachi EX1200-6 Performance Test & Troubleshooting Manual, you can perform a complete operational performance evaluation of the machine — engine speeds, travel speeds, swing speeds, hydraulic cylinder cycle times, control lever operating forces, and pump flow rates — and compare your measurements against the factory performance standards. When something is out of spec, the troubleshooting sections walk you through the diagnosis step by step, from the symptom to the faulty component.

The fault code sections cover the MC (Main), MC (Sub), ICF, Monitor Unit, and DLU2 controllers, with detailed flow charts for each code. You can diagnose CAN communication faults, sensor voltage abnormalities, solenoid valve circuit faults, and engine-related issues using the exact procedures the manual provides. The Troubleshooting B section is particularly useful when no fault code is displayed — it organizes diagnosis by symptom, so you can start with what the machine is actually doing wrong and trace it back to the failed part.

For technicians working on the hydraulic system, the component test group gives you the procedures to measure pilot pressures, main relief set pressure, overload relief valve set pressure, and pump flow rates using a hydraulic tester. The manual also covers swing motor and travel motor drainage measurements, which are essential for evaluating motor condition. The electrical system inspection group provides the foundational checks — fuse and fusible link inspection, battery voltage, alternator testing, continuity checks, and voltage/current measurement techniques — that underpin all the electronic diagnostics.

The Component Layout section is a practical reference for locating components on the machine, with illustrated layouts of the pump device, control valve, swing control valve, fuse boxes, electrical equipment box, engine, and radiator.

Why This Manual Matters

Diagnosing a modern excavator without the right procedures and specifications is guesswork. The Hitachi EX1200-6 is a complex machine with three main pumps, a fan pump, multiple controllers communicating over CAN, and a hydraulic system that depends on precise pressures and flow rates. This manual gives you the test procedures and the standard values, so you can measure, compare, and decide — instead of replacing parts and hoping.

The troubleshooting flow charts are structured to lead you to the actual cause efficiently. Each step tells you what to check, how to check it, and what the result means. Whether you are dealing with a machine that won’t travel in a straight line, a swing that drifts, a boom that is slow during combined operation, or a fault code that keeps coming back, the manual provides a path to the answer.

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The Hitachi EX1200-6 Excavator Performance Test & Troubleshooting Manual is delivered as an instant PDF download — no shipping, no waiting. You can view it on any device, print the pages you need for the workshop, and keep it as a permanent reference. Whether you are a technician, a fleet maintenance manager, or an owner-operator, this manual gives you the documented procedures and specifications to test, diagnose, and repair the EX1200-6 correctly.