Injector Solenoid Fault Detected by DataMind AI in Hitachi EX3600 Excavator

Injector faults on large mining excavators upset combustion balance, reducing engine power and putting the engine at risk of damage over time. DataMind AI continuously monitors injector-related OEM alarms together with cylinder exhaust temperatures, enabling early detection of combustion problems before they escalate into failure.

In this case, DataMind AI identified 80 OEM alarms for the cylinder 1 injector solenoid driver on a Hitachi EX3600-7 excavator over about one week. At the same time, the cylinder 1 exhaust temperature dropped to a very low average of around 95°C, while the neighboring exhaust port continued operating normally at around 400°C.

By correlating the injector alarms with the cylinder-level exhaust temperature drop, DataMind AI identified incorrect combustion in cylinder 1, pointing to a faulty injector solenoid, a faulty injector, or connector and wiring issues.

A cylinder cutout test confirmed a faulty cylinder 1 injector, which was replaced during a planned stop. Cylinder 1 exhaust temperature returned to around 400°C, matching the neighboring port, and the injector alarms stopped. Early detection helped avoid an estimated 2 days of unplanned downtime and approximately $35,000 in engine repair costs.