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TROUBLESHOOTING

5.1.2.1 Confirming Troubleshooting Log


The machine is provided with monitoring system that
stores past log and indicates present status, and system
that judges faults by engine controller and makes
troubleshooting.
If fault arises, fault information is collected, and at the
same time, monitoring data is downloaded and engine
fault diagnosis is made to identify faulty phenomenon.
Here, fault record concerning engine as well as specific
troubleshooting classified by fault record are shown
below.
For downloading of monitoring data, refer to 3.
Monitoring System, Functions and Construction.
For engine troubleshooting, refer to Operation Manual.
For outline of system, refer to 5.1.1.1 Engine Control
Connection Diagram, and 5.1.1.2 ECM and Monitoring
Diagram.

5-1-2-1

TROUBLESHOOTING
1. Checking Abnormal Stop Log
1.1 Checking Fault Occurrence, Engine Fault Analysis and Checking Fault Codes
Immediately after fault occurrence, keep key switch intact (do not turn key switch OFF), turn fault diagnosis
switch ON, and check if engine warning lamp is lit.
6-1 Engine speed *1 min-1 or moreFixing engine speed to Low idle.
With key switch OFF and ECM power OFFCancellation
6-2 Engine speed *2 min-1 or moreEngine stop .
With key switch OFF and ECM power OFFCancellation
2-5 Abnormal throttle sensor
Throttle sensor and harness in cab are abnormal.
2-3 Abnormal boost pressure sensor
Boost sensor and harness are abnormal.

Engine speed
Fixed to Low idle

Lamps in cab
Warning lamp ON

Engine stop

Stop lamp ON

To Check 2-1
To Check 2-2
Fixing to 1000

min-1

Warning lamp ON
To Check 2-3

Excess black smoke


No change in engine
speed
Engine stop

4-1 Abnormal actuator power


Actuator power or harness is abnormal.
4-5 Abnormal actuator sensor
Engine stop
Actuator angle sensor or harness is abnormal.
4-3 Abnormal sensor power
No change
Each sensor power (normally 5 V) from ECM or harness is abnormal.
Refer to 5.1.1.2 ECM and Monitoring Schematic Diagram.

S6R
S16R
S12A2

Warning lamp ON
To Check 2-4
Stop lamp ON
To Check 2-5
Stop lamp ON
To Check 2-6
Warning lamp ON
To Check 2-7
*1
1950
1950
2250

*2
2000
2000
2000

1.2 Checking Fault Occurrence:


Download monitoring data, and check event information.
Check if engine stops at other speeds than engine overrun speed.
Download monitoring data, and check event information by creating a report (Create Report Events).
Warning fault Codes for Engine Speed Adjustment
(Among Monitoring Event Information)

Item
Coolant Level (Low)
Coolant Temp. (Over Heat)
Eng. Oil Press. (Low)
Pump Trans. Oil Press. (Low)
Fuel Level (Low)
Engine Stop Sig.

Description
Check of coolant level, level switch and harnesses
Check of cooler, cooling system, overheat Switch and harnesses.
Check of lubricant level, filter, viscosity, pressure switch and harnesses.
Check of lubricant level, filter, viscosity, pressure switch and harnesses.
Check of fuel shortage
Engine stop signals caused by Items 1 to 4 above, and by abnormal engine
governor actuator sensor.
Engine Speed Derate
Engine speed control signals caused by Items 1 to 4 above, and by abnormal
engine governor actuator sensor.
Engine Torque Derate
Engine torque decrease signals by Items 1 to 4 above, and by abnormal engine
governor actuator sensor.
Engine
Log of engine ON/OFF signals
Emergency Switch
Log of emergency engine stop ON/OFF
Sensor Faults [Angle Sensor] Abnormality of engine actuator angle sensor or harnesses.
Refer to 5.1.1.2 ECM and Monitoring Schematic Diagram

5-1-2-2

Check Step
To Check 2-8
To Check 2-9
To Check 2-10
To Check 2-11
To Check 2-12
To Check 2-13
To Check 2-14
To Check 2-15
To Check 2-16
To Check 2-17
To Check 2-6

TROUBLESHOOTING
Check Step Check
Check 2-1

Description

Engine overrun 1
-1
Fixed to low idle as engine speed exceeds threshold speed *1 min .
1) Check engine speed.
Measure engine speed.
Are low idle, HiIdle and auto idle set to specification at relief of all
pumps?

S6R
S16R
S12A2

2) Check engine speed at auto idle or speed variation.


Is speed shift smooth from auto idle to high idle?
Is engine speed changed smoothly?
according to engine speed control lever stroke?
Is engine speed increased abruptly when loading at high idle and
unloading abruptly?
3) Check rotation pickup.
Is there any foreign abject at engine speed sensor tip?
Is there cutting or damage at engine speed sensor tip?
Is there abnormality at engine speed sensor or harness connector?
Is abnormality caused at MC when replacing engine speed sensor
(for ECM) and control (for MC)?
Is engine speed sensor attached smoothly?
Return one turn if it touches ring gear.
4) Does actuator link slide smoothly?
When moving lever by hand, is there noise or locking?
When moving and releasing lever by hand, is it returned smoothly?
Is there rattle at actuator link?
In direct control mode, is lever engaged with each stopper in range
of 0 to 100%?
Is there wear at sliding areas of actuator link?
Do engine stop solenoid and link move smoothly when key switch is
turned ON and OFF?
5) Check actuator for mounting.
Is actuator mounted positively?

*2
2000
2000
2000

Check 3), 4)

Check 4)
Check 4)
Check 4)

Clean, or replace.
Replace
Repair connector.
Clean, or replace.
Adjust

Check link and bearing.


Check link and bearing.
Check link and bearing.
Adjust link and stopper.
Replace worn parts.
Adjust parts.

Tighten bolts and replace


mount.

6) Check ECM controller power supply.


Is controller power turned ON when turning key switch ON and
OFF?
Check 2-2

*1
1950
1950
2250

Engine overrun 2
-1
Engine stops when engine speed exceeds threshold *2 min . Check as
described in Check 2-1 above.

5-1-2-3

Check relay and harness.

S6R
S16R
S12A2

*1
1950
1950
2250

*2
2000
2000
2000

TROUBLESHOOTING
Check 2-3

Abnormal throttle sensor


-1
Target engine speed is fixed to 1000 min when throttle sensor or
harness in cab is abnormal.
1) Throttle sensor
Is engine speed changed when regulating throttle sensor?
2) Throttle sensor connector
It there change when disconnecting throttle sensor connector?
3) Throttle sensor harness.
Is there problem in power line?
4) Throttle sensor
Is throttle sensor resistance changed?

Check 2-4

2) Turbo boost pressure sensor hose and supercharger line


Is there air leakage due to puncture of turbo boost pressure sensor
hose?
Is there air leakage in line from supercharger to intercooler and
engine?

Check 2-6

Check 2-7

Check harness.
Replace sensor.

Abnormal turbo boost pressure sensor


Because turbo boost pressure sensor or harness is abnormal, fuel
injection amount is not adjusted by boost pressure.
1) Turbo boost pressure sensor
Is difference caused when disconnecting turbo boost pressure
sensor connector? Fuel consumption is increased (increasing black
smoke) in transient period.
Are warming lamps turned ON in cab when disconnecting boost
sensor connector?

Check 2-5

Check sensor and


harness.
Check sensor and
harness.

Replace sensor.
Check sensor harness.

Repair or replace hose.


Repair or replace air leak
portion.

Abnormal actuator power


Abnormal actuator power or harness
1) Check that voltage is abnormal by disconnecting actuator connector.
2) Measure resistance on actuator side.
3) Check ECM output, and measure ECM output.

Check harness.
Check and replace actuator.
Check ECM.

Abnormal actuator sensor


1) Check actuator connector, and input/output and shield lines.
2) Check harness (including connector) from ECM to actuator.
3) Measure resistance on actuator side.

Repair connector.
Repair harness.
Check or replace actuator.

Abnormal sensor power


Abnormal power applied from ECM
1) Check each sensor power.
Check voltage applied to each sensor connector.

5-1-2-4

Check harness.

TROUBLESHOOTING
Check 2-8

Coolant Level (Low)


When coolant level lower signal is sent continuously for 10 seconds or
more, engine speed is set to low idle.
When signal is sent further for 120 seconds or longer, engine will stop.
Check sensor and harness by service manual.

Check 2-9

Coolant Temp. (Overheat)


Check overheat.
1) Check coolant for level and contamination.
2) Clean radiator.
3) Check cooling fan.
4) Check sensor.
5) Check sensor harness.

Check 2-10 Engine Oil Press. (Low)


1) Check oil level and its change intervals.
2) Check filter and its change intervals.
3) Check sensor.
4) Check harness. Is monitor turned ON in cab at short-circuiting?
-1
-1
At 1500 min or less, check with pressure low switch, at over 1500 min ,
check with pressure high switch.
There is possibility that alarm is sounded if engine speed sensor is
abnormal. Then, check rotation pickup.
Check 2-11 Pump Transmission Oil Pressure (Low)
1) Check oil level and its change intervals.
2) Check filer and its change intervals.
3) Check sensor.
4) Check harness. Is monitor turned ON in cab at short-circuiting?
5) Clean transmission oil cooler.
6) Check check valve.
Check 2-12 Fuel Level (Low)
Check fuel for shortage.
Vent air from fuel line sufficiently.
For V-shaped line, vent on left and right sides.
Check 2-13
Check 2-14 Recorded by Check 2-1, 2-2, 2-5, 2-6, and 2-8 to 2-11.
Check 2-15
Check 2-16 Engine ON and OFF
Recorded when engine speed goes over and under threshold speed.
This is different from key switch ON and OFF.
Key switch OFF is judged and recorded to be OFF after load dump relay
actuates and each system power is turned OFF completely.

5-1-2-5

Replenish, or change.
Clean.
Check drive.
Check or replace.
Check.

Plenish.
Change
Check and change.
Check

Plenish
Change
Check and change.
Check
Clean cooler
Check or replace.

TROUBLESHOOTING
Check 2-17 Emergency Switch (Only EX3600, EX1900)
Record emergency stop system ON/OFF.
There is possibility that engine stops by misoperation of engine stop
switch. If emergency stop switch ON is recorded, check if operator
presses the switch, and check the switch and harness if operator does
not press the switch.
Also, there is possibility that swing is disabled with faulty switch.
(Swing is disabled with emergency stop system ON.)
Check 2-18 Misoperation of limit switch at butterfly valve (Only EX3600, EX1900)
Check if butterfly valve lever is fixed positively to ON position. If the lever
is positioned improperly, limit switch goes ON, so that engine stops and
starter does not turn. A similar phenomenon arises due to faulty limit
switch or harness.

5-1-2-6

TROUBLESHOOTING
5.1.2.2 Front Speed Specifications
Engine speed and front speed under standard specifications and standard operation conditions are described.
Standard conditions: Maximum speed, using variable speed fan (Example: EX3600-5 radiator and oil cooler)
Coolant tempAfter warm-up operation (recommended: 70C or higher)
Hydraulic oil temp50C
For standard measuring method, refer to Technical Manual.
Notice that if the customer uses optional front and bucket, front speed differs from the standard.
It is desirable that respective items are measured at the delivery of the machine and at subsequent periodic
inspections to find aging changes.
Significant aging change leads to failure.

5-1-2-7

TROUBLESHOOTING
Measurements
Performance Test

Measurements

Measurements

EX1200-5

S/N (

EX1200-5C

S/N (

EX1900-5

S/N (

S6R-Y1TAA1

ES/N (

S6R-Y2TAA2

ES/N (

) S12A2-Y1TAA1 ES/N (

)
)

Measurements
EX3600-5

S/N (

S16R-Y1TAA1 ES/N (

ENGINE SPEED

SP MODE

SP MODE

Fast Idle Speed

1800+20-50

1800+20-50

197050

Slow Idle Speed

85030

85030

70050

80050

Auto-Idle Speed

1400100

1400100

145050

140050

)
)

174050

Quick Idle Speed

85030

85030

---

---

*All Pumps Relief

167050

167050

184050

161050

CYLINDER CYCLE TIME


BACKHOE

Std BKT

STD5.0m3(BE6.5m3)

m3 STD5.0m3(BE6.5m3)

m3

STD 12.0m3

m3

STD 22.0m3

Boom Raise

4.3 (BE4.5)0.5

4.3 (BE4.5)0.5

6.20.5

8.20.5

Boom Lower

3.1 (BE3.3)0.5

3.1 (BE3.3)0.5

4.10.5

5.90.5

Arm Roll-In

4.5 (BE4.5)0.5

4.5 (BE4.5)0.5

5.90.5

7.00.5

Arm Roll-Out

3.5 (BE4.0)0.5

3.5 (BE4.0)0.5

4.00.5

7.00.5

Bucket Roll-In

3.0 (BE3.3)0.5

3.0 (BE3.3)0.5

4.30.5

4.70.5

Bucket Roll-Out

2.3 (BE2.7)0.5

2.3 (BE2.7)0.5

3.50.5

LOADING SHOVEL

STD

6.5m3

m3

m3

STD 6.5m3

STD 11.0m3

4.20.5
m3

STD 21.0m3

Boom Raise

5.50.5

5.50.5

7.50.6

8.40.5

Boom Lower

4.00.5

4.00.5

5.80.5

5.90.3

Arm Extend

2.90.5

2.90.5

3.40.5

4.50.3

Arm Retract

2.50.5

2.50.5

3.90.5

3.90.3

Bucket Tilt-In

3.30.5

3.30.5

3.40.5

4.40.3

Bucket Tilt-Out

2.20.5

2.20.5

3.20.5

3.20.3

Bucket Open

1.10.5

1.10.5

2.30.3

2.30.3

Bucket Close

1.60.5

1.60.5

1.80.3

2.30.3

*All Pumps Relief


Engine speed at relief of every main pump, starting at high idle.
Generally, boom raise relief is made.

5-1-2-8

m3

m3

TROUBLESHOOTING
5.1.2.3 Engine Check Items
Engine Check Items are tabulated below.
Check method and items are shown at each inspection point.
At each check item, location, influence and failure are described.

5-1-2-9

TROUBLESHOOTING
Check Items (Example: S16R)
For cell with red mark in its right corner, comment is put.
Check Item
Rotation pickup

Check Item
Cap

Check Results
Date
Check
Check

R bank
L bank

Comment, including replacement

Sensor side
Harness side
L bank
Sensor side
Harness side
Exchange connectors in ECM (when checking failure)

Check
Check
Check
Check
Check

Anti-seawater treatment
Check pin and boot
Check pin and boot
Check pin and boot
Check pin and boot
Unnecessary because of dustproof box

Boost sensor

Operate after disconnecting connector.


Is warming lamp lit after disconnecting connector?
Deterioration of sensor hose clamping rubber
Hose damage
Connector
Sensor side
Harness side

Check
Check
Check
Check
Check
Check

Change Yes/No
Light
Yes/No / No
Deterioration Yes/No
Damage Yes/No
LPS-1 HIGHBON TAPE
LPS-1 HIGHBON TAPE

Link

Ball joint jolt

Check
Check
Check
Check
Check

Jolt Yes/No
Jolt Yes/No
Jolt Yes/No
Failure Yes/No
Failure Yes/No

Connector

R bank

R bank
L bank

Bearing jolt and drag


Cancel lever drag
Actuator mount rubber
Harness connector

Actuator connector
ECM connector

ECM ground
Engine ground
DRC connector

Throttle
ECM fault codes

Suction/discharge air
leak

Connector
Peripheral harnesses
2-5
2-3
4-1
4-5
4-3
6-1
6-3
2-1
Suction
Discharge

Outside ECM box


Inside ECM box
ECM connector
Inside ECM box
Outside ECM box
Sensor ground
Above electric part box
Under electric part box
Body

Actuator side Check


Harness Check
Check
Check
Check
Check
Check
Check
Check
Check
Check

Check during running


No
No

Monitoring

No
No
No
No
No

Yes. No during restoring.


Yes. No during restoring.
Yes
Yes
No
No

Check actuator and link for movement.

Yes

Manual cancel lever returns after pulling and releasing it.


Check sliding area of manual cancel lever.
Check mount.

No
No
Yes

No
No
Yes
Yes
Yes
No
No
Yes
Yes
Yes

No
No

Fault code check during


running: Yes

Yes
Yes
Yes

_ turn(s) return after contact


_ turn(s) return after contact

Anti-seawater treatment
Check pin and boot
Check pin and boot
Unnecessary because of dustproof box
Unnecessary because of dustproof box
Unnecessary because of dustproof box
Unnecessary because of dustproof box
Check pin and boot
Check pin and boot
Check pin and boot
Check pin and boot
Check pin and boot

Jolt and pin

Check
Check

Abnormal throttle
Abnormal boost sensor
Abnormal actuator power
Abnormal actuator sensor
Abnormal sensor power
Overrun 1
Overrun 2
Abnormal engine speed sensor

Check
Check
Check
Check
Check
Check
Check
Check

Code display
Code display
Code display
Code display
Code display
Code display
Code display
Code display

Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No

Air cleanerTurbocharger
Check
TurbochargerIntercoolereach cylinder Check
Each cylinder
Check
Check

Code display
Code display
Code display

Yes/No
Yes/No
Yes/No

Problem Yes/No
Problem Yes/No
Problem Yes/No
Problem Yes/No
Return to original state after replacement.
Turn OFF ECM power after reconnecting connector. Check that warning lamp is OFF.

Cancel lever
Link

Problem Yes/No
Sliding area
Problem Yes/No
Injection pump
Problem Yes/No Check for jolt by hand.
Actuator
(Shown is
S16R
Problem Yes/No Check for jolt by hand.
left bank.)
Problem Yes/No Check for jolt by hand.
Problem Yes/No
Problem Yes/No (No seat paint is normal.) Check contact area after removing bolts.
Problem Yes/No Tightened together with relay box under-cover. Ground common to all engine sensors.
Problem Yes/No Check for jolt by hand. Is clearance between connectors OK?
Problem Yes/No Check for jolt by hand. Is clearance between connectors OK?
Problem Yes/No Check for jolt by hand. Is clearance between connectors OK?

Unnecessary because of dustproof box Problem Yes/No


Unnecessary because of dustproof box Problem Yes/No
Forcibly fix engine speed to 1000 min-1.
Release boost control. Exhaust air concentration increase, or engine does not stop.
Emergency engine stop.
Emergency engine stop.
Engine does not stop.
Fix to engine Low idle
Emergency engine stop.
This code is displayed when engine stops. In emergency case, make emergency engine stop.

5-1-2-10

TROUBLESHOOTING
5.1.2.4 Engine Check List
Engine check list shows common daily check items and locations.

5-1-2-11

TROUBLESHOOTING
EX3600-5 (S16R), EX1900-5 (S12A2), EX1200-5 (S6R)
Engines

Others

Fuel

Check Items
Water/oil leak

Engine S/N
Hour meter
Check Locations
Bypass filter clamping area
Injection pump oil feed pipe
Injection pump rack boot
Rear gear train cover
Head
Hoses on thermostat case
Water pump mounting
surface
Water piping O-ring
Injection nozzle

Check Method
Oil, visual
Oil, visual
Oil, visual
Oil, visual
Oil, visual
Water, visual
Water, visual

Remarks
Leak
Leak
Leak
Leak
Leak
Leak
Leak

Water, visual
Check, spray test and
cleaning
Check, water separator

Leak
Change/clean intervals

Water separator filter


replacement and water drain
Actuator link
Check for movement by
hand
Actuator stop solenoid mount Visual check by shaking
Boost sensor hose
Visual check by touching
Engine harness
Visual check by
touching.
Exhaust
Visual check, black
smoke during running
Visual check, discharge
air leak
Belt
Check for tension
Dirt
Visual
Blow by
Visual

Check by water drain


Drag or jolt
Jolt and wear
Hardening or rubbing
Hardening or rubbing
Too much?
Smoke stained area
Loosening and jolt
Check around front seal.
Deviation of injection
amount

5-1-2-12

EX3600/EX1900/EX1200 EX3600/EX1900/EX1200 EX3600/EX1900/EX1200

TOROUBLESHOOTING
EX3600-5
S/N
Inspection
Data
Year Month
Hour meter
Hours
Inspector

Day

Air cleaner Cleaning

Compulsory check items


Check items when required

Radiator intercooler
clog, water/air leak

Oil leak around engine


Fuel /engine oil filters
Left and right fuel injection pumps
Front/rear gear cases
Head cover

Water separator filter/water drain

Boost sensor/hose check

Emergency switch operation check


Stop solenoid jolt and harness check
Engine room, front
Suction/discharge air leak
Engine room, rear
Radiator room
Pump room
Alternator belt tension
Oil cooler, front
Left

Right
Link operation check
Does A-stop lever (manual) move smoothly?
Is there play at link?

Oil leak from right boot


Oil leak from left boot

5-1-2-13

TOROUBLESHOOTING
EX1900-5
S/N
Inspection
Date
Year Month
Hour meter
Hours
Inspector

Day

Compulsory check items


Check items when required

Air cleaner Cleaning

Radiator intercooler
clog, water/air leak

Water separator filter/water drain

Oil leak around engine


Fuel /engine oil filters
Left and right fuel injection pumps
Front/rear gear cases
Head cover
Boost sensor/hose check
Stop solenoid jolt and harness check

Emergency switch operation

Suction/discharge air leak


Left

Fan belt tension

Right
Link operation check
Does stop lever (manual) move smoothly?
Is there play at link?

Alternator belt tension

Oil leak from right boot


Oil leak from left boot

5-1-2-14

TOROUBLESHOOTING
EX1200-5
S/N
Inspection
Date
Year Month
Hour meter
Hours
Inspector

Day

Compulsory check items


Check items when required
Water separator filter/water drain

Oil leak around engine


Fuel /engine oil filters
Left and right fuel injection pumps
Front/rear gear cases
Head cover

Air cleaner Cleaning


Radiator intercooler
clog, water/air leak

Boost sensor/hose check

Stop solenoid jolt and harness check


Suction/discharge air leak
Left

Right
Link operation check
Does A-stop lever (manual) move smoothly?
Is there play at link?

Fan belt tension


Alternator belt tension

5-1-2-15

Oil leak from boot

TROUBLESHOOTING
MEMO
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5-1-2-16

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