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”.

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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.
Engine speed Lamps in cab
6-1 Engine speed *1 min-1 or more→Fixing engine speed to Low idle. Fixed to Low idle Warning lamp ON
With key switch OFF and ECM power OFF→Cancellation To Check 2-1
6-2 Engine speed *2 min-1 or more→Engine stop . Engine stop Stop lamp ON
With key switch OFF and ECM power OFF→Cancellation To Check 2-2
2-5 Abnormal throttle sensor Fixing to 1000 min-1 Warning lamp ON
Throttle sensor and harness in cab are abnormal. To Check 2-3
2-3 Abnormal boost pressure sensor Excess black smoke Warning lamp ON
Boost sensor and harness are abnormal. No change in engine
speed To Check 2-4
4-1 Abnormal actuator power Engine stop Stop lamp ON
Actuator power or harness is abnormal. To Check 2-5
4-5 Abnormal actuator sensor Engine stop Stop lamp ON
Actuator angle sensor or harness is abnormal. To Check 2-6
4-3 Abnormal sensor power No change Warning lamp ON
Each sensor power (normally 5 V) from ECM or harness is abnormal. To Check 2-7
Refer to 5.1.1.2 “ECM and Monitoring Schematic Diagram”.
*1 *2
S6R 1950 2000
S16R 1950 2000
S12A2 2250 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 Description Check Step

① Coolant Level (Low) Check of coolant level, level switch and harnesses To Check 2-8
② Coolant Temp. (Over Heat) Check of cooler, cooling system, overheat Switch and harnesses. To Check 2-9
③ Eng. Oil Press. (Low) Check of lubricant level, filter, viscosity, pressure switch and harnesses. To Check 2-10
④ Pump Trans. Oil Press. (Low) Check of lubricant level, filter, viscosity, pressure switch and harnesses. To Check 2-11
⑤ Fuel Level (Low) Check of fuel shortage To Check 2-12
⑥ Engine Stop Sig. Engine stop signals caused by Items 1 to 4 above, and by abnormal engine To Check 2-13
governor actuator sensor.
⑦ Engine Speed Derate Engine speed control signals caused by Items 1 to 4 above, and by abnormal To Check 2-14
engine governor actuator sensor.
⑧ Engine Torque Derate Engine torque decrease signals by Items 1 to 4 above, and by abnormal engine To Check 2-15
governor actuator sensor.
⑨ Engine Log of engine ON/OFF signals To Check 2-16
⑩ Emergency Switch Log of emergency engine stop ON/OFF To Check 2-17
⑪ Sensor Faults [Angle Sensor] Abnormality of engine actuator angle sensor or harnesses. To Check 2-6
Refer to 5.1.1.2 “ECM and Monitoring Schematic Diagram”

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Check Step Check Description

Check 2-1 Engine overrun 1

-1
Fixed to low idle as engine speed exceeds threshold speed *1 min . *1 *2
S6R 1950 2000
1) Check engine speed. S16R 1950 2000
S12A2 2250 2000
• Measure engine speed.
Are low idle, HiIdle and auto idle set to specification at relief of all
pumps? Check 3), 4)

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

• Is speed shift smooth from auto idle to high idle? Check 4)
• Is engine speed changed smoothly?
according to engine speed control lever stroke? Check 4)
• Is engine speed increased abruptly when loading at high idle and
unloading abruptly? Check 4)

3) Check rotation pickup.

• Is there any foreign abject at engine speed sensor tip? Clean, or replace.
• Is there cutting or damage at engine speed sensor tip? Replace
• Is there abnormality at engine speed sensor or harness connector? Repair connector.
• Is abnormality caused at MC when replacing engine speed sensor
(for ECM) and control (for MC)? Clean, or replace.
• Is engine speed sensor attached smoothly?
Return one turn if it touches ring gear. Adjust

4) Does actuator link slide smoothly?

• When moving lever by hand, is there noise or locking? Check link and bearing.
• When moving and releasing lever by hand, is it returned smoothly? Check link and bearing.
• Is there rattle at actuator link? Check link and bearing.
• In direct control mode, is lever engaged with each stopper in range
of 0 to 100%? Adjust link and stopper.
• Is there wear at sliding areas of actuator link? Replace worn parts.
• Do engine stop solenoid and link move smoothly when key switch is Adjust parts.
turned ON and OFF?

5) Check actuator for mounting.

• Is actuator mounted positively? Tighten bolts and replace
mount.

6) Check ECM controller power supply.

• Is controller power turned ON when turning key switch ON and Check relay and harness.
OFF?

Check 2-2 Engine overrun 2

-1
Engine stops when engine speed exceeds threshold *2 min . Check as *1 *2
described in Check 2-1 above. S6R 1950 2000
S16R 1950 2000
S12A2 2250 2000

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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 Check sensor and

Is engine speed changed when regulating throttle sensor? harness.
2) Throttle sensor connector Check sensor and
It there change when disconnecting throttle sensor connector? harness.
3) Throttle sensor harness.
Is there problem in power line? Check harness.
4) Throttle sensor
Is throttle sensor resistance changed? Replace sensor.

Check 2-4 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. Replace sensor.
• Are warming lamps turned ON in cab when disconnecting boost
sensor connector? Check sensor harness.

2) Turbo boost pressure sensor hose and supercharger line

• Is there air leakage due to puncture of turbo boost pressure sensor Repair or replace hose.
hose?
• Is there air leakage in line from supercharger to intercooler and Repair or replace air leak
engine? portion.

Check 2-5 Abnormal actuator power

Abnormal actuator power or harness

1) Check that voltage is abnormal by disconnecting actuator connector. Check harness.

2) Measure resistance on actuator side. Check and replace actuator.
3) Check ECM output, and measure ECM output. Check ECM.

Check 2-6 Abnormal actuator sensor

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

Check 2-7 Abnormal sensor power

Abnormal power applied from ECM

1) Check each sensor power.

• Check voltage applied to each sensor connector. Check harness.

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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. Replenish, or change.
2) Clean radiator. Clean.
3) Check cooling fan. Check drive.
4) Check sensor. Check or replace.
5) Check sensor harness. Check.

Check 2-10 Engine Oil Press. (Low)

1) Check oil level and its change intervals. Plenish.
2) Check filter and its change intervals. Change
3) Check sensor. Check and change.
4) Check harness. Is monitor turned ON in cab at short-circuiting? Check
-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. Plenish
2) Check filer and its change intervals. Change
3) Check sensor. Check and change.
4) Check harness. Is monitor turned ON in cab at short-circuiting? Check
5) Clean transmission oil cooler. Clean cooler
6) Check check valve. Check or replace.

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.

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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.

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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 temp—After warm-up operation (recommended: 70°C or higher)
• Hydraulic oil temp—50°C

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.

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Measurements Measurements Measurements Measurements

EX1200-5 S/N ( ) EX1200-5C S/N ( ) EX1900-5 S/N ( ) EX3600-5 S/N ( )
Performance Test
S6R-Y1TAA1 ES/N ( ) S6R-Y2TAA2 ES/N ( ) S12A2-Y1TAA1 ES/N ( ) S16R-Y1TAA1 ES/N ( )

ENGINE SPEED SP MODE SP MODE

Fast Idle Speed 1800+20-50 1800+20-50 1970±50 1740±50
Slow Idle Speed 850±30 850±30 700±50 800±50
Auto-Idle Speed 1400±100 1400±100 1450±50 1400±50
Quick Idle Speed 850±30 850±30 --- ---
*All Pumps Relief 1670±50 1670±50 1840±50 1610±50

CYLINDER CYCLE TIME

BACKHOE Std BKT STD5.0m3(BE6.5m3) m3 STD5.0m3(BE6.5m3) m3 STD 12.0m3 m3 STD 22.0m3 m3
Boom Raise 4.3 (BE4.5)±0.5 4.3 (BE4.5)±0.5 6.2±0.5 8.2±0.5
Boom Lower 3.1 (BE3.3)±0.5 3.1 (BE3.3)±0.5 4.1±0.5 5.9±0.5
Arm Roll-In 4.5 (BE4.5)±0.5 4.5 (BE4.5)±0.5 5.9±0.5 7.0±0.5
Arm Roll-Out 3.5 (BE4.0)±0.5 3.5 (BE4.0)±0.5 4.0±0.5 7.0±0.5
Bucket Roll-In 3.0 (BE3.3)±0.5 3.0 (BE3.3)±0.5 4.3±0.5 4.7±0.5
Bucket Roll-Out 2.3 (BE2.7)±0.5 2.3 (BE2.7)±0.5 3.5±0.5 4.2±0.5
LOADING SHOVEL STD 6.5m3 m3 STD 6.5m3 m3 STD 11.0m3 m3 STD 21.0m3 m3
Boom Raise 5.5±0.5 5.5±0.5 7.5±0.6 8.4±0.5
Boom Lower 4.0±0.5 4.0±0.5 5.8±0.5 5.9±0.3
Arm Extend 2.9±0.5 2.9±0.5 3.4±0.5 4.5±0.3
Arm Retract 2.5±0.5 2.5±0.5 3.9±0.5 3.9±0.3
Bucket Tilt-In 3.3±0.5 3.3±0.5 3.4±0.5 4.4±0.3
Bucket Tilt-Out 2.2±0.5 2.2±0.5 3.2±0.5 3.2±0.3
Bucket Open 1.1±0.5 1.1±0.5 2.3±0.3 2.3±0.3
Bucket Close 1.6±0.5 1.6±0.5 1.8±0.3 2.3±0.3

*All Pumps Relief

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

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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.

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 TROUBLESHOOTING
Check Items (Example: S16R)
For cell with red mark in its right corner, comment is put.
Check Results
Check Item Check Item Date Comment, including replacement Check during running Monitoring
Rotation pickup Cap R bank Check _ turn(s) return after contact No ×
L bank Check _ turn(s) return after contact No ×

Anti-seawater treatment
Connector R bank Sensor side Check Check pin and boot Problem Yes/No No ×
Harness side Check Check pin and boot Problem Yes/No No ×
L bank Sensor side Check Check pin and boot Problem Yes/No No ×
Harness side Check Check pin and boot Problem Yes/No No ×
Exchange connectors in ECM (when checking failure) Check Unnecessary because of dustproof box Return to original state after replacement. No ×
Boost sensor Operate after disconnecting connector. Check Change Yes/No Turn OFF ECM power after reconnecting connector. Check that warning lamp is OFF. Yes. No during restoring. ×
Is warming lamp lit after disconnecting connector? Check Light Yes/No / No Yes. No during restoring. ×
Deterioration of sensor hose clamping rubber Check Deterioration Yes/No Yes ×
Hose damage Check Damage Yes/No Yes ×
Connector Sensor side Check LPS-1 • HIGHBON TAPE No ×
Harness side Check LPS-1 • HIGHBON TAPE No ×
Link Ball joint jolt R bank Check Jolt Yes/No Check actuator and link for movement. Yes ×
L bank Check Jolt Yes/No
Bearing jolt and drag Check Jolt Yes/No Manual cancel lever returns after pulling and releasing it. No ×
Cancel lever drag Check Failure Yes/No Check sliding area of manual cancel lever. Cancel lever No ×
Actuator mount rubber Check Failure Yes/No Check mount. Link Yes ×
Anti-seawater treatment
Harness connector Actuator connector Actuator side Check Check pin and boot Problem Yes/No No ○
Sliding area
Harness Check Check pin and boot Problem Yes/No No ○
ECM connector Outside ECM box Check Unnecessary because of dustproof box Problem Yes/No Check for jolt by hand. Injection pump (Shown is Actuator Yes △
Inside ECM box Check Unnecessary because of dustproof box Problem Yes/No Check for jolt by hand. S16R Yes △
left bank.)
ECM connector Check Unnecessary because of dustproof box Problem Yes/No Check for jolt by hand. Yes △
ECM ground Inside ECM box Check Unnecessary because of dustproof box Problem Yes/No ×
Outside ECM box Check Check pin and boot Problem Yes/No (No seat paint is normal.) Check contact area after removing bolts. No ×
Engine ground Sensor ground Check Check pin and boot Problem Yes/No Tightened together with relay box under-cover. Ground common to all engine sensors. No ×
DRC connector Above electric part box Check Check pin and boot Problem Yes/No Check for jolt by hand. Is clearance between connectors OK? Yes ×
Under electric part box Check Check pin and boot Problem Yes/No Check for jolt by hand. Is clearance between connectors OK? Yes ×
Body Check Check pin and boot Problem Yes/No Check for jolt by hand. Is clearance between connectors OK? Yes ×
Throttle Connector Jolt and pin Check Unnecessary because of dustproof box Problem Yes/No No ×
Peripheral harnesses Check Unnecessary because of dustproof box Problem Yes/No No ×

ECM fault codes 2-5 Abnormal throttle Check Code display Yes/No Forcibly fix engine speed to 1000 min-1. ×
2-3 Abnormal boost sensor Check Code display Yes/No Release boost control. Exhaust air concentration increase, or engine does not stop. ×
4-1 Abnormal actuator power Check Code display Yes/No Emergency engine stop. ×
4-5 Abnormal actuator sensor Check Code display Yes/No Emergency engine stop. Fault code check during ○
4-3 Abnormal sensor power Check Code display Yes/No Engine does not stop. running: Yes ×
6-1 Overrun 1 Check Code display Yes/No Fix to engine Low idle ×
6-3 Overrun 2 Check Code display Yes/No Emergency engine stop. ×
2-1 Abnormal engine speed sensor Check Code display Yes/No This code is displayed when engine stops. In emergency case, make emergency engine stop. △
Suction/discharge air Suction Air cleaner→Turbocharger Check Code display Yes/No Yes ×
leak Turbocharger→Intercooler→each cylinder Check Code display Yes/No Yes ×
Discharge Each cylinder Check Check Code display Yes/No Yes ×

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

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 TROUBLESHOOTING
EX3600-5 (S16R), EX1900-5 (S12A2), EX1200-5 (S6R)
Engines
Engine S/N
Hour meter
Check Locations Check Method Remarks EX3600/EX1900/EX1200 EX3600/EX1900/EX1200 EX3600/EX1900/EX1200
Bypass filter clamping area Oil, visual Leak
Injection pump oil feed pipe Oil, visual Leak
Injection pump rack boot Oil, visual Leak
Water/oil leak
Check Items

Rear gear train cover Oil, visual Leak

Head Oil, visual Leak
Hoses on thermostat case Water, visual Leak
Water pump mounting Water, visual Leak
surface
Water piping O-ring Water, visual Leak
Injection nozzle Check, spray test and Change/clean intervals
cleaning
Fuel

Water separator filter Check, water separator Check by water drain

replacement and water drain
Actuator link Check for movement by Drag or jolt
hand
Actuator stop solenoid mount Visual check by shaking Jolt and wear
Boost sensor hose Visual check by touching Hardening or rubbing
Engine harness Visual check by Hardening or rubbing
touching.
Others

Exhaust Visual check, black Too much?

smoke during running
Visual check, discharge Smoke stained area
air leak
Belt Check for tension Loosening and jolt
Dirt Visual Check around front seal.
Blow by Visual Deviation of injection
amount

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EX3600-5
S/N

Inspection
Data Year Month Day
Hour meter
Hours
Inspector

Air cleaner Cleaning

Compulsory check items

Check items when required

Radiator intercooler
clog, water/air leak

Oil leak around engine

① Fuel /engine oil filters Water separator filter/water drain
② Left and right fuel injection pumps
③ Front/rear gear cases
④ Head cover

⑥Boost sensor/hose check

Emergency switch operation check
⑦Stop solenoid jolt and harness check
Engine room, front
Suction/discharge air leak Engine room, rear
③ Radiator room
⑤Alternator belt tension Pump room
④ Oil cooler, front
⑥⑤
⑦ ① Left Right
Link operation check
②
Does A-stop lever (manual) move smoothly?
③ Is there play at link?
⑤ A

⑧
⑧Oil leak from right boot
⑧Oil leak from left boot

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EX1900-5
S/N

Inspection
Date Year Month Day
Hour meter
Hours
Inspector

Compulsory check items

Check items when required

Air cleaner Cleaning

Radiator intercooler
clog, water/air leak
①

② Water separator filter/water drain

Oil leak around engine

① Fuel /engine oil filters
② Left and right fuel injection pumps
③ Front/rear gear cases
④ Head cover
⑧Boost sensor/hose check

⑦Stop solenoid jolt and harness check Emergency switch operation

Suction/discharge air leak

Left Right
⑦⑧⑨ Link operation check
Does stop lever (manual) move smoothly?
⑥Fan belt tension Is there play at link?
④ ③ ⑤Alternator belt tension

⑧
③
⑦
⑨

⑥ ⑤
⑨Oil leak from right boot
⑨Oil leak from left boot

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EX1200-5
S/N

Inspection
Date Year Month Day
Hour meter
Hours
Inspector

Compulsory check items

Check items when required

Water separator filter/water drain

Oil leak around engine Air cleaner Cleaning

① Fuel /engine oil filters
② Left and right fuel injection pumps Radiator intercooler
③ Front/rear gear cases clog, water/air leak
④ Head cover

②
①
⑧Boost sensor/hose check

⑦ ③ ⑦Stop solenoid jolt and harness check

③
⑨Suction/discharge air leak

Left Right
⑨ Link operation check
Does A-stop lever (manual) move smoothly?
⑨ ⑨ ⑥Fan belt tension Is there play at link?

⑤Alternator belt tension Ａ

⑨
⑧

⑥ ⑩
⑤
⑩Oil leak from boot

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MEMO

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