GROUP 4 MECHATRONICS SYSTEM

1. ALL ACTUATORS SPEED ARE SLOW

Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
Spec : M-mode 1950 50rpm H -mode 1850 50rpm S-mode 1750 50rpm
Before carrying out below procedure, check all the related connectors are properly inserted.

1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO
Check electric NO Defective Replace
SPEC : 5~20kgf/cm2
current at EPPR See TEST 3
EPPR valve
Check if Er : 03 valve
current error display SPEC : 200~450mA Defective CPU Replace
on the LCD See TEST 2 NO
controller

YES
Short circuit or Check & repair
poor connection wire harness or
Check resistance between CN-50 - between CN-50-
YES at EPPR valve CN-75 CN-75

C)
SPEC : 45~50(20 Defective EPPR Replace
See TEST 1 NO
valve

Wiring diagram

RESISTOR
1
2 2
CN-47 1

CN-19B
CONTROLLER
8
FUSE
24
28 NO.11

36 EPPR VALVE
CN-50 1 2

2 1

CN-19A CN-19 CN-75

2907A6MS01

6-40
2) TEST PROCEDURE
SPEC : 45~50(20
C)
(1) Test 1 : Check resistance at connector
CN-75. CN-75

Starting key OFF.

Multimeter
Disconnect connector CN-75 from EPPR
valve at main hydraulic pump.
Check resistance between 2 lines as
figure.
EPPR valve

Main pump

2107A5MS15

(2) Test 2 : Check electric current at EPPR SPEC : 200~450mA(S mode)

valve.
CN-75
Install multimeter as figure.
Multimeter
Start engine.
Set the accel dial at "10"(MAX)
Set S-mode and cancel auto decel mode.
If tachometer show approx 175050rpm, EPPR valve
check electric current.

Main pump

2107A5MS12

(3) Test 3 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm2 (70~280psi)

Remove plug and connect pressure
Pressure adjusting
gauge as figure. screw locknut
Pilot pressure
Gauge capacity : 0 to 40~50kgf/cm2 supply line CN-75

(0 to 570~710psi)
Start engine.
Set the accel dial at "10"(Max).
Set S-mode and cancel auto decel mode.
If tachometer show approx 175050rpm, EPPR valve

check pressure.
If pressure is not correct, adjust it. Main pump
After adjust, test the machine.

2107A5MS13

6-41
2. ENGINE STALL
Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Not enough engine Contact cummins
YES Check pressure power engine dealer
at EPPR valve
Defective EPPR Replace
SPEC:5~20kgf/cm2 NO
See TEST 5
valve
Check electric
current at EPPR
valve YES
Short circuit or Check and repair
SPEC : 200~450mA
See TEST 4 poor connection wire harness
Check resistance
between between
NO at EPPR valve CN-50 - CN-75
SPEC : 45~50(20
C)
See TEST 1
NO
Defective EPPR Replace
valve

Wiring diagram

RESISTOR
1
2 2
CN-47 1

CN-19B
CONTROLLER
8
FUSE
24
28 NO.11

36 EPPR VALVE
CN-50 1 2

2 1

CN-19A CN-19 CN-75

2907A6MS01

6-42
2) TEST PROCEDURE SPEC : 200~450mA CN-75

(1) Test 4 : Check electric current at EPPR Multimeter

valve at S-mode
Install multimeter as figure.
Start engine.
EPPR valve
Set the accel dial at "10"(max)
Set S-mode with 175050rpm.
Check electric current.
Main pump

2107A5MS12

(2) Test 5 : Check pressure at EPPR valve at SPEC : 5~20kgf/cm2(70~280psi) Pressure adjusting
S-mode screw locknut
Pilot pressure
Connect pressure gauge at EPPR valve. supply line CN-75

Start engine.
Set the accel dial at "10"(max)
Set S-mode with 175050rpm.
Operate bucket lever completely push or
EPPR valve
pull.
Hold arm lever at the end of stroke.
Check pressure at relief position. Main pump

2107A5MS13

6-43
 3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

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

See if Co : Er Y R G
current error display NO
on the LCD
NO Y R G

NO

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

Wiring diagram

CPU CONTROLLER

CLUSTER
24
POWER IG(24V)
GND 28

RX 3 10 29

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

FUSE

NO.11(CPU)

36076MS02

6-44
4. AUTO DECEL SYSTEM DOES NOT WORK
Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective CPU Replace
controller

NO
Check resistance Short circuit or Replace or repair
between CN-51 poor connection
(1)-GND and vetween CN-51(1),
CN-51(13)-GND
(13)- pressure
SPEC : switches
Actuator operating :
0~1V
Actuator stop : 4~5V Defective auto Replace
See TEST 6 NO
See TEST 7 decel pressure
switch

Wiring diagram

WORK PRESSURE SWITCH

CPU CONTROLLER
1
Pa
1 2
CD-7

13 1
Pa
2

CN-51 CD-6
TRAVEL PRESSURE SWITCH

3607A6MS10

6-45
2) TEST PROCEDURE SPEC : Actuator stop : 4~5V
(1) Test 6 : Check voltage at CN-51(1) and Actuator operating : 0~1V
ground. Y R G

Prepare 1 piece of thin sharp pin, steel or CPU

CONTROLLER
copper. PIN
Starting key ON. CN-50
CN-51
Insert prepared pin to rear side of
connectors : One pin to (1) of CN-51.
Check voltage as figure.
(2) Test 7 : Check voltage at CN-51(13)and
ground.
Prepare 1 piece of thin sharp pin, steel or CN-51 12
24
1

copper 36 25

Starting key ON.

Ground
Insert prepared pin to rear side of
connectors : One pin to (13) of CN-51
Check voltage as figure. Multimeter

CN-51 12 1
24 13
36 25

Ground

Multimeter
R29076MS11

6-46
5. MALFUNCTION OF WARMING UP
Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective cluster or Repair or Replace
Check resistance CPU controller or
YES
between CN-50 ECU
(26) - ECU(47)
SPEC : Below 10 NO Poor connection Repair
Check resistance KEY OFF
between CN-
between CN -50
(25) - ECU(48) 50(26) - ECU(47)
SPEC : Below 10
KEY OFF

NO
Poor connection Repair
between CN-
50(25) - ECU(48)

Wiring diagram

RESISTOR RESISTOR
A A A A
ECU
ECM
B B
B C B C
CN-174 CN-99

CONTROLLER

25 5 48

26 6 47

27 7 37

CN-50 CN-3

2907A6ES02

6-47
6. MALFUNCTION OF POWER MAX
Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES Check resistance
between CN-88 Defective power Repair or replace
Resistance (1) - (2) max. solenoid valve
YES
between CN-51 SPEC: 15-30
(2)-GND normal? See TEST 8

NO Short circuit or poor Repair or replace

SPEC : Power max button pressed ON : 0 connection
Is voltage between Power max button released OFF : between CN-51(2) -
CN-88(2) -GND See TEST 9
normal? CS-29 and CN-50
(3) -CN-88(1)
SPEC
KEY ON : 241V
KEY OFF : 0V
See TEST 8
NO Short circuit or poor Repair or replace
connection
between CN-88(2)-
battery relay(+)

Wiring diagram

CPU CONTROLLER

POWER MAX SOLENOID

3 1

2
CN-50
CN-88
1

2 2

FUSE
CN-51 CN-4 NO.25
POWER MAX SWITCH
2

CS-29

50076MS04

6-48
2) TEST PROCEDURE SPEC : Key ON : 241V
Key OFF : 0V
(1) Test 8: Check voltage between connector Resistance : 15~30
CN-88 - GND.
Start key ON.
Disconnect connector CN-88 from power
Power max switch
max solenoid valve.
Check voltage as figure.

LH RCV-lever CN-88

CN-88

Power max.
solenoid valve

Multimeter

2107A5MS16

(2) Test 9 : Check resistance between

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

connector CN-51 from CPU controller. CPU

Check resistance as figure. CONTROLLER
CN-51

CN-50

CN-51
12 2
24 13
36 25

Ground

Multimeter
R29076MS15

6-49