GROUP 4 MECHATRONICS SYSTEM

1. ALL ACTUATORS SPEED ARE SLOW

※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
※ Spec : H-mode 2350±50(2250±50)rpm S-mode 2150±50(2100±50)rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted.
※ ( ) : TIER II (#1001 AND UP)
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO
Check electric NO Defective Replace
SPEC : 5~20kgf/cm2
YES current at EPPR See TEST 4 EPPR valve
valve
Check if Err : 03
on the cluster SPEC : 200~550mA Defective CPU Replace
See TEST 3 NO
controller
Check resistance
between CN-2(9)-
YES (10)
YES
Short circuit or Check & repair
SPEC : 17.5±1Ω(20°
C)
See TEST 1
poor connection wire harness or
Check resistance between CN-50 - between CN-50-
NO at EPPR valve CN-75 CN-75

SPEC : 17.5±1Ω(20°
C) Defective EPPR Replace
See TEST 2 NO
valve

Wiring diagram CN-92

FUSE Emergency
TIER I(UP TO #1001)
CN-2 NO.9
CN-75 CN-47
2 9 1 1
1 10 2 2
EPPR V/V PROLIX
RESISTOR
CN-50

8 24 Normal

CONTROLLER
TIER II(#1001 AND UP)

6-41
2) TEST PROCEDURE SPEC : 17.5±1Ω(20°C )
(1) Test 1 : Check resistance at connector
CN-2(9)-(10).
① Starting key OFF. CN-2
② Disconnect connector CN-2. 12 10 9 1

③ Check resistance between pin and at

connector CN-2(9)-(10).

Multimeter

(2) Test 2 : Check resistance at connector

SPEC : 17.5±1Ω(20°
C)
CN-75.
① Starting key OFF.
② Disconnect connector CN-75 from EPPR
CN-75
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure.

Multimeter

(3) Test 3 : Check electric current at EPPR valve. SPEC : 200~550mA (S mode)
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(MAX)
④ Set S-mode and cancel auto decel mode.
CN-75
⑤ If tachometer show approx 2150±50
(2100±50)rpm, check electric current.
※( ) : TIER II (#1001-)

EPPR VALVE
Multimeter

6-42
(2) Test 4 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm2(70~280psi)
① Remove plug and connect pressure
gauge as figure.
・Gauge capacity : 0 to 40~50kgf/cm2
(0 to 570~710psi)
② Start engine. Supply line, pilot press
③ Set the accel dial at "10"(Max)
④ Set S-mode and cancel auto decel mode. CN-75
⑤ If tachometer show approx 2150 50 Pressure adjusting
(2100 50)rpm, check pressure. screw locknut

⑥ If pressure is not correct, adjust it.

⑦ After adjust, test the machine.
※( ) : TIER II (#1001-)

6-43
2. ENGINE SPEED IS SLOW AT ALL MODE
※ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
Good
If test 7 is good,
Check tachometer check TEST 1~4
YES work properly or
not by changing YES
Misalignment Clean speed
the mode. between speed sensor and
Is resistance
YES Is resistance See TEST 6 sensor and fly adjust
between CN-50 between CN-51
No good wheel See : 5-20page
(12) - (23) (25) - (26)
SPEC : 0.2~0.4kΩ ⓐ
SPEC : 1~2Ω
See TEST 7 NO
See TEST 5
Check cable
between accel Defective accel Replace accel
NO
actuator and actuator or short actuator or
injection pump. circuit or poor harness
connection assembly
between CN-50-
CN-76

Improper operation Adjust or repair

NO
by loosening or
interference of cable
YES
Short circuit or poor Check and repair
connection
Is resistance
ⓐ between CN-51-
between CD-17
CN-2-CD-17
(1) - (2)
SPEC : 0.2~0.4kΩ
NO
Defective Replace
See TEST 8
speed sensor
Wiring diagram
ACCEL ACTUATOR
ACCEL ACTUATOR
CPU CONTROLLER
1 P+
2
2 SIG
1 3
12 3 P-
4 NC
5
5 M+ M 6
23 6 M-
CN-76 ACCEL DIAL
CN-50
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 12 1
rp
m

26 11 2
CN-51 CN-2 CD-17

6-44
2) TEST PROCEDURE SPEC : 1~2Ω
(1) Test 5 : Check resistance between CN-50 Y R G

(12)-(23). CPU
① Starting key OFF. CONTROLLER

② Disconnect connector CN-50 from CPU CN-50

CN-51
controller.
③ Check resistance as figure.

CN-50
12 1
23 13
36 25

Multimeter

Unit : rpm
(2) Test 6 : Check tachometer(Work properly
Spec Remark
or not)
① Start engine. 2350±50 Check rpm after
H-mode
② Check tachometer reading. *2250±50 cancel the Auto decel
2350±50 mode.
S-mode
*2100±50
* TIER II (#1001-)

(3) Test 7 : Check resistance between CN-51 SPEC : 0.2~0.4kΩ

(25) and CN-51(26).
Y R G
① Starting key OFF.
② Disconnect connector CN-51 from CPU CPU
CONTROLLER
controller. CN-51
③ Check resistance as figure. CN-50

CN-51 12 1
24 13
36 26 25

Multimeter

6-45
(4) Test 8 : Check resistance at speed
SPEC : 0.2~0.4kΩ
sensor.
① Starting key OFF.
Speed sensor
② Disconnect connector CD-17 of speed
sensor at engine flywheel housing.
③ Check resistance as figure.
CD-17 CD-17
1 2

Engine flywheel

Multimeter

6-46
3. ENGINE STALL
※ 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 power engine dealer
at EPPR Valve
Defective EPPR Replace
SPEC:5~20kgf/cm2 NO
See TEST 10 valve
Check electric
current at EPPR YES
valve Defective CPU Replace
controller
SPEC : 200~550mA
See TEST 9 Check resistance YES
between CN-50 Short circuit or Check and repair
NO (8)-(24) poor connection
SPEC : 17.5±1Ω(20°
C) between
See TEST 1 Check resistance CN-50 - CN-2 or
NO at EPPR valve
CN-50 - CN-75
SPEC : 17.5±1Ω(20°
C)
See TEST 2 Defective EPPR Replace
NO
valve

Wiring diagram CN-92

TIER I(UP TO #1001) FUSE Emergency

CN-2 NO.9
CN-75 CN-47
2 9 1 1
1 10 2 2
EPPR V/V PROLIX
RESISTOR
CN-50

8 24 Normal

CONTROLLER

TIER II(#1001 AND UP)

6-47
2) TEST PROCEDURE SPEC : 200~550mA
(1) Test 9 : Check electric current at EPPR
valve at S-mode CN-75
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(max)
④ Set S-mode with 2150±50 (2100±50)rpm.
⑤ Check electric current. EPPR VALVE
※( ) : TIER II (#1001-) Multimeter

(2) Test 10 : Check pressure at EPPR valve SPEC : 5~20kgf/cm2(70~280psi)

at S-mode
① Connect pressure gauge at EPPR valve.
② Start engine.
③ Set the accel dial at "10"(max) Supply line, pilot press
④ Set S-mode with 2150±50 (2100±50)rpm.
⑤ Operate bucket lever completely push or CN-75
pull. Pressure adjusting
screw locknut
⑥ Hold arm lever at the end of stroke.
⑦ Check pressure at relief position.
※( ) : TIER II (#1001-)

6-48
4. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
※ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
No power supply to Check fuse
See if all lamps the CPU controller
YES
off in the CPU
controller case YES
Y R G CPU failure Replace
Y R G
See if Co : Err
NO
on the cluster

NO Y R G
ⓐ
NO

OK
Check connection Cluster failure Replace
between CN-50
ⓐ (29) - CN-5(10) or
CN-50(30) - CN-
5(11) No connection Check and repair
NO
KEY OFF

Wiring diagram

CPU CONTROLLER

CLUSTER
POWER IG(24V) 24

GND 28

RX 3 10 29

TX 4 11 30
CN-56 CN-5 CN-50
CN-51

FUSE

NO.9(CPU)

6-49
5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
※ 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
between YES
connecting rod and Defective CPU Replace
Check voltage
accel actuator between CN-51(20) controller
YES
-(21) and check
resistance between
CN-51(20)-(22)
Check resistance Defective accel Replace
NO
between CN-50 SPEC : (20)-(21) : 5±1V actuator
NO (20)-(22) : 0.1~0.9kΩ
(12)-(23) See TEST 12

SPEC : 1~2Ω
See TEST 11 Defective accel Replace
NO
actuator

Wiring diagram

ACCEL ACTUATOR
ACCEL ACTUATOR
CPU CONTROLLER
1 P+
2
2 SIG
1 3
12 3 P-
4 NC
5
5 M+ M 6
23 6 M-
CN-76 ACCEL DIAL
CN-50
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 12 1
rp
m

26 11 2
CN-51 CN-2 CD-17

6-50
2) TEST PROCEDURE SPEC : 1~2Ω
(1) Test 11 : Check resistance. Y R G

① Starting key OFF.

CPU
② Disconnect connector CN-50 from CPU CONTROLLER
controller. CN-50
③ Check resistance between CN-50(12)- CN-51

(23) as figure.

CN-50
12 1
23 13
36 25

Multimeter

6-51
(2) Test 12 : Check voltage and resistance. SPEC : 0.1~0.9kΩ
① Check resistance between CN-51(20)- Y R G

(22). CPU
CONTROLLER
- Starting key OFF.
CN-51
- Disconnect connector CN-51 from CPU
CN-50
controller.
- Check resistance value with multimeter
as figure.

CN-51
12 1
24 22 20 13
36 25

Multimeter

② Check voltage between CN-51(20) and SPEC : 5±1V

CN-51(21). Y R G

- Prepare 2 pieces of thin sharp pin, steel CPU

or copper. CONTROLLER
PIN
- Starting key ON.
CN-50
- Insert prepared pins to rear side of CN-51

connectors : One pin to CN-51(20)

Other pin to CN-51(21)
- Check voltage.

CN-51
12 1
24 21 20 13
36 25

Multimeter

6-52
6. AUTO DECEL SYSTEM DOES NOT WORK
※ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective CPU Replace
controller

NO
Check resistance Short circuit or Replace or repair
between CN-51 poor connection
(1)-GND between CN-51(1)
pressure switches
SPEC :
Actuator operating :
4~5V
Actuator stop :0~1V
See TEST 13 Defective auto Replace
NO
decel pressure
switch

Wiring diagram

CONTROLLER
AUTO DECEL
PRESSURE SWITCH
1 Pa
1 2
CD-7

CN-51

6-53
2) TEST PROCEDURE SPEC : Actuator stop : 4~5V
(1) Test 13 : Check voltage at CN-51(1) and Actuator operating : 0~1V
ground. Y R G

① Prepare 1 piece of thin sharp pin, steel or CPU

CONTROLLER
copper. PIN
② Starting key ON. CN-50
CN-51

③ Insert prepared pin to rear side of

connectors : One pin to (1) of CN-51.
④ Check voltage as figure.

CN-51 12 1
24
36 25

Ground

Multimeter

6-54
7. MALFUNCTION OF WARMING UP
※ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective cluster or Repair or Replace
Check resistance CPU controller or
YES
between CN-51 CD-8(Sensor)
(31) - CD-8(2)
SPEC : Below10Ω NO Poor connection Repair
Check resistance KEY OFF
between CN-
between CN -51
(33) - CD-8(1) 51(31) - CD-8(2)
SPEC : Below 10Ω
KEY OFF

NO
Poor connection Repair
between CN-
51(33) - CD-8(1)

Wiring diagram

CONTROLLER

WATER TEMPERATURE SENSOR

31 6 2 C
33 5 1
CD-8

CN-51 CN-3

6-55
8. MALFUNCTION OF POWER MAX
※ Before carrying out below procedure, check all the related connectors are properly inserted.
1 ) INSPECTION PROCEDURE

Cause Remedy
YES Check resistance
between CN-88 Defective power Repair or replace
(1) - (2) max. solenoid valve
YES
Resistance
between CN-51 SPEC: 15-30Ω
(2)-GND normal? See TEST 15

NO Short circuit or poor Repair or replace

SPEC : Power max button pressed ON : 0 connection
Is voltage between Power max button released OFF : between CN-51(2) -
CN-88(1) -GND See Test 16
normal? CS-29 and CN-50
(3) -CN-88(1)
SPEC
KEY ON : 24±1V
KEY OFF : 0V
See TEST 15
NO Short circuit or poor Repair or replace
connection
between CN-88(2)-
battery relay(+)

Wiring diagram

CPU CONTROLLER
POWER MAX SOLENOID

3 1
FUSE
CN-50 2
NO.23
CN-88
POWER MAX SWITCH
1 1
2 2 2
CS-29
CN-51 CN-4

6-56
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 15: Check voltage between connector Resistance : 15~30Ω
CN-88 - GND.
① Start key ON.
② Disconnect connector CN-88 from power Power max. switch
max solenoid valve.
③ Check voltage as figure.

LH RCV-lever

CN-88
CN-88

Power max.
solenoid valve

Multimeter

(2) Test 16: Check resistance between

connector CN-51(2)-GND. SPEC : Power max button pressed ON : 0Ω
Power max button released OFF : ∞Ω
① Starting key OFF.
② Remove CPU controller and disconnect Y R G

connector CN-51 from CPU controller. CPU

③ Check resistance as figure. CONTROLLER
CN-51

CN-50

CN-51
12 2
24 13
36 25

Ground

Multimeter

6-57