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Antes de realizar el procedimiento de solucin, compruebe la escucha del men en el racimo. Antes de realiza
Hidrulico &
Parte mecnica
GRUPO 2
Parte elctrica
GRUPO 3
Mechatronics
parte
GRUPO 4
Problemas ocurren
Los cdigos de
la falta
mostrados en
la pantalla del
monitor
HCESPN 3digit
+ Dgito FMI 1
(mquina)
Ver pgina
5-15
3 o 4 dgito
(motor)
Ver pgina
5-18
6-1
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Multilizer PDF Translator Free version - translation is limited to ~ 3 pages per translation.
17W31SH03
EN EL
INSPECCIN
6-2
Multilizer PDF Translator Free version - translation is limited to ~ 3 pages per translation.
17W31SH05
P
Make a plan of the appropriate repairing
procedure to avoid consequential malfunctions.
17W31SH44
6-3
1. INTRODUCTION 1. INTRODUCTION
1)1)
MACHINE IN GENERALMACHINE 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.
Was there any strange thing about machine before failure occurred?
Under what conditions did the failure occur?
Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
Check oil and fuel level.
Check for any external leakage of oil from components.
Check for loose or damage of wiring and connections.
2)2)
MACHINE STATUS MONITORING ON THE CLUSTERMACHINE 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) (2)
SpecificationSpecification
No.
Description
Speci cation
Note 1
40+20 bar
Note 2
Note 3
0~40 bar
0~40 bar
Note 4
Note 5
0~40 bar
0~25 bar
Note 6
Note 7
Note 8
0~25 bar
350 bar
603 bar
6-46-4
1)1)UNUSUAL NOISE COMES OUT OF PUMP CONNECTIONUNUSUAL NOISE COMES OUT OF PUMP CONN
Cause
YES
Remove dust
plug under engine
flywheel and
check if rubber
pieces or particles
are not present.
YES
Coupling hub
spline is worn or
NO hub fastening
setscrew is slack.
Remedy
Replace hub or
retighten
setscrew.
6-5
2)2)
ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALLENGINE STARTS BUT MACHINE DOES N
Cause
NO
Is oil level in
hydraulic oil
tank within
standard level?
YES
Abnormal noise
comes out of
hydraulic pump
Replenish
specified oil to
the standard
level.
Disassemble
Hydraulic pump is and repair.
broken.
YES
Do not hydraulic
Abnormal noise
pump and pump YES comes out of
YES
connections
pump
YES
make abnormal
connection
noise?
Is pilot pump
pressure within
NO
standard level?
See Note 1
YES
Is pilot piping
YES clogged or is oil
leakage present
on pilot piping?
NO
YES
Is gear pump
NO delivering oil?
NO
6-66-6
Remedy
Clean pilot
piping interior or
repair piping.
RCV and safety
solenoid valve is
faulty.
Disassemble
and repair.
Disassemble
and repair.
3. HYDRAULIC SYSTEM
3. HYDRAULIC SYSTEM
HYDRAULIC OIL IS
CLOUDYHYDRAULIC OIL IS CLOUDY 1)1)
Cause
YES
Water is mixed.
Air is intruded.
NO
Remedy
NO
Remedy
Replenish
specified oil to
the standard
level.
Is hydraulic oil
volume proper?
YES
YES
Is fan belt
NO tension proper?
NO
6-76-7
Adjust belt
tension or
replace belt.
Readjust set
pressure.
Reduce load.
3)3)
CAVITATION OCCURS WITH PUMP CAVITATION OCCURS WITH PUMP
Cause
NO
Is hydraulic oil
volume proper?
Remedy
Replenish
specified oil to
the standard
level.
YES
Is not viscosity
of hydraulic oil
YES
too high?
YES
NO
Is not suction
strainer clogged?
Clean suction
strainer.
4)4)
HYDRAULIC OIL IS CONTAMINATED HYDRAULIC OIL IS CONTAMINATED
Cause
YES
Remedy
Replace
hydraulic oil to be
specified.
Flush with
hydraulic oil and
replace return
filter.
6-86-8
BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLEBOTH LH AND RH SWING ACTIONS ARE IMPOSS
1)1)
Cause
NO
YES
Does safety
YES solenoid valve
operation
Is gear pump pilot
normal?
pressure within
YES
standard level?
Is oil in hydraulic
YES
tank within
See Note 1
NO
standard level?
NO
Are attachment
and travel
motions
impossible at all?
Is MCV swing
Is travel function
NO normal?
within standard
level?
See Note 2
NO
NO
Does swing
YES
control valve
spool move?
Repair or replace.
YES
See Note 5
NO
YES
Replenish
specified oil to the
standard level.
Repair or replace.
Safety solenoid
valve faulty or not
operated.
Gear pump faulty.
YES
Remedy
Is swing parking
brake release
valve faulty?
Swing parking
Disassemble and
brake release valve repair.
is broken.
YES
Does swing
Swing reduction
unit is broken.
Disassemble and
repair.
Swing motor is
broken.
Disassemble and
repair.
NO motor rotate?
NO
YES
NO Is gear pump
delivering oil?
NO
YES
Is there oil
leakage from pilot
YES piping or is it
clogged?
6-96-9
NO
RCV is broken.
2)2)
SWING SPEED IS LOWSWING SPEED IS LOW
YES
YES Does swing spool
move?
Single direction
Disassemble and
repair or replace.
See Note 2
leak.
Is pilot piping
clogged or is it
NO
leaking oil?
Is the trouble in
one direction or
in both direction?
NO
RCV or shuttle
valve is faulty.
YES
Disassemble
and repair.
Swing spool is
stuck.
Disassemble
and repair.
Swing motor is
broken.
Disassemble
and repair.
RCV or shuttle
valve is faulty.
Disassemble
and repair.
Both directions
move?
pressure within
standard level?
Is Arm speed
within standard
value?
See Note 5
NO
NO
See Note 2
NO
Is swing motor's
drain rate within
standard value?
NO
or oil is leaking
from it?
YES
See Note 1
Is gear pump
NO delivering oil?
NO
NO
Remedy
NO
Is MCV pilot
pressure same
on LH and RH
sides?
Cause
Is main relief
valve setting
pressure normal?
See Note 7
Is MCV pilot
YES pressure within
standard level?
See Note 2
Disassemble and
repair or replace.
Gear pump is
broken.
Disassemble
and repair.
6-10
YES
NO
Disassemble
and repair.
Repair or replace.
Repair or replace.
Gear pump is
faulty.
Repair or replace.
3)3)
SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
YES
Does symptom
change when LH
YES
and RH port relief
valves are
exchanged?
NO
YES Does swing control
valve spool move?
Is MCV pilot
pressure same
for LH and RH?
See Note 2
Disassemble
and repair.
Shuttle valve is
faulty.
Disassemble
and repair.
NO
Check if pilot
piping is clogged
NO or does have oil
leakage.
Remedy
YES
RCV is faulty.
Clogged or oil
Disassemble
and repair.
Clean pilot piping
interior or repair
piping.
NO leak.
4)4)
MACHINE SWINGS BUT DOES NOT STOP MACHINE SWINGS BUT DOES NOT STOP
Cause
YES
YES Is MCV pilot
pressure within
standard value?
See Note 2
move?
NO
Is swing control
valve's return
spring normal?
NO
NO
6-11
Disassemble
and repair or
replace.
Gear pump is
broken.
Disassemble
and repair.
RCV is faulty.
Disassemble
and repair.
Swing spool is
stuck.
Disassemble
and repair.
Return spring is
faulty.
Disassemble
and replace.
pressure within
standard level?
See Note 1
NO
Remedy
5)5)
THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause
YES
YES Is swing shuttle
valve normal?
NO
YES Is brake spring
Remedy
Shuttle valve is
faulty.
Disassemble
and replace.
Brake spring is
faulty.
Disassemble
and replace.
Return spring of
swing control
valve is faulty.
Disassemble
and replace.
Disassemble
and repair or
replace.
Disassemble
and repair.
normal?
Is return spring
of swing spool
normal?
NO
NO
Is swing relief
pressure within
standard level?
Is drain rate of
YES swing motor
within standard
value?
SPEC : 26510kgf/cm2
YES
NO
Swing motor is
broken.
Adjust swing
relief valve
pressure or
replace swing
relief valve.
NO
6-126-12
valves (high/low)
normal?
NO
pressure within
standard?
YES
Travel pilot
solenoid valves
NO
normal?
NO
Is swing operation
possible?
YES
Remedy
Disassemble
and repair or
replace.
Travel pilot
solenoid valve is
faulty
Disassemble
and repair or
replace.
Transmission unit
is faulty
Disassemble
and repair.
Does travel
motor rotate?
NO
6-136-13
Disassemble
and repair.
2)2)
TRAVEL ACTION IS POWERLESS TRAVEL ACTION IS POWERLESS (travel only)
Cause
YES
NO
valves (high/low)
normal?
NO
YES
Travel pilot
solenoid valve
NO
normal?
NO
YES
Does travel
motor rotate?
NO
YES
YES
NO
6-146-14
Remedy
Disassemble
and repair or
replace.
Disassemble
and repair or
replace.
3)3)
THE HYDRAULIC MOTOR DOSE NOT GET STARTED
The hydraulic
motor does not
get started
Remedy
Screw the fitting
bolts one more
time with correct
tightening torque.
If the spool turns
out to be
damaged, it
should be
repaired or the
new one should be used
4)4)
IT TAKES TIME TO ACCELERATE THE MOTOR
Cause
Remedy
It takes time to
accelerate the
motor
6-156-15
Remove the
foreign matter by
disassembling
and cleaning.
Wrong setting of
pressure of the
relief valve.
Adjust at the
correct value.
If the relief valve
turns out to be
out of order, the
new one should
be used.
5)5)
IT IS NOT POSSIBLE TO REDUCE THE MOTOR SMOOTHLY
It is not possible
to reduce the
motor smoothly
Remedy
Remove the
foreign matter by
disassembling
and cleaning.
Wrong setting of
pressure of the
relief valve.
Adjust at the
correct value.
If the relief valve
turns out to be
out of order, the
new one should
be used.
6)6)
EXTRAORDINARY NOISE IS HEARD WHEN SUDDENLY REDUCING THE SPEED
FROM EXTRAORDINARY NOISE IS HEARD WHEN SUDDENLY REDUCING THE SPEED FROM THE HIG
Cause
It takes time to
accelerate the
motor
Remedy
6-166-16
6. ATTACHMENT SYSTEM
6. ATTACHMENT SYSTEM
1)1)
BOOM OR ARM ACTION IS IMPOSSIBLE AT ALLBOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause
Remedy
YES
pressure within
standard level?
See Note 3, 4
attachments
operatable?
Disassemble
and repair.
YES
Is gear pump
pilot pressure
NO within standard
level?
delivering oil?
See Note 1
Are travel
operations
possible?
Inspect oil
NO volume in
hydraulic oil tank.
Disassemble
YES main relief valve
and check if it is
Remove dust plug
not irregular.
under engine
OK flywheel and check
Faulty
if coupling element
particles are not
present.
Particles present
Disassemble
and repair or
replace.
Disassemble
Coupling at pump and repair.
connection is
broken.
Replenish
hydraulic oil.
Short
YES
Does control
valve spool
move?
See Note 5, 6
6-17
NO
Disassemble
and repair.
2)2)
BOOM, ARM OR BUCKET SPEED IS LOW BOOM, ARM OR BUCKET SPEED IS LOW
Cause
YES
Normal.
YES
Is combination
YES of oil streams
normal at boom
up and at arm
extrusion?
Are other
YES attachment
speeds within
standard levels? NO
Does spool of flow
summation check
NO valve move lightly
by hand?
YES
Is travel speed
Is MCV pilot
pressure within
NO
standard?
See Note 3, 4
YES
Does control
valve spool
move ?
See Note 7
Is MCV pilot
pressure within
standard level?
See Note 3, 4
YES
YES
NO
OK
MCV spool is
stuck.
NO
YES
NO
NO
AIs engine
NO
revolution within
standard level?
Disassemble
and repair.
Adjust engine
revolution.
YES
Is not orifice in
main control
valve clogged?
Disassemble
and repair or
replace.
Disassemble
and repair.
Clean pilot
piping interior or
repair piping.
Disassemble
RCV is defective. and repair.
Disassemble
Pilot relief valve is and repair or
replace.
faulty.
Disassemble
and repair.
Gear pump is
broken.
Is pilot pressure NO
Is gear pump
within standard
delivering oil?
level?
See Note 1
Disassemble
and repair.
Does the
Port relief valve is
symptom change
faulty.
YES
when port relief
valve is replaced
with other valve? NO Cylinder is faulty.
YES
Flow summation
check valve is
stuck.
NO
NO low?
Remedy
Clean orifice in
control valve.
YES
Is pilot piping
clogged or is oil
NO leaking from the
piping?
6-18
NO
Is RCV normal?
NO
RCV is faulty.
Clean pilot
piping interior or
repair piping.
Disassemble
and repair.
3)3)
BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause
YES
YES
Control valve's
NO return spring is
faulty.
NO
OK
Is cylinder
internal leakage
within standard
level?
Disassemble and
YES inspect load
check valve in
MCV and check
for any fault.
Abnormal
NO
6-19
Disassemble
and replace.
Locate the
cause of
hydraulic oil
temperature rise
and lower it to
proper level.
Replace with
genuine
hydraulic oil or
equivalent.
Abnormally high.
Is genuine
hydraulic oil or
equivalent being
used?
Remedy
Pressure
tightness
between control
valve casing and
spool is poor.
Contact surface
between poppet
and seat is poor.
Disassemble
and repair.
Cylinder is faulty.
Disassemble
and repair.
Disassemble
and repair.
4)4)
BOOM, ARM OR BUCKET POWER IS WEAK
Check according
to the procedure
in Item "Speed is
low".
Is cylinder
within standard
level?
Is relief pressure
Is relief pressure
in main relief
valve within
standard level?
Cylinder is faulty.
NO
valve within
standard level?
Remedy
Disassemble
and repair.
NO
See Note 7
NO
5)5)
ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause
YES
Does the
YES symptom change
when port relief
valve is replaced
with other valve?
YES
Is MCV pilot
pressure within
standard level?
Does control
valve spool
NO
move?
See Note 5
Adjust pressure,
repair or replace.
Remedy
MCV spool is
stuck.
Disassemble
and repair.
RCV is faulty.
Disassemble
and repair.
Adjust pressure,
repair or replace.
Disassemble
and repair.
See Note 4
Is boom speed
is normal?
NO
YES
Does the
symptom change
Does the
when main relief
symptom change
NO valves are
YES
when hydraulic
exchanged?
NO pump's discharge
hoses are
exchanged?
6-20
Hydraulic pump is
broken.
6)6)
BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
YES
Remedy
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil seal
and boom
proper.
Frictional
noise
will
disappear if
they are kept
used.
Boom foot pin
has run out of
grease.
NO
6-21
Supply grease
to it.
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.
14W96TS01
(210-7) 6-20(2)
6-22
7. FRONT AXLE AND REAR AXLE7. FRONT AXLE AND REAR AXLE
Problem
Insufficient braking
Cause
Correction
1. Incorrect adjustment
7. Incorrect adjustment
Overheating
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
in actuating cylinder(noteable
through loss of hydraulic oil or
increase of the oil level in axle)
20. If with limit slip differential,
worn discs
6-23
Rebuilt cylinder.
Replace discs.
Problem
Cause
Correction
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
than during coast
27. Incorrect lubricant
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
1.WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted and short
of fuse No.7, 11.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
Check voltage
between CN-56
(3) and (5)
Starting switch : ON
Voltage : 20~32V
Remedy
Check voltage
between
NO CN- 5 (3) and (5)
Starting switch : ON
Voltage : 20~32V
NO
20~32V
NO
0V
CLUSTER
FUSE
POWER(24V)
GND
POWER IG(24V)
NO.7
FUSE
NO.11
CN-56
CN-5
14W96ES01
6-256-25
2.2.
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
Remedy
Defective cluster
Replace
between CN-56
(4, 8) and (3)
Check voltage
between
CN-5 (1) and (2)
Starting switch : ON
Voltage : 2V
Starting switch : ON
Voltage : 2V
NO
Defective MCU
Replace
Disconnection in Repair or replace
wiring harness or (after clean)
poor contact
between CN-5 (1,
2)- CN-51(23, 33)
NO
2V
NO
0V
CLUSTER
GND
MCU
RS485 RX
23
RS485 TX
RS485 TX
33
RS485 RX
CN-51
CN-56
CN-5
14W96ES02
6-266-26
3.3.
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
YES Check voltage
between CN-51
(39) and chassis
Check voltage
YES
between CN-2
(9) and chassis
NO
Voltage : 20~32V
Voltage : 20~32V
Check voltage
between alternator
terminal "I" and
chassis
NO
Engine : Running
Voltage : 20~32V
Remedy
Defective MCU
Replace
Disconnection in
wiring harness or
poor contact
between CN-51
(39)-CN-2 (9)
Disconnection in
wiring harness or
poor contact
between CN-2 (9)
alternator terminal
"I"
Repair or replace
(after clean)
Repair or replace
(after clean)
NO
20~32V
NO
0V
MCU
ALTERNATOR
B+
39
I
GND
CN-51
G
3~
U
CN-74
CN-2
21096ES03
6-276-27
4.4.
WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UPWHEN COOLANT OVERHEAT WAR
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
Remedy
Check resistance
YES between engine
harness connector
(15)-(38)
Disconnection in Repair or replace
wiring harness or (after clean)
poor contact
between temp
sensor-engine
harness connector
Spec : 180~160 k
NO
Check resistance
between temp
sensor (A)-(B)
Starting switch : OFF
Spec : 180~160 k
See table
Defective coolant
temp sensor
NO
Replace
25
50
80
95
30~37
9.3~10.7
3.2~3.8
1.0~1.3
0.7~0.8
SERVICE TOOL
Engine ECM
CAN_Lo
21
31
CAN_Hi
20
21
RS232_TX
16
24
RS232_RX
15
34
P_DUMP
12
CN-5
ENGINE COOLANT
TEMPERATURE SENSOR
CN-93
CN-3
46
CAN_Hi
15
47
CAN_Lo
38
OEM
connector
Engine harness
connector
CN-51
21096ES04
6-286-28
5.5.
WHEN AIR CLEANER WARNING LAMP LIGHTS UPWHEN AIR CLEANER WARNING LAMP LIG
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
Does display go
off when
disconnect
CD-10?
Starting switch : ON
Engine : Start
Remedy
YES
Check resistance
between CN-53
NO (23) and chassis
Starting switch : OFF
Disconnect CN-53
NO
Short circuit in
wiring harness
between CD-10CN-53 (23)
Repair or replace
(After clean)
Defective MCU
Replace
MAX 1
NO
MIN 1M
MCU
Pa
23
CN-53
CD-10
21096ES05
6-296-29
6.
6.
WHEN ENGINE OI
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
NO
Defective circuit,
sensor or ECM.
Remedy
Contact Cummins.
active?
Starting switch : ON
Voltage above
Refer to engine
normal or shorted fault code 135
to high source
YES
Starting switch : ON
Voltage above
Refer to engine
normal or shorted fault code 386
to high source
YES
Signal
ENGINE OIL
PRESSURE SENSOR
CN-93
8
46
Engine
ECM
47
SERVICE TOOL
CAN_Lo
21
31
CAN_Hi
20
21
RS232_TX
16
24
RS232_RX
15
34
P_DUMP
12
CN-5
CN-3
OEM
connector
Return
13
38
3
2
33
Engine harness
connector
+5V supply
CN-51
21096ES06
6-30
7.7.
WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UPWHEN HYDRAULIC OIL T
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
YES
Cause
Remedy
High temperature
Check hydraulic
oil temperature
(105C 2C),
Defective temp
sensor
Replace
Short circuit
between temp
sensor and MCU
Repair or replace
Resistance
YES between CD-1
(1, 2) is in range
of 164~151?
Does display go
off when
disconnect
CD-1?
Starting switch : ON
Engine : Start
Starting switch : ON
Disconnect CD-1
NO
YES
Resistance
between CN-51
NO (36, 5) is 0~1?
Starting switch : OFF
Disconnect CN-51
NO
~ -10
22.22 8.16
~31.78 ~10.74
~0
~ 40
5.18
~ 6.6
~ 70
~ 80
~ 90
~ 100
105~
1.06
0.39 0.322 0.243 0.185
~1.28 ~0.476 ~0.298 ~0.219 ~0.167
0.164
0.151
MCU
HYDRAULIC OIL
TEMPERATURE SENDER
36
CD-1
CN-51
21096ES07
6-316-31
8. WHEN
FMI 3 or 4)
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
Remedy
Check resistance
YES between engine
harness connector
(15)-(38)
Spec : 180~160 k
NO
Check resistance
between temp
sensor (A)-(B)
Starting switch : OFF
Spec : 180~160 k
See table
Defective coolant
temp sensor
NO
Replace
25
50
80
95
30~37
9.3~10.7
3.2~3.8
1.0~1.3
0.7~0.8
SERVICE TOOL
Engine ECM
CAN_Lo
21
31
CAN_Hi
20
21
RS232_TX
16
24
RS232_RX
15
34
P_DUMP
12
CN-5
ENGINE COOLANT
TEMPERATURE SENSOR
CN-93
CN-3
46
CAN_Hi
15
47
CAN_Lo
38
OEM
connector
Engine harness
connector
CN-51
21096ES04
6-326-32
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
YES
Check resistance
between fuel
sender (1) and
(2)
Check resistance
between CN-51
(5) and (38)
Starting switch : OFF
Disconnect CN-51
Spec : 50~600
Remedy
NO
NO
Disconnection in
wiring harness or
poor contact
between fuel
sender-MCU
Repair or replace
Defective fuel
sender
Replace
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
1
CD-2
CN-51
21096ES09
6-336-33
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted and short
of fuse No.23.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
Hydraulic system
malfunction
of solenoid
Safety lever : ON-OFF
Check resistance
Starting switch : ON
Voltage : 20~30V
Safety state
Check voltage
NO between CN-68
(2) and chassis
YES
Check resistance
between CS-4
NO
(A)-(C)
Starting switch : OFF
Safety switch : ON-0
NO
OFF-
Check hydraulic
system
NO
YES
Check voltage
between CN-68
(1) - (2)
Remedy
NO
Disconnect in
wiring harness or
poor contact
between
CN-4-CN-68
Repair or replace
(after clean)
Disconnect in
wiring harness or
poor contact
between
CN-4-CS-4
Repair or replace
(after clean)
Defective safety
switch
Replace
Disconnection in
wiring harness
between
CN-68 (2)-fuse
Repair or replace
FUSE
NO.23
SAFETY SWITCH
C
CS-4
A
B
C
14
SAFETY SOLENOID
15
16
CN-4
CN-68
21096ES10
6-346-34
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERA
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted and short
of fuse No.25 .
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
Check resistance
(1)-(2) or
CN-181(1)-(2)
Starting switch : OFF
Spec : 30
Disconnect CN-70
Remedy
NO
167 active?
YES
Starting switch : ON
Check if travel
speed lamps(
,
) change when
turning the RH
multifunction switch
on the cluster
Check voltage
between CN-70
NO (1)-(2) or
CN-181(1)-(2)
Starting switch : ON
Spec : 20~30 V
Disconnect CN-70
NO
Starting switch : ON
YES
Check MCU
Y
NO
Starting switch : ON
Defective MCU
NO
Replace
FUSE
NO.25
MCU
CN-70
TRAVEL LOW SPEED SOLENOID
2
1
CN-181
CN-52
14W96ES11
6-35
lights up condition)
CN-93
Check voltage
CN-3 (13) and
chassis
YES
Starting switch : ON
Spec : 20~30V
Check operation
start motor
Disconnection in
NO
wiring harness or
poor contact
between CN-3
(13) -CN-93 (39)
Key switch : ON
Spec : 20~30V
YES
Check operation
of start relay
NO
CR-23
YES
between CN-2
(7) and chassis
Starting switch : ON
NO
Check operation
of anti-restart
NO relay CR-5
5
6
2
3
35
59
60
36
CR-45
1
2
NO.9
4 5 1
3
4
NO.1
3 2
ECM POWER RY
CR-35
NO.4
NO
ST C
CN-5
Repair or replace
0, I
ENGINE ECM
Defective ECM
Replace
power relay CR-45
NO
Check voltage
BATT (+)
BATT (+)
BATT (-)
BATT (-)
BR ACC
YES
Check voltage
YES
CN-93 (39) and
chassis
Remedy
4
3
2
1
H0I
CN-94
Cause
13
14
15
CS-2
After checking, insert the disconnected connectors again immediately unless otherwise specified.
START KEY SW
KEY IG
39
CN-3
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted and short
of fuse No. 1, 4, 9, 20.
CN-125
NO.20
POWER RY
CS-74
1
2
CN-95
2
1
MASTER SW
FUSIBLE LINK
YES
Check voltage
between CR-5
NO
(1, 2)
Starting switch : START
Spec : 20~30V
Check voltage
between CR-23
and chassis
2
1
Replace
CN-60
BATT RY
DO-1
YES
NO
2
1
DIODE
Repair or replace
CN-52
ANTI-RESTART RY
15
MCU
CR-5
1 5 4
1
2
3
4
YES
BATTERY
NO
Check voltage
between CR-5
(2) and chassis
CR-1
2 3
ANTI-RESTART RY
START MOTOR
CN-2
7
8
CR-23
2
1
START RY
CN-45
14W96ES12
6-36
BATT (+)
BATT (+)
BATT (-)
BATT (-)
YES
between DO-1
(1) and chassis
Voltage : 20~30V
between CS-2
(1) and chassis
YES
YES
Check voltage
between CS-74
NO
(1) and chassis
Voltage : 20~30V
NO.1
5
6
2
3
3 2
ECM POWER RY
CR-35
NO.4
Replace
4 5 1
3
4
NO.20
POWER RY
CS-74
1
2
CN-95
2
1
MASTER SW
FUSIBLE LINK
2
1
Battery capacity
too low
1
2
NO.9
CN-60
CR-1
BATTERY
BATT RY
DO-1
NO
NO
CR-45
Disconnection in Replace
wiring harness or
poor contact
between CS-2 (1)CN-5 (36)
Check voltage
between CN-5
NO
(36) and chassis
Voltage : 20~30V
35
59
60
36
Defective start
switch
Voltage : 20~30V
Check voltage
and specific
gravity of battery
CN-5
Remedy
NO
ST C
ENGINE ECM
Cause
BR ACC
0, I
4
3
2
1
CS-2
After checking, insert the disconnected connectors again immediately unless otherwise specified.
H0I
CN-94
13
14
15
START KEY SW
KEY IG
39
CN-3
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted, master
switch ON and check open circuit of fusible link (CN-60).
CN-125
2
1
Charge or replace
(after clean)
DIODE
CN-52
YES
Check voltage
between CS-74
(2)- chassis
Voltage : 20~30V
NO
ANTI-RESTART RY
Defective master
switch
Replace
15
MCU
CR-5
1 5 4
1
2
3
4
2 3
ANTI-RESTART RY
START MOTOR
CN-2
7
8
CR-23
2
1
START RY
CN-45
14W96ES13
6-37
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.
6, 17 and 18 is not blown out.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
CN-21
3
Cause
NO
Defective wiper
cut switch
NO
Check valtage
between CN-141
YES
(11) and chassis
YES
Check operation
YES of multifunction
SW
Starting switch : ON
Turn wiper switch
Washing
Starting switch : ON
Vottage : 20~30V
YES
NO
Check operation
of wiper motor
and controller
check voltage
YES
CN-141 (7) and
chassis, CN-21
(4) and chassis
Check continuity
NO
between
CN-141 (2)-CN-98 (3),
CN-141 (9)-CN-97 (10),
CN-141 (10)-CN-98 (5),
CN-141 (5)-Chassis ,
Check wiper
CN-141 (1)-CN-21 (5),
motor resistance
CN-141 (3)-CN-21 (6), YES between CN-21
CN-141 (4)-CN-21 (2),
(2)-CN-21 (6)
CN-141 (13)-CN-21 (3)
Resistance : 3~4
NO
Check voltage
CN-141 (6) and
YES
chassis
Starting switch : ON
Voltage : 20~30V
NO
YES
YES
CN-5
5
6
WIPER MOTOR
FUSE
18
NO.6
CN-141
Replace
FEED BACK
MOTOR DRIVE-
MOTOR DRIVE+
GND
VCC
CONTINUE 24V
WASHER P/P
WASHER SIG.
9
10
11
12
13
INT. SIG
WIPER CUT SW
Defective
Replace
multifunction
switch
1) Recheck fuse Replace
No.6
2) Disconnection Repair or replace
in wiring harness (after clean)
or poor contact
between
CN-141(7)-Fuse,
CN-21(4)-Fuse
NO
Replace
N.C
NO
Intermittent
NO Check voltage
between CN-97
(7) and chassis
Defective
multifunction
switch
1
2
Short circuit in
Repair or replace
wiring harness or (after clean)
poor contact
between CN-141
(11)- CS-53
Check operation
wiper cut switch
Front sliding door
open-close
Remedy
CN-17
NO.18
CN-22
M
2
1
19
WASHER PUMP
CN-98
FEED BACK
FUSE
24
43
(2) INT
1
2
3
4
(1) COM
(4) HO
7 WA
CS-53
Hi
8 COM
23
4
3
WIPER CUT SW
CN-97
37
10
7
1
2
3
4
5
6
7
8
9
10
11
12
WI
Lo
4 COM
5
Lo
Hi
12 B+
9
10 COM
11
Replace
Defective wiper
motor controller
Replace
MULTIFUNCTION SWITCH-LH
FUSE
NO.17
14W96ES14
6-38
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.17.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
FUSE
CN-151
NO.17
Cause
YES
Check voltage
YES between CL-4(2)
and chassis,CL3(2) and chassis
Voltage : 20~30V
NO
Check voltage
YES
between CN-151
(8) and chassis
YES
Starting switch : ON
Head lamp switch : ON
Voltage : 20~30V
Check voltage
NO between CN-98
(2) and chassis
Starting switch : ON
NO
Head lamp switch : ON
Voltage : 20~30V
Check voltage
between CN-152
(14) and chassis,
CN-152 (15) and
chassis
Starting
switch : ON
Defective bulb
Remedy
INT (2)
COM (1)
Replace
HO (4)
WA
Hi
1
2
3
4
CN-97
7
YES
WI
Lo
COM 4
Lo
Repair or replace
(after clean)
Hi
B+
12
1
2
3
4
5
6
7
8
9
10
11
12
CN-98
1
2
COM 10
R
Check voltage
between CN-5
NO
(49) and chassis
Recheck fuse
No. 17
Replace
Defective switch
panel
Replace
CABIN LAMP RY
WORK LAMP RY(COIL)
WORK LAMP RY
WORK LAMP RY
RELAY EARTH
HEAD LMP RY HI
HEAD LMP RY HI(COIL)
HEAD LMP RY LO
NC
OUTRINGER RY
HARNESS RY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
HARNESS RY
11
MULTIFUNCTION SW-LH
Disconnection in
wiring harness or
poor contact
between CN-152
(14) and chassis or
CN-152 (15)chassis
CABIN LAMP RY
CN-152
Replace
Repair or replace
(after clean)
12
COM 8
CN-5
ILL
HEAD LAMP
WORK LAMP
CABIN LAMP
PRE-HEAT
Front/ Left
Front/ Right
Rear/ Left
Rear/ Right
POWER
GND
DOZER PS
1
2
3
4
5
6
7
8
9
10
11
12
CL-4
1 Lo
2 Hi
CN-116
Voltage : 20~30V
Head lamp switch : ON
1
2
3
4
5
6
7
8
9
10
11
12
49
HEAD LAMP-RH
CL-3
1 Lo
2 Hi
3
HEAD LAMP-LH
SWITCH PANEL
Starting switch : ON
Voltage : 20~30V
Head lamp switch : ON
YES
Check voltage
between CN-116
NO
(2) and chassis
Starting switch : ON
Head lamp switch :
ON-OFF
NO
14W96ES15
6-39
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.15.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause
YES
YES
FUSE
Starting switch : ON
Voltage : 20~30V
NO
Replace
Check voltage
between CL-5 (2)
and chassis
NO
Check voltage
between CN-151
(6) and chassis,
CN-151(4) chassis
Defective bulb
Remedy
YES
Check voltage
between CN-116
NO
(3) and chassis
Starting switch : ON
Work lamp switch : ON NO
Voltage : 20~30V
NO.15
Defective switch
panel
CN-5
CN-151
CN-116
Replace
ILL
HEAD LAMP
WORK LAMP
CABIN LAMP
PRE-HEAT
Front/ Left
Front/ Right
Rear/ Left
50
HARNESS RY
CN-12
CL-5
POWER
10
GND
11
DOZER PS
12
Rear/ Right
WORK LAMP
SWITCH PANEL
1
2
3
4
5
6
7
8
9
10
11
12
1
2
CL-6
Replace
14W96ES16
6-40
1. ALL ACTUATORS SPEED ARE SLOW1. ALL ACTUATORS SPEED ARE SLOW
Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
S -mode 1500 50 rpm
E-mode 1350 50 rpm
Spec : P-mode 1700 50 rpm
Before carrying out below procedure, check all the related connectors are properly inserted and
fault code on the cluster.
1)1)
INSPECTION PROCEDUREINSPECTION PROCEDURE
Cause
YES
YES Check pressure
SPEC : 100~700 mA
See TEST 2
Check if HCESPN
140 active fault
display on the LCD
NO
YES
Check resistance
at EPPR valve
YES
SPEC : 15~25(20
C)
See TEST 1
Defective
hydraulic system
at EPPR valve
Check electric
current at EPPR
valve
NO
Remedy
NO
NO
Defective
EPPR valve
Replace
Defective MCU
Replace
Short circuit or
poor connection
between CN-53
-CN-75
Defective EPPR
valve
Replace
MCU
FUSE
4
NO.24
8
14
18
CN-53
CN-1
CN-75
14W96MS01
6-41
EPPR valve
Main pump
20W96MS01
(2) (2)
Test 2 Test 2 : Check electric current at
EPPR valve.
Spec : 100~700 mA
Adapter(P/no.:21Q6-50410)
CN-75
Start engine.
Set S-mode and cancel auto decel
mode.
EPPR valve
Multimeter
Main pump
20W95MS10
(3)(3)
Test 3 Test 3 : Check pressure at EPPR valve. Spec : 2~25 kgf/cm
2 (30~350 psi)
Remove plug and connect pressure
Pilot pressure
gauge as figure.
supply line
2
CN-75
Pressure adjusting
Gauge capacity : 0 to 50 kgf/cm
screw locknut
(0 to 710 psi)
Start engine.
EPPR valve
Set S-mode and cancel auto decel
mode.
Position the accel dial at 10.
If rpm display approx 1500 50 rpm
check pressure at relief position of bucket
circuit by operating bucket control lever.
If pressure is not correct, adjust it.
Main pump
20W95MS11
6-42
Cause
YES
YES Check pressure
Not enough
engine power
Check engine
fault
Contact cummins
Defective EPPR
valve
Replace
Short circuit or
poor connection
between
CN-53 - CN-75
Defective EPPR
valve
Replace
at EPPR valve
Check electric
current at EPPR
valve
SPEC : 100~700 mA
See TEST 4
SPEC:5~20 kgf/cm2
See TEST 5
NO
YES
Check resistance
between
NO at EPPR valve
SPEC : 15~25 (20C)
See TEST 1
NO
Remedy
MCU
FUSE
4
NO.24
8
14
18
CN-53
CN-1
CN-75
14W96MS01
6-43
Spec : 100~700 mA
Adapter(P/no.:21Q6-50410)
CN-75
EPPR valve
Multimeter
Start engine.
Set S-mode and cancel auto decel mode.
Position the accel dial at 10.
If rpm display approx 1500 50 rpm
check electric current at bucket circuit
relief position.
Main pump
20W95MS10
(2)(2)
Test 5 Test 5 : Check pressure at EPPR valve.
Remove plug and connect pressure
gauge as figure.
2
Gauge capacity : 0 to 50 kgf/cm
(0 to 710 psi)
Start
engine.
2 (30~350 psi)
Spec : 2~25 kgf/cm
Pilot pressure
supply line
CN-75
Pressure adjusting
screw locknut
EPPR valve
Main pump
20W95MS11
6-44
3. MALFUNCTION OF CLUSTER
Before carrying out below procedure, check all the related connectors are properly inserted.
1)1)INSPECTION PROCEDUREINSPECTION PROCEDURE
Cause
YES
YES
Y
See if HCESPN
840 active fault
display on the LCD
Remedy
MCU failure
Replace
NO
NO
NO
OK
Check connection
between CN-51
(33) - CN-56(4) or
CN-51(23) CN-56(8)
NO
Cluster failure
Replace
No connection
KEY OFF
CLUSTER
MCU
BATT. 24V
SIG_3
GND
TX
33
IG 24V
23
SIG_2
CAMERA SIG
CN-56
CN-5
CN-51
RX
FUSE
NO.3
21096MS03
6-45
Replace
YES
Open circuit or
poor connection
between CN-16
(2) -CN-52 (21)
Replace or repair
Open circuit or
poor connection
between CN-7
(15) -CN-16 (2)
Replace or repair
Defective accel
dial
Replace
Open circuit or
poor connection
between CN-142
(B) -CN-7 (15)
Replace or repair
Open circuit or
poor connection
between CN-142
(A) -CN-7 (14) or
CN-142 (C )CN-7 (16)
Replace or repair
between CN-16
(2)-GND
between
CN-7(15)-GND
Check resistance
between
NO CN-142(B)CN-7(15)
Check voltage
between
NO
CN142(A)-(C)
Spec : 0
Spec : 5V
YES
NO
YES
Check voltage
between
NO CN-7(14)-(16)
YES
Spec : 5V
Check voltage
between CN-16
NO
(1)-(3)
Spec : 5V
NO
CN-52
21
MCU
ACCEL DIAL
+
Check voltage
between
CN-52(21)-GND
Remedy
Open circuit or
Replace or repair
poor connection
between CN-7
(14) -CN-16 (3) or
CN-7 (16 )- CN-16
(1)
Open circuit or
poor connection
between CN-16
(3) -CN-51 (6) or
CN-16 (1 )CN-51 (7)
YES
14
15
16
CN-142
CN-7
CN-16
CN-51
Replace or repair
21096MS04
6-46
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
2 1
20
11
21
30
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS04A
6-47
Check voltage
between CD-6(A)
and (C)
SPEC :
Key ON : 242V
SPEC :
Actuator operating : 1~5V
See TEST 7, 8
YES
NO
Defective MCU
Replace
Defective travel
pressure switch
Replace
NO
Check voltage
between CN-52
(26)-GND and
CN-52(35)-GND
Remedy
Defective work
pressure sensor
Check voltage
between CD-7(A)
and (C)
Replace
NO
SPEC :
Key ON : 242V
CN-51
CD-6
4
A
B
C
SUPPLY
SIG
RETURN
MCU
26
CD-7
35
SUPPLY
SIG
RETURN
CN-52
21096MS05
6-486-48
MCU
PIN
CN-51 CN-52
CN-53
10 9 8 7 6
5 4
3 2 1
20
11
26
30
21
40 39 38 37 36
CN-52
Female
34 33 32 31
GROUND
Multimeter
10 9 8 7 6
5 4
3 2 1
20
11
30
21
35
40 39 38 37 36
CN-52
Female
35 34 33 32 31
GROUND
Multimeter
21096MS05A
6-496-49
between
CN-1(3)-GND
Check voltage
between CN-52
(29) - GND
SPEC :
Actuator operating: 1~5V NO
Check voltage
YES between
CD-42(A)-(C)
SPEC :
Actuator operating: 1~5V
See TEST 9
SPEC :
Key ON : 242V
Check voltage
between
NO CN-1(2)-(4)
Remedy
Defective MCU
Replace
Short circuit or
poor connection
between CN-52(29)-CN-1(3)
Replace or repair
Detective P1
Replace or repair
pressure sensor
Short circuit or
Replace or repair
poor connection
between CN-1(3)CD-42(B)
Short circuit or
Replace or repair
poor connection
between
CD-42(A)-CN-1(2)
or CD-42(C)CN-1(4)
NO
SPEC :
Key ON : 242V
Short circuit or
Replace or repair
poor connection
between CN-1(2)CN-51(4) or CN-1
(4) - CN-51(5)
NO
CN-51
CD-42
4
5
SUPPLY
SIG
RETURN
CN-1
MCU
29
CN-52
21096MS06
6-50
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
20
30
5 4 3
2 1
11
21
29
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS06A
6-51
between
CN-1(1)-GND
Check voltage
between CN-52
(38) - GND
SPEC :
Actuator operating: 1~5V NO
Check voltage
YES between
CD-43(A)-(C)
SPEC :
Actuator operating: 1~5V
See TEST 10
SPEC :
Key ON : 242V
Check voltage
between
NO CN-1(2)-(4)
Remedy
Defective MCU
Replace
Short circuit or
poor connection
between CN-52(38)-CN-1(1)
Replace or repair
Detective P2
Replace or repair
pressure sensor
Short circuit or
Replace or repair
poor connection
between CN-1(1)CD-43(B)
Short circuit or
Replace or repair
poor connection
between
CD-43(A)-CN-1(2)
or CD-43(C)CN-1(4)
NO
SPEC :
Key ON : 242V
Short circuit or
Replace or repair
poor connection
between CN-1(2)CN-51(4) or CN-1
(4) - CN-51(5)
NO
CN-51
CD-43
4
5
SUPPLY
SIG
RETURN
CN-1
MCU
38
CN-52
21096MS07
6-52
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
2 1
20
30
11
21
38
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS07A
6-53
between
CN-1(5)-GND
Check voltage
between CN-52
(36) - GND
SPEC :
Actuator operating: 1~5V NO
Check voltage
YES between
CD-44(A)-(C)
SPEC :
Actuator operating: 1~5V
See TEST 11
SPEC :
Key ON : 242V
Check voltage
between
NO CN-1(2)-(4)
Remedy
Defective MCU
Replace
Short circuit or
poor connection
between CN-52(36)-CN-1(5)
Replace or repair
Detective P3
Replace or repair
pressure sensor
Short circuit or
Replace or repair
poor connection
between CN-1(5)CD-44(B)
Short circuit or
Replace or repair
poor connection
between
CD-44(A)-CN-1(2)
or CD-44(C)CN-1(4)
NO
SPEC :
Key ON : 242V
Short circuit or
Replace or repair
poor connection
between CN-1(2)CN-51(4) or CN-1
(4) - CN-51(5)
NO
CN-51
CD-44
4
5
SUPPLY
SIG
RETURN
CN-1
MCU
36
CN-52
21096MS08
6-54
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
2 1
20
30
11
21
36
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS08A
6-55
Check voltage
between CN-52
(37) - GND
YES
SPEC :
Actuator operating: 1~5V
See TEST 12
Check voltage
between CD-70
NO
(A)-(C)
SPEC :
Key ON : 242V
Remedy
Defective MCU
Replace
Detective N1
pressure sensor
Short circuit or
poor connection
between CN-52
(37)-CD-70 (B)
Replace or repair
Replace or repair
Short circuit or
Replace or repair
poor connection
between CD-70
(A)-CN-51(4) or
CD-70(C)- CN-51
(5)
NO
CN-51
CD-70
4
5
SUPPLY
SIG
RETURN
MCU
37
CN-52
21096MS09
6-56
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
2 1
20
30
11
21
37
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS09A
6-57
Check voltage
between CN-52
(27) - GND
YES
SPEC :
Actuator operating: 1~5V
See TEST 13
Check voltage
between CD-71
NO
(A)-(C)
SPEC :
Key ON : 242V
Remedy
Defective MCU
Replace
Detective N2
pressure sensor
Short circuit or
poor connection
between CN-52
(27)-CD-71 (B)
Replace or repair
Replace or repair
Short circuit or
Replace or repair
poor connection
between CD-71
(A)-CN-51(4) or
CD-71(C)- CN-51
(5)
NO
CN-51
CD-71
4
5
SUPPLY
SIG
RETURN
MCU
27
CN-52
21096MS10
6-58
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
20
30
5 4 3
2 1
11
21
27
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS10A
6-59
Check voltage
between CN-52
(24) - GND
YES
SPEC :
Actuator operating: 1~5V
See TEST 14
Check voltage
between CD-24
NO
(A)-(C)
SPEC :
Key ON : 242V
Remedy
Defective MCU
Replace
Detective swing
pressure sensor
Short circuit or
poor connection
between CN-52
(24)-CD-24 (B)
Replace or repair
Replace or repair
Short circuit or
Replace or repair
poor connection
between CD-24
(A)-CN-51(4) or
CD-24(C)- CN-51
(5)
NO
CN-51
CD-24
4
5
SUPPLY
SIG
RETURN
MCU
24
CN-52
21096MS11
6-60
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
20
2 1
11
21
24
30
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS11A
6-61
12. MALFUNCTION OF A
Check voltage
between CN-52
(25) - GND
YES
SPEC :
Actuator operating: 1~5V
See TEST 15
Check voltage
between CD-35
NO
(A)-(C)
SPEC :
Key ON : 242V
Remedy
Defective MCU
Replace
Replace or repair
Replace or repair
Short circuit or
Replace or repair
poor connection
between CD-35
(A)-CN-51(4) or
CD-35(C)- CN-51
(5)
NO
CN-51
CD-35
4
5
SUPPLY
SIG
RETURN
MCU
25
CN-52
21096MS12
6-62
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
20
5 4 3
2 1
11
21
25
30
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS12A
6-63
Defective MCU
Check voltage
between CN-52
(23) - GND
YES
Remedy
Replace
SPEC :
Actuator operating: 1~5V
See TEST 16
Check voltage
between CD-32
NO
(A)-(C)
SPEC :
Key ON : 242V
Short circuit or
Replace or repair
poor connection
between CD-32
(A)-CN-51(4) or
CD-32(C)- CN-51
(5)
NO
CN-51
CD-32
4
5
SUPPLY
SIG
RETURN
MCU
23
CN-52
21096MS13
6-64
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
20
2 1
11
21
23
30
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS13A
6-65
Defective MCU
Check voltage
between CN-52
(34) - GND
YES
Remedy
Replace
SPEC :
Actuator operating: 1~5V
See TEST 17
Check voltage
between CD-5
NO
(A)-(C)
SPEC :
Key ON : 242V
Short circuit or
poor connection
between CD-5
(A)-CN-51(4) or
CD-5(C)- CN-51
(5)
NO
Replace or repair
CN-51
CD-5
4
5
SUPPLY
SIG
RETURN
TRANSMISSION OIL
PRESSURE SENSOR
MCU
34
CN-52
14W96MS20
6-66
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
2 1
20
11
21
30
40 39 38 37 36
34
35 34 33 32 31
GROUND
Multimeter
14W96MS20A
6-67
Defective MCU
Check voltage
between CN-52
(33) - GND
YES
Remedy
Replace
SPEC :
Actuator operating: 1~5V
See TEST 18
Check voltage
between CD-3
NO
(A)-(C)
SPEC :
Key ON : 242V
Short circuit or
Replace or repair
poor connection
between CD-3 (A)CN-51(4) or CD-3
(C)- CN-51 (5)
NO
CN-51
CD-3
4
5
SUPPLY
SIG
RETURN
MCU
33
CN-52
14W96MS21
6-68
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
2 1
20
11
21
30
40 39 38 37 36
33
35 34 33 32 31
GROUND
Multimeter
14W96MS21A
6-69
Defective MCU
Check voltage
between CN-52
(28) - GND
YES
Remedy
Replace
SPEC :
Actuator operating: 1~5V
See TEST 19
Check voltage
between CD-73
NO
(A)-(C)
SPEC :
Key ON : 242V
Short circuit or
Replace or repair
poor connection
between CD-73
(A)-CN-51(4) or
CD-73(C)- CN-51
(5)
NO
CN-51
CD-73
4
5
SUPPLY
SIG
RETURN
TRAVEL FORWARD
PRESSURE SENSOR
MCU
28
CN-52
14W96MS22
6-70
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
20
30
5 4 3
2 1
11
21
28
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
14W96MS22A
6-71
Defective MCU
Check voltage
between CN-52
(32) - GND
YES
Remedy
Replace
SPEC :
Actuator operating: 1~5V
See TEST 20
Check voltage
between CD-74
NO
(A)-(C)
SPEC :
Key ON : 242V
Short circuit or
Replace or repair
poor connection
between CD-74
(A)-CN-51(4) or
CD-74(C)- CN-51
(5)
NO
CN-51
CD-74
4
5
SUPPLY
SIG
RETURN
TRAVEL REVERSE
PRESSURE SENSOR
MCU
32
CN-52
14W96MS23
6-72
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
2 1
20
11
21
30
40 39 38 37 36
32
35 34 33 32 31
GROUND
Multimeter
14W96MS23A
6-73
between CN-88
(1)-(2)
between CN-53
(30)-GND
Is voltage between
CN-88(2)-GND
normal?
SPEC
KEY ON : 241V
KEY OFF : 0V
See TEST 21
SPEC: 15-35
See TEST 22
NO
SPEC : Power max button pressed ON : 0
Power max button released OFF :
NO
Remedy
NO
MCU
CN-88
1
CN-52
30
FUSE
NO.28
CN-53
CN-4
CS-29
1
2
21096MS14
6-74
LH RCV-lever
CN-88
Power max
solenoid valve
1
GROUND
Multimeter
21096MS14A
SPEC : 15~35
LH RCV-lever
CN-88
Power max
solenoid valve
2
1
Multimeter
6-75
21096MS14B
19. MALFUNCTION OF19. MALFUNCTION OF BOOM PRIORITY EPPR VALVEBOOM PRIORITY EPPR VA
Fault code : HCESPN 141, FMI 5 or 6
Before carrying out below procedure, check all the related connectors are properly inserted.
1)1)INSPECTION PROCEDUREINSPECTION PROCEDURE
Cause
YES
Remedy
Check resistance
between
CN-133(1)-(2)
SPEC : 20~30V
KEY : ON
Defective EPPR
valve
NO
Repair or replace
MCU
19
CN-133
1
BOOM PRIORITY
EPPR VALVE
CN-53
21096MS15
6-76
Cause
YES
YES
Check voltage
between CN-52
(1)-GND
SPEC :
KEY ON 242V
See TEST 23
Check voltage
between CN-135(2)
- GND
Defective MCU
YES
SPEC :
KEY ON : 20~30V
Replace
Short circuit or
Replace or repair
poor connection
between CN-52
(1)-CN-135 (1)
Check resistance
between arm
NO regen solenoid
SPEC : 15~35
Remedy
Defective
solenoid valve
NO
Replace
Open circuit
Replace or repair
between CN-135
(2)-Fuse No. 28
NO
MCU
CN-135
1
1
2
CN-52
21096MS16
6-77
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
20
11
21
30
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
21096MS16A
6-786-78
Cause
YES
YES
Check voltage
between CN-52
(3)-GND
SPEC :
KEY ON 242V
See TEST 24
Check voltage
between CN-69(2) GND
Defective MCU
YES
SPEC :
KEY ON : 20~30V
Replace
Short circuit or
Replace or repair
poor connection
between CN-52
(3)-CN-69 (1)
Check resistance
between ram
NO
lock solenoid
SPEC : 15~35
Remedy
NO
NO
Defective
solenoid valve
Replace
Open circuit
between CN-69
(2)-Fuse No. 28
Replace or repair
MCU
CN-69
3
1
2
CN-52
14W96MS25
6-79
MCU
PIN
CN-51 CN-52
CN-53
CN-52 Female
10 9 8 7 6
5 4 3
2 1
20
11
21
30
40 39 38 37 36
35 34 33 32 31
GROUND
Multimeter
14W96MS25A
6-80