Section 6 Troubleshooting

SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting 6-1

Group 2 Hydraulic and Mechanical System 6-4
Group 3 Electrical System 6-24
Group 4 Mechatronics System 6-41
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics
system. At each system part, an operator can check the machine according to the troubleshooting
process diagram.
Hydraulic &
GROUP 2
Mechanical part
Troubles occur Electrical part GROUP 3
Mechatronics
GROUP 4
part
6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.
STEP 1. Study the machine system

Study and know how the machine is operating,
how the system is composing, what kinds of
function are installed in the machine and what
are specifications of the system components by
the machine service manual.
Especially, deepen the knowledge for the
related parts of the trouble.
STEP 2. Ask the operator

Before inspecting, get the full story of
malfunctions from a witness --- the operator.
1) How the machine is used and when it is
serviced?
2) When the trouble was noticed and what
work the machine was doing at that time?
3) What is the phenomenon of the trouble?
Was the trouble getting worse, or did it
come out suddenly for the first time?
4) Did the machine have any troubles
previously? If so, which parts were repaired
before.
STEP 3. Inspect the machine

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system ON THE
INSPECTION
such as low battery voltage, loose connections
and blown out fuses will result in malfunction of
the controllers causing total operational failures
of the machine.
6-2
STEP 4. Inspect the trouble actually on the
machine
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.
STEP 5. Perform 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.
STEP 6. Trace a cause

Before reaching a conclusion, check the most
suspectible causes again. Try to trace what
the real cause of the trouble is.
Make a plan of the appropriate repairing

procedure to avoid consequential malfunctions.
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE 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.
① Was there any strange thing about machine before failure occurred?
② Under what conditions did the failure occur?
③ Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
① Check oil and fuel level.
② Check for any external leakage of oil from components.
③ Check for loose or damage of wiring and connections.
6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust plug
under engine
flywheel and
YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic Abnormal noise
pump and pump YES comes out of YES
connections pump See item 1).
YES make abnormal
connection at page 6-5
noise?
Is primary pilot
pressure within ⓐ
NO standard level?
YES
Clean pilot
Is not pilot piping piping interior or
YES clogged or is not
oil leakage present repair piping.
on pilot piping?
NO
Pilot valve is Disassemble
ⓐ faulty. and repair.
YES
Pilot relief valve is Repair or
Is gear pump faulty. replace.
NO delivering oil?
NO Gear pump is Disassemble

broken. and repair.
6-6
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY
Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot dispose it or
plate and check if replace hydraulic
foams come up. oil.
NO Air is intruded. Check suction

line and return
line and eliminate
the air intruding
source.
2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY
Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Clean oil cooler.
Is not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES
ⓐ
air circulation?
Is fan belt
NO tension proper?
Adjust belt
NO
tension or
replace belt.
Is not the set YES
pressure of main Readjust set
relief, relief and pressure.
ⓐ
travel relief valve Is main relief
lower than the YES
valve used very Reduce load.
standard level? NO often?
6-7
3) CAVITATION OCCURS WITH PUMP
Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Replace oil with
one of proper
Is not viscosity viscosity.
of hydraulic oil
YES YES
too high? Clean suction
Is not suction strainer.
NO strainer clogged? Is not air intruding
from pump Check for air
NO
suction line? intrusion in
suction line and
retighten or
replace parts.
4) HYDRAULIC OIL IS CONTAMINATED
Cause Remedy
YES
Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO proper intervals?
hydraulic oil and
replace return
filter.
6-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE
Cause Remedy
NO
Replenish
YES specified oil to the
Is safety solenoid ⓐ
YES
valve pressure standard level.
Is gear pump pilot within standard? Safety valve faulty Repair or replace.
NO
pressure within or not operated.
YES standard level?
Is oil in hydraulic
YES tank within
Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ⓐ when dust plug
under engine fly Is not main relief NO Hydraulic pump is
Are attachment wheel is removed? NO valve faulty? Disassemble and
and travel out of order. repair.
motions
impossible at all? NO Swing control valve Disassemble and
Does swing
YES control valve spool is stuck. repair.
spool move
Is MCV pilot
YES
pressure within
lightly by hand? YES ⓑ
standard level?
Does RH travel NO
ⓒ
NO function?
Does not symptom
change when front YES
Hydraulic pump is Disassemble and
NO and rear pump
discharge hoses broken. repair.
are exchanged?
YES
Swing brake Disassemble and
release valve is repair.
Is swing brake broken.
ⓑ release valve
faulty? YES Swing reduction Disassemble and
Does swing unit is broken. repair.
NO motor rotate?
Swing motor is Disassemble and
NO
broken. repair.
YES Pilot relief valve is Disassemble and

NO Is gear pump faulty. repair or replace.
delivering oil?
Gear pump is out Disassemble and
Is gear pump pilot NO
of order. repair.
ⓒ pressure within
standard level? YES
Is not there oil Clean pilot piping
leakage from interior or repair
YES pilot piping or is piping.
not it clogged? Pilot valve is Disassemble and
NO
broken. repair.
6-9
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES
Does swing control valve is faulty. repair or replace.
valve spool move
smoothly by hand?
Swing control valve Disassemble
Is MCV pilot NO
spool is stuck. and repair.
pressure same
on LH and RH YES Clogged or oil
sides? Clean pilot piping
leak. interior or repair
Is not pilot piping
Single direction clogged or is not piping.
NO it leaking oil?
Is the trouble in Pilot valve or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? YES ⓐ
Does swing
YES control valve
Both directions spool move
Is MCV pilot lightly by hand?
YES Swing control valve Disassemble
pressure within NO
Is Arm speed spool is stuck. and repair.
standard level?
within standard ⓑ
value? NO
ⓒ
NO
Is swing motor's NO
ⓐ drain rate within Swing motor is Disassemble
standard value? Check that pilot broken. and repair.
piping is not
YES clogged or oil is NO
Pilot valve or Disassemble
not leaking from shuttle valve is and repair.
it? faulty.
Clogged or oil leak. Clean pilot piping
Is gear pump pilot interior or repair
ⓑ pressure within piping.
standard level?
YES
Pilot relief valve Disassemble and
Is gear pump is defective. repair or replace.
NO delivering oil?
Gear pump is Disassemble
NO
broken. and repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief valve Does the symptom YES Hydraulic pump Disassemble
ⓒ setting pressure change when front
YES
and rear pump is broken. and repair.
normal?
discharge hoses
Is safety valve are exchanged? NO Shuttle valve is Repair or replace.
pilot pressure faulty.
YES within standard
level? YES
Is gear pump Pilot relief valve Repair or replace.
output pressure is faulty.
NO within standard
level? Gear pump is Repair or replace.
NO
faulty.
6-10
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
Does symptom YES
Swing port relief Disassemble and
change when LH
YES and RH port relief valve is faulty. repair.
valves are
exchanged Shuttle valve is Disassemble and
Does swing control NO
YES faulty. repair.
valve spool move
smoothly by hand?
Is MCV pilot NO Swing control valve Disassemble and

pressure same spool is stuck. repair.
for LH and RH?
Check if pilot YES
Pilot valve is faulty. Disassemble and
piping is not repair.
clogged or does
NO
not have oil Clogged or oil
leakage. leak. Clean pilot piping
interior or repair
piping.
4) MACHINE SWINGS BUT DOES NOT STOP
Cause Remedy
YES Pilot relief valve is Disassemble and
Is MCV pilot faulty. repair or replace.
YES YES Is gear pump pilot
pressure within pressure within
standard value? standard level?
Gear pump is Disassemble and
NO
broken. repair.
YES Does swing control
valve spool move
smoothly by hand? Pilot valve is faulty. Disassemble and
NO
repair.
Is swing control
valve's return
spring normal? Swing control Disassemble and
NO
valve spool is repair.
stuck.
Return spring is Disassemble and
NO
faulty. replace.
6-11
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
YES
ⓐ
YES Is swing shuttle
valve normal?
Shuttle valve is Disassemble
NO
faulty. and replace.
YES Is brake spring
normal?
Is return spring
of swing control Brake spring is Disassemble
NO
valve normal? faulty. and replace.
NO Return spring of Disassemble

swing control and replace.
valve is faulty.
YES
Is drain rate of Swing relief valve Disassemble
YES swing motor is faulty. and repair or
within standard replace.
Is swing relief value? Disassemble
NO Swing motor is
ⓐ pressure within broken. and repair.
standard level?
NO Adjust swing
relief valve
pressure or
replace swing
relief valve.
6-12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES
Does counterbalance ⓐ
YES spool in travel
brake valve move
lightly by hand?
Is travel brake Counter spool in Disassemble
NO
YES valve pressure travel brake valve and repair or
within standard is stuck. replace.
level? Does the symptom
change when
relief valves in YES
Relief valve built Disassemble
Has travel NO travel motor are
YES control valve exchanged? in travel motor is and repair.
spool changed faulty.
over positively?
YES
Control system is Disassemble
defective. inspect and
Does spool move repair.
NO lightly by hand?
NO Travel control Disassemble

valve spool is and repair.
stuck.
Is bucket or arm
operation YES Disassemble
Travel reduction
possible? Do not metallic
particles come unit is faulty. and repair.
ⓐ out of drain port
in travel
reduction unit? Travel motor is Disassemble
NO
out of order. and repair.
Does the symptom
NO
change when front YES
and rear pump Hydraulic pump is Disassemble
Does the discharge hoses
symptom change broken. and repair.
are exchanged?
when LH/RH
NO travel relief valves
are exchanged?
YES Travel relief Disassemble
valves are faulty. and repair or
replace.
6-13
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES
Cause Remedy
YES
Brake valve is Disassemble
Do LH and RH
travel speeds defective. and repair or
YES change when LH replace.
and RH travel YES
Does the symptom Relief valve built Disassemble
brake valves are change when in travel motor is and repair.
exchanged? relief valves in
faulty.
NO LH and RH
Has control valve travel motors are
YES
spool changed exchanged? ⓐ
over positively? NO
YES
Control system is Disassemble,
Does spool move faulty . inspect and
lightly when it is
repair.
Is the lower NO cut off from
speed(Bucket or control spool?
arm) within Control valve Disassemble
NO
standard level? spool is stuck. and repair.
YES
Travel relief valve Disassemble
Do LH and RH is faulty. and repair or
travel speeds Does the symptom replace.
change over when change when
NO travel relief valves YES front and rear YES
pump discharge Hydraulic pump is Disassemble
are exchanged?
Is external pilot hoses are broken. and repair.
pressure within exchanged?
NO
standard level?
External pilot Disassemble
NO
piping is clogged and clean.
or oil is leaking
Does travel speed from it.
change when
YES parking brake YES
spring in the Travel motor's Disassemble
slower travel parking brake is and clean pilot
Is leak rate of motor is removed? not released piping.
ⓐ travel motor within
standard level? properly.
Travel motor is Disassemble

NO
faulty. and repair.
6-14
3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.
Cause Remedy
None Is parking brake YES
friction plate Friction plate is Disassemble
YES Check if parking worn? faulty. and repair.
brake pilot line is
not clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES travel motor NO
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?
Brake valve is Disassemble

NO
faulty. and repair or
replace.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE
Cause Remedy
YES
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
Is bucket or arm disabled is
operation extremelyseldom
possible? statistically.
OK
Disassemble both faulty. repair.
OK travel relief valves
Remove dust and inspect for
plug under engine any fault.
OK flywheel and Travel relief valve Disassemble and
check that there is Faulty
is faulty. repair or replace.
no coupling
element particles.
Check oil volume Particles present. Coupling at pump Disassemble and
in hydraulic oil connection is repair.
NO tank.
broken.
Replenish
Short hydraulic oil.
6-15
5) TRAVEL ACTION IS POWERLESS(Travel only)
Cause Remedy
YES
ⓐ
Is travel motor's
YES
drain rate within
standard level?
Is travel brake Travel motor is Disassemble
YES pressure within NO
faulty. and repair.
standard level?
Is travel relief
valve pressure Travel brake Disassemble
NO
within standard valve is defective. and repair or
level?
replace.
NO Travel relief valve Disassemble
is faulty. and repair or
replace.
YES
Hydraulic circuit Disassemble
Does parking that releases and clean.
brake piston travel parking
Increases move lightly by
Remove parking brake is clogged
brake spring in hand?
with dirt.
travel motor,
draw out piston Parking brake Disassemble
ⓐ NO
completely, refit piston in travel and repair.
cover and check motor is stuck.
if travel power
changes. Remains
unchanged Travel reduction Disassemble
unit is defective. and repair.
6) MACHINE RUNS RECKLESSLY ON A SLOPE
Cause Remedy
Travel brake valve
(counterbalance Disassemble
valve) is faulty. and repair or
replace.
6-16
7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND
ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME
Cause Remedy
YES
Normal.
YES Is select valve

normal?
Select valve is Repair or

Is pilot pressure NO
for travel select faulty. replace.
valve within
standard level? YES
Remove dirt on
Is filter in pilot pilot line filter.
piping between
gear pump and YES Is pilot relief NO
NO control valve not Pilot relief valve is Disassemble
valve normal?
clogged? defective. and repair or
Is gear pump
replace.
NO delivering oil?

NO
broken. and repair.
6-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
replace.
valve is replaced
Is MCV pilot with other valve? NO ⓐ
YES
pressure within
standard level?
Inspect if pilot
piping is not
OK
clogged or oil is Pilot valve is Disassemble
Are other NO
YES
not leaking from faulty. and repair.
attachments the piping.
operatable?
YES
Pilot relief valve is Disassemble
Is gear pump pilot YES
Is gear pump faulty. and repair or
pressure within
NO delivering oil? replace.
standard level?
NO
broken. and repair.
Are LH/RH travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and Faulty
Main relief valve Disassemble
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Particles present Coupling at pump Disassemble
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.
YES
Cylinder interior is Disassemble
Does control
broken. and repair.
ⓐ valve spool move
lightly by hand?
NO Control valve Disassemble
6-18
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ⓐ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ⓑ
in composite YES
normal at boom YES
operation? hoisting and at Flow summation Disassemble and
Does spool of flow
arm extrusion? summation check check valve spool repair.
NO valve move lightly is stuck.
Are LH/RH travel
by hand?
NO speeds within NO
standard levels?
YES
Are both LH/RH faulty. repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
OK
Does the Port relief valve is Disassemble and
symptom change faulty. repair or replace.
YES
when port relief
valve is replaced
Does control with other valve? Cylinder is faulty. Disassemble and
YES NO
valve spool move repair.
lightly by hand?
NO Control valve spool Disassemble and

Is MCV pilot
ⓐ pressure within is stuck. repair.
standard level?
YES
Clean pilot piping
Is not MCV pilot
pressure piping interior or repair
NO clogged or is not piping.
there oil leakage? Pilot valve is Disassemble and
NO
defective. repair.
YES
Pilot relief valve is Disassemble and
Is primary pilot NO Is gear pump faulty. repair or replace.
ⓑ pressure within
delivering oil?
standard level?
NO
Gear pump is Disassemble and
broken. repair.
Is engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil interior or repair
NO not leaking from piping.
the piping? Is pilot valve
Pilot valve is faulty. Disassemble and
NO normal? NO
repair.
6-19
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the symptom faulty. and repair or
change when port
Normal replace.
relief valve is YES
replaced with ⓐ
normal valve? Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
high? NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the cause
hydraulic oil or of hydraulic oil
equivalent being temperature rise
used?
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
YES inspect check between control
valve in hydraulic
circuit and check valve casing and
for any fault. spool is poor.
Is cylinder internal Abnormal Contact surface Disassemble
ⓐ leakage within between poppet and repair.
standard level?
and seat is poor.
Cylinder is faulty. Disassemble

NO
6-20
4) BOOM, ARM OR BUCKET POWER IS WEAK
Cause Remedy
YES
Check according
Is cylinder to the procedure
YES internal leakage in Item "Speed is
within standard low".
level?
Is relief pressure
YES in port relief Cylinder is faulty. Disassemble
valve within NO
and repair.
standard level?
Is relief pressure
in main relief Port relief valve is Adjust pressure,
valve within NO
faulty. repair or replace.
standard level?
Main relief valve Adjust pressure,

NO
is defective. repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
YES
Port relief valve is Disassemble
Does the
symptom change defective. and repair or
YES
when port relief replace.
YES
valve is replaced Does control Cylinder interior is Disassemble
with other valve? valve spool broken. and repair.
Is MCV pilot NO move smoothly
pressure within by hand?
NO
Control valve Disassemble
standard level?
NO Pilot valve is Disassemble

faulty. and repair.
6-21
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil
Is boom foot pin seal and boom
greased proper.
sufficiently?
※ Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. ※
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.
6-22
※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
2. Disconnect hose(A) from rod side of boom

cylinder and drain oil from cylinders and
hose.(Put cups on piping and hose ends)
A
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.
6-23
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.
・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective clucter Replace
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-5(3) poor contact (After clean)
and chassis between CN-5(3)-
CN-56(1)
Starting switch : ON
Voltage : 20~32V
NO Disconnection in Repair or
wiring harness or replace
poor contact (After clean)
between CN-5(3)-
and fuse No.7
CLUSTER FUSE
POWER IG(24V) 1 3
2 9 NO.7
GND
RX
TX
CN-56 CN-5
Check voltage
YES 20 ~ 30V
NO 0V
6-24
2. COMMUNICATION ERROR "Co : Err" FLASHES ON THE CLUSTER
・Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Defective controller Replace
YES Check voltage

between CN-56
(3,4) and chassis
Disconnection in Repair or replace
NO wiring harness or (After clean)
Check voltage
between CN-5 poor contact
between CN-56
(10,11)and (3,4) CN-5(10,11)
chassis
KEY ON
NO
wiring harness or (After clean)
poor contact
between CN-5
(10,11)-CN-50
(29,30)
CONTROLLER
Check voltage
YES *4V *12V 29
NO 0V 0V
30
CN-50
CLUSTER
POWER IG(24V)
GND 2 9
RX *12V
3 10
TX *4V 4 11
CN-56 CN-5
6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)
Cause Remedy
YES
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
NO
YES Check voltage poor contact
between CN-3
(3) and chassis between CN-51(9)
-CN3(3)
Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "I" and between
chassis CN-3(3)-alternator
Voltage : 20~32V terminal "I"
Engine : Running
Defective alternator Replace

NO
Check voltage
YES 20 ~ 32V
NO 0V
ALTERNATOR
CONTROLLER B+
G
3~
9 3 I
U
GND
CN-51 CN-3 CN-74
6-26
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Coolant overheat Check engine
Resistance
YES between CD-8 (110°C ±2°C ) cooling system
(1,2) is in range
of 120~150Ω?
NO
Defective temp Replace
Disconnect CD-8 sensor
Does display go
off when
disconnect CD-8?
YES
Starting switch : ON Short circuit in Repair or replace
Engine : Start Resistance wiring harness (After clean)
between CN-51
NO
(31,33) is 0~1
Defective Controller Replace
Disconnect CN-51 NO
KEY OFF
CONTROLLER WATER TEMPERATURE

SENSOR
33 5 1 C
31 6 2
CN-51 CN-3 CD-8
6-27
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect CD-
10? YES
Short circuit in Repair or replace
Engine : Start Check resistance wiring harness (After clean)
between CN-51
NO
(16) and chassis
Starting switch : OFF Defective controller Replace
NO
Disconnect CN-51
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
CONTROLLER AIR CLEANER SWITCH
Pa
16
20
CD-10
CN-50
51
6-28
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
Does display go off switch
when disconnect
YES
CD-18? Defective controller Replace
Starting switch : ON Check resistance
Engine : Start between CN-51
NO
(4) and chassis
Starting switch : OFF
NO
Disconnect CN-51 wiring harness or (After clean)
poor contact
between
CN-51(4)-CD-18
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
CONTROLLER ENGINE OIL PRESSURE SWITCH
4 1 Pa
CN-51 CN-2 CD-18
6-29
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1
(1,2) is in range (100°C ±2°C ) ,
of 130~150Ω? Replace
Starting switch : ON Defective torque Replace
Does display go NO
Disconnect CD-1 sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Starting switch : ON Resistance
Engine : Start between CN-51
NO (31,34) is 0~1Ω?
Starting switch : OFF NO Defective controller Replace

Disconnect CN-51
CONTROLLER HYDRAULIC OIL

TEMPERATURE SENDER
34 2
C
31 1
CN-51 CD-1
6-30
8. WHEN COOLANT LEVEL WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Insufficient coolant Refill coolant or
or Defective switch replace switch
Does display go
off when
disconnect CD-
16? YES
Short circuit Check and repair
Starting switch : ON Check resistance
Engine : Start
between CN-51
NO (15) and chassis
Starting switch : OFF NO Defective controller Replace

Disconnect CN-51
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
COOLANT LEVEL SENSOR

CONTROLLER
15
18 2
51
CN-50 CD-16
6-31
9. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
Cause Remedy
YES
Is resistance poor contact
YES between CN-51 between
(31) and (33) CN-51-CD-8
over 2kΩ?
Starting switch : OFF YES
Disconnect CN-50 Defective controller Replace
Does the gauge
light up and Check resistance
down at lamp NO
between CN-3(5)
check? and (6)
Defective temp Replace
See Table
NO
Starting switch : ON sensor
Defective cluster Replace

NO
Check Table
Green range Red range Temperature White range Green range Red range
Item (~29° C) (30~105° C) (105°C ~)
Unit Resistance(Ω) 1646~ 1645~158 ~139
White range Tolerance(%) ±20 ±20 ±20
CONTROLLER WATER TEMPERATURE

SENSOR
33 5 1 C
31 6 2
CN-51 CN-3 CD-8
6-32
10. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1kΩ? YES
Starting switch : OFF
Disconnect CN-51
Check resistance
Does the gauge between CD-2(1)
light up and NO and (2)
down at lamp Defective fuel Replace
NO
check? Disconnect CD-2
sensor
See Table

NO
Green range Red range Check Table

Level White range Green range Red range
Item
Unit Resistance(Ω) 700~601 600~101 ~100
White range Tolerance(%) ±5 ±5 ±5
CONTROLLER
FUEL SENDER
24 1
CD-2
31
CN-51
6-33
11. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No.24.
Cause Remedy
YES
Hydraulic Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
ⓐ
YES Check voltage
between CS-4
Check voltage (C) and chassis
between CN-68 Disconnect in Repair or replace
(1) - CN-68(2) Check voltage Starting switch : ON NO
YES between CN-4(8) Voltage : 20~30V wiring harness or (After clean)
Starting switch : ON and chassis Disconnect CN-4 poor contact
Voltage : 20~30V between
Safety state Starting switch : ON CN-4(8)-CS-4(C)
Voltage : 20~30V
Disconnect CN-4
Check voltage Disconnect in Repair or replace
between CN-68 NO
NO (1) with chassis
poor contact
Safety lever : OFF between
Starting switch : ON CN-4(8)-CN-68(1)
Voltage : 20~30V
NO Disconnection in Replace
fuse
YES
Defective switch Repair or replace
Check voltage
ⓐ between CS-20 (CS-20)
and chassis
NO
Defective switch Repair or replace
Starting switch : ON (CS-4)
Voltage : 20~30V
SAFETY SWITCH
FUSE
CS-20
NO.24
EARTH 1
SAFETY SWITCH
B C A SAFETY SOLENOID
B 2
A C 8 1
CS-4 CN-68
CN-4
6-34
12. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
short of fuse No.22 .
Cause Remedy
YES
Defective hydraulic Check hydraulic
system system
YES Check voltage YES Check operation
between CN-50 YES
of solenoid Defective controller Replace
(13) and chassis
Check resistance
Check if travel Starting switch : ON Starting switch : ON between CN-70
Volage : 20~30V : OFF NO
speed lamps( , (1) and (2)
Disconnect CN-50 : ON
) change when Defective solenoid Replace
Starting switch : OFF NO
pressing the travel
speed switch on SPEC : 15~25Ω
Disconnect CN-70
the cluster YES
Check controller
Y R G
NO
NO
FUSE
NO.22
TRAVEL SOLENOID
CONTROLLER
2
13 1
CN-70
CN-50
6-35
13. WHEN ENGINE DOES NOT START
・Check supply of the power at engine stop solenoid while starting switch is ON.
Cause Remedy CN-60

YES 2
POWER RY 1
Defective battery Check engine
FUSIBLE LINK
system charge or
87a 87 85
30 86
replace(After CR-1
checking specific
CR-35
87a
gravity of battery)
30
86
85
87
Check operation YES
BATTERY
Check voltage Defective magnet Replace BATT RY
12V X 2
of start motor YES between starter of start motor DO-2
magnet coil and 2
Starting switch : START chassis Defective start relay Replace 1
NO DIODE
Starting switch : START YES
SPEC : 20~30V ⓐ, ⓑ FUSE
MASTER SW
Check operation YES
Check voltage 12
NO of start relay
between CR-5 CN-8 1
(30) and chassis 9
Disconnection in Repair or replace 10
Starting switch : START
NO
Starting switch :START wiring harness or (After clean) 11
Check operation poor contact 12
of start safety between CR-5
NO relay
(86) and CN-8(9)
CS-2
3
5
4
1
6
2
YES
Check voltage Defective relay Replace
between CR-
NO 5(87) and ⓒ ST
NO ACC
Starting switch : ON OFF
HT
YES OFF C R2 R1 IG BR B
Defective fuel cut Replace START KEY SW
Check voltage
off solenoid
ⓐ between CN-79 CN-45 CR-23 CN-3
(2) and chassis
Disconnection in Repair or replace M
M
1 1
NO
Voltage : 20~30V wiring harness or (After clean) 2 2
Starting switch : START poor contact B+ START RY
between CN-2(4)- STARTER
CN-79(2)
CN-74
YES G B+
Check voltage Defective relay Replace
~3
ⓑ between CR-23 U
I
CR-5
GND
and chassis 30
87a 87 85
NO Disconnection in Repair or replace ALTERNATOR 86
wiring harness or (After clean) CN-79 CN-2 87
poor contact E 3 3 85
S 2 4 87a 30 86
between CR-5(30)-
I 1 5 SAFETY
CR-23(2)
FUEL CUT-OFF
YES
Check voltage Defective fuel cut- Replace
ⓒ between CN-79 off solenoid
(1) and chassis
NO
Starting switch : ON wiring harness or (After clean)
poor contact
between CN-2(5)
and Fuse No.12
6 - 36
14. WHEN STARTING SWITCH ON DOES NOT OPERATE
master switch ON. CN-60
2
・After checking, insert the disconnected connectors again immediately unless otherwise specified. POWER RY 1
FUSIBLE LINK
87a 87 85
30 86
CR-1
CR-35
87a
Cause
30
Remedy
86
85
87
YES
BATTERY
BATT RY
12V X 2
wiring harness or (After clean) DO-2
2
poor contact 1
YES Check voltage
between DO-2 between DO-2(2)- DIODE
(1) and chassis CR-1 or defective FUSE
MASTER SW
12
Voltage : 20~30V
battery relay CN-8 1
9
10
YES Check voltage Disconnection in Replace 11
between CS-2 NO
12
wiring harness or
(2) and chassis
poor contact
CS-2
Voltage : 20~30V between CS-2(2)-
3
5
4
1
6
2
Check voltage
YES CN-8(11)- DO-2(1)
between CS-2(1)
and chassis
ST
Defective start Replace ACC
Voltage : 20~30V NO OFF
switch
HT
OFF C R2 R1 IG BR B
Check voltage Disconnection in Replace START KEY SW
and specific NO
gravity of battery wiring harness or CN-45 CR-23 CN-3
poor contact M
Specific gravity : MIN 1.28 M 1 1
Voltage : MIN 24V between CS-2(1)- 2 2
CN-8(12)-CR-1- B+ START RY
STARTER
Battery
CN-74
G B+
Battery capacity too Charge or replace ~3
NO I
low (After clean) U
GND
CR-5
30
ALTERNATOR 87a 87 85
86
CN-79 CN-2 87
E 3 3 85
S 2 4 87a 30 86
I 1 5 SAFETY
FUEL CUT-OFF
6-37
15. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE FUSE BOX
21
24
20
23
26
27
25
28
11
13
22
10
14
15
17
19
12
16
18
2
9
1
6
20A
20A
20A
20A
20A
10A
20A
10A
10A
10A
10A
10A
10A
10A
10A
10A
10A
10A
5A
5A
5A
5A
5A
5A
5A
5A
5A
5A
・Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
ETHER(PRE-HEAT)
CASSETTE RADIO
No.4,11 and 13 is not blown out.
FUEL FILLER P/P

CIGAR LIGHTER
SWITCH PANEL
FUEL CUT-OFF
WIPER MOTOR
BEACON LAMP
AC & HEATER
AC & HEATER
CONVERTOR
SAFETY SOL
ROOM LAMP
WORK LAMP
CABIN LAMP
AC BLOWER
SOLENOID 1
SOLENOID 3
HEAD LAMP
START KEY
CLUSTER
TRAVEL
WIPER+
CPU B+
SPARE
SPARE
CN-46
HORN
CPU
Cause Remedy
NO
Defective wiper Replace
cut switch
YES
Check operation wiring harness or (After clean) CN-9
1
wiper cut switch poor contact 2
between CN-141 3
Front sliding door Check valtage (11)- CS-53 4
open-close 5
between CN-141 YES 6
YES (11) and chassis Defective switch Replace
CN-116 7
panel
NO Check voltage HEAD LIGHT OUT 1 8
Front sliding door-close between CN-116 WORK LIGHT OUT 2
Voltage : 0~1V (6) and chassis WORK LIGHT OUT 3 CN-7
Check operation 1)Recheck fuse Replace WIPER MOTOR DRIVE 4 1
Starting switch : ON NO NO.11 PRE-HEAT 5 2
of switch panel
NO Vottage : 20~30V POWER 24V 6 3
LED ON. 2)Disconnection in Repair or replace CABIN LIGHT OUT 7 4
wiring harness or (After clean) CABIN LIGHT OUT 8 5
Starting switch : ON ⓐ poor contact HEAD LIHGT 24V 9
Push wiper switch button YES 6
between CN- WORK LIGHT 24V 10 7
116(6)-Fuse WORK LIGHT 24V 11 8
WASHER SIG 12 9
between CN- GND 13 10
116(13)-Chassis TRAVEL ALARM 14 11
NO INT. SIG 15 12
Check voltage between Defective switch Replace CABIN LIGHT 24V 16
CN-116(4) and chassis panel CABIN LIGHT 24V 17
Intermittent SWITCH PANEL

NO
1) Recheck fuse Replace
Check voltage CN-116 NO.4
ⓐ (12) and chassis 2) Disconnection Repair or replace
Washing
Check operation in wiring harness (After clean) WIPER
of wiper motor or poor contact CUT SW CN-6
Check voltage CN-116 and controller CN-21 1
between CN- 3 1 2
(15) and chassis check voltage 141(7)-Fuse,
CS-53
YES CN-141(7) and 2 3
Sarting switch : ON CN-21(4)-Fuse 5 3 4
Voltage : 0~1V
chassis, CN-21(4) 4 5
NO 4
and chassis 1) Recheck fuse Replace 5 6
6 M 2 6 7
Starting switch : OFF NO.13
Voltage : 20~30V Check voltage 8
2) Disconnection Repair or replace 9 CN-22
CN-141(6)-and WIPER MOTOR
YES chassis CN-141(6)-Fuse (After clean) 10 2 M
CN-141 11 1
FEED BACK 1
Starting switch : ON ⓑ 2
MOTOR DRIVE SIG CN-17
12 WASHER PUMP
Check continuity YES
Voltage : 20~30V 3 1 CN-5
NO MOTOR DRIVE-
between Disconnection in Repair or replace MOTOR DRIVE+ 4 2 1
CN-141(2)-CN-116(4), wiring harness or (After clean) GND 5 3 2
CN-141(9)-CN-116(12), poor contact VCC 6 4 3
CN-141(10)-CN-116(15), CONTINUE 24V 7 5 4
ⓑ NO WASHER P/P 8 6 5
CN-141(5)-Chassis , Check wiper Defective wiper Replace 9 7 6
WASHER SIG.
CN-141(1)-CN-21(5), motor resistance motor INT. SIG 10 8 7
CN-141(3)-CN-21(6),
YES between CN-21 WIPER CUT SW 11 8
CN-141(4)-CN-21(2), (2)-CN-21(6) Defective wiper Replace N.C 12 9
CN-141(13)-CN-21(3) YES motor controller FEED BACK 13 10
Resistance : 3~4Ω WIPER MOTOR CONTROLLER 11
12
6-38
16. 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 FUSE BOX
21
24
20
23
26
27
25
28
11
13
22
10
14
15
17
19
12
16
18
short of fuse No.14.
9
1
20A
20A
20A
20A
20A
10A
20A
10A
10A
10A
10A
10A
10A
10A
10A
10A
10A
10A
5A
5A
5A
5A
5A
5A
5A
5A
5A
5A
ETHER(PRE-HEAT)
CASSETTE RADIO
FUEL FILLER P/P

CIGAR LIGHTER
SWITCH PANEL
FUEL CUT-OFF
WIPER MOTOR
BEACON LAMP
AC & HEATER
AC & HEATER
CONVERTOR
SAFETY SOL
ROOM LAMP
WORK LAMP
CABIN LAMP
AC BLOWER
SOLENOID 1
SOLENOID 3
Cause Remedy
HEAD LAMP
START KEY
CLUSTER
TRAVEL
NO
WIPER+
CPU B+
SPARE
SPARE
CN-46
Defective lamp Replace switch
HORN
CPU
switch
Check voltage
YES
between CN-116 YES
(1) and (9) Defective bulb Replace
YES
Check voltage
Starting switch : ON between CL-4(2)
Head lamp switch : ON and chassis
Voltage : 20~30V Disconnection in Repair or replace
Starting switch : ON NO
Head lamp switch : ON wiring harness or (After clean)
Check voltage
between CN-7(1)
Voltage : 20~30V poor contact
YES and chassis between CN-7(1)-
CL-4(2)
Head lamp switch : ON
Check voltage Voltage : 20~30V Disconnection in Repair or replace
NO
between CN-116 wiring harness or (After clean)
(9) and chassis
poor contact
Starting switch : ON between CN-4
Head lamp switch : CN-116 CN-7 1
ON-OFF
CN-116(1)-CN- HEAD LIGHT OUT 1 1 2
WORK LIGHT OUT 2 2
7(1) HEAD LAMP
WORK LIGHT OUT 3 3
WIPER MOTOR DRIVE 4 4
YES PRE-HEAT 5 5
POWER 24V 6 6
wiring harness or (After clean) CABIN LIGHT OUT 7 7
CABIN LIGHT OUT 8 8
Check voltage poor contact
HEAD LIHGT 24V 9 9
between CN- between CN-116 WORK LIGHT 24V 10 10
NO 7(7) and chassis
WORK LIGHT 24V 11 11
(9)-CN-7(7)
WASHER SIG 12 12
Head lamp switch : ON GND 13
TRAVEL ALARM 14
Recheck fuse Replace
NO INT. SIG 15
CABIN LIGHT 24V 16
CABIN LIGHT 24V 17
SWITCH PANEL
6-39
17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
short of fuse No.15. FUSE BOX
21
24
20
23
26
27
25
28
11
13
22
10
14
15
17
19
12
16
18
2
9
1
20A
20A
20A
20A
20A
10A
20A
10A
10A
10A
10A
10A
10A
10A
10A
10A
10A
10A
5A
5A
5A
5A
5A
5A
5A
5A
5A
5A
ETHER(PRE-HEAT)
CASSETTE RADIO
Cause Remedy
FUEL FILLER P/P

CIGAR LIGHTER
SWITCH PANEL
FUEL CUT-OFF
WIPER MOTOR
BEACON LAMP
AC & HEATER
AC & HEATER
CONVERTOR
NO
SAFETY SOL
ROOM LAMP
WORK LAMP
CABIN LAMP
AC BLOWER
SOLENOID 1
SOLENOID 3
HEAD LAMP
START KEY
Defective lamp Replace switch
CLUSTER
TRAVEL
WIPER+
CPU B+
SPARE
SPARE
switch
CN-46
HORN
CPU
Check voltage
YES
between CN-116 YES
(10,11) and (2,3) Defective bulb Replace
Check voltage
YES
Starting switch : ON between CL-5(2)
Work lamp switch : ON and chassis CL-6
Voltage : 20~30V Disconnection in Repair or replace 2
Starting switch : ON NO 1
Work lamp switch : ON wiring harness or (After clean)
Check voltage WORK LAMP CN-12
Voltage : 20~30V poor contact 2 1
between CN-7(2) 2
YES and chassis between CN-7(2) 1
CL-5
-CL-5(2) and
Work lamp switch : ON
CL-6 (2)
Check voltage Voltage : 20~30V
between CN-116
(10,11) and Disconnection in Repair or replace
NO
chassis wiring harness or (After clean)
Starting switch : ON poor contact
Work lamp switch :
ON-OFF
between CN-116
Voltage : 20~30V (2,3)-CN-7(2)
CN-116 CN-7
HEAD LIGHT OUT 1 1
YES WORK LIGHT OUT 2 2
Disconnection in Repair or replace WORK LIGHT OUT 3 3
WIPER MOTOR DRIVE 4 4
wiring harness or (After clean) PRE-HEAT 5 5
Check voltage poor contact POWER 24V 6 6
between CN-7(8) between CN-116
CABIN LIGHT OUT 7 7
NO and chassis CABIN LIGHT OUT 8 8
(10,11)-CN-7(8) HEAD LIHGT 24V 9 9
Head lamp switch : ON
Voltage : 20~30V
NO Recheck fuse Replace WASHER SIG 12 12
GND 13
TRAVEL ALARM 14
INT. SIG 15
CABIN LIGHT 24V 16
CABIN LIGHT 24V 17
SWITCH PANEL
6-40
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 : H-mode 2350±50(2250±50)rpm S-mode 2150±50(2100±50)rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted.
※ ( ) : TIER II (#1001 AND UP)
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
YES current at EPPR See TEST 4 EPPR valve
valve
Check if Err : 03
on the cluster SPEC : 200~550mA Defective CPU Replace
See TEST 3 NO
controller
Check resistance
between CN-2(9)-
YES (10)
YES
Short circuit or Check & repair
SPEC : 17.5±1Ω(20°
C)
See TEST 1
poor connection wire harness or
Check resistance between CN-50 - between CN-50-
NO at EPPR valve CN-75 CN-75
SPEC : 17.5±1Ω(20°
C) Defective EPPR Replace
See TEST 2 NO
valve
Wiring diagram CN-92
FUSE Emergency
TIER I(UP TO #1001)
CN-2 NO.9
CN-75 CN-47
2 9 1 1
1 10 2 2
EPPR V/V PROLIX
RESISTOR
CN-50
8 24 Normal
CONTROLLER
TIER II(#1001 AND UP)
6-41
2) TEST PROCEDURE SPEC : 17.5±1Ω(20°C )
(1) Test 1 : Check resistance at connector
CN-2(9)-(10).
① Starting key OFF. CN-2
② Disconnect connector CN-2. 12 10 9 1
③ Check resistance between pin and at

connector CN-2(9)-(10).
Multimeter
(2) Test 2 : Check resistance at connector

SPEC : 17.5±1Ω(20°
C)
CN-75.
① Starting key OFF.
② Disconnect connector CN-75 from EPPR
CN-75
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure.
Multimeter
(3) Test 3 : Check electric current at EPPR valve. SPEC : 200~550mA (S mode)
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(MAX)
④ Set S-mode and cancel auto decel mode.
CN-75
⑤ If tachometer show approx 2150±50
(2100±50)rpm, check electric current.
※( ) : TIER II (#1001-)
EPPR VALVE
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 2150 50 Pressure adjusting
(2100 50)rpm, check pressure. screw locknut
⑥ If pressure is not correct, adjust it.

⑦ After adjust, test the machine.
※( ) : TIER II (#1001-)
6-43
2. ENGINE SPEED IS SLOW AT ALL MODE
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 between CN-51
No good 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
Improper operation Adjust or repair

NO
by loosening or
interference of cable
YES
Short circuit or poor Check and repair
connection
Is resistance
ⓐ between CN-51-
between CD-17
CN-2-CD-17
(1) - (2)
SPEC : 0.2~0.4kΩ
NO
Defective Replace
See TEST 8
speed sensor
Wiring diagram
ACCEL ACTUATOR
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
6-44
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
CN-51
controller.
③ Check resistance as figure.
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. 2350±50 Check rpm after
H-mode
② Check tachometer reading. *2250±50 cancel the Auto decel
2350±50 mode.
S-mode
*2100±50
* TIER II (#1001-)
(3) Test 7 : Check resistance between CN-51 SPEC : 0.2~0.4kΩ

(25) and CN-51(26).
Y R G
② Disconnect connector CN-51 from CPU CPU
CONTROLLER
controller. CN-51
③ Check resistance as figure. CN-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.
Speed sensor
② Disconnect connector CD-17 of speed
sensor at engine flywheel housing.
③ Check resistance as figure.
CD-17 CD-17
1 2
Engine flywheel
Multimeter
6-46
3. ENGINE STALL
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 : 200~550mA
See TEST 9 Check resistance YES
between CN-50 Short circuit or Check and repair
NO (8)-(24) 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 CN-92
TIER I(UP TO #1001) FUSE Emergency
CN-2 NO.9
CN-75 CN-47
2 9 1 1
1 10 2 2
EPPR V/V PROLIX
RESISTOR
CN-50
8 24 Normal
CONTROLLER
TIER II(#1001 AND UP)
6-47
2) TEST PROCEDURE SPEC : 200~550mA
(1) Test 9 : Check electric current at EPPR
valve at S-mode CN-75
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(max)
④ Set S-mode with 2150±50 (2100±50)rpm.
⑤ Check electric current. EPPR VALVE
※( ) : TIER II (#1001-) Multimeter
(2) Test 10 : Check pressure at EPPR valve SPEC : 5~20kgf/cm2(70~280psi)

at S-mode
① Connect pressure gauge at EPPR valve.
② Start engine.
③ Set the accel dial at "10"(max) Supply line, pilot press
④ Set S-mode with 2150±50 (2100±50)rpm.
⑤ Operate bucket lever completely push or CN-75
pull. Pressure adjusting
screw locknut
⑥ Hold arm lever at the end of stroke.
⑦ Check pressure at relief position.
※( ) : TIER II (#1001-)
6-48
4. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
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 : Err
NO
on the cluster
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
POWER IG(24V) 24
GND 28
RX 3 10 29
TX 4 11 30
CN-56 CN-5 CN-50
CN-51
FUSE
NO.9(CPU)
6-49
5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
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-51(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
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

CPU
② Disconnect connector CN-50 from CPU CONTROLLER
controller. CN-50
③ Check resistance between CN-50(12)- CN-51
(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
② Check voltage between CN-51(20) and SPEC : 5±1V

CN-51(21). Y R G
- Prepare 2 pieces of thin sharp pin, steel CPU

or copper. CONTROLLER
PIN
- Starting key ON.
CN-50
- Insert prepared pins to rear side of CN-51
connectors : One pin to CN-51(20)

Other pin to CN-51(21)
- Check voltage.
CN-51
12 1
24 21 20 13
36 25
Multimeter
6-52
6. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
Defective CPU Replace
controller
NO
Check resistance Short circuit or Replace or repair
between CN-51 poor connection
(1)-GND between CN-51(1)
pressure switches
SPEC :
Actuator operating :
4~5V
Actuator stop :0~1V
See TEST 13 Defective auto Replace
NO
decel pressure
switch
Wiring diagram
CONTROLLER
AUTO DECEL
PRESSURE SWITCH
1 Pa
1 2
CD-7
CN-51
6-53
2) TEST PROCEDURE SPEC : Actuator stop : 4~5V
(1) Test 13 : Check voltage at CN-51(1) and Actuator operating : 0~1V
ground. Y R G
① Prepare 1 piece of thin sharp pin, steel or CPU

CONTROLLER
copper. PIN
② Starting key ON. CN-50
CN-51
③ Insert prepared pin to rear side of

connectors : One pin to (1) of CN-51.
④ Check voltage as figure.
CN-51 12 1
24
36 25
Ground
Multimeter
6-54
7. MALFUNCTION OF WARMING UP
Cause Remedy
YES
Defective cluster or Repair or Replace
Check resistance CPU controller or
YES
between CN-51 CD-8(Sensor)
(31) - CD-8(2)
SPEC : Below10Ω NO Poor connection Repair
Check resistance KEY OFF
between CN-
between CN -51
(33) - CD-8(1) 51(31) - CD-8(2)
SPEC : Below 10Ω
KEY OFF
NO
Poor connection Repair
between CN-
51(33) - CD-8(1)
Wiring diagram
CONTROLLER
WATER TEMPERATURE SENSOR

31 6 2 C
33 5 1
CD-8
CN-51 CN-3
6-55
8. MALFUNCTION OF POWER MAX
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
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(1) -GND See Test 16
normal? CS-29 and CN-50
(3) -CN-88(1)
SPEC
KEY ON : 24±1V
KEY OFF : 0V
See TEST 15
NO Short circuit or poor Repair or replace
connection
between CN-88(2)-
battery relay(+)
Wiring diagram
CPU CONTROLLER
POWER MAX SOLENOID
3 1
FUSE
CN-50 2
NO.23
CN-88
POWER MAX SWITCH
1 1
2 2 2
CS-29
CN-51 CN-4
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
(2) Test 16: Check resistance between

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

③ Check resistance as figure. CONTROLLER
CN-51
CN-50
CN-51
12 2
24 13
36 25
Ground
Multimeter
6-57

Section 6 Troubleshooting

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Section 6 Troubleshooting

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SECTION 6 TROUBLESHOOTING

Group 1 Before Troubleshooting 6-1

Troubles occur Electrical part GROUP 3

STEP 1. Study the machine system

STEP 2. Ask the operator

STEP 3. Inspect the machine

STEP 5. Perform troubleshooting

STEP 6. Trace a cause

Make a plan of the appropriate repairing

NO Gear pump is Disassemble

NO Air is intruded. Check suction

2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

4) HYDRAULIC OIL IS CONTAMINATED

YES Pilot relief valve is Disassemble and

Is MCV pilot NO Swing control valve Disassemble and

4) MACHINE SWINGS BUT DOES NOT STOP

NO Return spring of Disassemble

NO Travel control Disassemble

Travel motor is Disassemble

Brake valve is Disassemble

4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE

6) MACHINE RUNS RECKLESSLY ON A SLOPE

YES Is select valve

Select valve is Repair or

Gear pump is Disassemble

NO Control valve spool Disassemble and

Cylinder is faulty. Disassemble

Main relief valve Adjust pressure,

5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE

NO Pilot valve is Disassemble

Boom foot pin Supply grease

2. Disconnect hose(A) from rod side of boom

3. Raise bucket OFF the ground by retracting

If oil leaks from piping side and boom

YES Check voltage

Check voltage Disconnection in Repair or replace

Defective alternator Replace

CN-51 CN-3 CN-74

CONTROLLER WATER TEMPERATURE

CN-51 CN-3 CD-8

CONTROLLER AIR CLEANER SWITCH

CONTROLLER ENGINE OIL PRESSURE SWITCH

CN-51 CN-2 CD-18

Starting switch : OFF NO Defective controller Replace

CONTROLLER HYDRAULIC OIL

Starting switch : OFF NO Defective controller Replace

COOLANT LEVEL SENSOR

Defective cluster Replace

CONTROLLER WATER TEMPERATURE

CN-51 CN-3 CD-8

Defective cluster Replace

Green range Red range Check Table

Cause Remedy CN-60

Voltage : MIN 24V between CS-2(1)- 2 2

FUEL FILLER P/P

Intermittent SWITCH PANEL

FUEL FILLER P/P

FUEL FILLER P/P

1. ALL ACTUATORS SPEED ARE SLOW

Wiring diagram CN-92

③ Check resistance between pin and at

(2) Test 2 : Check resistance at connector