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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
6-40
2) TEST PROCEDURE
SPEC : 45~50(20
C)
(1) Test 1 : Check resistance at connector
CN-75. CN-75
Main pump
2107A5MS15
Main pump
2107A5MS12
(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
2907A6MS01
6-42
2) TEST PROCEDURE SPEC : 200~450mA CN-75
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
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
copper 36 25
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
Wiring diagram
CPU CONTROLLER
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
CN-50
CN-51
12 2
24 13
36 25
Ground
Multimeter
R29076MS15
6-49