6 Troubleshooting

SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1

Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4
Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-25
Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-41
SECTION 6 TROUBLESHOOTING
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and
Mechatronics system. At each system part, an operator can check the machine according to the
troubleshooting process diagram.
※ Before carring out troubleshooting procedure, check monitoring menu in the cluster.
Hydraulic &
Mechanical part GROUP 2
Electrical part GROUP 3
Troubles occur
Mechatronics
part GROUP 4
HCESPN 3digit See page

+ FMI 1 digit 5-15
Fault codes (machine)
displayed on
monitor display
3 or 4 digit See page
(engine) 5-18
6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.
STEP 1. Study the machine system

Study and know how the machine is operating,
how the system is composing, what kinds of
function are installed in the machine and what
are specifications of the system components by
the machine service manual.
Especially, deepen the knowledge for the
related parts of the trouble.
17W31SH02
STEP 2. Ask the operator

Before inspecting, get the full stor y of
malfunctions from a witness --- the operator.
1) How the machine is used and when it is
serviced?
2) When the trouble was noticed and what
work the machine was doing at that time?
3) What is the phenomenon of the trouble?
Was the trouble getting worse, or did it
come out suddenly for the first time?
4) Did the machine have any troubles
previously? If so, which par ts were
17W31SH03
repaired before.
STEP 3. Inspect the machine

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system
ON THE
such as low battery voltage, loose connections INSPECTION
and blown out fuses will result in malfunction of

6-2(3) 140-7
the controllers causing total operational failures
of the machine.
6-2
STEP 4. Inspect the trouble actually on the
machine
In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.
6-3(1) 140-7
STEP 5. Perform troubleshooting

According to where the trouble parts are
located, hydraulic & mechanical system part or
electrical system part or mechatronics system
part, perform troubleshooting the machine refer
to the each system part's troubleshooting
process diagram.
17W31SH05
STEP 6. Trace a cause

Before reaching a conclusion, check the most
suspectible causes again. Try to trace what the
real cause of the trouble is.
P
Make a plan of the appropriate repairing
procedure to avoid consequential malfunctions.
17W31SH44
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
Η Was there any strange thing about machine before failure occurred?
Θ Under what conditions did the failure occur?
Ι Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
Η Check oil and fuel level.
Θ Check for any external leakage of oil from components.
Ι Check for loose or damage of wiring and connections.
2) MACHINE STATUS MONITORING ON THE CLUSTER
(1) The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can be
checked by this menu.
Note 7
Note 4
Note 2
Note 5
Note 6
Note 1
Note 8
Note 3
Analog 1 Analog 2 14W96HS01
(2) Specification
No. Description Specification
Note 1 Pilot pump pressure 40+20 bar
Note 2 Swing pilot pressure 0~40 bar
Note 3 Boom up pilot pressure 0~40 bar
Note 4 Arm/bucket pilot pressure 0~40 bar
Note 5 P1 pump control pressure 0~25 bar
Note 6 P2 pump control pressure 0~25 bar
Note 7 Pump 1 pressure 350 bar
Note 8 Brake pedal pressure 60Ü3 bar
6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust
plug under engine
flywheel and
YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic Abnormal noise

pump and pump YES comes out of YES
connections pump See item 1).
YES
make abnormal connection at page 6-5
noise?
Is pilot pump
pressure within ͽ
NO standard level?
See Note 1
YES
Clean pilot
Is pilot piping piping interior or
YES clogged or is oil
repair piping.
leakage present
on pilot piping?
RCV and safety Disassemble
NO
solenoid valve is and repair.
ͽ faulty.
YES
Pilot relief valve in Repair or
gear pump is replace.
Is gear pump
faulty.
NO delivering oil?
Gear pump is Disassemble

NO
broken. and repair.
6-6
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY
Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot dispose it or
plate and check if replace hydraulic
foams come up. oil.
NO
Air is intruded. Check suction
line and return
line and eliminate
the air intruding
source.
2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY
Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Oil cooler clogged. Clean oil cooler.
Bypass check Replace
Is oil cooler clogged
and is bypass check valve is defective.
YES valve always open? YES ͽ
Is fan belt
NO tension proper?
Adjust belt
NO tension or
replace belt.
Is not the set
pressure of main YES Readjust set
relief, port relief pressure.
ͽ and travel relief
Is main relief
valve lower than
valve used very YES Reduce load.
the standard NO often?
level?
6-7
3) CAVITATION OCCURS WITH PUMP
Cause Remedy
NO Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Replace oil with
one of proper
Is not viscosity viscosity.
of hydraulic oil
YES YES
too high? Clean suction
Is not suction strainer.
NO strainer clogged? Is not air intruding
from pump Check for air
NO intrusion in
suction line?
suction line and
retighten or
replace parts.
4) HYDRAULIC OIL IS CONTAMINATED
Cause Remedy
YES Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO proper intervals?
hydraulic oil and
replace return
filter.
6-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE
Cause Remedy
NO
Replenish
Does safety YES
ͽ specified oil to the
YES solenoid valve
standard level.
operation
Is gear pump pilot normal? Safety solenoid Repair or replace.
NO
pressure within valve faulty or not
YES standard level?
Is oil in hydraulic operated.
YES tank within
See Note 1 Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ͽ when dust plug
under engine fly Is main relief NO
Are attachment wheel is removed? NO valve faulty? Hydraulic pump is Disassemble and
and travel out of order. repair.
motions
impossible at all? NO
Does swing Swing control valve Disassemble and
YES
control valve spool is stuck. repair.
Is MCV swing spool move?
YES pilot pressure ;
YES
within standard See Note 5
level? Ϳ
Is travel function See Note 2 NO
NO normal?
Does not symptom
change when front YES
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing parking Disassemble and
brake release valve repair.
Is swing parking is broken.
; brake release
valve faulty? YES
Swing reduction Disassemble and
Does swing unit is broken. repair.
NO motor rotate?
Swing motor is Disassemble and
NO
broken. repair.
YES
Pilot relief valve in Disassemble and
NO Is gear pump gear pump is faulty. repair or replace.
delivering oil?
Gear pump is out of Disassemble and
NO
Is gear pump pilot order. repair.
Ϳ pressure within
standard level? YES
Is there oil Clean pilot piping
See Note 1 interior or repair
leakage from
YES pilot piping or is it piping.
clogged? RCV is broken. Disassemble and
NO
repair.
6-9
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES Does swing spool valve is faulty. repair or replace.
move?
Swing control valve Disassemble
Is MCV pilot NO
spool is stuck. and repair.
pressure same
on LH and RH YES Clogged or oil
sides? Clean pilot piping
leak. interior or repair
See Note 2 Is pilot piping
Single direction clogged or is it piping.
NO leaking oil?
Is the trouble in RCV or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? YES
ͽ
YES Does swing spool
Both directions move?
YES Is MCV pilot Swing spool is Disassemble
pressure within NO
Is Arm speed See Note 5 stuck. and repair.
standard level?
within standard ;
value? See Note 2 NO
Ϳ
NO
Is swing motor's NO
ͽ drain rate within Swing motor is Disassemble
standard value? broken. and repair.
Check that pilot
YES piping is clogged NO
or oil is leaking RCV or shuttle Disassemble
from it? valve is faulty. and repair.
Clogged or oil leak. Clean pilot piping

Is gear pump pilot interior or repair
; pressure within piping.
standard level?
Pilot relief valve
YES
See Note 1 in gear pump is Disassemble and
Is gear pump defective. repair or replace.
NO delivering oil?
NO
broken. and repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief Does the symptom YES Hydraulic pump Disassemble
Ϳ valve setting change when front
YES is broken. and repair.
pressure normal? and rear pump
discharge hoses
See Note 7
are exchanged? NO Shuttle valve is Repair or replace.
Is MCV pilot faulty.
YES pressure within
standard level? YES
Is gear pump Pilot relief valve Repair or replace.
See Note 2 output pressure is faulty.
NO within standard
level? Gear pump is Repair or replace.
See Note 1
NO
faulty.
6-10
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
YES
Does symptom Swing port relief Disassemble
change when LH
YES valve is faulty. and repair.
and RH port
relief valves are
exchanged? NO Shuttle valve is Disassemble
YES Does swing control faulty. and repair.
valve spool move?
Is MCV pilot Swing control valve Disassemble

NO
pressure same spool is stuck. and repair.
for LH and RH?
YES
See Note 2
Check if pilot RCV is faulty. Disassemble
piping is clogged and repair.
NO or does have oil
leakage. Clogged or oil
NO leak.
Clean pilot piping
interior or repair
piping.
4) MACHINE SWINGS BUT DOES NOT STOP
Cause Remedy
YES
Pilot relief valve is Disassemble
faulty. and repair or
YES Is MCV pilot YES Is gear pump pilot
pressure within pressure within replace.
standard value? standard level?
See Note 2 See Note 1 Gear pump is Disassemble
NO
broken. and repair.
YES Does swing spool
move?
RCV is faulty. Disassemble
NO
and repair.
Is swing control
valve's return
spring normal? Swing spool is Disassemble
NO
stuck. and repair.
Return spring is Disassemble

NO
faulty. and replace.
6-11
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
YES
ͽ
YES Is swing shuttle
valve normal?
Shuttle valve is Disassemble
NO
faulty. and replace.
YES Is brake spring
normal?
Is return spring
of swing spool Brake spring is Disassemble
NO
normal? faulty. and replace.
Return spring of Disassemble

NO
swing control and replace.
valve is faulty.
YES
Is drain rate of Swing port relief Disassemble
YES swing motor valve is faulty. and repair or
within standard replace.
Is swing relief value? Swing motor is Disassemble
NO
ͽ pressure within broken. and repair.
standard level?
SPEC : 265±10kgf/cm2 Adjust swing
NO
relief valve
pressure or
replace swing
relief valve.
6-12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION
Cause Remedy
YES
ͽ
Travel motor relief
YES valve within
standard pressure
Are the travel Travel relief valve is Disassemble
NO
YES speed solenoid faulty and repair or
valves (high/low) replace.
normal?
Travel speed Disassemble

NO
solenoid valves and repair or
YES Is the travel pilot
pressure within (high/low) are faulty replace.
standard?
YES
Accelerator pedal Disassemble
or travel Forward/ and repair or
Travel pilot
Reverse solenoid replace.
solenoid valves
NO normal? cartridge is faulty
Travel pilot Disassemble

NO
solenoid valve is and repair or
Is swing operation
faulty replace.
possible?
YES Transmission unit Disassemble

is faulty and repair.
ͽ Does travel
motor rotate?
Travel motor is out Disassemble
NO
of order and repair.
Does the symptom
change when front
YES
and rear pump Hydraulic pump is Disassemble
NO discharge hoses
broken and repair.
are exchanged?
6-13
2) TRAVEL ACTION IS POWERLESS (travel only)
Cause Remedy
YES
ͽ
Travel motor relief
YES valve within
standard
Are the travel pressure
YES speed solenoid
Travel relief valve is Disassemble
NO
valves (high/low) faulty and repair or
normal? replace.
Travel speed Disassemble
NO
solenoid valves and repair or
YES
Is the travel pilot
pressure within (high/low) are faulty replace.
standard?
YES
Accelerator pedal Disassemble
or travel Forward/ and repair or
Travel pilot Reverse solenoid replace.
solenoid valve
NO normal? cartridge is faulty
Travel pilot solenoid Disassemble

NO
valve is faulty and repair or
Is the travel action replace.
powerless in both Transmission unit is
direction? YES
faulty Disassemble
Does travel and repair.
ͽ
motor rotate? Travel motor is out
of order Disassemble
NO
and repair.
The travel relief
YES
valve is faulty Disassemble
Does the symptom and repair or
change when Travel motor is out replace.
YES
NO travel relief valve is Does the symptom of order Disassemble
exchanged? change when travel and repair.
motor suction
NO Travel motor
hoses are
exchanged? suction valve is Disassemble
NO
faulty and repair or
replace.
6-14
3) THE HYDRAULIC MOTOR DOSE NOT GET STARTED
Cause Remedy
The spool does Screw the fitting

work properly. bolts one more
(The spool keeps time with correct
fully open) tightening torque.
If the spool turns
The hydraulic out to be damaged,
motor does not
it should be
get started
repaired or the
new one should
be used
The anti-avitation Ditto

check valve does
not work properly.
(The check valve
is kept open.)
4) IT TAKES TIME TO ACCELERATE THE MOTOR
Cause Remedy
The spool does Screw the fitting

not work properly. bolts one more
time with correct
tightening torque.
If the spool turns
out to be
damaged, it should
It takes time to be repaired, or the
accelerate the new one should be
motor used.
The orifice for Remove the

closing the foreign matter by
counterbalance is disassembling
clogged. and cleaning.
Wrong setting of Adjust at the

pressure of the correct value.
relief valve. If the relief valve
turns out to be
out of order, the
new one should
be used.
6-15
5) IT IS NOT POSSIBLE TO REDUCE THE MOTOR SMOOTHLY
Cause Remedy
The orifice for Remove the

closing the foreign matter by
counterbalance is disassembling
clogged. The and cleaning.
It is not possible
opening of the
to reduce the
motor smoothly neutral position of
the spool is
clogged.
Wrong setting of Adjust at the

pressure of the correct value.
relief valve. If the relief valve
turns out to be
out of order, the
new one should
be used.
6) EXTRAORDINARY NOISE IS HEARD WHEN SUDDENLY REDUCING THE SPEED FROM

THE HIGH-SPEED MODE
Cause Remedy
It takes time to
accelerate the The anti-cavitation Screw the fitting
motor valve does not not bolts one more
work properly. time with correct
tightening torque.
If the valve turns
out to be
damaged, is
should be
repaired.
6-16
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
YES symptom change faulty. and repair or
when port relief replace.
valve is replaced
with other valve? NO ͽ
YES Is MCV pilot
pressure within
standard level?
Inspect if pilot
See Note 3, 4 piping is clogged OK
RCV is faulty. Disassemble
NO or oil is leaking
YES Are other from the piping. and repair.
attachments
operatable?
YES
Is gear pump
pilot pressure YES Is gear pump faulty. and repair or
NO within standard delivering oil? replace.
level? Gear pump is Disassemble
See Note 1 NO
broken. and repair.
Are travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and
Main relief valveDisassemble
Faulty
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Coupling at pump Disassemble
Particles present
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.
YES
Cylinder interior is Disassemble
Does control broken. and repair.
ͽ valve spool
move?
MCV spool is Disassemble
See Note 5, 6 NO
stuck. and repair.
6-17
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ͽ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ;
in composite YES
normal at boom YES
operation? up and at arm Does spool of flow Flow summation Disassemble
extrusion? summation check check valve is and repair.
Are travel NO valve move lightly stuck.
by hand?
speeds within NO
NO
standard levels?
YES
Hydraulic pump is Disassemble
Is travel speed faulty. and repair.
NO low? YES Ϳ
Is MCV pilot
pressure within
NO
standard? ΀
NO
See Note 3, 4
OK
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
valve is replaced replace.
Does control with other valve? Cylinder is faulty. Disassemble
YES valve spool NO
and repair.
move ?
See Note 7
NO MCV spool is Disassemble
Is MCV pilot
ͽ pressure within stuck. and repair.
standard level?
Is not MCV pilot YES
Clean pilot
See Note 3, 4
pressure piping piping interior or
clogged or is not
NO
there oil repair piping.
leakage? RCV is defective. Disassemble
NO
and repair.
YES
Is pilot pressure NO faulty. and repair or
; Is gear pump
within standard
delivering oil? replace.
level?
NO
See Note 1
broken. and repair.
AIs engine NO
Ϳ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
΀ main control YES
valve clogged? Is pilot piping Clean pilot
clogged or is oil piping interior or
NO leaking from the repair piping.
piping? Is RCV normal? RCV is faulty. Disassemble
NO NO
and repair.
6-18
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the symptom faulty. and repair or
change when port
Normal
relief valve is replace.
YES
replaced with ͽ
normal value? Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
high? NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the
hydraulic oil or cause of
equivalent being hydraulic oil
used?
temperature rise
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
inspect load between control
YES
check valve in
MCV and check valve casing and
for any fault. spool is poor.
Is cylinder Contact surface Disassemble
internal leakage Abnormal
ͽ between poppet and repair.
within standard
level? and seat is poor.
Cylinder is faulty. Disassemble

NO
and repair.
6-19
4) BOOM, ARM OR BUCKET POWER IS WEAK
Cause Remedy
YES
Check according
Is cylinder to the procedure
YES internal leakage in Item "Speed is
within standard low".
level?
Is relief pressure
YES in port relief Cylinder is faulty. Disassemble
valve within NO
and repair.
standard level?
Is relief pressure
in main relief Port relief valve is Adjust pressure,
valve within NO
standard level? faulty. repair or replace.
See Note 7
Main relief valve Adjust pressure,
NO
is defective. repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
YES
Port relief valve is Disassemble
Does the defective. and repair or
YES
symptom change
when port relief replace.
YES
valve is replaced Cylinder interior is Disassemble
with other valve? Does control broken. and repair.
valve spool
Is MCV pilot NO move?
YES
pressure within MCV spool is Disassemble
standard level? See Note 5 NO
stuck. and repair.
See Note 4
Is boom speed RCV is faulty. Disassemble

NO
is normal? and repair.
Does the YES

Main relief valve Adjust pressure,
symptom change is faulty. repair or
Does the
when main relief
NO valves are symptom change replace.
when hydraulic YES
exchanged? Hydraulic pump is Disassemble
NO pump's discharge
hoses are broken. and repair.
exchanged?
6-20
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil
Is boom foot pin seal and boom
greased proper.
sufficiently?
ö Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. ö If seizure is
in an initial
stage, supply
sufficient
grease.
If seizure is
in a grown
state, correct
it by paper
lapping or
with an oil
stone.
6-21
ö HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
14W96TS01
2. Disconnect hose (A) from rod side of boom

cylinder and drain oil from cylinders and
hose. (put cups on piping and hose ends) A
(210-7) 6-20(2)
3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
14W96TS02
6-22
7. FRONT AXLE AND REAR AXLE
Problem Cause Correction
Insufficient braking 1. Incorrect adjustment Inspect disc thickness and if discs are usable
readjust brakes to the specifications in the
manual.
2. Brake discs worn out Inspect disc thickness and replace if necessary.
3. Incorrect brake fluid Replace all seals in axle and master cylinder
that have made contact with the incorrect fluid
and all brake hoses.
If incorrect fluid leaked into axle oil, seals and
O-rings in axle must be replaced.
4. Loss of brake fluid Inspect for and repair any leaks in outside circuit
or master cylinder.
If caused by incorrect brake fluid see correction
No.3.
If leak is to the outside replace the O-rings
between the center and intermediate housings.
If leak is to the inside replace above O-rings and
brake piston O-rings.
5. Overheated axle causing brake See “overheating” problem.
fluid to vaporize.
(Brake return when axle cools)
Soft brake pedal 6. Air in brake circuit Bleed air in brake circuit.
Ineffective safety brake 7. Incorrect adjustment See correction No.1.
8. Brake disc worn out See correction No.2.
Overheating 9. Oil level wrong Drain, flush and refill oil to proper level.
10. Too small of a brake gap Readjust brakes to the specifications.
11. Park brake dragging Unlock the brake and adjust the correct gap.
12. Incorrect brake fluid in system See correction No.3.
13. No free-pedal at master Readjust brake pedal.
cylinder
14. Restriction in brake lines Inspect for and replace damage lines.
15. Restriction in return line of Inspect for and replace damaged return line.
brake servo system Inspect for and remove any filter, tee’d in line or
any other source of back pressure from the
return line.
16. Incorrect lubricant Change the retaining rings of the brake circuit
and brake pump.
Diff-lock inoperative 17. If manual control, loose or Inspect and correct linkage and readjust.
misadjusted linkage
18. If hydraulic control, problems Refer to the hydraulic or electrical section in this
in the hydraulic or electrical manual.
circuits of the machine.
19. If hydraulic control problems Rebuilt cylinder.
in actuating cylinder(noteable
through loss of hydraulic oil or
increase of the oil level in axle)
20. If with limit slip differential, Replace discs.
worn discs
6-23
Problem Cause Correction
Oil coming out of breather 21. Leak in internal brake system See correction No.2 and No.3.
22. Leak in diff-lock actuating See correction No.19.
cylinder
Nospin indexing noise 23. Unequal tire pressure left and Inflate tires to the recommended pressure in this
when driving straight right manual, or until the rolling radius is equal.
ö With nospin, fatigue
damage can occur on the 24. Different style, size or brand of Change tires to make the rolling radius equal.
side with the larger tire. tires between left and right Vary the tire pressure within the specifications
hand side until the rolling radius is equal.
Noise during coast and 25. Wheel bearings damaged Replace and adjust
under power the same
Noise under power greater 26. Low oil level Refill oil to proper level
than during coast
27. Incorrect lubricant See correction No.16.
28. Ring and pinion worn Inspect through top cover.
Replace and adjust.
29. Worn ring and pinion bearings Replace and adjust
30. Worn planetary gears or Replace.
bearings
Noise during coast greater 31. Loose pinion nut Inspect ring, pinion and pinion bearings.
than under power If undamaged, retighten nut.
32. Only pinion bearing damaged See correction No.29.
Noise during turn 33. Worn spider and/or side gears Replace.
(Without nospin)
A stick slip noise when 34. Worn or damaged cardan Inspect and replace.
going from forward to shaft
reverse
35. Loose wheel Inspect for wheel and wheel stud damage.
Replace if needed and retorque lugnuts.
36. Articulation box joint and Inspect and replace.
achsel shaft damaged
37. Spider pins loose in diff-carrier Inspect through top cover. Replace.
38. Damaged or missing spider See correction No.33.
and/or side gear washers
6-24
GROUP 3 ELECTRICAL SYSTEM
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.7, 11.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage YES

Disconnection in Repair or replace
between CN-56
(3) and (5) wiring harness or (after clean)
Check voltage poor contact
Starting switch : ON between
Voltage : 20~32V between
NO CN- 5 (3) and (5)
CN-5-CN-56
Starting switch : ON
Voltage : 20~32V Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-5 (3)
-GND or fuse
No.7, 11
Check voltage
YES 20~32V
NO 0V
CLUSTER FUSE
POWER(24V) 1 6
NO.7
GND 3 3
FUSE
POWER IG(24V) 5 5
NO.11
CN-56 CN-5
14W96ES01
6-25
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2)
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
YES Check voltage

between CN-56
(4, 8) and (3) Disconnection in Repair or replace
NO wiring harness or (after clean)
Check voltage Voltage : 2V poor contact
between between CN-56
CN-5 (1) and (2) (4, 8)-CN-5 (1, 2)
Voltage : 2V Defective MCU Replace
NO Disconnection in Repair or replace
poor contact
between CN-5 (1,
2)- CN-51(23, 33)
Check voltage
YES 2V
NO 0V
CLUSTER
GND 3 3 MCU
RS485 RX 8 2 23 RS485 TX
RS485 TX 4 1 33 RS485 RX
CN-51
CN-56 CN-5
14W96ES02
6-26
3. BATTERY CHARGING WARNING LAMP LIGHTS UP
UP(Starting switch : ON)
Cause Remedy
YES
Defective MCU Replace
YES Check voltage
between CN-51
(39) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or (after clean)
YES Voltage : 20~32V
between CN-2 poor contact
(9) and chassis between CN-51
(39)-CN-2 (9)
Voltage : 20~32V
Check voltage Disconnection in Repair or replace
between alternator poor contact
terminal "I" and between CN-2 (9)
chassis alternator terminal
Engine : Running "I"
Voltage : 20~32V
Defective alternator Replace

NO
Check voltage
YES 20~32V
NO 0V
MCU ALTERNATOR
B+ G
39 9
3~
I
U
GND
CN-51 CN-2 CN-74
21096ES03
6-27
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Check use HRDT Check or replace
Check resistance
YES between engine
harness connector
(15)-(38)
Spec : 180̫~160 k̫ Disconnection in Repair or replace
NO
Check resistance poor contact
between temp between temp
sensor (A)-(B)
sensor-engine
Starting switch : OFF harness connector
Spec : 180̫~160 k̫
See table
Defective coolant Replace

NO
temp sensor
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (k̫) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
SERVICE TOOL Engine ECM

CAN_Lo F 21 31 ENGINE COOLANT
CN-93 TEMPERATURE SENSOR
CAN_Hi E 20 21
8 46 CAN_Hi 15 A
RS232_TX C 16 24
9 47 CAN_Lo 38 B C
RS232_RX B 15 34
CN-3 OEM Engine harness
P_DUMP A 9 12 connector connector
CN-5 CN-51
21096ES04
6-28
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect YES
CD-10? Short circuit in Repair or replace
Starting switch : ON wiring harness (After clean)
Engine : Start Check resistance
between CD-10-
between CN-53
NO CN-53 (23)
(23) and chassis
Starting switch : OFF
Disconnect CN-53
NO
Check resistance
YES MAX 1̫
NO MIN 1M̫
MCU AIR CLEANER SWITCH
Pa
23
CD-10
CN-53
21096ES05
6-29
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
NO
Defective circuit, Contact Cummins.
sensor or ECM.
NO Fault code 135

active?
Fault code 386 Voltage above Refer to engine
YES
active? normal or shorted fault code 135
to high source
Voltage above Refer to engine
YES
normal or shorted fault code 386
to high source
Signal Return
ENGINE OIL
CN-93 PRESSURE SENSOR
8 46 13 3
Engine 38 2
9 47 ECM
SERVICE TOOL 33 1
CAN_Lo F 21 31
connector connector
CAN_Hi E 20 21
+5V supply
RS232_TX C 16 24
RS232_RX B 15 34
P_DUMP A 9 12
CN-5 CN-51
21096ES06
6-30
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1 (105˚CÜ2˚C),
(1, 2) is in range
of 164~151̫?
Does display go Starting switch : ON Defective temp Replace
Disconnect CD-1 NO
off when sensor
disconnect
CD-1? YES
Short circuit Repair or replace
Starting switch : ON between temp
Resistance
Engine : Start
between CN-51 sensor and MCU
NO (36, 5) is 0~1̫?
Defective controller Replace

Starting switch : OFF NO
Disconnect CN-51
Check Table
Temperature (˚C ) ~ -30 ~ -10 ~0 ~ 40 ~ 70 ~ 80 ~ 90 ~ 100 105~
22.22 8.16 5.18 1.06 0.39 0.322 0.243 0.185 0.164
Resistance (k̫)
~31.78 ~10.74 ~ 6.6 ~1.28 ~0.476 ~0.298 ~0.219 ~0.167 0.151
MCU
HYDRAULIC OIL
TEMPERATURE SENDER
36 2 C
5 1
CD-1
CN-51
21096ES07
6-31
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE (HCESPN 304,
FMI 3 or 4)
Cause Remedy
YES
Check use HRDT Check or replace
Check resistance
YES between engine
harness connector
(15)-(38)
Spec : 180̫~160 k̫ Disconnection in Repair or replace
NO
between temp between temp
sensor (A)-(B)
sensor-engine
Starting switch : OFF harness connector
Spec : 180̫~160 k̫
See table
Defective coolant Replace

NO
temp sensor
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (k̫) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
SERVICE TOOL Engine ECM

CAN_Lo F 21 31 ENGINE COOLANT
CN-93 TEMPERATURE SENSOR
CAN_Hi E 20 21
8 46 CAN_Hi 15 A
RS232_TX C 16 24
9 47 CAN_Lo 38 B C
RS232_RX B 15 34
P_DUMP A 9 12 connector connector
CN-5 CN-51
21096ES04
6-32
9. WHEN FUEL GAUGE DOES NOT OPERATE
OPERATE(HCESPN 301, FMI 3 or 4)
Cause Remedy
YES
Defective MCU or Replace
cluster
YES
Check resistance
between CN-51
(5) and (38)
Starting switch : OFF Disconnection in Repair or replace

Check resistance Disconnect CN-51 NO
between fuel Spec : 50~600̫ wiring harness or
sender (1) and poor contact
(2) between fuel
Starting switch : OFF sender-MCU
Spec : 50~600̫
See table
Defective fuel Replace
NO
sender
Check Table
Range Resistance (̫) Range Resistance (̫)
Full 50 5/12 400
11/12 100 4/12 450
10/12 150 3/12 500
9/12 200 2/12 550
8/12 250 1/12 600
7/12 300 Empty warning 700
6/12 350 - -
MCU
FUEL LEVEL SENDER
38 2
5 1
CD-2
CN-51
21096ES09
6-33
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No.23.
Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
Disconnect in Repair or replace
Check voltage wiring harness or (after clean)
between CN-68 poor contact
Check resistance
(1) - (2) YES between CN-4 between
(16) and chassis CN-4-CN-68
Voltage : 20~30V YES
Safety state Starting switch : OFF Disconnect in Repair or replace
Safety state
Spec : 0̫
Disconnect CN-4 Check resistance poor contact
Check voltage
between CS-4 between
between CN-68 NO
NO (A)-(C) CN-4-CS-4
(2) and chassis
Safety lever : OFF Defective safety Replace
Safety switch : ON-0̫
Starting switch : ON NO
Voltage : 20~30V
OFF-∞ switch

NO
wiring harness
between
CN-68 (2)-fuse
FUSE
NO.23
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2
A C 16 1
CS-4 CN-68
CN-4
21096ES10
6-34
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 5 or 6)
short of fuse No.25 .
Cause Remedy
YES
wiring harness or
YES between CN-70 between CN-70-
(1)-(2) or CN-52 or CN-181-
CN-181(1)-(2) CN-52
Spec : 30̫ Defective solenoid Replace
NO
YES Check fault code Disconnect CN-70
167 active?
YES
Starting switch : ON Defective hydraulic Check hydraulic
Check voltage system system
Check if travel between CN-70
speed lamps( , NO (1)-(2) or
) change when CN-181(1)-(2)
turning the RH Starting switch : ON Disconnection in Repair or replace
Spec : 20~30 V NO wiring harness or
multifunction switch
Disconnect CN-70 poor contact
on the cluster
between CN-70-
fuse No. 25 or CN-
181-fuse No.25
YES
Check MCU
Y R G
NO
NO
FUSE TRAVEL HIGH SPEED SOLENOID

2
NO.25
1
MCU CN-70
TRAVEL LOW SPEED SOLENOID
2
8 1
CN-181
CN-52
14W96ES11
6-35
12. WHEN ENGINE DOES NOT START ( lights up condition)
CN-93 START KEY SW
short of fuse No. 1, 4, 9, 20. CN-3 39 KEY IG H BR ACC ST C
5
6
2
3
4
H0 I
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified. 13 CN-94
14 4 BATT (+)
15 3 BATT (+) 0, I
1
Cause Remedy 2 BATT (-) B
CN-125
CS-2
1 BATT (-)
2
YES
3
2
6
1
4
5
Defective ECM or Replace ENGINE ECM
Check voltage
YES CN-93 (39) and battery
chassis CN-5
Disconnection in Repair or replace 35
NO wiring harness or 59
YES Check voltage Key switch : ON 60
CN-3 (13) and Spec : 20~30V poor contact
36
chassis between CN-3
(13) -CN-93 (39) CR-45
1
Starting switch : ON 4 5 1
NO.9 2
Spec : 20~30V Defective ECM Replace 3
NO
power relay CR-45 4
NO.1 5 3 2
Check operation YES
Defective magnet Replace ECM POWER RY
Check voltage
start motor of start motor NO.4 CR-35
YES between starter
magnet coil and
Starting switch : START chassis Defective start relay Replace
NO
Starting switch : START
Check operation Spec : 20~30V YES
YES Check voltage ͽ NO.20
POWER RY
of start relay between CN-2
NO
CR-23 (7) and chassis Disconnection in Repair or replace CS-74
NO wiring harness or 1
Starting switch : START 2
Starting switch : START poor contact
Spec : 20~30V CN-95
Check operation between CN-2 (7) 2
of anti-restart -CR-5 (5) 1 MASTER SW
NO relay CR-5
FUSIBLE LINK
2
YES
Starting switch : ON Defective anti- Replace 1
Check voltage
restart relay CN-60
between CR-5 CR-1
NO BATTERY
(1, 2)
ⓑ
NO
Starting switch : START
Spec : 20~30V
BATT RY
DO-1
YES 2
Check voltage Defective start relay Replace 1
ͽ between CR-23 DIODE
and chassis Disconnection in Repair or replace
NO CN-52
wiring harness or
ANTI-RESTART RY 15
Starting switch : START poor contact
Spec : 20~30V MCU
between CN-2-
CR-5
CR-5 1
1 5 4
2
START MOTOR
3 CN-2 CR-23
YES
2 3 5 7
wiring harness or 2
Check voltage ANTI-RESTART RY 8 1
poor contact
ⓑ between CR-5 between CN-52 START RY CN-45
(2) and chassis (15)-CR-5 (1)
Starting switch : START NO Disconnection in Repair or replace
Spec : 20~30V wiring harness or
poor contact
between CS-2 (6)- 14W96ES12
CR-5 (2)
6-36
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
ÂBefore disconnecting the connector, always turn the starting switch OFF. CN-93 START KEY SW
CN-3 39 KEY IG H BR ACC ST C
ÂBefore carrying out below procedure, check all the related connectors are properly inserted, master
5
6
2
3
4
H0 I
13 CN-94
switch ON and check open circuit of fusible link (CN-60). 14 4 BATT (+)
15 3 BATT (+) 0, I
1
2 B
BATT (-)
CN-125
CS-2
1 BATT (-)
3
2
6
1
4
5
ENGINE ECM
Cause Remedy CN-5

35
YES 59
wiring harness or (after clean) 36
poor contact CR-45
YES Check voltage between DO-1 (1)- 1
between DO-1 CR-1 or defective 4 5 1
NO.9 2
(1) and chassis battery relay 3
4
Voltage : 20~30V NO.1 3 2
5
YES Check voltage NO wiring harness or (after clean) ECM POWER RY
between CS-2 NO.4 CR-35
poor contact
(2) and chassis
between CS-2 (2)-
Voltage : 20~30V CN-5(60)- DO-1 (1)
Defective start Replace NO.20
NO
YES Check voltage switch POWER RY
between CS-2
YES CS-74
(1) and chassis Disconnection in Replace 1
wiring harness or 2
Voltage : 20~30V
poor contact CN-95
between CS-2 (1)- 2
Check voltage 1 MASTER SW
CN-5 (36)
between CN-5 FUSIBLE LINK
NO
Check voltage (36) and chassis YES 2
Disconnection in Charge or replace
and specific wiring harness or (after clean)
1
gravity of battery Voltage : 20~30V CN-60

Check voltage poor contact CR-1
BATTERY
Specific gravity : MIN 1.28 between CS-74 between CS-74 (1)
Voltage : MIN 24V NO -CN-5 (36)
(1) and chassis
Voltage : 20~30V ⓐ BATT RY
NO DO-1
2
1
Battery capacity Charge or replace
NO DIODE
too low (after clean)
CN-52
YES ANTI-RESTART RY 15
Defective master Replace MCU
Check voltage
ͽ switch CR-5
between CS-74 1
(2)- chassis 1 5 4
2
NO
Disconnection in Charge or replace START MOTOR
3 CN-2 CR-23
Voltage : 20~30V wiring harness or (after clean) 4
poor contact 2 3 5 7 2
between CS-74 (2) ANTI-RESTART RY 8 1
-CR-1 CN-45
START RY
14W96ES13
6-37
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the fuse
No. 6, 17 and 18 is not blown out.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified. CN-21
3 1
Cause Remedy 2
NO 5 3 CN-5
Defective wiper Replace
4 4
cut switch
5
NO
Short circuit in Repair or replace 6 M 2 6
Check operation wiring harness or (after clean)
wiper cut switch poor contact FUSE
WIPER MOTOR
between CN-141 18
NO.6
Front sliding door
Check valtage (11)- CS-53 CN-141
open-close
between CN-141 YES FEED BACK 1
YES (11) and chassis Defective Replace MOTOR DRIVE SIG 2 CN-17
multifunction
NO Check voltage MOTOR DRIVE- 3 1
Front sliding door-close between CN-97 switch
Voltage : 4~5V MOTOR DRIVE+ 4 2
(7) and chassis
Check operation 1)Recheck fuse Replace GND 5 3
FUSE
Starting switch : ON NO 6 4 24
YES of multifunction No.17 VCC
SW Vottage : 20~30V 2)Disconnection in Repair or replace CONTINUE 24V 7 5 NO.18
wiring harness or (after clean) CN-22
WASHER P/P 8 6
Starting switch : ON ͽ poor contact 2 M
Turn wiper switch YES WASHER SIG. 9 7
between INT. SIG 10 8 19 1
CN-97(7)-Fuse
WIPER CUT SW 11 WASHER PUMP
N.C 12
Check voltage between NO FEED BACK 13 CN-98 (2) INT
Defective Replace
CN-5 (23) and chassis multifunction WIPER MOTOR CONTROLLER
1 (1) COM
43 5 2
Intermittent switch 3 (4) HO
NO 1) Recheck fuse Replace

4
7 WA
Check voltage CN-97 No.6 CS-53
ͽ 1 Hi
(10) and chassis 2) Disconnection Repair or replace
Washing Check operation in wiring harness (after clean)
8 COM
of wiper motor or poor contact 4 1

6 WI
Check voltage CN-98 and controller between 23 3 2
3
(5) and chassis check voltage CN-141(7)-Fuse, WIPER CUT SW 4
2 Lo
YES CN-141 (7) and
Sarting switch : ON
CN-21(4)-Fuse 5
6
4 COM
Voltage : 0~1V
chassis, CN-21 7
5 Lo
(4) and chassis NO CN-97 8

1) Recheck fuse Replace 9
Starting switch : OFF No.18 37 10 10
Voltage : 20~30V Check voltage 2) Disconnection Repair or replace 11 3 Hi
CN-141 (6) and 7 12
YES chassis CN-141(6)-Fuse (after clean) 12 B+
9 L
10 COM
Starting switch : ON ; 11 R
Check continuity YES
Voltage : 20~30V
NO
between Disconnection in Repair or replace MULTIFUNCTION SWITCH-LH
CN-141 (2)-CN-98 (3), wiring harness or (after clean)
CN-141 (9)-CN-97 (10), poor contact FUSE
; CN-141 (10)-CN-98 (5),
NO
CN-141 (5)-Chassis , Check wiper Defective wiper Replace NO.17
CN-141 (1)-CN-21 (5), motor resistance motor
CN-141 (3)-CN-21 (6),
YES between CN-21
CN-141 (4)-CN-21 (2), (2)-CN-21 (6) Defective wiper Replace
CN-141 (13)-CN-21 (3) YES motor controller
Resistance : 3~4̫
14W96ES14
6-38
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified. FUSE
CN-151
NO.17 1 CABIN LAMP RY(COIL)
2 CABIN LAMP RY
3 CABIN LAMP RY
4
Cause Remedy INT (2)
1 5
WORK LAMP RY(COIL)
WORK LAMP RY
YES COM (1) 2 6 WORK LAMP RY
Defective bulb Replace 3 7 RELAY EARTH
Check voltage HO (4)
4 8 HEAD LMP RY HI
YES between CL-4(2) CN-97 9 HEAD LMP RY HI(COIL)
and chassis,CL- WA 7 10 HEAD LMP RY LO
7 11 NC
3(2) and chassis Disconnection in Repair or replace
Hi 1
12 OUTRINGER RY
Voltage : 20~30V NO
wiring harness or (after clean) COM 8 12 HARNESS RY
poor contact CN-152
Check voltage between CN-151 WI 6
1 1 FUEL HEAT RY(COIL)
YES 2 CN-98 2 FUEL HEAT RY
between CN-151 (8)-CL-4 (1) or 3 3 HEAD LMP RY LO(COIL)
Lo 2
(8) and chassis CN-151(8)-CL-3(2) 4 1 4 HEAD LMP RY(COIL)
COM 4 5 2 5 REAR LH RY
YES 6 6 REAR RH RY
Defective Replace Lo 5
7 7 FRONT LH RY
Head lamp switch : ON
Voltage : 20~30V
multifunction 8 8 FUEL HEAT RY
Check voltage switch
9 9 FRONT RH RY
10 10
between CN-98 REAR LH RY(COIL)
NO Hi 3 11 11 REAR RH RY(COIL)
(2) and chassis 12 12 FRONT LH RY(COIL)
B+ 12
13
Disconnection in Repair or replace L 9
FRONT RH RY(COIL)
Starting switch : ON NO
14 HEAD LMP RY
Check voltage Head lamp switch : ON wiring harness or (after clean) COM 10 15 HEAD LMP POWER RY
between CN-152 Voltage : 20~30V poor contact R 11 HARNESS RY
(14) and chassis, between CN-98
CN-152 (15) and CN-5
CL-4
chassis (2)-CN-151 (9) MULTIFUNCTION SW-LH 1 Lo
2 Hi
Starting switch : ON CN-116 3 E
Voltage : 20~30V ILL 1
YES HEAD LAMP-RH
Head lamp switch : ON Disconnection in Repair or replace HEAD LAMP 2 49
WORK LAMP 3
wiring harness or (after clean) CL-3
CABIN LAMP 4 1 Lo
poor contact PRE-HEAT 5
2 Hi
Front/ Left 6
between CN-152 Front/ Right 7
3 E
(14) and chassis or Rear/ Left 8 HEAD LAMP-LH

Rear/ Right 9
CN-152 (15)- POWER 10
chassis GND 11
Check voltage DOZER PS 12
between CN-5 SWITCH PANEL
NO (49) and chassis
Recheck fuse Replace
No. 17
Voltage : 20~30V
Head lamp switch : ON YES 14W96ES15
Defective switch Replace
panel
Check voltage
between CN-116
NO
(2) and chassis
Head lamp switch :
ON-OFF poor contact
between CN-5(49)
and CN-116(2)
6-39
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause Remedy
YES
Defective bulb Replace
YES
Check voltage
between CL-5 (2) FUSE
and chassis
NO.15
Disconnection in Repair or replace CN-5
NO wiring harness or (after clean) CN-151
poor contact 1 CABIN LAMP RY(COIL)
between CN-151 2
YES Check voltage
CABIN LAMP RY
3 CABIN LAMP RY
between CN-151 (5)-CL-5 (2)
4 WORK LAMP RY(COIL)
(5) and chassis 5 WORK LAMP RY
6 WORK LAMP RY
Starting switch : ON 7 RELAY EARTH
Work lamp switch : ON 8 HEAD LMP RY HI
Voltage : 20~30V YES CN-116 9 HEAD LMP RY HI(COIL)
Defective switch Replace 10 HEAD LMP RY LO
ILL 1
panel 2
11 NC
Check voltage HEAD LAMP
Check voltage 12 OUTRINGER RY
between CN-151 between CN-116 WORK LAMP 3 50
HARNESS RY
(6) and chassis, NO CABIN LAMP 4
(3) and chassis
PRE-HEAT 5
CN-151(4) chassis Front/ Left 6
Starting switch : ON Starting switch : ON Disconnection in Repair or replace
Voltage : 20~30V Work lamp switch : ON NO wiring harness or (after clean)
Front/ Right 7
CN-12 CL-5
Voltage : 20~30V Rear/ Left 8
poor contact Rear/ Right 9 2 1
between CN-151 POWER 10 2
1
(5)-CN-116 (3) GND 11
DOZER PS 12
WORK LAMP
SWITCH PANEL
NO
poor contact 2
between CN-151 CL-6
(6) and chassis or
CN-151 (4) and
chassis
Recheck fuse Replace

No.15
14W96ES16
6-40
GROUP 4 MECHATRONICS SYSTEM
1. ALL ACTUATORS SPEED ARE SLOW

ö Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
ö Spec : P-mode 1700 Ü 50 rpm S -mode 1500 Ü 50 rpm E-mode 1350 Ü 50 rpm
ö Before carrying out below procedure, check all the related connectors are properly inserted and
fault code on the cluster.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO Check electric Defective Replace
current at EPPR SPEC : 5~20 kgf/cm2
NO
EPPR valve
valve See TEST 3
SPEC : 100~700 mA
See TEST 2
Check if HCESPN NO
140 active fault
display on the LCD YES
Short circuit or Check & repair
poor connection wire harness or
between CN-53 between CN-53
Check resistance
YES at EPPR valve -CN-75 -CN-75
SPEC : 15~25̫(20ÁC) Defective EPPR Replace

See TEST 1 NO
valve
Wiring diagram
MCU
FUSE
4
NO.24
8
14 PUMP EPPR VALVE
7 1
18 8 2
CN-53 CN-1 CN-75
14W96MS01
6-41
2) TEST PROCEDURE SPEC : 15~25̫(20˚C)
(1) Test 1 : Check resistance at connector
CN-75
CN-75.
Η Starting key OFF.
Θ Disconnect connector CN-75 from EPPR EPPR valve
valve at main hydraulic pump. Multimeter
Ι Check resistance between 2 lines as

figure.
Main pump
20W96MS01
(2) Test 2 : Check electric current at EPPR Spec : 100~700 mA

valve.
Η Disconnect connector CN-75 from EPPR Adapter(P/no.:21Q6-50410)
valve.
Θ Insert the adapter to CN-75 and install CN-75
EPPR valve
multimeter as figure.
Ι Start engine. Multimeter
Κ Set S-mode and cancel auto decel
mode.
Λ Position the accel dial at 10.
Μ If rpm display approx 1500Ü50 rpm
check electric current at bucket circuit
Main pump
relief position.
20W95MS10
(3) Test 3 : Check pressure at EPPR valve. Spec : 2~25 kgf/cm2 (30~350 psi)
Η Remove plug and connect pressure
gauge as figure. Pilot pressure
supply line
ÂGauge capacity : 0 to 50 kgf/cm2 CN-75 Pressure adjusting
screw locknut
(0 to 710 psi)
Θ Start engine.
Ι Set S-mode and cancel auto decel EPPR valve
mode.
Κ Position the accel dial at 10.
Λ If rpm display approx 1500Ü50 rpm
check pressure at relief position of bucket
circuit by operating bucket control lever. Main pump
Μ If pressure is not correct, adjust it.
Ν After adjust, test the machine. 20W95MS11
6-42
2. ENGINE STALL
ö Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Not enough Check engine
engine power fault
YES Check pressure Contact cummins
at EPPR valve
SPEC:5~20 kgf/cm2 Defective EPPR Replace

See TEST 5 NO
Check electric valve
current at EPPR
valve
YES
Short circuit or Check and repair
SPEC : 100~700 mA poor connection wire harness
See TEST 4
Check resistance between
between CN-53 - CN-75
NO at EPPR valve
SPEC : 15~25̫(20˚C)
See TEST 1
NO
Defective EPPR Replace
valve
Wiring diagram
MCU
FUSE
4
NO.24
8
14 PUMP EPPR VALVE
7 1
18 8 2
CN-53 CN-1 CN-75
14W96MS01
6-43
2) TEST PROCEDURE Spec : 100~700 mA
(1) Test 4 : Check electric current at EPPR
Adapter(P/no.:21Q6-50410)
valve.
Η Disconnect connector CN-75 from EPPR
EPPR valve
valve. CN-75
Θ Insert the adapter to CN-75 and install

multimeter as figure. Multimeter
Ι Start engine.
Κ Set S-mode and cancel auto decel mode.
Position the accel dial at 10.
Μ check electric current at bucket circuit Main pump
relief position.
20W95MS10
(2) Test 5 : Check pressure at EPPR valve. Spec : 2~25 kgf/cm2 (30~350 psi)
Η Remove plug and connect pressure
gauge as figure. Pilot pressure
supply line
ÂGauge capacity : 0 to 50 kgf/cm2 CN-75 Pressure adjusting
screw locknut
(0 to 710 psi)
Θ Start engine.
Ι Set S-mode and cancel auto decel EPPR valve
mode.
Κ Position the accel dial at 10.
check pressure at relief position of bucket
circuit by operating bucket control lever. Main pump
Μ If pressure is not correct, adjust it.
Ν After adjust, test the machine. 20W95MS11
6-44
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse No.3
See if all lamps the MCU
YES off in the MCU
case YES
Y R G MCU failure Replace
Y R G
See if HCESPN
840 active fault NO
display on the LCD
NO Y R G
ͽ
NO
OK
Check connection Cluster failure Replace
between CN-51
ͽ (33) - CN-56(4) or
CN-51(23) -
CN-56(8) No connection Check and repair
NO
KEY OFF
Wiring diagram
CLUSTER MCU
BATT. 24V
SIG_3
GND
TX 4 1 33
IG 24V 8 2 23
SIG_2
CN-56 CN-5 2
CAMERA SIG
RX CN-51
FUSE
NO.3
21096MS03
6-45
4. MALFUNCTION OF ACCEL DIAL
Cause Remedy
YES
YES
Open circuit or Replace or repair
poor connection
YES Check voltage between CN-16
between CN-16
(2) -CN-52 (21)
(2)-GND
Check voltage
between YES Check voltage Spec : actuator operating
NO
CN-52(21)-GND between 1~5V poor connection
CN-7(15)-GND between CN-7
Spec : actuator operating (15) -CN-16 (2)
1~5V Spec : actuator operating
1~5V YES
See TEST 6 Check resistance Defective accel Replace
between dial
NO CN-142(B)- CN-52
Check voltage CN-7(15) Open circuit or Replace or repair
NO
between Spec : 0̫ poor connection
NO between CN-142 21
CN142(A)-(C)
(B) -CN-7 (15)
Spec : 5V
YES
poor connection MCU
between CN-142
(A) -CN-7 (14) or ACCEL DIAL
Check voltage CN-142 (C )- + A 14 3 6
between CN-7 (16) B
NO CN-7(14)-(16) S 15 2 7
YES
- C 16 1
Spec : 5V poor connection CN-142
between CN-7 CN-7 CN-16 CN-51
Check voltage (14) -CN-16 (3) or
NO
between CN-16 CN-7 (16 )-
(1)-(3) CN-16 (1)
Spec : 5V
NO poor connection
between CN-16
(3) -CN-51 (6) or
CN-16 (1 )-
CN-51 (7)
21096MS04
6-46
2) TEST PROCEDURE SPEC : Actuator operating : 1~5 V
(1) Test 6 : Check voltage at CN-52(21) and
ground.
Η Prepare 1 piece of thin sharp pin, steel or
copper.
MCU
Θ Insert prepared pin to rear side of PIN
connectors : One pin to (21) of CN-52. CN-51 CN-52 CN-53
Ι Starting key ON.

Κ Check voltage as figure.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS04A
6-47
5. AUTO DECEL SYSTEM DOES NOT WORK
· Fault code : HCESPN 105, FMI 0~4 (work pressure sensor)
HCESPN 108, FMI 0~4 (travel oil pressure sensor)
Cause Remedy
YES
YES
Defective travel Replace
Check voltage
NO pressure switch
between CD-6(A)
and (C)
Short circuit or poor Replace or repair
NO
Check voltage SPEC : connection
between CN-52 Key ON : 24±2V between CN-51(4)-
(26)-GND and CD-6(A) and / or
CN-52(35)-GND CN-51(5)-CD-6(C)
(fault code 108
SPEC :
Actuator operating : 1~5V
displayed)
See TEST 7, 8 YES
Defective work Replace
Check voltage
pressure sensor
between CD-7(A)
NO and (C)
Short circuit or poor Replace or repair
NO
SPEC : connection
Key ON : 24±2V between CN-51(4)-
CD-7(A) and / or
CN-51(5)-CD-7(C)
(fault code 105
displayed)
Wiring diagram
CN-51
CD-6
4 A SUPPLY
B SIG
5 C RETURN
TRAVEL PRESSURE SENSOR
MCU
26 CD-7
A SUPPLY
35 B SIG
C RETURN
CN-52 WORK PRESSURE SENSOR
21096MS05
6-48
ground.
MCU
copper.
PIN
Θ Insert prepared pin to rear side of CN-51 CN-52 CN-53
connectors : One pin to (26) of CN-52.

Ι Starting key ON.
(2) Test 8 : Check voltage at CN-52(35)and
ground.
10 9 8 7 6 5 4 3 2 1
copper CN-52
Θ Insert prepared pin to rear side of 20
26
11 Female
30 21
40 39 38 37 36 34 33 32 31
Ι Starting key ON.
Κ Check voltage as figure. GROUND
Multimeter
10 9 8 7 6 5 4 3 2 1
CN-52
20 11 Female
30 21
35
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS05A
6-49
6. MALFUNCTION OF PUMP 1 PRESSURE SENSOR
· Fault code : HCESPN 120, FMI 0~4
Cause Remedy
YES
YES
Short circuit or Replace or repair
poor connection
YES Check voltage between CN-52-
between
CN-1(3)-GND (29)-CN-1(3)
Check voltage SPEC : Detective P1 Replace or repair
between CN-52 Actuator operating: 1~5V NO
Check voltage pressure sensor
(29) - GND YES between Short circuit or Replace or repair
SPEC : CD-42(A)-(C) poor connection
Actuator operating: 1~5V between CN-1(3)-
See TEST 9 SPEC :
Key ON : 24±2V CD-42(B)
Check voltage Short circuit or Replace or repair

NO
between poor connection
NO CN-1(2)-(4) between
CD-42(A)-CN-1(2)
SPEC :
Key ON : 24±2V
or CD-42(C)-
CN-1(4)

NO poor connection
between CN-1(2)-
CN-51(4) or CN-1
(4) - CN-51(5)
Wiring diagram
CN-51
CD-42
4 2 A SUPPLY
3 B SIG
5 4 C RETURN
PUMP 1 PRESSURE SENSOR
CN-1
MCU
29
CN-52
21096MS06
6-50
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
29
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS06A
6-51
Cause Remedy
YES
YES
poor connection
between
CN-1(1)-GND (38)-CN-1(1)
See TEST 10 SPEC :
Key ON : 24±2V CD-43(B)

NO
CD-43(A)-CN-1(2)
SPEC :
Key ON : 24±2V
or CD-43(C)-
CN-1(4)

NO poor connection
between CN-1(2)-
CN-51(4) or CN-1
(4) - CN-51(5)
Wiring diagram
CN-51
CD-43
4 2 A SUPPLY
1 B SIG
5 4 C RETURN
CN-1
MCU
38
CN-52
21096MS07
6-52
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
38
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS07A
6-53
Cause Remedy
YES
YES
poor connection
between
CN-1(5)-GND (36)-CN-1(5)
See TEST 11 SPEC :
Key ON : 24±2V CD-44(B)

NO
CD-44(A)-CN-1(2)
SPEC :
Key ON : 24±2V
or CD-44(C)-
CN-1(4)

NO poor connection
between CN-1(2)-
CN-51(4) or CN-1
(4) - CN-51(5)
Wiring diagram
CN-51
CD-44
4 2 A SUPPLY
5 B SIG
5 4 C RETURN
CN-1
MCU
36
CN-52
21096MS08
6-54
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
36
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS08A
6-55
9. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective N1 Replace or repair
(37) - GND pressure sensor
SPEC : Short circuit or Replace or repair
Actuator operating: 1~5V Check voltage poor connection
See TEST 12 between CD-70 between CN-52
NO (A)-(C) (37)-CD-70 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-70
(A)-CN-51(4) or
CD-70(C)- CN-51
(5)
Wiring diagram
CN-51
CD-70
4 A SUPPLY
B SIG
5 C RETURN
NEGATIVE 1 PRESSURE SENSOR
MCU
37
CN-52
21096MS09
6-56
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
37
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS09A
6-57
10. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective N2 Replace or repair
NO (A)-(C) (27)-CD-71 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-71
(A)-CN-51(4) or
CD-71(C)- CN-51
(5)
Wiring diagram
CN-51
CD-71
4 A SUPPLY
B SIG
5 C RETURN
NEGATIVE 2 PRESSURE SENSOR
MCU
27
CN-52
21096MS10
6-58
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 27 11
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS10A
6-59
11. MALFUNCTION OF SWING PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective swing Replace or repair
NO (A)-(C) (24)-CD-24 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-24
(A)-CN-51(4) or
CD-24(C)- CN-51
(5)
Wiring diagram
CN-51
CD-24
4 A SUPPLY
B SIG
5 C RETURN
SWING PRESSURE SENSOR
MCU
24
CN-52
21096MS11
6-60
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
24
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS11A
6-61
12. MALFUNCTION OF ARM IN/OUT & BUCKET IN PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective arm in/ Replace or repair
(25) - GND out & bucket in
SPEC : pressure sensor
Actuator operating: 1~5V Check voltage Short circuit or Replace or repair
See TEST 15 between CD-35 poor connection
NO (A)-(C) between CN-52
(25)-CD-35 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-35
(A)-CN-51(4) or
CD-35(C)- CN-51
(5)
Wiring diagram
CN-51
CD-35
4 A SUPPLY
B SIG
5 C RETURN
ARM IN/OUT & BUCKET IN
PRESSURE SENSOR
MCU
25
CN-52
21096MS12
6-62
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
25
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS12A
6-63
13. MALFUNCTION OF BOOM UP PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective boom up Replace or repair
NO (A)-(C) (23)-CD-32 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-32
(A)-CN-51(4) or
CD-32(C)- CN-51
(5)
Wiring diagram
CN-51
CD-32
4 A SUPPLY
B SIG
5 C RETURN
BOOM UP PRESSURE SENSOR
MCU
23
CN-52
21096MS13
6-64
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
23
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS13A
6-65
14. MALFUNCTION OF TRANSMISSION OIL PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

NO (A)-(C) (34)-CD-5 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-5
(A)-CN-51(4) or
CD-5(C)- CN-51
(5)
Wiring diagram
CN-51
CD-5
4 A SUPPLY
B SIG
5 C RETURN
TRANSMISSION OIL
PRESSURE SENSOR
MCU
34
CN-52
14W96MS20
6-66
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
34
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
14W96MS20A
6-67
15. MALFUNCTION OF BRAKE OIL PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

NO (A)-(C) (33)-CD-3 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-3 (A)-
CN-51(4) or CD-3
(C)- CN-51 (5)
Wiring diagram
CN-51
CD-3
4 A SUPPLY
B SIG
5 C RETURN
BRAKE OIL PRESSURE SENSOR
MCU
33
CN-52
14W96MS21
6-68
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
33
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
14W96MS21A
6-69
16. MALFUNCTION OF TRAVEL FORWARD PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

NO (A)-(C) (28)-CD-73 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-73
(A)-CN-51(4) or
CD-73(C)- CN-51
(5)
Wiring diagram
CN-51
CD-73
4 A SUPPLY
B SIG
5 C RETURN
TRAVEL FORWARD
PRESSURE SENSOR
MCU
28
CN-52
14W96MS22
6-70
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 28 11
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
14W96MS22A
6-71
17. MALFUNCTION OF TRAVEL REVERSE PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

NO (A)-(C) (32)-CD-74 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-74
(A)-CN-51(4) or
CD-74(C)- CN-51
(5)
Wiring diagram
CN-51
CD-74
4 A SUPPLY
B SIG
5 C RETURN
TRAVEL REVERSE
PRESSURE SENSOR
MCU
32
CN-52
14W96MS23
6-72
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
32
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
14W96MS23A
6-73
18. MALFUNCTION OF POWER MAX
· Fault code : HCESPN 166, FMI 4 or 6
Cause Remedy
YES
Short circuit or poor Repair or replace
connection between
YES Check resistance CN-88(1)-CN-52 (7)
between CN-88
(1)-(2)
Defective power
NO
YES Check resistance SPEC: 15-35̫ max. solenoid valve Repair or replace
between CN-53 See TEST 22 Check hydraulic
(30)-GND
system
Is voltage between Short circuit or poor Repair or replace

NO
CN-88(2)-GND connection between
SPEC : Power max button pressed ON : 0̫
normal? Power max button released OFF : â ̫ CN-53(30)-CS-29
SPEC
KEY ON : 24Ü1V
KEY OFF : 0V Short circuit or poor Repair or replace
See TEST 21 NO
connection between
CN-88(2)-
Fuse No. 28
Wiring diagram
MCU
CN-88
7 1
2
CN-52
POWER MAX SOLENOID
30 5
FUSE
6
NO.28
CN-53 CN-4
CS-29
1
2
POWER MAX SWITCH
21096MS14
6-74
2) TEST PROCEDURE SPEC : Key ON : 24Ü1V
Key OFF : 0V
(1) Test 21:
21 Check voltage between connector
CN-88(2) - GND.
Η Disconnect connector CN-88 from power
max solenoid valve. Power max switch
Θ Start key ON.
Ι Check voltage as figure.
LH RCV-lever
CN-88
Power max
solenoid valve
2 1
1 2
GROUND
Multimeter
21096MS14A
(2) Test 22:

22 Check resistance of the solenoid SPEC : 15~35̫
valve between CN-88(1)-(2).
Η Starting key OFF.
Power max switch
Θ Disconnect connector CN-88 from power
max solenoid valve.
Ι Check resistance as figure.
LH RCV-lever
CN-88
Power max 2 1
solenoid valve
1 2
Multimeter
21096MS14B
6-75
19. MALFUNCTION OF BOOM PRIORITY EPPR VALVE
Cause Remedy
YES
Short circuit or poor Repair or replace
connection between
CN-53(19)-CN-133
Check resistance (1) or CN-53(9)-
between CN-133(2)
CN-133(1)-(2)
SPEC : 20~30V
KEY : ON
Defective EPPR Repair or replace
NO
valve
Wiring diagram
MCU
19
CN-133
9 2
BOOM PRIORITY
EPPR VALVE
CN-53
21096MS15
6-76
20. MALFUNCTION OF ARM REGENERATION SOLENOID
Cause Remedy
YES
YES Check voltage

YES
between CN-52 Short circuit or Replace or repair
(1)-GND
poor connection
Check resistance between CN-52
SPEC :
KEY ON 24±2V between arm
Check voltage NO (1)-CN-135 (1)
See TEST 23 regen solenoid
between CN-135(2)
- GND SPEC : 15~35̫ Defective Replace
NO
SPEC : solenoid valve
KEY ON : 20~30V
Open circuit Replace or repair

NO
between CN-135
(2)-Fuse No. 28
Wiring diagram
MCU
CN-135
1 1
ARM REGENERATION SOLENOID
FUSE
NO.28
CN-52
21096MS16
6-77
2) TEST PROCEDURE SPEC : Key ON : 24±2 V
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS16A
6-78
21. MALFUNCTION OF RAM LOCK SOLENOID
Cause Remedy
YES
YES Check voltage

YES
between CN-52 Short circuit or Replace or repair
(3)-GND
poor connection
Check resistance between CN-52
SPEC :
KEY ON 24±2V between ram
Check voltage NO (3)-CN-69 (1)
See TEST 24 lock solenoid
between CN-69(2) -
GND SPEC : 15~35̫ Defective Replace
NO
SPEC : solenoid valve
KEY ON : 20~30V
Open circuit Replace or repair

NO
between CN-69
(2)-Fuse No. 28
Wiring diagram
MCU
CN-69
3 1
RAM LOCK SOLENOID
FUSE
NO.28
CN-52
14W96MS25
6-79
2) TEST PROCEDURE SPEC : Key ON : 24±2 V
ground.
copper. MCU
CN-51 CN-52 CN-53
Ι Starting key ON.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
3
20 11
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
14W96MS25A
6-80

6 Troubleshooting

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6 Troubleshooting

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SECTION 6 TROUBLESHOOTING

Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1

Electrical part GROUP 3

HCESPN 3digit See page

STEP 1. Study the machine system

STEP 2. Ask the operator

STEP 3. Inspect the machine

and blown out fuses will result in malfunction of

STEP 5. Perform troubleshooting

STEP 6. Trace a cause

Analog 1 Analog 2 14W96HS01

Do not hydraulic Abnormal noise

Gear pump is Disassemble

2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

4) HYDRAULIC OIL IS CONTAMINATED

Clogged or oil leak. Clean pilot piping

Is MCV pilot Swing control valve Disassemble

4) MACHINE SWINGS BUT DOES NOT STOP

Return spring is Disassemble

Return spring of Disassemble

Travel speed Disassemble

Travel pilot Disassemble

YES Transmission unit Disassemble

Travel pilot solenoid Disassemble

The spool does Screw the fitting

The anti-avitation Ditto

4) IT TAKES TIME TO ACCELERATE THE MOTOR

The spool does Screw the fitting

The orifice for Remove the

Wrong setting of Adjust at the

The orifice for Remove the

Wrong setting of Adjust at the

6) EXTRAORDINARY NOISE IS HEARD WHEN SUDDENLY REDUCING THE SPEED FROM

Cylinder is faulty. Disassemble

5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE

Is boom speed RCV is faulty. Disassemble

Does the YES

Boom foot pin Supply grease

2. Disconnect hose (A) from rod side of boom

3. Raise bucket OFF the ground by retracting

Check voltage YES

YES Check voltage

Defective alternator Replace

Defective coolant Replace

SERVICE TOOL Engine ECM

MCU AIR CLEANER SWITCH

NO Fault code 135

Defective controller Replace

Defective coolant Replace

SERVICE TOOL Engine ECM

Starting switch : OFF Disconnection in Repair or replace

FUEL LEVEL SENDER

Disconnection in Repair or replace

FUSE TRAVEL HIGH SPEED SOLENOID

Cause Remedy CN-5

gravity of battery Voltage : 20~30V CN-60

NO 1) Recheck fuse Replace

of wiper motor or poor contact 4 1

(4) and chassis NO CN-97 8

(14) and chassis or Rear/ Left 8 HEAD LAMP-LH

Recheck fuse Replace

1. ALL ACTUATORS SPEED ARE SLOW

SPEC : 15~25̫(20ÁC) Defective EPPR Replace