Académique Documents
Professionnel Documents
Culture Documents
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
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
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
2000
2000
2000
Check 3), 4)
Check 4)
Check 4)
Check 4)
Clean, or replace.
Replace
Repair connector.
Clean, or replace.
Adjust
*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
S6R
S16R
S12A2
*1
1950
1950
2250
*2
2000
2000
2000
TROUBLESHOOTING
Check 2-3
Check 2-4
Check 2-6
Check 2-7
Check harness.
Replace sensor.
Check 2-5
Replace sensor.
Check sensor harness.
Check harness.
Check and replace actuator.
Check ECM.
Repair connector.
Repair harness.
Check or replace actuator.
5-1-2-4
Check harness.
TROUBLESHOOTING
Check 2-8
Check 2-9
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
1800+20-50
1800+20-50
197050
85030
85030
70050
80050
Auto-Idle Speed
1400100
1400100
145050
140050
)
)
174050
85030
85030
---
---
167050
167050
184050
161050
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
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
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
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
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
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
Monitoring
No
No
No
No
No
Yes
No
No
Yes
No
No
Yes
Yes
Yes
No
No
Yes
Yes
Yes
No
No
Yes
Yes
Yes
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
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?
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
5-1-2-12
TOROUBLESHOOTING
EX3600-5
S/N
Inspection
Data
Year Month
Hour meter
Hours
Inspector
Day
Radiator intercooler
clog, water/air leak
Right
Link operation check
Does A-stop lever (manual) move smoothly?
Is there play at link?
5-1-2-13
TOROUBLESHOOTING
EX1900-5
S/N
Inspection
Date
Year Month
Hour meter
Hours
Inspector
Day
Radiator intercooler
clog, water/air leak
Right
Link operation check
Does stop lever (manual) move smoothly?
Is there play at link?
5-1-2-14
TOROUBLESHOOTING
EX1200-5
S/N
Inspection
Date
Year Month
Hour meter
Hours
Inspector
Day
Right
Link operation check
Does A-stop lever (manual) move smoothly?
Is there play at link?
5-1-2-15
TROUBLESHOOTING
MEMO
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
.....................................................................................................................................................................................
5-1-2-16