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Group 4 Mechatronics System: 1. All Actuators Speed Are Slow
Group 4 Mechatronics System: 1. All Actuators Speed Are Slow
SPEC : 17.5±1Ω(20°
C) Defective EPPR Replace
See TEST 2 NO
valve
※ Normal :
Wiring diagram
Emergency :
RESISTOR PROLIX SWITCH
1 1 3
2
2 2
1
CN-47 3
4 6
5
5 4
6
CONTROLLER CS-7
8
FUSE
24
28 NO.9
36
9 2
32
10 1
6 - 41
2) TEST PROCEDURE SPEC : 17.5±1Ω(20°
C)
(1) Test 1 : Check resistance at connector Y R G
CN-50(8)-(36). CN-50
CPU 12 8 1
① Starting key OFF. CONTROLLER 24 13
connector CN-50(8)-(36).
Multimeter
Multimeter
6 - 42
(2) Test 4 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm2(70~280psi)
① Remove plug and connect pressure
gauge as figure.
・Gauge capacity : 0 to 40~50kgf/cm2
(0 to 570~710psi)
② Start engine. Supply line, pilot press
③ Set the accel dial at "10"(Max).
④ Set S-mode and cancel auto decel mode. CN-75
⑤ If tachometer show approx 1950 50rpm, Pressure adjusting
1850±50rpm(TIER II) check pressure. screw locknut
6 - 43
2. ENGINE SPEED IS SLOW AT ALL MODE
※ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
Good
If test 7 is good,
Check tachometer check TEST 1~4
YES work properly or
not by changing YES
Misalignment Clean speed
the mode. between speed sensor and
Is resistance
YES Is resistance See TEST 6 sensor and fly adjust
between CN-50 No good between CN-51 wheel See : 5-20page
(12) - (23) (25) - (26)
SPEC : 0.2~0.4kΩ ⓐ
SPEC : 1~2Ω
See TEST 7 NO
See TEST 5
Check cable
between accel Defective accel Replace accel
NO
actuator and actuator or short actuator or
injection pump. circuit or poor harness
connection assembly
between CN-50-
CN-76
26 11 2
CN-51 CN-2 CD-17
6 - 44
2) TEST PROCEDURE SPEC : 1~2Ω
(1) Test 5 : Check resistance between CN-50 Y R G
(12)-(23). CPU
① Starting key OFF. CONTROLLER
② Disconnect connector CN-50 from CPU CN-50
controller. CN-51
CN-50
12 1
23 13
36 25
Multimeter
Unit : rpm
(2) Test 6 : Check tachometer(Work properly
Spec Remark
or not)
① Start engine. H-mode 2050±50 Check rpm after cancel
the Auto decel mode.
② Check tachometer reading. S-mode 1950±50
CN-51 12 1
24 13
36 26 25
Multimeter
6 - 45
(4) Test 8 : Check resistance at speed
SPEC : 0.2~0.4kΩ
sensor.
① Starting key OFF.
② Disconnect connector CD-17 of speed Speed sensor
sensor at engine flywheel housing.
③ Check resistance as figure.
CD-17 CD-17
1 2
Engine flywheel
Multimeter
6 - 46
3. 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 10 valve
Check electric
current at EPPR YES
valve Defective CPU Replace
controller
SPEC : 200~450mA
See TEST 9 Check resistance YES
between CN-50 Short circuit or Check and repair
NO (8) - (36) poor connection
SPEC : 17.5±1Ω(20°
C) between
See TEST 1 Check resistance CN-50 - CN-2 or
NO at EPPR valve
CN-50 - CN-75
SPEC : 17.5±1Ω(20°
C)
See TEST 2 Defective EPPR Replace
NO
valve
Wiring diagram
※ Normal :
Emergency :
RESISTOR PROLIX SWITCH
1 1 3
2
2 2
1
CN-47 3
4 6
5
5 4
6
CONTROLLER CS-7
8
FUSE
24
28 NO.9
36
9 2
32
10 1
6 - 47
2) TEST PROCEDURE SPEC : 200~450mA
(1) Test 9 : Check electric current at EPPR
valve at S-mode
① Install multimeter as figure. CN-75
② Start engine.
③ Set the accel dial at "10"(max)
④ Set S-mode with 1950±50rpm.
⑤ Check electric current.
EPPR VALVE
Multimeter
6 - 48
4. 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
Y R G
See if Co : Er
NO
on the cluster
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-51
ⓐ (29) - CN-50(10)
or CN-50(30) -
CN-5(11) No connection Check and repair
NO
KEY OFF
Wiring diagram
6 - 49
5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
※ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Slow action of Check and repair
engine speed
control due to
interference
Check interference
between YES
connecting rod and Defective CPU Replace
Check voltage
accel actuator between CN-5(20)- controller
YES
(21) and check
resistance between
CN-51(20)-(22)
Check resistance Defective accel Replace
NO
between CN-50 SPEC : (20)-(21) : 5±1V actuator
NO (20)-(22) : 0.1~0.9kΩ
(12)-(23) See TEST 12
SPEC : 1~2Ω
See TEST 11 Defective accel Replace
NO
actuator
Wiring diagram
ACCEL ACTUATOR
CPU CONTROLLER
1 P+
2
2 SIG
1 3
12 3 P-
4 NC
5
5 M+ M 6
23 6 M-
CN-76 ACCEL DIAL
CN-50
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 12 1
rp
m
26 11 2
CN-51 CN-2 CD-17
6 - 50
2) TEST PROCEDURE SPEC : 1~2Ω
(1) Test 11 : Check resistance. Y R G
(23) as figure.
CN-50
12 1
23 13
36 25
Multimeter
6 - 51
(2) Test 12 : Check voltage and resistance. SPEC : 0.1~0.9kΩ
① Check resistance between CN-51(20)- Y R G
(22). CPU
CONTROLLER
- Starting key OFF.
CN-51
- Disconnect connector CN-51 from CPU
CN-50
controller.
- Check resistance value with multimeter
as figure.
CN-51
12 1
24 22 20 13
36 25
Multimeter
CN-51
12 1
24 21 20 13
36 25
Multimeter
6 - 52
6. 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 :
11~13V
Actuator stop :0~2V Defective auto Replace
See TEST 13 NO
See TEST 14 decel pressure
switch
Wiring diagram
CD-7
13 1
Pa
2
CN-51 CD-6
6 - 53
2) TEST PROCEDURE SPEC : Actuator stop : 11~13V
(1) Test 13 : Check voltage at CN-51(1) and Actuator operating : 0~2V
ground. Y R G
copper 36 25
CN-51 12 1
24 13
36 25
Ground
Multimeter
6 - 54
7. 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-51 CD8(Sensor)
(31) - CD-8(1)
SPEC : Below10Ω NO Poor connection Repair
Check resistance KEY OFF
between CN-
between CN -51
(33) - CD-8(2) 51(31) - CD-8(1)
SPEC : Below 10Ω
KEY OFF
NO
Poor connection Repair
between CN-
51(33) - CD-8(2)
Wiring diagram
CONTROLLER
31 6 1
C
33 7 2
CD-8
CN-51 CN-2
6 - 55
8. 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
(1) - (2) max. solenoid valve
YES
Resistance
between CN-51 SPEC: 15-30Ω
(2)-GND normal? See TEST 15
Wiring diagram
6 - 56
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 15: Check voltage between connector Resistance : 15~30Ω
CN-88 - GND.
① Start key ON.
② Disconnect connector CN-88 from power Power max. switch
max solenoid valve.
③ Check voltage as figure.
LH RCV-lever
CN-88
CN-88
Power max.
solenoid valve
Multimeter
CN-50
CN-51
12 2
24 13
36 25
Ground
Multimeter
6 - 57