GROUP 3 MECHATRONICS SYSTEM

1. ALL SPEED ARE SLOW

Ɠ Boom, Arm, Bucket, Swing and travel but engine speed is good.
Ɠ Spec : H-mode 2050 +50rpm S-mode 2050 +50rpm
L-mode 1850 +50rpm F-mode 1550 +50rpm
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.

1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective
YES Check pressure hydraulic system.
at EPPR valve

YES Check electric NO

Defective Replace.
current value SPEC : 4~20 kg/cm2
SEE : TEST 4 EPPR valve.
at EPPR valve
SPEC:270~450 mA
NO Defective CPU Replace.
Check resistance SEE:TEST 3
controller.
value between
CN-50(6) - (8) YES
Short circuit or Check & repair
SPEC:24Ţ1‫(י‬20Ƅ) poor connection wire harness or
SEE : TEST 1 Check resistance between CN-50 - between CN-50 -
value at EPPR
NO CN-75. CN-75.
valve
SPEC:24Ţ1‫(י‬20Ƅ) Defective EPPR Replace
SEE : TEST 2 NO
valve.

Wiring diagram

2 Ɠ Normal :
1
CN-47 Emergency :

PROLIX S.W
6
5
4
9 3
8 2
6 1
CN-50 CS-7

11 1
EPPR V/V
2
CN-75
CN-51 CN-2

6 - 38
2) TEST PROCEDURE
SPEC : 24 Ţ 1ѻ(20Ƅ)
(1) Test 1 : Check resistance value (6)-(8) at
connector CN-50.
‫ ڸ‬Starting key OFF. CN-50
‫ ڹ‬Remove CPU controller and disconnect CPU 1 2 3 4 5
connector CN-50. CONTROLLER 6 7 8 9 10
‫ ں‬Check resistance value between pin No. CN53 CN52 CN51 CN-50

6 and No. 8 at connector CN-50.

Multimeter

(2) Test 2 : Check resistance value at

connector CN-75. SPEC : 24 Ţ 1ѻ(20Ƅ)
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CN-75 from
EPPR valve at main hydraulic pump. CN-75
‫ ں‬Check resistance value between 2 lines
as below.

Multimeter

(3) Test 3 : Check electric current value at

EPPR valve. SPEC : 270~450mA
‫ ڸ‬Start engine.
‫ ڹ‬Set S-mode and cancel auto decel
mode.
‫ ں‬If tachometer show approx 2050+50rpm,
CN-75
disconnect one wire harness from EPPR
valve.
‫ ڻ‬Install multimeter as Fig.
‫ ڼ‬Check electric current value at bucket
circuit relief position. EPPR VALVE

Multimeter

6 - 39
(2) Test 4 : Check pressure at EPPR valve.
‫ ڸ‬Remove plug and connect pressure SPEC : 4~20 kg/cm2(58~290 psi)
gauge as Fig.
Gauge capacity : 0 to 40~50 kg/cm2
(0 to 580~730 psi)
‫ ڹ‬Start engine.
‫ ں‬Set S-mode and cancel auto decel Supply line, pilot press

mode.
CN-75
‫ ڻ‬If tachometer show approx. 2350+50rpm,
Pressure adjusting
check pressure at relief position of screw
locknut
bucket circuit by operating bucket control
lever.
‫ ڼ‬If pressure is not correct, adjust it.
‫ ڽ‬After adjust, test the machine.

6 - 40
2. ENGINE SPEED IS SLOW AT ALL MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
If test 7 is good
Check tachometer Check TEST 1~4
YES work properly or
YES
not by changing Check resistance Misalignment Clean speed
the mode. value between between speed sensor and adjust.
Check resistance
SEE : TEST 6 CN-52(14) - CN- sensor and fly SEE: 5-8page
YES value between NO 51(12)
CN-50(2) - (3) and wheel
(4) - (5) SPEC:0.2~0.4‫ױ‬ ‫ڞ‬
SEE : TEST 7 NO
SPEC:5~6‫י‬
Replace governor
Check linkage SEE : TEST 5 Defective governor motor or harness.
NO
between governor motor or short circuit assembly.
motor - injection or poor connection
pump. between CN-50 -
CN-2 and CN-2 -
CN-76 Adjust or repair.
Improper operation
NO
by loosening or
interference of Check and repair.
linkage.
YES
Short circuit or poor
Check resistance connection between
‫ڞ‬ value between CN-51(12) - CD- Replace.
CD-17(1) - (2) 17(2) or CN-52(14) -
CD-17(1)
SPEC:0.2~0.4‫ױ‬ NO
SEE : TEST 8 Defective
speed sensor.
Wiring diagram

2 Ɠ Mnql`k9
1
CN-47 Dldqfdmbx9
5 PROLIX S.W
4 6
3 5
2 4
9 3
8 2
6 1
CN-50 CS-7
11 1
12
2 EPPR V/V
10
CN-51 CN-2 CN-75 SPEED SENSOR
24 2
23 1
14 CD-17
CN-52 5 1
4 2 POT(POTENTIOMETER)
3 3
7
6 CN-77
9
10 1 A
11 2 A-
12 3 B
4 B-
CN-2
CN-76 GOVERNOR MOTOR

6 - 41
2) TEST PROCEDURE
(1) Test 5 : Check resistance value between CPU
(2)-(3) and (4)-(5) at connector CONTROLLER
CN-50. CN53 CN52 CN51 CN-50
‫ ڸ‬Starting key OFF.
‫ ڹ‬Remove CPU controller and disconnect
connector CN-50 from CPU controller.
‫ ں‬Check resistance value as below.

CN-50 CN-50

1 2 3 4 5 1 2 3 4 5
6 7 8 9 10 6 7 8 9 10

Multimeter Multimeter

unit : rpm
(2) Test 6 : Check tachometer
Spec Remark
(Work properly or not.)
‫ ڸ‬Start engine. H-mode 2050+50rpm
‫ ڹ‬Check tachometer reading. S-mode 2050+50rpm Check rpm after
cancel the one touch
L-mode 1850+50rpm decel mode.
F-mode 1550+50rpm

(2) Test 7 : Check resistance value between

SPEC : 0.2 ~ 0.4 ‫ױ‬
(14) of CN-52 and (12) of CN-51.
‫ ڸ‬Starting key OFF.
‫ ڹ‬Remove CPU controller and disconnect CPU
connector CN-51 and CN-52 from CPU CONTROLLER
controller. CN53 CN52 CN51 CN-50
‫ ں‬Check resistance value as below.

CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18

Multimeter

6 - 42
(4) Test 8 : Check resistance value at speed
SPEC : 0.2 - 0.4‫ױ‬
sensor.
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CD-17 of speed Speed sensor

sensor at engine flywheel housing.

‫ ں‬Check resistance value as Fig.
CD-17 CD-17
1 2

Engine flywheel

Multimeter

6 - 43
3. ENGINE STALL
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Not enough engine Contact cummins
YES Check pressure at power. engine dealer.
EPPR valve.

NO
Defective EPPR Replace.
SPEC:30~33 kg/cm2 valve.
Check electric SEE:TEST 10
current value at YES
EPPR valve. Defective CPU Replace.
controller.
SPEC:570~600 mA
SEE:TEST 9 Check resistance
value between YES
Short circuit or poor Check and
NO CN-50(6) - (8)
connection repair.
SPEC:24Ţ1Ѥ(20Ƅ) Check resistance between
SEE : TEST 1 value at EPPR CN-50 - CN-2 or
NO
valve. CN-50 - CN-75
SPEC:24Ţ1Ѥ(20Ƅ)
SEE : TEST 2 Defective EPPR Replace.
NO
valve.

Wiring diagram

Ɠ Mnql`k9
Dldqfdmbx9
2
1
CN-47

PROLIX S.W
6
5
4
9 3
8 2
6 1
CN-50 CS-7

11 1
EPPR V/V
2
CN-75
CN-51 CN-2

6 - 44
2) TEST PROCEDURE
SPEC : 570~600mA
(1) Test 9 : Check electric current value at
EPPR valve at F-mode
‫ ڸ‬Start engine. CN-75
‫ ڹ‬Set F-mode with 1550 +50rpm
‫ ں‬Install multimeter as below.
‫ ڻ‬Check electric current value at bucket
circuit relief position.
EPPR VALVE

Multimeter

(2) Test 10 : Check pressure at EPPR valve

SPEC : 30~33 kg/cm2(440~480 psi)
at F-mode
‫ ڸ‬Connect pressure gauge at EPPR valve.
‫ ڹ‬Start engine.
‫ ں‬Set F-mode with 1550 +50rpm
‫ ڻ‬Operate bucket lever completely push or Supply line, pilot press

pull. CN-75
‫ ڼ‬Hold arm lever at the end of stroke. Pressure adjusting
screw
‫ ڽ‬Check pressure at relief position. locknut

6 - 45
4. CLUSTER LAMPS ARE OFF IMMEDIATELY AFTER KEY SWITCH OFF
Ɠ Before carrying out below procedure, check all the related connector are properly inserted.
Normal condition : Lamps "ON" approx. 3-12 second after key switch OFF.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective Replace.
CPU controller.

Check voltage at YES

CN-50(10) Poor connection Check and
or short circuit repair.
SPEC:24Ţ1 VOLT between
SEE : TEST 11
Check CN-50(10) - CN-
NO Fuse No. 17 60(2)

SEE : TEST 12
Defective fuse. Replace.
NO

Wiring diagram

FUSE BOX

BATTERY
10 1 17 2 2 2
CN-40 CN-5 CN-60
CN-39
CN-50

6 - 46
2) TEST PROCEDURE
SPEC : 24 Ţ 1Volt
(1) Test 11 : Check voltage at (10) of CN-50.
‫ ڸ‬Starting key OFF. CN-50

‫ ڹ‬Disconnect connector CN-50 from CPU CPU 1 2 3 4 5

CONTROLLER 6 7 8 9
controller. 10
CN53 CN52 CN51 CN-50

Ground

Multimeter

(2) Test 12 : Check fuse at (17) of fuse Box.

‫ ڸ‬Starting key OFF. Fuse box
CPU WIPER &

20A
10A
12

1
CONTROLLER WASHER

‫ ڹ‬Selecting the fuse at (17) of fuse Box.

20A
20A
CLUSTER

2
13
SOL. B+

‫ ں‬Check if the fuse is defective or not.

CASSETTE &

20A
20A

3
WORK LAMP

14
RADIO

CIGAR &

20A
20A
15
SPARE

4
ETHER SOL.

CASSETTE & HORN &

20A
10A
16

5
CLOCK B+ SAFETY

MONITOR &

20A
20A
17

6
HEAD LAMP
CPU B+

F/PUMP &

10A

10A
18
ROOM LAMP

7
T/ALARM

AIR-CON

30A

20A
SPARE

8
BREAKER

30A

30A
SPARE

9
CABIN LIGHT

10A
30A

10
SPARE SPARE

10A
SPARE

11
FUSE

20A
12
PULLER SPARE

SPEC : 20A

Fuse No. 17 for CPU B+

6 - 47
5. CLUSTER LAMPS ARE STILL ON AFTER STARTING KEY OFF
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Improper Check and
operation of repair.
governor motor.
Check interference So, governor
YES of connecting rod motor supply
when governor
signal to
motor move to low
rpm side. cluster panel
continuously.
Replace.
Check voltage at Defective
CN-50(9). NO
CPU controller. Replace.
SPEC : YES
Key ON : 24Ţ1 VOLT Defective battery
Key OFF : 0 VOLT
SEE : TEST 13 Is the voltage 24V relay.
Replace.
NO between CN-50(4)
and GND?
NO
Defective CPU
TEST :
Repeat key switch controller
ON and OFF
SEE : TEST 14

Wiring diagram

FUSE BOX

9 3 3 START
14
1 IGNITION

CN-38 CS-2
CN-50 START KEY SWITCH

6 - 48
2) TEST PROCEDURE
SPEC :
(1) Test 13 : Check voltage at(9) of CN-50. Key ON : 24Ţ1 Volt
‫ ڸ‬Starting key "ON". Key OFF : 0 Volt
‫ ڹ‬Disconnect connector CN-50 from CPU
CN-50
controller. CPU 1 2 3 4 5
‫ ں‬Check voltage as below. CONTROLLER 6 7 8 9 10
CN53 CN52 CN51 CN-50

Ground

Multimeter

(2) Test 14 : Check operating status of main

SPEC :
power supply at (9) of CN-50.
Key OFF : 0 Volt
‫ ڸ‬Starting key "ON".
‫ ڹ‬Disconnect CN-50 from CPU controller. CN-50
‫ ں‬Check if the voltage remains at 24Ţ CPU 1 2 3 4 5
1volt inspire of operating key switch on CONTROLLER 6 7 8 9 10
and off. CN53 CN52 CN51 CN-50

Ɠ If there is certain amount of voltage,

replace CPU controller. Ground

Multimeter

6 - 49
6. CLUSTER LAMPS ARE ON WHEN ENGINE RUN OR MALFUNCTION OF MODE SELECTION
SYSTEM
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective lamps or Repair or Replace
Check voltage for cluster
YES
between CN-50(7)
- CN-57(5).

SPEC : 24Ţ1V NO
Defective CPU Replace.
Check resistance SEE : TEST 16 controller.
value for switches. Poor connection Check and repair.
between CN-50 -
SPEC :
Switch ON : 0‫י‬ CN-57.
Switch OFF : Ũ‫י‬
SEE : TEST 15 NO
Defective switch at Replace.
cluster.

Wiring diagram

8 8

4
CN-56 CN-7
5
6
7
8
9

7 7
CN-51
1 1
2 2
9 9
8 8
5 5 7
CN-57 CN-8

CN-50

6 - 50
2) TEST PROCEDURE
(1) Test 15 : Check resistance value for CPU
switches. CONTROLLER
‫ ڸ‬Starting key OFF. CN53 CN52 CN51 CN-50
‫ ڹ‬Disconnect connector CN-51 from CPU
controller.
‫ ں‬Check resistance value as below.

CN-51

1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18

Ground

Multimeter

(2) Test 16 : Check voltage for CN-50, CN-57

ňCN-50:output power(24Ţ1volt) SPEC : 24Ţ1 Volt
ňCN-57:input power(24Ţ1volt)
‫ ڸ‬Starting key ON.
CN-50
‫ ڹ‬Remove cluster from panel. CPU 1 2 3 4 5
Ɠ Don't disconnect connector CN-50 from CONTROLLER 6 7 8 9 10
CPU controller. CN53 CN52 CN51 CN-50
‫ ں‬Disconnect connector CN-57 from
cluster. Ground

‫ ڻ‬Check voltage CN-50,CN-57 with

ground as Fig. Multimeter

CN-57
1 2 3 4 5 6
7 8 9 10 11 12

Ground

Multimeter

6 - 51
7. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Slow action of Check and repair.
engine speed
control due to
interference.
Check interference Replace.
Check voltage YES
between between CN- Defective CPU
connecting rod 52(24) - CN-51(10) controller.
and governor YES
and check
resistance value Replace.
Check resistance between CN- Defective governor
value between CN- 52(23) - CN-51(10). NO
motor.
NO 50(2) - (3) and CN- SPEC : (24)-(10) : 5Ţ1 volt
50(4) - (5) (23)-(10) : 0-5‫ױ‬
SEE : TEST 18 Replace.
SPEC : 5~6‫י‬
SEE : TEST 17 Defective governor
NO
motor.

Wiring diagram

2
3
4
5

CN-50
5 1
4 2 POT(POTENTIOMETER)
10 3 3

CN-77
CN-51
12 4 B-
11 3 B
10 2 A-
24 9 1 A
23
CN-2 CN-76 GOVERNOR MOTOR

CN-52

6 - 52
2) TEST PROCEDURE
Test - a
(1) Test 17 : Check resistance value
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CN-50 from CPU CN-50
CPU
controller. 1 2 3 4 5
CONTROLLER
‫ ں‬Check resistance value between (2) and 6 7 8 9 10
CN53 CN52 CN51 CN-50
(3), (4) and (5) of CN-50 as below.

Multimeter

Test - b

CN-50
CPU
1 2 3 4 5
CONTROLLER
6 7 8 9 10
CN53 CN52 CN51 CN-50

Multimeter

6 - 53
(2) Test 18 : Check voltage and resistance
SPEC : 0 ~ 5 ‫ױ‬
value.
‫ ڸ‬Check resistance value between (23) of
CN-52 and (10) of CN-51. CPU
CONTROLLER
Ť Starting key OFF.
CN53 CN52 CN51 CN-50
Ť Disconnect connector CN-52 and CN-51
from CPU controller.
Ť Check resistance value with multimeter
as below.

CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18

Multimeter

‫ ڹ‬Check voltage between (24) of CN-52

SPEC : 5 Ţ 1Volt
and (10) of CN-51.
CPU
Ť Prepare 2 pieces of thin sharp pin, steel
CONTROLLER
or copper. Pin Pin
Ť Starting key ON.
Ť Insert prepared pins to rear side of
connectors :
One pin to (24) of CN-52
Other pin to (10) of CN-51
Ť Check voltage.
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18

Multimeter

6 - 54
8. ONE TOUCH DECEL SYSTEM DOES NOT WORK
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective CPU Replace.
controller.
Short circuit or poor Replace or repair.
connection
Check resistance
between CN-51(3)
value between
CN-51(4) - GND. - (4)

SPEC :
Switch ON : 0‫װ‬
Switch OFF : ſ‫װ‬
SEE : TEST 19
NO
Defective cluster. Replace.

Wiring diagram

11 11 2
CS-29
8 8 CN-36

3
4
CN-56 CN-7 5
6
7
8
9
7 7
1 1 CN-51
2 2
9 9
8 8
5 5 7
CN-57 CN-8

CN-50

6 - 55
2) TEST PROCEDURE
SPEC :
(1) Test 19 : Check resistance value at One touch decel switch ON(Light ON) : 0‫װ‬
CN-51(4) and ground. One touch decel switch OFF(Light OFF) : ſ‫װ‬
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CN-51 from CPU
CPU controller. CONTROLLER
‫ ں‬Turn start key ON. CN53 CN52 CN51 CN-50
Check resistance value as Fig.

CN-51

1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18

Ground

Multimeter

6 - 56
9. MALFUNCTION OF WARMING UP
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective cluster or Repair or
Check resistance CPU controller or Replace.
YES
value between CN- CD8(sensor)
57(3) - CD-8
Check resistance SPEC : 0ѻ Poor connection Repair.
NO
value between CN SEE : TEST 21 between CN-57(3)
-51(20) - CN-56(16) - CD-8.
SPEC : 0ѻ
SEE : TEST 20
Poor connection Repair.
NO
between CN-
52(20) - CN-56(16).

Wiring diagram

WATER TEMP SENSOR

20 4 16
CD-8
CN-52 CN-9

CN-56

3 6

CN-1
CN-57

6 - 57
2) TEST PROCEDURE
SPEC : 0ѻ
(1) Test 20 : Check resistance value between
connector (20) of CN-52- (16) of
CN-56. CPU
‫ ڸ‬Starting key OFF. CONTROLLER
‫ ڹ‬Remove CPU controller and disconnect CN53 CN52 CN51 CN50

CN-52 from CPU controller.

‫ ں‬Remove cluster and disconnect CN-56 Cluster

from cluster.
‫ ڻ‬Check resistance value as Fig.
CN-56

9 10 1112 1314 15 16

1 2 3 4 5 6 7 8
CN-52
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24

Multimeter

(2) Test 21 : Check resistance value between

connector (3) of CN-57 - CD-8. SPEC : 0ѻ
‫ ڸ‬Starting key OFF.
CN-57
‫ ڹ‬Remove cluster and disconnect CN-57 12 11 10 9 8 7

from cluster. 6 5 4 3 2 1
‫ ں‬Disconnect connector CD-8 of water
temp sensor at engine head.
‫ ڻ‬Check resistance value as Fig.

Cluster
CD-8 Water temp sensor

Multimeter

6 - 58
10. MALFUNCTION OF OVERHEAT
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective overheat Replace
switch
Check resistance
value between YES
CD-9 - GND. Defective CPU Replace
SPEC : Check resistance controller
Region мƊſѻ value between CN-
(Fig.) нƊſѻ NO
51(1) - CD-9
оƊſѻ
SEE : TEST 22 Short circuit or poor Check or Repair
SPEC : 0ѻ NO
SEE : TEST 23 connection between
CN-51(1) - CD-9.

coolant
temperature

110Ƅ

Ɠ Overheat switch ON coolant temperature 110Ƅ 110Ƅ

Ɠ Overheat switch OFF coolant temperature 100Ƅ

Time
Region ѓ Region є Region ѕ
Temperature curve
Wiring diagram
Overheat switch

1 3

CD-9
CN-51 CN-1

15 3

CN-59

CN-56

6 - 59
2) TEST PROCEDURE
SPEC : 0ѻ
(1) Test 22 : Check resistance value between
connector CD-9 - GND. CD-9 Overtheat switch
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CD-9 of overheat
switch at engine head.
‫ ں‬Check resistance value as Fig.

Ground
Multimeter

(2) Test 23 : Check resistance value between

SPEC : 0ѻ
connector (1) of CN-51 - CD-9.
CPU
‫ ڸ‬Starting key OFF.
CONTROLLER
‫ ڹ‬Remove CPU controller and disconnect
connector CN-51 from CPU controller. CN53 CN52 CN51 CN-50

‫ ں‬Disconnect connector CD-9 of overheat

switch at engine head.
‫ ڻ‬Check resistance value as Fig.

CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18

CD-9
Overtheat switch

Multimeter

6 - 60