6 1. 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 ---------------------------------------------------------------------------------------- 6-40
SECTION 6 TROUBLESHOOTING
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.
侍 Before carring out troubleshooting procedure, check monitoring menu in the cluster.
Hydraulic &
GROUP 2
Mechanical part
Electrical part GROUP 3
Troubles occur
Mechatronics
part GROUP 4
Fault codes HCESPN 3digit See page

displayed on + FMI 1 or 2 digit
monitor display (machine) 5-24
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.
13031SH02
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
13031SH03
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
(210-7) 6-2(3)
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.
(210-7) 6-3(1)
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.
13031SH05
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.
(210-7) 6-3(3)
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.
刮 Was there any strange thing about machine before failure occurred?
刯 Under what conditions did the failure occur?
到 Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
刮 Check oil and fuel level.
刯 Check for any external leakage of oil from components.
到 Check for loose or damage of wiring and connections.
2) MACHINE 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 3
Note 5 Note 4
Note 6 Note 2
Note 1
Analog
Analog 11 Analog
Analog22 220S6HS01
(2) Specification
No. Description Speciﬁcation
Note 1 Work pilot pressure 40 +20 bar
Note 2 Swing pilot pressure 0~40 bar
Note 3 Boom up pilot pressure 0~40 bar
Note 4 Arm/bucket pilot pressure 0~40 bar
Note 5 Pump 1 regulator pressure 0~50 bar
Note 6 Pump 2 regulator pressure 0~50 bar
Note 7 Pump 1 pressure 350 bar
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 YES
comes out of 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 pilot pump
pressure within 刔
NO standard level?
See Note 1
YES
Clean pilot
Is pilot piping piping interior or
YES clogged or is oil
repair piping.
leakage present
on pilot piping?
RCV and safety Disassemble
NO
solenoid valve is and repair.
刔 faulty.
YES
Pilot relief valve in Repair or
gear pump is replace.
Is gear pump
faulty.
NO delivering oil?
Gear pump is Disassemble

NO
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
Oil cooler clogged. Clean oil cooler.
Bypass check Replace
Is oil cooler clogged
and is bypass check valve is defective.
YES valve always open? YES 刔
Is fan belt
NO tension proper?
Adjust belt
NO tension or
replace belt.
Is not the set
pressure of main YES Readjust set
relief, port relief pressure.
刔 and travel relief
Is main relief
valve lower than
valve used very YES Reduce load.
the standard NO often?
level?
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 intrusion in
suction line?
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
Does safety YES
刔 specified oil to the
YES solenoid valve
standard level.
operation
Is gear pump pilot normal? Safety solenoid Repair or replace.
NO
pressure within valve faulty or not
YES standard level?
Is oil in hydraulic operated.
YES tank within
See Note 1 Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
刔 when dust plug
under engine fly Is main relief NO
Are attachment wheel is removed? NO valve faulty? Hydraulic pump is Disassemble and
and travel out of order. repair.
motions
impossible at all? NO
Does swing Swing control valve Disassemble and
YES
control valve spool is stuck. repair.
Is MCV swing spool move?
YES pilot pressure YES
刕
within standard See Note 5
level?
刖
Is RH travel See Note 2 NO
NO function normal?
Does not symptom
change when front YES
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing parking Disassemble and
brake release valve repair.
Is swing parking is broken.
刕 brake 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 in Disassemble and
NO Is gear pump gear pump is faulty. repair or replace.
delivering oil?
Gear pump is out of Disassemble and
NO
Is gear pump pilot order. repair.
刖 pressure within
standard level? YES
Is there oil Clean pilot piping
See Note 1 interior or repair
leakage from
YES pilot piping or is it piping.
clogged? RCV is broken. Disassemble and
NO
repair.
6-9
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES Does swing spool valve is faulty. repair or replace.
move?
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
See Note 2 Is pilot piping
Single direction clogged or is it piping.
NO leaking oil?
Is the trouble in RCV or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? YES
刔
YES Does swing spool
Both directions move?
YES Is MCV pilot Swing spool is Disassemble
pressure within NO
Is Arm speed See Note 5 stuck. and repair.
standard level?
within standard 刕
value? See Note 2 NO
刖
NO
Is swing motor's NO
刔 drain rate within Swing motor is Disassemble
standard value? broken. and repair.
Check that pilot
YES piping is clogged NO
or oil is leaking RCV or shuttle Disassemble
from it? valve is faulty. and repair.
Clogged or oil leak. Clean pilot piping

Is gear pump pilot interior or repair
刕 pressure within piping.
standard level?
Pilot relief valve
YES
See Note 1 in gear pump is Disassemble and
Is gear pump defective. repair or replace.
NO delivering oil?
NO
broken. and repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief Does the symptom YES Hydraulic pump Disassemble
刖 valve setting change when front
YES is broken. and repair.
pressure normal? and rear pump
discharge hoses
See Note 7
are exchanged? NO Shuttle valve is Repair or replace.
Is MCV pilot faulty.
YES pressure within
standard level? YES
Is gear pump Pilot relief valve Repair or replace.
See Note 2 output pressure is faulty.
NO within standard
level? Gear pump is Repair or replace.
See Note 1
NO
faulty.
6-10
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
Does symptom YES
change when LH Swing port relief Disassemble
YES and RH port valve is faulty. and repair.
relief valves of
swing motor are
exchanged? NO Shuttle valve is Disassemble
YES Does swing control faulty. and repair.
valve spool move?
Is MCV pilot Swing control valve Disassemble

NO
pressure same spool is stuck. and repair.
for LH and RH?
NO
See Note 2
Check if pilot RCV is faulty. Disassemble
piping is clogged and repair.
NO or does have oil
leakage. Clogged or oil
YES leak.
Clean pilot piping
interior or repair
piping.
4) MACHINE SWINGS BUT DOES NOT STOP
Cause Remedy
YES
Pilot relief valve is Disassemble
faulty. and repair or
YES Is MCV pilot YES Is gear pump pilot
pressure within pressure within replace.
standard value? standard level?
See Note 2 See Note 1 Gear pump is Disassemble
NO
broken. and repair.
YES Does swing spool
move?
RCV is faulty. Disassemble
NO
and repair.
Is swing control
valve's return
spring normal? Swing spool is Disassemble
NO
stuck. and repair.
Return spring is Disassemble

NO
faulty. and replace.
6-11
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
YES
刔
YES Is swing shuttle
valve normal?
Shuttle valve is Disassemble
NO
faulty. and replace.
YES Is brake spring
normal?
Is return spring
of swing spool Brake spring is Disassemble
NO
normal? faulty. and replace.
Return spring of Disassemble

NO
swing control and replace.
valve is faulty.
YES
Is drain rate of Swing port relief Disassemble
YES swing motor valve is faulty. and repair or
within standard replace.
Is swing relief value? Swing motor is Disassemble
pressure within NO
刔 broken. and repair.
standard level?
SPEC : 300佳10kgf/cm2 Adjust swing
NO
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 刔
YES counterbalance
spool move lightly
by hand? Counter spool is
Is travel brake Disassemble
NO
YES valve pressure stuck. and repair or
within standard replace.
level? Does the symptom
change when
relief valves in YES
Relief valve built Disassemble
NO travel motor are
Has travel spool exchanged? in travel motor is and repair.
YES
changed over faulty.
positively?
YES Control system is Disassemble
defective. inspect and
Does travel spool
repair.
NO move?
NO
Travel spool is Disassemble
stuck. and repair.
Is bucket or arm
operation YES Travel reduction Disassemble
possible? Do not metallic
unit is faulty. and repair.
particles come
刔 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.
YES
and RH travel 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
YES Has travel spool travel motors are
changed over exchanged? 刔
positively? NO
YES
Control system is Disassemble,
faulty . inspect and
Does spool move? repair.
Is the lower NO
speed (bucket or
arm) within See Note 5, 6 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
travel motor is parking brake is and clean pilot
Is drain rate of removed? not released piping.
刔 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
clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES NO
travel motor
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?
SPEC : 17 kgf/cm2
Brake valve is Disassemble

NO
faulty. and repair or
replace.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE
YES
Cause Remedy
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
disabled is
Is bucket or arm
operation extremely seldom
possible? statistically.
OK
Hydraulic pump is Disassemble
Disassemble both faulty. and repair.
OK travel relief valves
Remove dust and inspect for
plug under engine any fault.
OK flywheel and Travel relief valve Disassemble
check that there is Faulty is faulty. and repair or
no coupling
replace.
element particles.
Check oil volume Particles present. Coupling at pump
in hydraulic oil connection is Disassemble
NO tank. broken. and repair.
Short Replenish
hydraulic oil.
6-15
5) TRAVEL ACTION IS POWERLESS (travel only)
Cause Remedy
YES
刔
Is travel motor's
YES
drain rate within
standard level?
Is travel brake Travel motor is Disassemble
YES NO
pressure within faulty. and repair.
standard level?
Is travel relief
valve pressure Travel brake valve Disassemble
NO
within standard 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
刔 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 straight spool

normal?
Straight spool is Repair or

Is pilot pressure NO
for travel straight faulty. replace.
spool within
standard level? YES
Remove dirt on
signal orifice.
Is signal orifice
YES Is pilot relief NO
NO clogged? Pilot relief valve is Disassemble
valve normal?
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
YES symptom change faulty. and repair or
when port relief replace.
valve is replaced
with other valve? NO 刔
YES Is MCV pilot
pressure within
standard level?
Inspect if pilot
See Note 3, 4 piping is clogged OK
RCV is faulty. Disassemble
NO or oil is leaking
YES Are other from the piping. and repair.
attachments
operatable?
YES
Is gear pump
pilot pressure YES Is gear pump faulty. and repair or
NO within standard delivering oil? replace.
level? Gear pump is Disassemble
See Note 1 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
Main relief valveDisassemble
Faulty
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Coupling at pump Disassemble
Particles present
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.
刔 valve spool
move?
MCV spool is Disassemble
See Note 5, 6 NO
stuck. and repair.
6-18
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other 刔
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO 刕
in composite YES
normal at boom YES
operation? up and at arm Does spool of flow Flow summation Disassemble
extrusion? summation check check valve is and repair.
NO valve move lightly stuck.
Are LH/RH travel by hand?
NO speeds within NO
standard levels?
YES
Hydraulic pump is Disassemble
Are both LH/RH faulty. and repair.
travel speeds YES 刖
NO
low? Is MCV pilot
pressure within
NO
standard? 列
NO
See Note 3, 4
OK
Does the Port relief valve is Disassemble
YES
symptom change faulty. and repair or
when port relief
valve is replaced replace.
Does control with other valve? Cylinder is faulty. Disassemble
YES NO
valve spool and repair.
move ?
See Note 7
NO MCV spool is Disassemble
Is MCV pilot
刔 pressure within stuck. and repair.
standard level?
YES
Is not MCV pilot Clean pilot
See Note 3, 4
pressure piping piping interior or
clogged or is not
NO
there oil repair piping.
leakage? RCV is defective. Disassemble
NO
and repair.
YES
Is pilot pressure NO faulty. and repair or
刕 Is gear pump
within standard
delivering oil? replace.
level?
NO
See Note 1
broken. and repair.
AIs engine NO
刖 revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
列 main control YES
valve clogged? Is pilot piping Clean pilot
clogged or is oil piping interior or
NO leaking from the repair piping.
piping? Is RCV normal? RCV is faulty. Disassemble
NO NO
and 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
relief valve is replace.
YES
replaced with 刔
normal value? 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
hydraulic oil or cause of
equivalent being hydraulic oil
used?
temperature rise
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
inspect load between control
YES
check valve in
MCV and check valve casing and
for any fault. spool is poor.
Is cylinder Contact surface Disassemble
internal leakage Abnormal
刔 between poppet and repair.
within standard
level? and seat is poor.
Cylinder is faulty. Disassemble

NO
and repair.
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
standard level? faulty. repair or replace.
See Note 7
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 defective. and repair or
YES
symptom change
when port relief replace.
YES
valve is replaced Cylinder interior is Disassemble
with other valve? Does control broken. and repair.
valve spool
Is MCV pilot NO move?
YES
pressure within MCV spool is Disassemble
standard level? See Note 5 NO
stuck. and repair.
See Note 4
Is LH travel RCV is faulty. Disassemble

NO
possible? and repair.
Does the YES

Main relief valve Adjust pressure,
symptom change is faulty. repair or
Does the
when main relief
NO valves are symptom change replace.
when hydraulic YES
exchanged? Hydraulic pump is Disassemble
NO pump's discharge
hoses are broken. and repair.
exchanged?
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?
侍 Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. 侍 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
侍 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.
300L6TS01
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
(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.
300L6TS02
6-23
GROUP 3 ELECTRICAL SYSTEM
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
余Before disconnecting the connector, always turn the starting switch OFF.
余Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 8, 10.
余After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage YES
between Disconnection in Repair or replace
CN-56A (2) wiring harness or (after clean)
and (3)
Check voltage poor contact
Starting switch : ON between CN-5
Voltage : 20~32V between
NO (9) and (10)
CN-5-CN-56A
Starting switch : ON
Voltage : 20~32V Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-5 (9)
-GND or fuse No.
8, 10
Check voltage
YES 20~32V
NO 0V
CLUSTER FUSE
BATT (24V) 1 11
No.8
POWER IG (24V) 2 10
FUSE
GND 3 9
No.10
CN-56A CN-5
220S6ES01
6-24
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2)
余Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Check voltage
YES between
CN-56A (6, 7)
and (3) Disconnection in Repair or replace
NO wiring harness or (after clean)
Check voltage Voltage : 2V poor contact
between between CN-56A
CN-5 (5) and (6) (6, 7)-CN-5 (5, 6)
Voltage : 2V Defective MCU Replace
NO Disconnection in Repair or replace
poor contact
between CN-5 (5,
6)- CN-51(22, 32)
Check voltage
YES 2V
NO 0V
CLUSTER
GND 3 9 MCU
CAN 2 HIGH 6 6 22 CAN 2 HIGH
CAN 2 LOW 7 5 32 CAN 2 LOW
CN-51
CN-56A CN-5
300L6ES02
6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON)
Cause Remedy
YES
Defective MCU Replace
YES Check voltage
between CN-52
(27) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or (after clean)
YES Voltage : 20~32V
between CN-2 poor contact
(9) and chassis between CN-52
(27)-CN-2 (9)
Voltage : 20~32V
Check voltage Disconnection in Repair or replace
NO wiring harness or (after clean)
between alternator poor contact
terminal "2" and between CN-2 (9)
chassis -alternator terminal
Engine : Running "2"
Voltage : 20~32V
Defective alternator Replace

NO
Check voltage
YES 20~32V
NO 0V
ALTERNATOR
MCU B+
G
1 P
3~
ALT VOLTAGE 27 9 2 L
U
3 FI
4 NC
CN-74
CN-52 CN-2
220S6ES03
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 (100˚C 佳2˚C ) cooling system
(1,2) is in range
of 120~150凂?
Defective temp Replace
Disconnect CD-8 NO
Does display go sensor
off when
disconnect CD-8?
YES
Starting switch : ON Resistance Short circuit in Repair or replace
Engine : Running between CN-51 wiring harness (after clean)
NO (11) & CN-52
(25) is 0~1凂?
Disconnect CN-51 NO
KEY OFF
Normal type Check Table

Temperature (˚C ) 0 25 50 80 95
Resistance (k凂) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
Premium type
CN-51
GND_MAIN 11
MCU
WATER TEMP SENDER
5 1 C
ENG COOLANT TEMP 25 6 2
CN-3 CD-8
CN-52 220S6ES04
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 YES
CD-10? Short circuit in Repair or replace
Starting switch : ON wiring harness (After clean)
Engine : Start Check resistance
between CD-10-
between CN-51
NO CN-51 (29)
(29) and chassis
Starting switch : OFF
Disconnect CN-53
NO
Check resistance
YES MAX 1凂
NO MIN 1M凂#
MCU AIR CLEANER SWITCH
Pa
AIR CLEANER CLOGGING SW 29
CD-10
CN-51
220S6ES05
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 MCU Replace
Starting switch : ON Check resistance
Engine : Running between CN-51
NO
(27) and chassis
Disconnection in Repair or replace
NO
Disconnect CN-51 wiring harness or (after clean)
poor contact
between
CN-51 (27)-CD-18
Check resistance
YES MAX 1凂
NO MIN 1M凂
MCU ENGINE OIL PRESSURE SWITCH
ENG OIL PS 27 1 Pa
CN-51 CN-1 CD-18
220S6ES06
6-29
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance system
YES between CD-1
(1, 2) is in range
of 164~151凂?
Does display go Starting switch : ON Defective temp Replace
Disconnect CD-1 NO
off when senser
disconnect
CD-1? YES
Short circuit Repair or replace
Starting switch : ON Resistance between temp
Engine : Start between CN-51
senser and MCU
NO (11) and CN-52
(24) is 0~1凂?
Starting switch : OFF NO
Disconnect CN-51
Normal type
Check Table
Temperature (˚C ) ~ -30 ~ -10 ~0 ~ 40 ~ 70 ~ 80 ~ 90 ~ 100 105~
22.22 8.16 5.18 1.06 0.39 0.298 0.219 0.167 0.151
Resistance (k凂)
~31.78 ~10.74 ~ 6.6 ~1.28 ~0.476 ~0.322 ~0.243 ~0.185 ~0.164
Premium type
CN-51 HYDRAULIC OIL

TEMPERATURE SENDER
2 C
GND_MAIN 11 1
CD-1
MCU
HYD OIL TEMP SENDER 24
CN-52 220S6ES08
6-30
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE (HCESPN 304,
FMI 3 or 4)
Cause Remedy
YES
Is resistance poor contact
YES between CN-51
between
(11) and CN-52
CN-51-CD-8
(25) over 2k凂?
Starting switch : OFF YES
Disconnect CN-50 Defective MCU Replace
Does the gauge
Check resistance
light up and
between CN-2
down at lamp NO
(5) and (6)
check? Defective temp Replace
NO
Starting switch : ON See Table
sensor CD-8

NO

Temperature (˚C ) 0 25 50 80 95
Resistance (k凂) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
Premium type
CN-51
GND_MAIN 11
MCU
WATER TEMP SENDER
5 1 C
ENG COOLANT TEMP 25 6 2
CN-3 CD-8
CN-52 220S6ES04
6-31
9. WHEN FUEL GAUGE DOES NOT OPERATE (HCESPN 301, FMI 3 or 4)
Cause Remedy
YES
Defective MCU or Replace
Check resistance cluster
YES between CN-51
(11) and CN-52
(26)
Starting switch : OFF Disconnection in Repair or replace
Check resistance Disconnect CN-51 NO
between fuel Spec : 50~600凂 wiring harness or
sender (1) and poor contact
(2) between fuel
Starting switch : OFF sender-MCU
Spec : 50~600凂
See table
Defective fuel Replace
NO
sender

Range Resistance (凂) Range Resistance (凂)
Full 50 5/12 400
11/12 100 4/12 450
10/12 150 3/12 500
Premium type
9/12 200 2/12 550
8/12 250 1/12 600
7/12 300 Empty warning 700
6/12 350 - -
CN-51
FUEL LEVEL SENDER
GND-MAIN 5 1
CD-2
MCU
FUEL LEVEL SENDER 26
CN-52 220S6ES10
6-32
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No. 25.
Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
Disconnect in Repair or replace
Check voltage wiring harness or (after clean)
between CN-68 poor contact
Check resistance
(1) - (2) YES between CN-4 between
(16) and chassis CN-4-CN-68
Voltage : 20~30V YES
Safety state Starting switch : OFF Disconnect in Repair or replace
Safety state
Spec : 0凂
Disconnect CN-4 Check resistance poor contact
Check voltage
between CS-4 between
between CN-68 NO
NO (A)-(C) CN-4-CS-4
(2) and chassis
Safety lever : OFF Defective safety Replace
Safety switch : ON-0凂
Starting switch : ON NO
Voltage : 20~30V
#############OFF-佹 switch

NO
wiring harness
between CN-68
(2)-fuse No. 25
FUSE
No.25
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2
A C 16 1
CS-4 CN-68
CN-4
220S6ES12
6-33
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6)
short of fuse No. 30.
Cause Remedy
YES
wiring harness or
Check resistance poor contact
YES
between CN-70 between CN-70-
(1) and (2) CN-52
Starting switch : OFF Defective solenoid Replace
Spec : 30凂 NO
YES Check fault code Disconnect CN-70
167 active?
YES
Defective hydraulic Check hydraulic
system system
Check voltage
Check if travel between CN-70
speed lamps( , NO (1) and (2)
) change when
pressing the travel Starting switch : ON Disconnection in Repair or replace
Spec : 20~30 V NO
speed switch on wiring harness or
Disconnect CN-70
the cluster poor contact
between CN-70-
fuse No. 30
YES
Check MCU
Y R G
NO
NO
FUSE
MCU No.30
TRAVEL HIGH SOLENOID
TRAVEL SPEED SOL 3 1
CN-70
CN-52
220S6ES13
6-34
12. WHEN ENGINE DOES NOT START ( lights up condition)
余Check supply of the power at engine stop solenoid while starting switch is ON.
77
R 77
R
余Before carrying out below procedure, check all the related connectors are properly inserted and fuse
GPS CONN.
2
4
3
1
No. 1, 2, 5, 10 and 16 burnt out.
CN-125
2
4
3
1
START SW
Cause Remedy CN-5
YES CS-2A
H0 I
Check voltage Defective ECM or Replace 35 1
YES
0, I
battery 36 2
CN-93 (39) and CS-74
40 3 4
H
chassis 39
BR ACC
4 1
B
2
Disconnection in
CS-74B
5 3
NO
Starting switch : ON wiring harness or
2
1
6
ST C
Spec : 24V between CR-35 5
Check operation (87)-CN-93 (39)
6
No.1
of start motor
YES CR-35
Check voltage Defective magnet Replace No.2
Starting switch : START YES between starter of start motor
No.10
magnet coil and
chassis Defective start relay Replace
NO
Starting switch : START YES No.5
Check operation Spec : 24V 刔 POWER RY
Check voltage
of start relay YES
between CN-1
NO CR-23
(7) and chassis Disconnection in Repair or replace CS-74A
CS-74
NO wiring harness or (after clean) 1
Starting switch : START Starting switch : START
Check operation poor contact
2
Spec : 24V No.16 CN-95
of anti-restart between CN-1 (7)
NO relay CR-5 2
and CR-5 (87) 1 MASTER SW
CN-93 CN-12
YES CIRCUIT BREAKER
Starting switch : ON Check voltage Defective relay Replace
ANTI-RESTART RY 39
15 2
ANTI-RESTART RY 40
between CR-5 1
ANTI-RESTART RY 42 13
NO (85, 86) and 刕 ECM CN-60
12
chassis NO
8 CR-1
Starting switch : ON CN-94 BATTERY
Spec : 24V ANTI-RESTART RY 4
YES
Defective start Replace ANTI-RESTART RY 3
Check voltage ECM EARTH
relay BATT RY
刔 between CR-23
and chassis CN-51 DO-3
Disconnection in Repair or replace ANTI-RESTART RY 2
NO wiring harness or (after clean) 20
1
Starting switch : ON MCU
Spec : 24V poor contact CR-5
DIODE
between CN-1
(7)-CR-23 (2)
YES
Disconnect Repair or replace
Check voltage between CN-51 (after clean)
刕 between CR-5 (20) - CR-5 (85) ANTI-RESTART RY
(86) and chassis CR-36 START MOTOR
CN-1 CR-23
Disconnection in Repair or replace 1
Starting switch : ON 1 5 4
NO wiring harness or (after clean) 2 8 1
Spec : 24V poor contact 3 7 2
No.22
between CS-2 (6) 4
CN-45
2 3 5 START RY
-CR-5 (86)
PRE-HEAT RY
220S6ES14
6-35
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
77
R 77
R
余Before carrying out below procedure, check all the related connectors are properly inserted, master
GPS CONN.
2
4
3
1
switch ON and check open circuit of circuit breaker (CN-60).
CN-125
2
4
3
1
START SW
CN-5
CS-2A
Cause Remedy
H0 I
35 1
YES
0, I
36 2
Disconnection in Repair or replace CS-74
40 3 4
H
wiring harness or (after clean) 39
BR ACC
4 1
B
2
poor contact
CS-74B
5 3
YES Check voltage between DO-3
2
1
6
between DO-3
ST C
5
(2)-CR-1 or defective 6
(2) and chassis battery relay No.1
Voltage : 20~30V No.2 CR-35

YES Check voltage NO wiring harness or (after clean) No.10
between CS-2A
poor contact
(2) and chassis
between CS-2A
Voltage : 20~30V (2)-CN-5 (39)- No.5
POWER RY
Starting switch : ON DO-3 (2)
YES Check voltage Defective start key Replace

between CS-2A NO CS-74A
switch
CS-74
1
(1) and chassis
YES 2
Disconnection in Replace No.16 CN-95
Voltage : 20~30V
wiring harness or 2
poor contact 1 MASTER SW
CN-93 CN-12
between CS-2A ANTI-RESTART RY
CIRCUIT BREAKER
Check voltage 39
between CN-5 (1)-CN-5 (36) ANTI-RESTART RY 40 15 2

1
Check voltage NO YES
ANTI-RESTART RY 42 13
(36) and chassis ECM CN-60
of battery Disconnection in Charge or replace 12
Voltage : 20~30V Check voltage wiring harness or (after clean) 8 CR-1
poor contact CN-94 BATTERY
Voltage : MIN 24V between ANTI-RESTART RY 4
between CS-74B
NO CS-74B (1) and ANTI-RESTART RY 3
chassis (1) -CN-5 (36)
ECM EARTH
BATT RY
Voltage : 20~30V 刔 CN-51 DO-3
NO 2
ANTI-RESTART RY 20
1
MCU
DIODE
Battery Replace CR-5
NO
discharged
YES
Defective master Replace
Check voltage switch
刔 between CS-74B ANTI-RESTART RY
(2)- chassis Disconnection in Charge or replace CR-36 START MOTOR
NO CN-1 CR-23
Voltage : 20~30V wiring harness or (after clean) 1 5 4
1
2 8
poor contact 1
between CS-74B 3
No.22
7 2
4
(2) -CR-1 2 3 5 START RY CN-45
PRE-HEAT RY
220S6ES15
6-36
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
余Before carrying out below procedure, check all the related connectors are properly inserted and fuse No. 7,
13 and 19 is not blown out. CN-21
余After checking, insert the disconnected connectors again immediately unless otherwise specified. 3 1
2
5 3
Cause Remedy
4 4 CN-22
NO CN-5
Defective wiper Replace 5
2 M
cut switch 6 M 2 6
NO 1
Short circuit in Repair or replace WIPER MOTOR WASHER PUMP
Check operation wiring harness or (after clean)
wiper cut switch poor contact DO-5
CN-141
between CN-141 2
FEED BACK 1
Front sliding door
Check valtage (11)- CS-53 1
open-close MOTOR DRIVE SIG 2 CN-17
between CN-141 YES MOTOR DRIVE- 3 1 15
YES (11) and chassis Defective switch Replace FUSE
panel MOTOR DRIVE+ 4 2
NO Check voltage GND 5 3
16
Front sliding door-close between CN-116 No.19
Voltage : 4~5V 6 4 17
(10) and chassis VCC FUSE
Check operation 1)Recheck fuse Replace CONTINUE 24V 7 5 18
Starting switch : ON NO
YES of switch panel No.13 WASHER P/P 8 6 19 No.7
LED ON. Vottage : 20~30V 2)Disconnection in Repair or replace WASHER SIG. 9 7
Starting switch : ON 刔 INT. SIG 10 8
Push wiper switch button YES
poor contact 21
WIPER CUT SW 11
between
CN-376 (1)-Fuse N.C 12
No.13 FEED BACK 13
NO WIPER MOTOR CONTROLLER

Check voltage between Defective switch Replace
CN-116 (4) and chassis panel CS-53
Intermittent
NO 1) Recheck fuse Replace
Check voltage CN-116 No.7
刔
(5) and chassis 2) Disconnection Repair or replace
Washing Check operation in wiring harness (after clean) WIPER CUT SW FUSE
of wiper motor or poor contact
Check voltage CN-116 and controller between No.13
(3) and chassis check voltage CN-141(7)-Fuse
YES CN-141 (7) and
Sarting switch : ON
No.7, CN-21
Voltage : 0~1V
chassis, CN-21 (4)-Fuse No.7
(4) and chassis
NO
Starting switch : OFF 1) Recheck fuse Replace
Voltage : 20~30V No.19
Check voltage 2) Disconnection Repair or replace
CN-376
CN-141 (6) and CN-141(6)-Fuse (after clean)
10
11
12
13
14
15
16
17
18
19
26
27
34
YES chassis
1
2
3
4
5
6
7
8
9
No.19
Starting switch : ON 刕
YES
BEACO LAMP SW
Check continuity Voltage : 20~30V
OVERLOAD SW
NO
TRVEL ALARM
between Disconnection in Repair or replace
WORK LIGHT
CABIN LIGHT
HEAD LIGHT
CAN_LO(2)
INT WIPER
CN-141 (2)-CN-116 (4),
CAN_HI(2)
WASHER
CN-141 (9)-CN-116 (5),
WIPER
poor contact
IG 24V
GND
GND
NC
CN-141 (10)-CN-116 (3),
NC
NC
NC
NC
NC
NC
NC
刕# NO
CN-141 (5)-Chassis , Check wiper Defective wiper Replace
CN-141 (1)-CN-21 (5), motor resistance motor MEMBRANE CONTROLLER
CN-141 (3)-CN-21 (6),
YES between CN-21
CN-141 (4)-CN-21 (2), (2)-CN-21 (6) Defective wiper Replace
CN-141 (13)-CN-21 (3) YES motor controller
Resistance : 3~4凂
220S6ES16
6-37
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
short of fuse No.13 and 20.
FUSE
Cause Remedy
YES No.20
Defective bulb Replace
Check voltage FUSE
YES between CL-4
CR-13
(1), CL-3 (2), No.13 30 30 86
CL-24 (2) and Disconnection in Repair or replace 86
chassis NO
Voltage : 20~30V poor contact 85
Check voltage between CR-13 87a
87a 87 85
YES
between CR-13 (87)-CL-4 (1) or
HEAD LAMP RY
(87) and chassis CR-13 (87)-CL-3
(2) CL-4
Head lamp switch : ON YES 2
Defective switch Replace
Voltage : 20~30V 1
panel
Check voltage Check voltage
between CR-13 HEAD LAMP
CN-376
between CN-376
10
11
12
13
14
15
16
17
18
19
26
27
34
(30) and chassis, NO
1
2
3
4
5
6
7
8
9
CR-13 (86) and (13) and chassis CL-24
chassis Disconnection in Repair or replace 1
Starting switch : ON NO wiring harness or (after clean)
BEACO LAMP SW
Starting switch : ON Head lamp switch : ON 2
OVERLOAD SW
TRVEL ALARM
Voltage : 20~30V poor contact
WORK LIGHT
Voltage : 20~30V
CABIN LIGHT
HEAD LIGHT
CAN_LO(2)
INT WIPER
between CN-376 HEAD LAMP-REAR
CAN_HI(2)
WASHER
(13)-CR-13 (85)
WIPER
IG 24V
CL-3
GND
GND
NC
NC
NC
NC
NC
NC
NC
NC
Disconnection in Repair or replace 1
NO wiring harness or (after clean) MEMBRANE CONTROLLER 2
poor contact
HEAD LAMP
between CR-13
(30) and fuse
No.20 or CR-13
(86) - fuse No.20
Recheck fuse Replace

No. 20
220S6ES17
6-38
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
short of fuse 13 and 17.
Cause Remedy
YES FUSE
Defective bulb Replace
No.17
YES
Check voltage
between CL-5 (2)
and chassis
FUSE
NO No.13 CR-4
poor contact 30 30 86
between CR-4 86
YES Check voltage
between CR-4 (87)-CL-5 (2) 87
(87) and chassis 85

87a 87 85
87a
Starting switch : ON WORK LAMP RY
Work lamp switch : ON
Voltage : 20~30V YES CL-5
Defective switch Replace CN-12
panel 1 1
Check voltage Check voltage
between CR-4 between CN-376 2 2
(30) and chassis, NO
(4) and chassis
CR-4 (86) chassis WORK LAMP
Starting switch : ON Starting switch : ON Disconnection in Repair or replace
Voltage : 20~30V Work lamp switch : ON NO wiring harness or (after clean) 1
Voltage : 20~30V poor contact 2
between CR-4
(85)-CN-376 (4) CL-6
CN-376
10
11
12
13
14
15
16
17
18
19
26
27
34
1
2
3
4
5
6
7
8
9
BEACO LAMP SW
NO
OVERLOAD SW
TRVEL ALARM
WORK LIGHT
CABIN LIGHT
poor contact
HEAD LIGHT
CAN_LO(2)
INT WIPER
CAN_HI(2)
WASHER
between CR-4
WIPER
IG 24V
(30) and fuse
GND
GND
NC
NC
NC
NC
NC
NC
NC
NC
No.17 or CR-4
(86) and fuse
MEMBRANE CONTROLLER
No.17
Recheck fuse Replace

No.17
220S6ES18
6-39
GROUP 4 MECHATRONICS SYSTEM
1. ALL ACTUATORS SPEED ARE SLOW

侍 Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
侍 Spec : P-mode 1900 佳 50 rpm S -mode 1800 佳 50 rpm E-mode 1700 佳 50 rpm
侍 Before carrying out below procedure, check all the related connectors are properly inserted and
fault code on the cluster.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO Check electric Defective Replace
current at EPPR SPEC : 2~25 kgf/cm2
NO
EPPR valve
valve See TEST 3
SPEC : 100~700 mA
See TEST 2
Check if HCESPN NO
140 active fault
display on the LCD YES
Short circuit or Check & repair
poor connection wire harness or
between CN-52 between CN-52
Check resistance
YES at EPPR valve -CN-75 -CN-75
SPEC : 15~25凂(20佘C) Defective EPPR Replace

See TEST 1 NO
valve
Wiring diagram
MCU
FUSE
EPPR POWER 24V 8
No.12
PUMP SHIFT EPPR - 19
PUMP SHIFT EPPR + 9 PUMP EPPR VALVE
13 2
GROUND (EPPR) 18
14 1
CN-52 CN-1 CN-75
220S6MS01
6-40
2) TEST PROCEDURE SPEC : 15~25凂(20˚C)
(1) Test 1 : Check resistance at connector CN-75
CN-75.
Multimeter
刮 Starting key OFF.
刯 Disconnect connector CN-75 from EPPR
valve at main hydraulic pump. EPPR valve
到 Check resistance between 2 lines as
figure.
Main pump
220S5MS20
(2) Test 2 : Check electric current at EPPR Spec : 100~700 mA

valve.
Adapter(P/no.:21Q6-50410)
刮 Disconnect connector CN-75 from EPPR
valve. CN-75
Multimeter
刯 Insert the adapter to CN-75 and install
multimeter as figure.
到 Start engine.
刱 Set S-mode and cancel auto decel EPPR valve
mode.
刲 Position the accel dial at 10.
刳 If tachometer show approx 1800佳50 rpm
disconnect one wire harness from EPPR
Main pump
valve.
刴 Check electric current at bucket circuit
relief position. 220S5MS21
(3) Test 3 : Check pressure at EPPR valve. Spec : 2~25 kgf/cm2 (30~350 psi)
刮 Remove plug and connect pressure Pressure adjusting
screw locknut
gauge as figure.
余Gauge capacity : 0 to 50 kgf/cm2 CN-75
(0 to 725 psi)
刯 Start engine. EPPR valve
到 Set S-mode and cancel auto decel

mode.
刱 Position the accel dial at 10.
刲 If tachometer show approx 1800佳50 rpm
check pressure at relief position of bucket
circuit by operating bucket control lever.
刳 If pressure is not correct, adjust it.
Main pump
刴 After adjust, test the machine. 220S5MS22
6-41
2. ENGINE STALL
侍 Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Not enough Check engine
engine power fault
YES Check pressure Contact cummins
at EPPR valve
SPEC:2~25 kgf/cm2 Defective EPPR Replace

See TEST 5 NO
Check electric valve
current at EPPR
valve
YES
Short circuit or Check and repair
SPEC : 100~700 mA poor connection wire harness
See TEST 4
Check resistance between
between CN-52 - CN-75
NO at EPPR valve
SPEC : 15~25凂(20˚C)
See TEST 1
NO
Defective EPPR Replace
valve
Wiring diagram
MCU
FUSE
EPPR POWER 24V 8
No.12
PUMP SHIFT EPPR - 19
PUMP SHIFT EPPR + 9 PUMP EPPR VALVE
13 2
GROUND (EPPR) 18
14 1
CN-52 CN-1 CN-75
220S6MS01
6-42
2) TEST PROCEDURE Spec : 100~700 mA Adapter(P/no.:21Q6-50410)
(1) Test 4 : Check electric current at EPPR CN-75
valve. Multimeter
刮 Disconnect connector CN-75 from EPPR
valve.
刯 Insert the adapter to CN-75 and install EPPR valve
multimeter as figure.
到 Start engine.
刱 Set S-mode and cancel auto decel
mode.
Main pump
刲 Position the accel dial at 10.
刳 If rpm show approx 1800佳50 rpm
disconnect one wire harness from EPPR 220S5MS21
valve.
刴 Check electric current at bucket circuit
relief position.
(2) Test 5 : Check pressure at EPPR valve. SPEC : 2~25 kgf/cm2 (30~350 psi) Pressure adjusting
刮 Remove plug and connect pressure screw locknut
gauge as figure.
余Gauge capacity : 0 to 50 kgf/cm2 CN-75
(0 to 725 psi) EPPR valve

刯 Start engine.
到 Set S-mode and cancel auto decel
mode.
刱 Position the accel dial at 10.
刲 If rpm show approx 1800佳50 rpm check
pressure at relief position of bucket
circuit by operating bucket control lever.
刳 If pressure is not correct, adjust it. Main pump
220S5MS22
刴 After adjust, test the machine.
6-43
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse No.3
See if all lamps the MCU
YES off in the MCU
case YES
Y R G MCU failure Replace
Y R G
See if HCESPN
840 active fault NO
display on the LCD
NO Y R G
刔
NO
OK
Check connection Cluster failure Replace
between CN-51
刔 (22) - CN-56A (6)
or CN-51 (32) -
CN-56A (7) No connection Check and repair
NO
Starting switch OFF
Wiring diagram
BATT.24V
IG 24V MCU
GND
CAN1 HI
CAN1 LO
CAN2 HI 6 6 22 CAN #2 Hi
CAN2 LO 7 5 32 CAN #2 Lo
RS-232 RX
RS-232 TX CN-56A CN-5 1 BATT POWER 24V
AUX LEFT
CN-51
AUX RIGHT
AUX GND FUSE
CLUSTER No.3
220S6MS02
6-44
4. AUTO DECEL SYSTEM DOES NOT WORK
余 Fault code : HCESPN 105, FMI 0~4 (work pressure sensor)
HCESPN 108, FMI 0~4 (travel oil pressure sensor)
Cause Remedy
YES
YES
Defective travel Replace
Check voltage
NO pressure switch
between CD-6
(A) and (C)
Short circuit or poor Replace or repair
NO
Check voltage SPEC : 24佳2V connection
between CN-52 Starting switch ON between CN-51
(38)-GND and (3)-CD-6 (A) and /
CN-52 (37)-GND or CN-51 (13)-
CD-6 (C) (fault
SPEC : 1~5
Actuator operating
code 108
See TEST 7, 8 displayed)
YES
Defective work Replace
Check voltage pressure sensor
between CD-7
NO (A) and (C)
Short circuit or poor Replace or repair
NO connection
SPEC : 24佳2V
Starting switch ON between CN-51
(3)-CD-7 (A) and /
or CN-51 (13)-
CD-7 (C) (fault
code 105
Wiring diagram displayed)
CN-51
CD-6
SENSOR 24V 3 A SUPPLY
B SIG
GROUND (SENSOR) 13 C RETURN
TRAVEL PRESSURE SENSOR
MCU
TRAVEL PILOT PRESSURE 38 CD-7

A SUPPLY
WORKING PILOT PRESSURE 37 B SIG
C RETURN
CN-52 WORK PRESSURE SENSOR
220S6MS03
6-45
2) TEST PROCEDURE SPEC : Actuator operating : 1~5 V
(1) Test 7 : Check voltage at CN-52 (38) and
ground.
刮 Prepare 1 piece of thin sharp pin, steel or MCU
copper.
PIN
刯 Insert prepared pin to rear side of CN-51 CN-52
connectors : One pin to (38) of CN-52.

到 Starting switch key ON.
刱 Check voltage as figure.
ground.
刮 Prepare 1 piece of thin sharp pin, steel or 10 9 8 7 6 5 4 3 2 1
copper CN-52
20 11 Female
刯 Insert prepared pin to rear side of 30
38
21
connectors : One pin to (37) of CN-52. 40 39 38 37 36 34 33 32 31
到 Starting switch ON. GROUND

Multimeter
10 9 8 7 6 5 4 3 2 1
CN-52
20 11 Female
30 21
37
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
300L6MS04
6-46
5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR
余 Fault code : HCESPN 120, FMI 0~4
Cause Remedy
YES
YES
Short circuit or Replace or repair
poor connection
YES Check voltage between CN-52-
between CN-2
(4)-GND (29)-CN-2 (4)
Check voltage SPEC : 1~5V Detective P1 Replace or repair
between CN-52 Actuator operating NO
(29) - GND YES between CD-42 Short circuit or Replace or repair
SPEC : 1~5V (A)-(C) poor connection
Actuator operating between CN-2
See TEST 9 SPEC : 24佳2V
Starting switch ON (4)-CD-42 (B)
Check voltage Short circuit or Replace or repair

NO
between CN-2 poor connection
NO (1)-(2) between CD-42
(A)-CN-2 (2) or
SPEC : 24佳2V
Starting switch ON
CD-42 (C)-CN-2
(1)

NO poor connection
between CN-2
(2)-CN-51 (3) or
CN-2 (1) - CN-51
(13)
Wiring diagram
CN-51
CD-42
SENSOR 24V 3 2 A SUPPLY
4 B SIG
GROUND (SENSOR) 13 1 C RETURN
PUMP 1 PRESSURE SENSOR
MCU CN-2
P1 PRESSURE SENSOR 29
CN-52
220S6MS05
6-47
ground.
刮 Prepare 1 piece of thin sharp pin, steel or
copper.
MCU
刯 Insert prepared pin to rear side of
connectors : One pin to (29) of CN-52. PIN
CN-51 CN-52
到 Starting switch ON.
10 9 8 7 6 5 4 3 2 1
CN-52
20
29
11 Female
30 21
40 39 38 37 36 34 33 32 31
GROUND
Multimeter
300L6MS06
6-48
Cause Remedy
YES
YES
poor connection
between CN-2
(3)-GND (30)-CN-2 (3)
Start switch ON (3)-CD-43 (B)

NO
(A)-CN-2 (2) or
SPEC : 24佳2V
Starting switch ON
CD-43 (C)-CN-2
(1)

NO poor connection
between CN-2
(2)-CN-51 (3) or
CN-2 (1) - CN-51
(13)
Wiring diagram
CN-51
CD-43
3 B SIG
MCU CN-2
P2 PRESSURE SENSOR 30
CN-52
220S6MS07
6-49
(1) Test 10 : Check voltage at CN-52 (30)
and ground.
copper.
MCU
CN-51 CN-52
10 9 8 7 6 5 4 3 2 1
20 11 CN-52
30 21
30 Female
40 39 38 37 36 34 33 32 31
GROUND
Multimeter
220S6MS08
6-50
Cause Remedy
YES
YES
poor connection
between CN-2
(5)-GND (32)-CN-2 (5)

NO
(A)-CN-2 (2) or
SPEC : 24佳2V
Starting switch ON
CD-44 (C)-CN-2
(1)

NO poor connection
between CN-2
(2)-CN-51 (3) or
CN-2 (1) - CN-51
(13)
Wiring diagram
CN-51
CD-44
5 B SIG
MCU CN-2
PUMP EPPR 2ND PS SENSOR 32
CN-52
220S6MS09
6-51
and ground.
copper.
MCU
PIN
CN-51 CN-52
10 9 8 7 6 5 4 3 2 1
CN-52
20 11 Female
30 21
32
40 39 38 37 36 34 33 32 31
GROUND
Multimeter
300L6MS10
6-52
8. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR
Cause Remedy
YES
YES
poor connection
between CN-2
(6)-GND (39)-CN-2 (6)
Check voltage SPEC : 1~5V Detective N1 Replace or repair

NO
(A)-CN-2 (2) or
SPEC : 24佳2V
Starting switch ON
CD-70 (C)-CN-2
(1)

NO poor connection
between CN-2
(2)-CN-51 (3) or
CN-2 (1) - CN-51
(13)
Wiring diagram
CN-51
CD-70
N1 PILOT PRESSURE 39 6 B SIG
NEGATIVE 1 PRESSURE SENSOR
MCU CN-2
220S6MS11
6-53
and ground.
copper.
刯 Insert prepared pin to rear side of MCU
到 Starting switch ON. CN-51 CN-52
10 9 8 7 6 5 4 3 2 1
CN-52
20 11 Female
30 21
39
40 39 38 37 36 34 33 32 31
GROUND
Multimeter
220S6MS12
6-54
9. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR
Cause Remedy
YES
YES
poor connection
between CN-2
(7)-GND (40)-CN-2 (7)
Check voltage SPEC : 1~5V Detective N2 Replace or repair

NO
(A)-CN-2 (2) or
SPEC : 24佳2V
Starting switch ON
CD-44 (C)-CN-2
(1)

NO poor connection
between CN-2
(2)-CN-51 (3) or
CN-2 (1) - CN-51
(13)
Wiring diagram
CN-51
CD-71
N2 PILOT PRESSURE 40 7 B SIG
NEGATIVE 2 PRESSURE SENSOR
MCU CN-2
220S6MS13
6-55
and ground.
copper.
MCU
PIN
connectors : One pin to (40) of CN-52. CN-51 CN-52
10 9 8 7 6 5 4 3 2 1
CN-52
20 11 Female
30 21
40
40 39 38 37 36 34 33 32 31
GROUND
Multimeter
220S6MS14
6-56
10. MALFUNCTION OF SWING PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective swing Replace or repair
(36) - GND pressure sensor
SPEC : 1~5V Short circuit or Replace or repair
Actuator operating Check voltage poor connection
See TEST 14 between CD-24 between CN-52
NO (A)-(C) (36)-CD-24 (B)
SPEC : 24佳2V
Starting switch ON
NO
poor connection
between CD-24
(A)-CN-51 (3) or
CD-24 (C)- CN-51
(13)
Wiring diagram
CN-51
CD-24
B SIG
SWING PRESSURE SENSOR
MCU
SWING PILOT PRESSURE 36
CN-52
220S6MS15
6-57
and ground.
copper.
CN-51 CN-52
10 9 8 7 6 5 4 3 2 1
CN-52
20 11 Female
30 21
36
40 39 38 37 36 34 33 32 31
GROUND
Multimeter
300L6MS16
6-58
11. MALFUNCTION OF ARM IN/OUT & BUCKET IN PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective arm in/ Replace or repair
(28) - GND out & bucket in
SPEC : 1~5V pressure sensor
Actuator operating Check voltage Short circuit or Replace or repair
See TEST 15 between CD-35 poor connection
NO (A)-(C) between CN-52
(35)-CD-35 (B)
SPEC : 24佳2V
Starting switch ON
NO
poor connection
between CD-35
(A)-CN-51 (3) or
CD-35 (C)- CN-51
(13)
Wiring diagram
CN-51
CD-35
B SIG
ARM IN/OUT & BUCKET IN
PRESSURE SENSOR
MCU
ARM IN/OUT BUCKET IN PS 28
CN-52
220S6MS17
6-59
and ground.
copper.
PIN
到 Starting key ON. CN-51 CN-52
10 9 8 7 6 5 4 3 2 1
CN-52
20 11 Female
30 21
28
40 39 38 37 36 34 33 32 31
GROUND
Multimeter
220S6MS18
6-60
12. MALFUNCTION OF BOOM UP PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective boom up Replace or repair
NO (A)-(B) (35)-CD-32 (B)
SPEC : 24佳2V
Starting switch ON
NO
poor connection
between CD-32
(A)-CN-51 (3) or
CD-32 (C)- CN-51
(13)
Wiring diagram
CN-51
CD-32
B SIG
BOOM UP PRESSURE SENSOR
MCU
BOOM UP PILOT PRESSURE 35
CN-52
220S6MS19
6-61
and ground.
copper.
10 9 8 7 6 5 4 3 2 1
CN-52
20 11 Female
30 21
35
40 39 38 37 36 34 33 32 31
GROUND
Multimeter
220S6MS20
6-62
13. MALFUNCTION OF BOOM DOWN PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective boom up Replace or repair
NO (A)-(B) (34)-CD-85 (B)
SPEC : 24佳2V
Starting switch ON
NO
poor connection
between CD-85
(A)-CN-51 (3) or
CD-85 (C)- CN-51
(13)
Wiring diagram
CN-51 CD-85
B SIG
BOOM DOWN PRESSURE SENSOR
MCU
BOOM DOWN PILOT PRESSURE 34
CN-52 220S6MS25
6-63
and ground.
copper.
PIN
10 9 8 7 6 5 4 3 2 1
CN-52
20 11 Female
30 21
34
40 39 38 37 36 34 33 32 31
GROUND
Multimeter
220S6MS26
6-64
14. MALFUNCTION OF POWER MAX
余 Fault code : HCESPN 166, FMI 4 or 6
Cause Remedy
YES
Short circuit or poor Repair or replace
connection between
YES Check resistance CN-88 (1)-CN-52
between CN-88 (2)
(1)-(2)
YES Check resistance SPEC: 15-35凂 Defective power Repair or replace
between CN-51 See TEST 19
NO
max. solenoid valve
(18)-(11)
Check hydraulic
system
SPEC
Is voltage between Power max button
CN-88 (2)-GND pressed ON : 0凂 Short circuit or poor Repair or replace
NO
normal? pressed OFF : 佹凂 connection between
CN-51 (18)-CS-29
SPEC
Starting switch (1)
ON : 24 佳#1V
OFF : OV Short circuit or poor Repair or replace
NO
connection between
CN-88 (2)-
Fuse No. 30
Wiring diagram
CN-52
CN-88
POWER BOOST SOL 2 1
2
MCU
POWER MAX SOLENOID
POWER BOOST SW 18 5
FUSE
GROUND MAIN 11 6
No.30
CN-51 CN-4
CS-29
1
2
POWER MAX SWITCH
220S6MS21
6-65
2) TEST PROCEDURE SPEC : Starting switch ON : 24佳1V
Starting switch OFF : 0V
(1) Test 18: Check voltage between connector
CN-88 (2) - GND.
刮 Disconnect connector CN-88 from power
max solenoid valve.
刯 Start switch ON. Power max switch
到 Check voltage as figure.
LH RCV-lever
CN-88
Power max
solenoid valve
2 1
1 2
Ground
Multimeter
140L6MS123
(2) Test 19: Check resistance of the solenoid SPEC : 15~35凂

valve between CN-88 (1)-(2).
刮 Starting switch OFF.
Power max switch
刯 Disconnect connector CN-88 from power
max solenoid valve.
到 Check resistance as figure.
LH RCV-lever
CN-88
Power max 2 1
solenoid valve
1 2
Multimeter
140L6MS124
6-66
15. MALFUNCTION OF BOOM PRIORITY EPPR VALVE
余 Fault code : HCESPN 141, FMI 5 or 6
Cause Remedy
YES
Short circuit or poor Repair or replace
connection between
CN-52 (17)-CN-133
Check resistance (1) or CN-52 (7)-CN-
between CN-133 133 (2)
(1)-(2)
SPEC : 20~30V
Defective EPPR Repair or replace
NO
valve
Wiring diagram
MCU
BOOM PRIORITY EPPR (-) 17
CN-133
BOOM PRIORITY EPPR (+) 7 2
BOOM PRIORITY
EPPR VALVE
CN-52
220S6MS23
6-67

6 1. Troubleshooting

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6 1. Troubleshooting

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SECTION 6 TROUBLESHOOTING

Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1

Electrical part GROUP 3

Fault codes HCESPN 3digit See page

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

Do not hydraulic Abnormal noise

Gear pump is Disassemble

2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

4) HYDRAULIC OIL IS CONTAMINATED

Clogged or oil leak. Clean pilot piping

Is MCV pilot Swing control valve Disassemble

4) MACHINE SWINGS BUT DOES NOT STOP

Return spring is Disassemble

Return spring of 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 straight spool

Straight spool is Repair or

Gear pump is Disassemble

Cylinder is faulty. Disassemble

5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE

Is LH travel RCV is faulty. Disassemble

Does the YES

Boom foot pin Supply grease

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

3. Raise bucket OFF the ground by retracting

Defective alternator Replace

Normal type Check Table

MCU AIR CLEANER SWITCH

MCU ENGINE OIL PRESSURE SWITCH

CN-51 CN-1 CD-18

CN-51 HYDRAULIC OIL

HYD OIL TEMP SENDER 24

Defective cluster Replace

Normal type Check Table

Normal type Check Table

FUEL LEVEL SENDER 26

Disconnection in Repair or replace

TRAVEL HIGH SOLENOID

TRAVEL SPEED SOL 3 1

YES Check voltage between DO-3

Voltage : 20~30V No.2 CR-35

YES Check voltage Defective start key Replace

between CN-5 (1)-CN-5 (36) ANTI-RESTART RY 40 15 2

NO WIPER MOTOR CONTROLLER

Recheck fuse Replace

(87) and chassis 85

Recheck fuse Replace

1. ALL ACTUATORS SPEED ARE SLOW

SPEC : 15~25凂(20佘C) Defective EPPR Replace

PUMP SHIFT EPPR + 9 PUMP EPPR VALVE

CN-52 CN-1 CN-75

(2) Test 2 : Check electric current at EPPR Spec : 100~700 mA

到 Set S-mode and cancel auto decel

SPEC:2~25 kgf/cm2 Defective EPPR Replace

PUMP SHIFT EPPR + 9 PUMP EPPR VALVE

CN-52 CN-1 CN-75