6 Troubleshooting

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SOLUCIN DEL ARTCULO 6 TROUBLESHO

Grupo 1 Antes de Solucin--------------------------------------------------------------------------Sistema Hidrulico y Mecnico-------------------------------------------------------------------Gr
elctrico-----------------------------------------------------------------------------------------------Gr
Mechatronics----------------------------------------------------------------------------------------6-4
SOLUCIN DEL ARTCULO 6 TROUBLESHO

GRUPO 1 ANTES DE TROUBLESHOOTINGGROUP 1 ANTES DE SOLUCIN
1. INTRODUCTION1. INTRODUCCIN
Cuando un problema sea ocurrido en la mquina, esta seccin ayudar a un operador a mantener la
mquina con el fcil.
El problema de mquina es separado sistema Hidrulico & Mecnico, Electrical system y sistema
de Mechatronics. En cada parte del sistema, un operador puede comprobar la mquina segn el
diagrama de proceso de solucin.
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
2. DIAGNOSTICAR PROCEDURE2. DIAGNOSTICAR PROCEDIMIENTO

Para realizar la solucin eficazmente, los pasos siguientes deben ser observados.
El PASO 1. Estudie la mquina systemSTEP 1. Estudie el sistema de la mquina
Estudie y sepa cmo la mquina funciona, cmo
el sistema forma, que clases de la funcin son
instaladas en la mquina y lo que es
especificaciones de los componentes del
sistema por el manual de servicio de la mquina.
Sobre todo, profundice el conocimiento para
las partes relacionadas del problema.
17W31SH02
El PASO 2. Pregunte a operatorSTEP 2. Pregunte al operador

Antes de la inspeccin, consiga la historia
llena de funcionamientos defectuosos de un
testigo---el operador.
1) Cmo la mquina es usada y cundo es
atendida?
2) Cundo el problema fue notado y qu
trabaja la mquina haca entonces?
Cul es el fenmeno del problema?
3) Era el empeoramiento de problema, o
sali de repente por primera vez?
4) Tena la mquina algn problema
antes? De ser as, qu partes fueron
reparadas antes.
17W31SH03
El PASO 3. Inspeccione machineSTEP 3. Inspeccione la mquina

Antes de la solucin inicial, examine la
mquina para ver los puntos de
mantenimiento diarios como mostrado en el
manual del operador.
Y tambin compruebe el sistema elctrico incluso
bateras, como los problemas en el sistema
elctrico como el voltaje de la batera bajo, suelte
conexiones y los fusibles apagados causarn el
funcionamiento defectuoso de los reguladores
que causan fracasos operacionales totales de la
mquina.
EN EL
INSPECCIN
6-2 (3) 140-7
6-2
STEP 4. STEP 4. Inspect the trouble actually

on theInspect the trouble actually on the machinemachine
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.STEP 5. Perform troubleshootingPerform 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.STEP 6. Trace a causeTrace 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
GROUP 2 HYDRAULIC AND M
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
Pilot pump pressure
40+20 bar
Note 2
Note 3
Swing pilot pressure

Boom up pilot pressure
0~40 bar
0~40 bar
Note 4
Note 5
Arm/bucket pilot pressure

P1 pump control pressure
0~40 bar
0~25 bar
Note 6
Note 7
Note 8
P2 pump control pressure

Pump 1 pressure
Brake pedal pressure
0~25 bar
350 bar
603 bar
6-46-4
2. DRIVE SYSTEM 2. DRIVE SYSTEM
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.
Coupling element Disassemble

is broken.
and repair.
YES
Coupling hub
spline is worn or
NO hub fastening
setscrew is slack.
Remedy
Replace hub or
retighten
setscrew.
If hydraulic pump or engine is

suspected as a culprit refer to this
NO
manual "Structure and function".
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?
See item 1).

at page 6-5
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.
Pilot relief valve in Repair or

gear pump is
replace.
faulty.
Gear pump is
broken.
Disassemble
and repair.
3. HYDRAULIC SYSTEM
3. HYDRAULIC SYSTEM
HYDRAULIC OIL IS
CLOUDYHYDRAULIC OIL IS CLOUDY 1)1)
Cause
YES
Water is mixed.
Put hydraulic oil

still, separate
water and
dispose it or
replace hydraulic
oil.
Air is intruded.
Check suction line

and return line
and eliminate the
air intruding
source.
Drop hydraulic oil

sample on hot
plate and check if
foams come up.
NO
2)2)HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY
Remedy
HYDRAULIC OIL TEMPERATURE HAS R

Cause
NO
Remedy
Replenish
specified oil to
the standard
level.
Is hydraulic oil
volume proper?
YES
Oil cooler clogged. Clean oil cooler.

Bypass check
Replace
valve is defective.
Is oil cooler clogged

and is bypass check
YES
valve always open?
YES
Is fan belt
NO tension proper?
NO
Is not the set

pressure of main YES
relief, port relief
and travel relief
Is main relief
valve lower than
valve used very YES
the standard
NO often?
level?
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
Replace oil with

one of proper
viscosity.
Is not viscosity
of hydraulic oil
YES
too high?
YES
NO
Is not suction
strainer clogged?
Clean suction
strainer.
Is not air intruding

from pump
NO suction line?
Check for air

intrusion in
suction line and
retighten or
replace parts.
4)4)
HYDRAULIC OIL IS CONTAMINATED HYDRAULIC OIL IS CONTAMINATED
Cause
YES
Has not hydraulic

oil passed
specified replacement hours?
Remedy
Replace
hydraulic oil to be
specified.
Has return filter

NO
been replaced at
NO proper intervals?
Flush with
hydraulic oil and
replace return
filter.
6-86-8
4. SWING SYSTEM 4. SWING SYSTEM
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.
Hydraulic pump is Disassemble and

out of order.
repair.
Swing control valve Disassemble and
spool is stuck.
repair.
YES
See Note 5
NO
Does not symptom

change when front YES
NO and rear pump
discharge hoses
are exchanged?
Hydraulic pump is Disassemble and

broken.
repair.
YES
Replenish
specified oil to the
standard level.
Repair or replace.
Pump connection Disassemble and

coupling is broken. repair.
Are broken pieces

of coupling present
when dust plug
under engine fly
Is main relief
wheel is removed? NO valve faulty?
YES pilot pressure
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
Pilot relief valve in Disassemble and

gear pump is faulty. repair or replace.
delivering oil?
Is gear pump pilot

pressure within
standard level?
See Note 1
NO
YES
Is there oil
leakage from pilot
YES piping or is it
clogged?
6-96-9
Gear pump is out of Disassemble and

order.
repair.
NO
RCV is broken.
Clean pilot piping

interior or repair
piping.
Disassemble and
repair.
2)2)
SWING SPEED IS LOWSWING SPEED IS LOW
YES
YES Does swing spool
move?
Single direction
Swing port relief

valve is faulty.
Disassemble and
repair or replace.
YES Clogged or oil
See Note 2
Clean pilot piping

interior or repair
piping.
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?
YES Is MCV pilot
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
Check that pilot

YES piping is clogged NO
or oil is leaking
from it?
Is gear pump pilot

pressure within
standard level?
Clean pilot piping

interior or repair
piping.
Clogged or oil leak.
YES
See Note 1
Is gear pump
NO delivering oil?
NO
NO
Remedy
Swing control valve Disassemble

spool is stuck.
and repair.
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.
Main relief valve

faulty.
Main relief valve

pressure resetting
or repair.
Does the symptom YES Hydraulic pump

YES change when front
is broken.
and rear pump
discharge hoses
are exchanged? NO Shuttle valve is
faulty.
Is gear pump
output pressure
NO within standard
level?
See Note 1
6-10
Pilot relief valve

in gear pump is
defective.
YES
NO
Disassemble
and repair.
Repair or replace.
Pilot relief valve

is faulty.
Repair or replace.
Gear pump is
faulty.
Repair or replace.
3)3)
SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
SWING MOTION IS IMPOSSIBLE IN ONE DIREC

Cause
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
Swing port relief

valve is faulty.
Disassemble
and repair.
Shuttle valve is
faulty.
Disassemble
and repair.
Swing control valve Disassemble

spool is stuck.
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
YES Is gear pump pilot
move?
NO
Is swing control
valve's return
spring normal?
NO
NO
6-11
Pilot relief valve is

faulty.
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
THE SWING UNIT DRIFTS
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.
Swing port relief

valve is faulty.
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
5. TRAVEL SYSTEM 5. TRAVEL SYSTEM

TRAVEL DOES NOT
FUNCTIONTRAVEL DOES NOT FUNCTION 1)1)
Cause
YES
Are the travel
Travel motor relief

YES
valve within
standard pressure
NO
YES speed solenoid
valves (high/low)
normal?
NO
YES Is the travel pilot
pressure within
standard?
YES
Travel pilot
solenoid valves
NO
normal?
NO
Is swing operation
possible?
YES
Remedy
Travel relief valve is Disassemble

faulty
and repair or
replace.
Travel speed
Disassemble
solenoid valves
and repair or
(high/low) are faulty replace.
Accelerator pedal
or travel Forward/
Reverse solenoid
cartridge is faulty
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
Does the symptom

change when front
YES
and rear pump
NO
discharge hoses
are exchanged?
Travel motor is out Disassemble

of order
and repair.
Hydraulic pump is
broken
6-136-13
Disassemble
and repair.
2)2)
TRAVEL ACTION IS POWERLESS TRAVEL ACTION IS POWERLESS (travel only)
Cause
YES
Are the travel
Travel motor relief

YES valve within
standard pressure
YES speed solenoid
NO
valves (high/low)
normal?
NO
Is the travel pilot

YES
pressure within
standard?
YES
Travel pilot
solenoid valve
NO
normal?
NO
Is the travel action

powerless in both
direction?
YES
Does travel
motor rotate?
NO
YES
Does the symptom

change when travel
NO relief valve is
exchanged?
Does the symptom

change when travel
NO motor suction hoses
are exchanged?
YES
NO
6-146-14
Remedy
Travel relief valve is Disassemble

faulty
and repair or
replace.
Disassemble
Travel speed
and repair or
solenoid valves
(high/low) are faulty replace.
Accelerator pedal
or travel Forward/
Reverse solenoid
cartridge is faulty
Disassemble
and repair or
replace.
Travel pilot solenoid Disassemble

and repair or
valve is faulty
replace.
Transmission unit is
faulty
Disassemble
and repair.
Travel motor is out
of order
Disassemble
and repair.
The travel relief
valve is faulty
Disassemble
and repair or
Travel motor is out replace.
Disassemble
of order
and repair.
Travel motor
suction valve is
faulty
Disassemble
and repair or
replace.
3)3)
THE HYDRAULIC MOTOR DOSE NOT GET STARTED
THE HYDRAULIC MOTOR DOSE NOT GET STAR

Cause
The spool does
work properly.
( The spool keeps
fully open)
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
The anti-avitation Ditto

check valve does
not work properly.
( The check valve
is kept open.)
4)4)
IT TAKES TIME TO ACCELERATE THE MOTOR
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
be repaired, or the
new one should be
used.
It takes time to
accelerate the
motor
6-156-15
The orifice for

closing the
counterbalance is
clogged.
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
IT IS NOT POSSIBLE TO REDUCE THE M

Cause
Remedy
The orifice for

closing the
counterbalance is
clogged. The
opening of the
neutral position of
the spool is
clogged.
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
The anti-cavitation Screw the fitting

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.
6-166-16
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
YES Is MCV pilot
pressure within
standard level?
See Note 3, 4
YES Are other
attachments
operatable?
Port relief valve is Disassemble

Does the
faulty.
and repair or
YES symptom change
when port relief
replace.
valve is replaced
with other valve? NO
Inspect if pilot
piping is clogged OK
RCV is faulty.
NO or oil is leaking
from the piping.
Disassemble
and repair.
YES
Is gear pump
pilot pressure
NO within standard
level?
YES Is gear pump
delivering oil?
See Note 1
Are travel
operations
possible?
Pilot relief valve is Disassemble

and repair or
faulty.
replace.
Disassemble
Gear pump is
and repair.
NO
broken.
OK
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
Hydraulic pump is Disassemble

broken.
and repair.
Main relief valve

is defective.
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
Cylinder interior is Disassemble

broken.
and repair.
MCV spool is
stuck.
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?
Is speed low only

in composite
operation?
Are travel
speeds within
NO
standard levels?
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
Is not MCV pilot

pressure piping
clogged or is not
NO
there oil
leakage?
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.
Hydraulic pump is Disassemble

faulty.
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
Does the symptom

change when port
Normal
relief valve is
replaced with
Is control valve
normal value?
return spring
Is not hydraulic
NO
YES
normal?
oil temperature
high?
YES

faulty.
and repair or
replace.
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
BOOM, ARM OR BUCKET POWER IS WEAK

Cause
YES
Check according
to the procedure
in Item "Speed is
low".
Is cylinder
YES internal leakage
within standard
level?
Is relief pressure
YES in port relief
Is relief pressure
in main relief
valve within
standard level?
Cylinder is faulty.
NO
valve within
standard level?
Remedy
Disassemble
and repair.
Port relief valve is Adjust pressure,

faulty.
repair or replace.
NO
See Note 7
Main relief valve

is defective.
NO
5)5)
ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
ONLY BUCKET OPERATION IS TOTALLY IMPOS
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

defective.
and repair or
replace.
YES
Cylinder interior is Disassemble
and repair.
broken.
NO
MCV spool is
stuck.
Disassemble
and repair.
RCV is faulty.
Disassemble
and repair.
Main relief valve

is faulty.
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
BOOM MAKES A SQUEAKING NO

Cause
YES
Remedy
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil seal
and boom
proper.
Is boom foot pin

greased
sufficiently?
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.
HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGEHOW TO CHECK INTERNAL BOOM CY

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)
(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 AXLE7. FRONT AXLE AND REAR AXLE
Problem
Insufficient braking
Cause
Correction
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.

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.
3. Incorrect brake fluid
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
9. Oil level wrong
Drain, flush and refill oil to proper level.
Overheating
10. Too small of a brake gap
Readjust brakes to the specifications.

Unlock the brake and adjust the correct gap.
11. Park brake dragging
12. Incorrect brake fluid in system
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

brake servo system
Inspect for and replace damaged return line.

Inspect for and remove any filter, teed in line or
any other source of back pressure from the
return line.
Change the retaining rings of the brake circuit
and brake pump.
16. Incorrect lubricant

Diff-lock inoperative
17. If manual control, loose or

misadjusted linkage
Inspect and correct linkage and readjust.
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
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 andInflate tires to the recommended pressure in this
when driving straight
right
manual, or until the rolling radius is equal.
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
than during coast
27. Incorrect lubricant
Refill oil to proper level
Noise during coast greater 31. Loose pinion nut

than under power
Inspect ring, pinion and pinion bearings.

If undamaged, retighten nut.

Inspect through top cover.
28. Ring and pinion worn
Replace and adjust.
Replace and adjust
29. Worn ring and pinion bearingsReplace.
30. Worn planetary gears or
bearings
32. Only pinion bearing damaged See correction No.29.

Noise during turn
(Without nospin)
33. Worn spider and/or side gears Replace.
A stick slip noise when

going from forward to
reverse
34. Worn or damaged cardan Inspect and replace.

shaft
35. Loose wheel
Inspect for wheel and wheel stud damage.

Replace if needed and retorque lugnuts.
36. Articulation box joint and

achsel shaft damaged
Inspect and replace.
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
GROUP 3 ELECTRICAL SYSTEM
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
Defective cluster Replace

YES
Check voltage
between CN-56
(3) and (5)
Starting switch : ON
Voltage : 20~32V
Remedy
Disconnection in Repair or replace

wiring harness or (after clean)
poor contact
between
CN-5-CN-56
Check voltage
between
NO CN- 5 (3) and (5)
Voltage : 20~32V

poor contact
between CN-5 (3)
-GND or fuse
No.7, 11
NO
Check voltageCheck voltage

YES
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.
COMMUNICATION ERROR FLASHES ON THE CLUSTER
COMMUNICATION ERROR FLA
Before carrying out below procedure, check all the related connectors are properly inserted.
Cause
YES
Remedy
Defective cluster
Replace
YES Check voltage
between CN-56
(4, 8) and (3)
Check voltage
between
CN-5 (1) and (2)
Voltage : 2V
Voltage : 2V

poor contact
between CN-56
(4, 8)-CN-5 (1, 2)
NO
Defective MCU
Replace
poor contact
between CN-5 (1,
2)- CN-51(23, 33)
NO

YES
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.
BATTERY CHARGING WARNING LAMP LIGHTS UPBATTERY CHARGING WARNING LAM
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)
Defective alternator Replace
NO

YES
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
Cause
YES
Remedy
Check use HRDT Check or replace
Check resistance
YES between engine
harness connector
(15)-(38)
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
Check TableCheck Table

Temperature (C)
Resistance (k)
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
Cause
YES
Clogged air filter or Check filter or

defective switch
replace switch
Does display go
off when
disconnect
CD-10?
Engine : Start
Remedy
YES
Check resistance
between CN-53
NO (23) and chassis
Disconnect CN-53
NO
Short circuit in
wiring harness
between CD-10CN-53 (23)
Repair or replace
(After clean)
Defective MCU
Replace
Check resistanceCheck resistance

YES
MAX 1
NO
MIN 1M
MCU
AIR CLEANER SWITCH
Pa
23
CN-53
CD-10
21096ES05
6-296-29
6.
WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP
6.
WHEN ENGINE OI
Cause
NO
Defective circuit,
sensor or ECM.
Remedy
Contact Cummins.
NO Fault code 135
active?
Fault code 386

active?
Voltage above
Refer to engine
normal or shorted fault code 135
to high source
YES
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
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?
Engine : Start
Disconnect CD-1
NO
YES
Resistance
between CN-51
NO (36, 5) is 0~1?
Disconnect CN-51
Defective controller Replace
NO

Temperature (C ) ~ -30
Resistance (k)
~ -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 COOLANT TEMPERATURE GAUGE DOES NOT OPERATE

COOLANT TEMPERATURE GAUGE DOES NOT OPERATE (HCESPN 304,
8. WHEN
FMI 3 or 4)
Cause
YES
Remedy
Check use HRDT Check or replace
Check resistance
YES between engine
harness connector
(15)-(38)
Spec : 180~160 k

poor contact
between temp
sensor-engine
harness connector
NO
Check resistance
between temp
sensor (A)-(B)
Spec : 180~160 k
See table
Defective coolant
temp sensor
NO
Replace

Temperature (C)
Resistance (k)
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
9. WHEN FUEL GAUGE DOES NOT OPERATE
9. WHEN FUEL GAUGE DOES NOT OPERATE(HCE
Cause
YES
YES
Check resistance
between fuel
sender (1) and
(2)
Defective MCU or Replace

cluster
Check resistance
between CN-51
(5) and (38)
Disconnect CN-51
Spec : 50~600
Remedy
NO

Spec : 50~600
See table
NO
Disconnection in
wiring harness or
poor contact
between fuel
sender-MCU
Repair or replace
Defective fuel
sender
Replace

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
1
CD-2
CN-51
21096ES09
6-336-33
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
10. WHEN SAFETY SOLENOID DOES NOT O
of fuse No.23.
Cause
YES
Hydraulic system
malfunction
YES Check operation
of solenoid
Safety lever : ON-OFF
Check resistance
YES between CN-4
(16) and chassis
Voltage : 20~30V
Safety state
Check voltage
NO between CN-68
(2) and chassis

Safety state
Spec : 0
Disconnect CN-4
YES
Check resistance
between CS-4
NO
(A)-(C)
Safety switch : ON-0
NO
OFF-
Safety lever : OFF

Voltage : 20~30V
Check hydraulic
system
Defective solenoid Replace
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
of fuse No.25 .
Cause
YES

wiring harness or
poor contact
between CN-70CN-52 or CN-181CN-52
Defective solenoid Replace
Check resistance
YES between CN-70
(1)-(2) or
CN-181(1)-(2)
Spec : 30
Disconnect CN-70
YES Check fault code
Remedy
NO
167 active?
YES
Check if travel
speed lamps(
,
) change when
turning the RH
multifunction switch
on the cluster
Defective hydraulic Check hydraulic

system
system
Check voltage
between CN-70
NO (1)-(2) or
CN-181(1)-(2)
Spec : 20~30 V
Disconnect CN-70

wiring harness or
poor contact
between CN-70fuse No. 25 or CN181-fuse No.25
Defective cluster Replace
NO
YES
Check MCU
Y
NO
Defective MCU
NO
Replace
TRAVEL HIGH SPEED SOLENOID
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
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
magnet coil and

chassis
Starting switch : START
Check operation
of start relay
NO
CR-23
YES
YES Check voltage
between CN-2
(7) and chassis
NO

Spec : 20~30V
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
Defective start relay Replace
NO

Spec : 20~30V
ST C
CN-5
Repair or replace
Defective magnet Replace

of start motor
YES between starter
0, I
ENGINE ECM
Defective ECM
Replace
power relay CR-45
NO
Check voltage
Defective ECM or Replace

battery
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
START KEY SW
KEY IG
39
CN-3
of fuse No. 1, 4, 9, 20.
12. WHEN ENGINE DOES NOT START (
CN-125
12. WHEN ENGINE DOES NOT START
NO.20
POWER RY

wiring harness or
poor contact
between CN-2 (7)
-CR-5 (5)
CS-74
1
2
CN-95
2
1
MASTER SW
FUSIBLE LINK
YES
Check voltage
between CR-5
NO
(1, 2)
Spec : 20~30V
Check voltage
between CR-23
and chassis
Defective antirestart relay
2
1
Replace
CN-60
BATT RY
DO-1
YES
NO
2
1
Defective start relay Replace

Disconnection in
wiring harness or
poor contact
between CN-2CR-5
DIODE
Repair or replace
CN-52
ANTI-RESTART RY

Spec : 20~30V
15
MCU
CR-5
1 5 4
1
2
3
4
YES
BATTERY
NO

Spec : 20~30V
Check voltage
between CR-5
(2) and chassis
CR-1

wiring harness or
poor contact
between CN-52
(15)-CR-5 (1)
Repair or replace
NO Disconnection in
wiring harness or
poor contact
between CS-2 (6)CR-5 (2)
2 3
ANTI-RESTART RY
START MOTOR
CN-2
7
8
CR-23
2
1
START RY
CN-45
14W96ES12
6-36
13. WHEN STARTING SWITCH ON DOES NOT OPERATE

CN-93
BATT (+)
BATT (+)
BATT (-)
BATT (-)
YES
YES Check voltage
between DO-1
(1) and chassis
Voltage : 20~30V
YES Check voltage

between CS-2
(2) and chassis
Voltage : 20~30V
between CS-2
(1) and chassis
YES
YES
Check voltage
between CS-74
NO
(1) and chassis
Specific gravity : MIN 1.28

Voltage : MIN 24V
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
Disconnection in Charge or replace

poor contact
between CS-74 (1)
-CN-5 (36)
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

poor contact
between DO-1 (1)CR-1 or defective
battery relay
Defective start
switch
Voltage : 20~30V
Check voltage
and specific
gravity of battery
CN-5
Remedy

NO wiring harness or (after clean)
poor contact
between CS-2 (2)CN-5(60)- DO-1 (1)
NO
YES Check voltage
ST C
ENGINE ECM
Cause
BR ACC
0, I
4
3
2
1
CS-2
H0I
CN-94
13
14
15
START KEY SW
KEY IG
39
CN-3
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
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
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
Disconnection in Charge or replace

poor contact
between CS-74 (2)
-CR-1
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 carrying out below procedure, check all the related connectors are properly inserted and the fuse No.
6, 17 and 18 is not blown out.
CN-21
3
Cause
NO
Defective wiper
cut switch
NO
Check valtage
between CN-141
YES
(11) and chassis
YES
Front sliding door-close

Voltage : 4~5V
Check operation
YES of multifunction
SW
Turn wiper switch
Check voltage between

CN-5 (23) and chassis
Washing
Check voltage CN-98

(5) and chassis
Sarting switch : ON
Voltage : 0~1V
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
Voltage : 20~30V
NO
YES
YES
CN-5
5
6
WIPER MOTOR
FUSE
18
NO.6
CN-141
Replace
1) Recheck fuse Replace

No.17
2) Disconnection in Repair or replace
poor contact
between
CN-97(7)-Fuse
FEED BACK
MOTOR DRIVE SIG
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
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

Voltage : 20~30V
Replace
N.C
NO
Intermittent
Check voltage CN-97

(10) and chassis
NO Check voltage
between CN-97
(7) and chassis
Defective
multifunction
switch
1
2
Short circuit in
Repair or replace
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
WIPER MOTOR CONTROLLER
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

No.18
2) Disconnection Repair or replace
CN-141(6)-Fuse (after clean)
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

poor contact
Defective wiper
motor
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 carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.17.
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
Head lamp switch : ON
Voltage : 20~30V
Check voltage
NO between CN-98
(2) and chassis
NO
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)

poor contact
between CN-151
(8)-CL-4 (1) or
CN-151(8)-CL-3(2)
Defective
multifunction
switch
Disconnection in
wiring harness or
poor contact
between CN-98
(2)-CN-151 (9)
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
FUEL HEAT RY(COIL)

FUEL HEAT RY
HEAD LMP RY LO(COIL)
HEAD LMP RY(COIL)
REAR LH RY
REAR RH RY
FRONT LH RY
FUEL HEAT RY
FRONT RH RY
REAR LH RY(COIL)
REAR RH RY(COIL)
FRONT LH RY(COIL)
FRONT RH RY(COIL)
HEAD LMP RY
HEAD LMP POWER RY
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)
CABIN LAMP RY(COIL)
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
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
Voltage : 20~30V
YES
Check voltage
between CN-116
NO
(2) and chassis
Head lamp switch :
ON-OFF
NO
14W96ES15

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
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
short of fuse No.15.
Cause
YES
YES
FUSE
YES Check voltage

between CN-151
(5) and chassis
Work lamp switch : ON
Voltage : 20~30V
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
Work lamp switch : ON NO
Voltage : 20~30V
NO.15

poor contact
between CN-151
(5)-CL-5 (2)
Defective switch
panel
CN-5
CN-151
CN-116
Replace

poor contact
between CN-151
(5)-CN-116 (3)
ILL
HEAD LAMP
WORK LAMP
CABIN LAMP
PRE-HEAT
Front/ Left
Front/ Right
Rear/ Left
50
CABIN LAMP RY(COIL)

CABIN LAMP RY
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
CN-12
CL-5
POWER
10
GND
11
DOZER PS
12
Rear/ Right
WORK LAMP
SWITCH PANEL

poor contact
between CN-151
(6) and chassis or
CN-151 (4) and
chassis
Recheck fuse
No.15
1
2
3
4
5
6
7
8
9
10
11
12
1
2
CL-6
Replace
14W96ES16
6-40
GROUP 4 MECHATRONICS SYSTEM
GROUP 4 MECHATRONICS SYSTEM
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
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
SPEC : 5~20 kgf/cm2

See TEST 3
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
Check & repair

wire harness or
between CN-53
-CN-75
Defective EPPR
valve
Replace
Wiring diagramWiring diagram
MCU
FUSE
4
NO.24
8
14
18
CN-53
PUMP EPPR VALVE

7
CN-1
CN-75
14W96MS01
6-41
2)2)TEST PROCEDURE TEST PROCEDURE

SPEC : 15~25(20C)
(1)(1)
Test 1Test 1 : Check resistance at connector
CN-75
CN-75.
Starting key OFF.
Disconnect connector CN-75 from EPPR
Multimeter
valve at main hydraulic pump.
Check resistance between 2 lines as
figure.
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)

valve.
Insert the adapter to CN-75 and install
multimeter as figure.
CN-75
Start engine.
Set S-mode and cancel auto decel
mode.
EPPR valve
Multimeter
Position the accel dial at 10.

If rpm display approx 1500 50 rpm
check electric current at bucket circuit
relief position.
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
mode.
check pressure at relief position of bucket
circuit by operating bucket control lever.
If pressure is not correct, adjust it.
Main pump
After adjust, test the machine.
20W95MS11
6-42
2. ENGINE STALL2. ENGINE STALL

1)1)INSPECTION PROCEDUREINSPECTION PROCEDURE
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
Check and repair

wire harness
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
PUMP EPPR VALVE

7
CN-1
CN-75
14W96MS01
6-43
2)2)TEST PROCEDURE TEST PROCEDURE

(1) (1)
Test 4Test 4 : Check electric current at
EPPR valve.
Spec : 100~700 mA
Adapter(P/no.:21Q6-50410)

valve.
Insert the adapter to CN-75 and install
multimeter as figure.
CN-75
EPPR valve
Multimeter
Start engine.
Set S-mode and cancel auto decel mode.
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.

mode.
check pressure at relief position of bucket
circuit by operating bucket control lever.
If pressure is not correct, adjust it.
2 (30~350 psi)
Spec : 2~25 kgf/cm
Pilot pressure
supply line
CN-75
Pressure adjusting
screw locknut
EPPR valve
Main pump
After adjust, test the machine.
20W95MS11
6-44
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
3. MALFUNCTION OF CLUSTER
Cause
YES
No power supply to Check fuse No.3

the MCU
See if all lamps

YES off in the MCU
case Y R G
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
Check and repair
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
4. MALFUNCTION OF4. MALFUNCTION OF ACCEL DIALACCEL DIAL

Cause
Defective MCU
Replace
YES
Open circuit or
poor connection
between CN-16
(2) -CN-52 (21)
Replace or repair
Spec : actuator operating

NO
1~5V
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
YES Check voltage
between
CN-7(15)-GND

1~5V
See TEST 6

1~5V
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
+
YES Check voltage
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
2)2)TEST PROCEDURETEST PROCEDURE
SPEC : Actuator operating : 1~5 V
Test 6Test 6 : Check voltage at CN-52(21)

(1)(1)
and ground.
Prepare 1 piece of thin sharp pin, steel or
copper.
MCU
Insert prepared pin to rear side of

connectors : One pin to (21) of CN-52.
PIN
CN-51 CN-52
CN-53
Starting key ON.

Check voltage as figure.
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
5. AUTO DECEL SYSTEM DOES NOT WORK
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
YES
YES
NO
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
Short circuit or poor Replace or repair

connection
between CN-51(4)CD-6(A) and / or
CN-51(5)-CD-6(C)
(fault code 108
displayed)
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
Short circuit or poor Replace or repair

connection
between CN-51(4)CD-7(A) and / or
CN-51(5)-CD-7(C)
(fault code 105
displayed)
NO
SPEC :
Key ON : 242V
CN-51
CD-6
4
A
B
C
SUPPLY
SIG
RETURN
TRAVEL PRESSURE SENSOR
MCU
26
CD-7
35
SUPPLY
SIG
RETURN
WORK PRESSURE SENSOR
CN-52
21096MS05
6-486-48

(1)(1)
and ground.
copper.
MCU
PIN

CN-51 CN-52
CN-53
Starting key ON.

Test 8Test 8 : Check voltage at
(2)(2)
CN-52(35)and ground.
copper
10 9 8 7 6

5 4
3 2 1
20
11
26
30
21
40 39 38 37 36
Starting key ON.

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
6. MALFUNCTION OF PUMP 1 PRESSURE SENSOR
6. MALFUNCTION OF PUMP 1 PRESSURE SEN
Fault code : HCESPN 120, FMI 0~4

Cause
YES
YES
YES Check voltage
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
PUMP 1 PRESSURE SENSOR
29
CN-52
21096MS06
6-50

(1)(1)
and ground.
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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

Cause
YES
YES
YES Check voltage
between
CN-1(1)-GND
Check voltage
between CN-52
(38) - GND
SPEC :
Check voltage
YES between
CD-43(A)-(C)
SPEC :
See TEST 10
SPEC :
Key ON : 242V
Check voltage
between
NO CN-1(2)-(4)
Remedy
Defective MCU
Replace
Short circuit or
poor connection
Replace or repair
Detective P2
Replace or repair
pressure sensor
Short circuit or
Replace or repair
poor connection
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
(4) - CN-51(5)
NO
CN-51
CD-43
4
5
SUPPLY
SIG
RETURN
CN-1
MCU
38
CN-52
21096MS07
6-52
Test 10 : Check voltage at CN-52(38) and

(1)(1)
ground.
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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

Cause
YES
YES
YES Check voltage
between
CN-1(5)-GND
Check voltage
between CN-52
(36) - GND
SPEC :
Check voltage
YES between
CD-44(A)-(C)
SPEC :
See TEST 11
SPEC :
Key ON : 242V
Check voltage
between
NO CN-1(2)-(4)
Remedy
Defective MCU
Replace
Short circuit or
poor connection
Replace or repair
Detective P3
Replace or repair
pressure sensor
Short circuit or
Replace or repair
poor connection
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
(4) - CN-51(5)
NO
CN-51
CD-44
4
5
SUPPLY
SIG
RETURN
CN-1
MCU
36
CN-52
21096MS08
6-54

(1)(1)
CN-52(36) and ground.
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
9. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR
9. MALFUNCTION OF NEGATIVE 1 PRESS

Cause
YES
Check voltage
between CN-52
(37) - GND
YES
SPEC :
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
NEGATIVE 1 PRESSURE SENSOR
MCU
37
CN-52
21096MS09
6-56

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
10. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR
10. MALFUNCTION OF NEGATIVE 2 PRE

Cause
YES
Check voltage
between CN-52
(27) - GND
YES
SPEC :
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
NEGATIVE 2 PRESSURE SENSOR
MCU
27
CN-52
21096MS10
6-58

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
11. MALFUNCTION OF SWING PRESSURE SENSOR
11. MALFUNCTION OF SWING PRESSURE SE

Cause
YES
Check voltage
between CN-52
(24) - GND
YES
SPEC :
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
SWING PRESSURE SENSOR
MCU
24
CN-52
21096MS11
6-60
Test 14 : Check voltage at CN-52(24) and

(1)(1)
ground.
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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 ARM IN/OUT & BUCKET IN PRESSURE SENSOR
12. MALFUNCTION OF A

Cause
YES
Check voltage
between CN-52
(25) - GND
YES
SPEC :
See TEST 15
Check voltage
between CD-35
NO
(A)-(C)
SPEC :
Key ON : 242V
Remedy
Defective MCU
Replace
Detective arm in/

out & bucket in
pressure sensor
Short circuit or
poor connection
between CN-52
(25)-CD-35 (B)
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
ARM IN/OUT & BUCKET IN

PRESSURE SENSOR
MCU
25
CN-52
21096MS12
6-62

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
13. MALFUNCTION OF BOOM UP PRESSURE SENSOR
13. MALFUNCTION OF BOOM UP PRESSU

Cause
YES
Defective MCU
Check voltage
between CN-52
(23) - GND
YES
Remedy
Replace
Detective boom up Replace or repair

pressure sensor
Short circuit or
Replace or repair
poor connection
between CN-52
(23)-CD-32 (B)
SPEC :
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
BOOM UP PRESSURE SENSOR
MCU
23
CN-52
21096MS13
6-64

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
14. MALFUNCTION OF TRANSMISSION OIL PRESSURE SENSOR
14. MALFUNCTION OF TRANSM

Cause
YES
Defective MCU
Check voltage
between CN-52
(34) - GND
YES
Remedy
Replace

pressure sensor
Short circuit or
Replace or repair
poor connection
between CN-52
(34)-CD-5 (B)
SPEC :
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

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
15. MALFUNCTION OF BRAKE OIL PRESSURE SENSOR
15. MALFUNCTION OF BRAKE OIL PRESS

Cause
YES
Defective MCU
Check voltage
between CN-52
(33) - GND
YES
Remedy
Replace

pressure sensor
Short circuit or
Replace or repair
poor connection
between CN-52
(33)-CD-3 (B)
SPEC :
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
BRAKE OIL PRESSURE SENSOR
MCU
33
CN-52
14W96MS21
6-68

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
16. MALFUNCTION OF TRAVEL FORWARD PRESSURE SENSOR
16. MALFUNCTION OF TRAVEL

Cause
YES
Defective MCU
Check voltage
between CN-52
(28) - GND
YES
Remedy
Replace

pressure sensor
Short circuit or
Replace or repair
poor connection
between CN-52
(28)-CD-73 (B)
SPEC :
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

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
17. MALFUNCTION OF TRAVEL REVERSE PRESSURE SENSOR
17. MALFUNCTION OF TRAVEL R

Cause
YES
Defective MCU
Check voltage
between CN-52
(32) - GND
YES
Remedy
Replace

pressure sensor
Short circuit or
Replace or repair
poor connection
between CN-52
(32)-CD-74 (B)
SPEC :
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

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
18. MALFUNCTION OF POWER MAX18. MALFUNCTION OF POWER MAX

Fault code : HCESPN 166, FMI 4 or 6
Cause
YES
YES Check resistance
between CN-88
(1)-(2)
YES Check resistance
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
Short circuit or poor Repair or replace

connection between
CN-88(1)-CN-52 (7)
Defective power
max. solenoid valve Repair or replace
Check hydraulic
system
connection between
CN-53(30)-CS-29

connection between
CN-88(2)Fuse No. 28
NO
Wiring diagram Wiring diagram
MCU
CN-88
1
CN-52
POWER MAX SOLENOID
30
FUSE
NO.28
CN-53
CN-4
CS-29
1
2
POWER MAX SWITCH
21096MS14
6-74
SPEC : Key ON : 241V

Key OFF : 0V
Test 21Test 21: Check voltage between

(1)(1)
connector CN-88(2) - GND.
Disconnect connector CN-88 from power
max solenoid valve.
Start key ON.
Power max switch
LH RCV-lever
CN-88
Power max
solenoid valve
1
GROUND
Multimeter
21096MS14A
(2)(2)Test 22Test 22: Check resistance of the

solenoid valve between CN-88(1)-(2).
SPEC : 15~35
Starting key OFF.

Disconnect connector CN-88 from power
max solenoid valve.
Check resistance as figure.
Power max switch
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
Cause
YES
Remedy

connection between
CN-53(19)-CN-133
(1) or CN-53(9)CN-133(2)
Check resistance
between
CN-133(1)-(2)
SPEC : 20~30V
KEY : ON
Defective EPPR
valve
NO
Repair or replace
Wiring diagram Wiring diagram
MCU
19
CN-133
1
BOOM PRIORITY
EPPR VALVE
CN-53
21096MS15
6-76
20. MALFUNCTION OF ARM20. MALFUNCTION OF ARM REGENERATION SOLENOIDREGENERATION S

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
ARM REGENERATION SOLENOID

FUSE
NO.28
CN-52
21096MS16
6-77
SPEC : Key ON : 242 V

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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
21. MALFUNCTION OF RAM21. MALFUNCTION OF RAM LOCK SOLENOIDLOCK SOLENOID

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
RAM LOCK SOLENOID

FUSE
NO.28
CN-52
14W96MS25
6-79
SPEC : Key ON : 242 V

(1)(1)
copper.
MCU

PIN
CN-51 CN-52
CN-53
Starting key ON.

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

6 Troubleshooting

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6 Troubleshooting

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SOLUCIN DEL ARTCULO 6 TROUBLESHO

SOLUCIN DEL ARTCULO 6 TROUBLESHO

2. DIAGNOSTICAR PROCEDURE2. DIAGNOSTICAR PROCEDIMIENTO

El PASO 2. Pregunte a operatorSTEP 2. Pregunte al operador

El PASO 3. Inspeccione machineSTEP 3. Inspeccione la mquina

6-2 (3) 140-7

STEP 4. STEP 4. Inspect the trouble actually

STEP 5.STEP 5. Perform troubleshootingPerform troubleshooting

STEP 6.STEP 6. Trace a causeTrace a cause

GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM

GROUP 2 HYDRAULIC AND M

Pilot pump pressure

Swing pilot pressure

Arm/bucket pilot pressure

P2 pump control pressure

2. DRIVE SYSTEM 2. DRIVE SYSTEM

Coupling element Disassemble

If hydraulic pump or engine is

See item 1).

Pilot relief valve in Repair or

Put hydraulic oil

Check suction line

Drop hydraulic oil

2)2)HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

HYDRAULIC OIL TEMPERATURE HAS R

Oil cooler clogged. Clean oil cooler.

Is oil cooler clogged

Is not the set

Replace oil with

Is not air intruding

Check for air

Has not hydraulic

Has return filter

4. SWING SYSTEM 4. SWING SYSTEM

Hydraulic pump is Disassemble and

Does not symptom

Hydraulic pump is Disassemble and

Pump connection Disassemble and

Are broken pieces

YES pilot pressure

Pilot relief valve in Disassemble and

Is gear pump pilot

Gear pump is out of Disassemble and

Clean pilot piping

Swing port relief

YES Clogged or oil

Clean pilot piping

YES Does swing spool

YES Is MCV pilot

Check that pilot

Is gear pump pilot

Clean pilot piping

Clogged or oil leak.

Swing control valve Disassemble

Main relief valve

Main relief valve

Does the symptom YES Hydraulic pump

Pilot relief valve

Pilot relief valve

SWING MOTION IS IMPOSSIBLE IN ONE DIREC

Swing port relief

Swing control valve Disassemble