Group 3 Mechatronics System: 1. All Speed Are Slow
Group 3 Mechatronics System: 1. All Speed Are Slow
Group 3 Mechatronics System: 1. All Speed Are Slow
Wiring diagram
2
1
CN-47
Ɠ Normal :
PROLIX S.W Emergency :
6
5
4
9 3
8 2
6 1
CN-50 CS-7
11 1
EPPR V/V
2
CN-75
CN-51 CN-2
6-38
2) TEST PROCEDURE
SPEC : 24 Ţ 1Ѥ(20ŭ)
(1) Test 1 : Check resistance value (6)-(8) at
connector CN-50.
CN-50
ڡStarting key OFF. CPU 1 2 3 4 5
CONTROLLER
ڢRemove CPU controller and disconnect 6 7 8 9 10
CN53 CN52 CN51 CN-50
connector CN-50.
ڣCheck resistance value between pin No. 6
and No. 8 at connector CN-50.
Multimeter
Multimeter
ڡStart engine.
ڢSet S-mode and cancel auto decel mode.
ڣIf tachometer show approx 2350+50rpm, CN-75
6-39
(4) Test 4 : Check pressure at EPPR valve.
ڡRemove plug and connect pressure gauge SPEC : 4~15ָ/ֲ(58~220 psi)
as Fig.
Gauge capacity : 0 to 40~50ָ/ֲ
(0 to 580~730 psi)
ڢStart engine. Supply line, pilot press
6-40
2. ENGINE SPEED IS SLOW AT ALL MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
If test 7 is good
Check tachometer Check TEST 1~4
YES work properly or Check resistance
not by changing YES
value between Misalignment Clean speed
the mode.
Check resistance CN-52(14) - CN- between speed sensor and adjust.
YES value between SEE : TEST 6
51(12) sensor and fly wheel SEE: 5-8page
NO
CN-50(2) - (3)
SPEC:0.2~0.4ך ڞ
and (4) - (5)
SEE : TEST 7 NO
SPEC:5~6י
SEE : TEST 5 NO Defective governor Replace governor
Check linkage
between governor motor or short circuit motor or harness.
motor - injection or poor connection assembly.
pump. between CN-50 -
CN-2 and CN-2 -
CN-76
NO
Improper operation Adjust or repair.
by loosening or inter-
ference of linkage.
YES
Short circuit or poor Check and repair.
Check resistance connection between
ڞ value between
CN-51(12) - CD-17(2) or
CD-17(1) - (2)
CN-52(14) - CD-17(1)
NO
Defective Replace.
SPEC:0.2~0.4ך
SEE : TEST 8 speed sensor.
Wiring diagram
2
1 Ɠ Mnql`k9
CN-47 Dldqfdmbx9
5 PROLIX S.W
4 6
3 5
2 4
9 3
8 2
6 1
CN-50 CS-7
11 1
12
2 EPPR V/V
10
CN-51 CN-2 CN-75 SPEED SENSOR
24 2
23 1
14 CD-17
CN-52 5 1
4 2 POT(POTENTIOMETER)
3 3
7
6 CN-77
9 1
10 2 A
11 3 A-
12 4 B
CN-2 B-
CN-76 GOVERNOR MOTOR
6-41
2) TEST PROCEDURE
CN-50 CN-50
1 2 3 4 5 1 2 3 4 5
6 7 8 9 10 6 7 8 9 10
Multimeter Multimeter
(3) Test 7 : Check resistance value between (14) SPEC : 0.2 ~ 0.4 ך
of CN-52 and (12) of CN-51.
CPU
ڡStarting key OFF. CONTROLLER
ڢRemove CPU controller and disconnect CN53 CN52 CN51 CN-50
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18
Multimeter
6-42
(4) Test 8 : Check resistance value at speed
SPEC : 0.2 - 0.4 ך
sensor.
Engine flywheel
Multimeter
6-43
3. ENGINE STALL
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Not enough Contact cummins
Check pressure engine power. engine dealer.
YES at EPPR valve.
Defective EPPR Replace.
SPEC:36~39 ָ/ֲ NO valve.
Check electric
SEE:TEST 10
current value at YES
EPPR valve. Defective CPU Replace.
controller.
SPEC:650~680 mA
SEE:TEST 9 Check resistance
YES
value between Short circuit or Check and
NO
CN-50(6) - (8) poor connection repair.
Check resistance between
SPEC:24Ţ1Ѥ(20ŭ)
SEE : TEST 1 value at EPPR CN-50 - CN-2 or
NO
valve. CN-50 - CN-75
SPEC:24Ţ1Ѥ(20ŭ)
SEE : TEST 2 Defective EPPR Replace.
NO
valve.
Wiring diagram
Ɠ Mnql`k9
2
1 Dldqfdmbx9
CN-47
PROLIX S.W
6
5
4
9 3
8 2
6 1
CN-50 CS-7
11 1
EPPR V/V
2
CN-75
CN-51 CN-2
6-44
2) TEST PROCEDURE SPEC : 650~680mA
(1) Test 9 : Check electric current value at
EPPR valve at F-mode CD-75
ڡStart engine.
ڢSet F-mode with 1750 +50rpm
ڣInstall multimeter as below.
ڤCheck electric current value at bucket
EPPER VALVE
circuit relief position. Multimeter
6-45
4. CLUSTER LAMPS ARE OFF IMMEDIATELY AFTER KEY SWITCH OFF
Ɠ Before carrying out below procedure, check all the related connector are properly inserted.
Normal condition : Lamps "ON" approx. 3-12 second after key switch OFF.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective Replace.
CPU controller.
Check voltage at
CN-50(10) YES
Poor connection Check and repair.
or short circuit
SPEC:24Ţ1 VOLT Check between
SEE : TEST 11
Fuse No. 17 CN-50(10) - CN-
NO
60(2)
SEE : TEST 12
Defective fuse. Replace.
NO
Wiring diagram
FUSE BOX
BATTERY
10 1 17 2 2 2
CN-40 CN-5 CN-60
CN-39
CN-50
6-46
2) TEST PROCEDURE
SPEC : 24 Ţ 1Volt
(1) Test 11 : Check voltage at (10) of CN-50. CN-50
CPU
ڡStarting key OFF. 1 2 3 4 5
CONTROLLER 6 7 8 9 10
ڢDisconnect connector CN-50 from CPU CN51 CN-50
CN53 CN52
controller.
Multimeter
20A
10A
ڡStarting key OFF.
12
1
CONTROLLER WASHER
20A
20A
CLUSTER
2
13
SOL. B+
20A
20A
3
WORK LAMP
14
RADIO
CIGAR &
20A
20A
15
SPARE
4
ڣCheck if the fuse is defective or not.
ETHER SOL.
20A
10A
16
5
CLOCK B+ SAFETY
MONITOR &
20A
20A
17
6
HEAD LAMP
CPU B+
F/PUMP &
10A
10A
18
ROOM LAMP
7
T/ALARM
AIR-CON
30A
20A
SPARE
8
BREAKER
30A
30A
SPARE
9
CABIN LIGHT
10A
30A
10
SPARE SPARE
10A
SPARE
11
FUSE
20A
12
PULLER SPARE
SPEC : 20A
6-47
5. CLUSTER LAMPS ARE STILL ON AFTER STARTING KEY OFF
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES Improper operation Check and
of governor motor. repair.
Check interference So, governor motor
of connecting rod supply signal to
YES when governor
cluster pannel
motor move to low
continuously.
rpm side.
YES
SPEC : Check operating Defective battery Replace.
Key ON : 24Ţ1 VOLT status of main relay.
Key OFF : 0 VOLT
SEE : TEST 13 power supply at
NO
CN-50(9).
NO
Defective CPU Replace.
SPEC :
Key ON : 24Ţ1 VOLT
controller
Key OFF : 0 VOLT
SEE : TEST 14
Wiring diagram
FUSE BOX
9 3 4 3 START
12
4 IGNITION
6-48
2) TEST PROCEDURE
Multimeter
Multimeter
6-49
6. CLUSTER LAMPS ARE ON WHEN ENGINE RUN OR MALFUNCTION OF MODE
SELECTION SYSTEM
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES Defective lamps or Repair or Replace
Check voltage for cluster
YES
between CN-50(7)
- CN-57(5).
Check resistance SPEC : 24Ţ1V
Defective CPU Replace.
NO
value for switches. SEE : TEST 16 controller.
Poor connection Check and repair.
SPEC : between CN-50 -
Switch ON : 0י CN-57.
Switch OFF : Ũי
SEE : TEST 15 NO Defective switch at Replace.
cluster.
Wiring diagram
8 9
7
CN-56 CN-7
1
2
9
8
5
7 7
CN-51
1 1
2 2
9 9
8 8
5 5 7
CN-57 CN-8
CN-50
6-50
2) TEST PROCEDURE
CN-50
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Ground
Multimeter
(2) Test 16 : Check voltage for CN-50, CN-57 SPEC : 24Ţ1 Volt
ňCN-50:output power(24Ţ1volt)
ňCN-57:input power(24Ţ1volt) CN-50
CPU 1 2 3 4 5
ڡStarting key ON. CONTROLLER 6 7 8 9 10
ڢRemove cluster from pannel. CN53 CN52 CN51
CN-50
ż Don't disconnect connector CN-50 from
CPU controller. Ground
Fig.
CN-57
1 2 3 4 5 6
7 8 9 10 11 12
Ground
Multimeter
6-51
7. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
Slow action of Check and repair.
YES
engine speed control
due to interference.
Wiring diagram
2
3
4
5
CN-50
5 1
4 2 POT(POTENTIOMETER)
10 3 3
CN-50
CN-50
12 4 B-
11 3 B
10 2 A-
24 9 1 A
23
CN-50 CN-50 GOVERNOR MOTOR
CN-50
6-52
2) TEST PROCEDURE Test - a
Multimeter
Test - b
CN-50
CPU
1 2 3 4 5
CONTROLLER
6 7 8 9 10
CN53 CN52 CN51 CN-50
Multimeter
6-53
(2) Test 18 : Check voltage and resistance value.
SPEC : 0 ~ 5
Check resistance value between (23) of
CN-52 and (10) of CN-51. CPU
CONTROLLER
Starting key OFF. CN53 CN52 CN51 CN-50
Disconnect connector CN-52 and CN-51
from CPU controller.
Check resistance value with multimeter as
below.
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18
Multimeter
Multimeter
6-54
8. AUTO IDLE SYSTEM DOES NOT WORK
Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective CPU Replace.
controller.
Short circuit or poor Replace or repair.
Check resistance
YES value between CN- connection between
51(3) - GND. CN-51(3) - (4)
SPEC :
Check resistance Neutral : 0
value CN-51(4) - Operated : Defective pressure Replace.
NO
GND.
switch.
SPEC :
Switch ON : 0
Switch OFF :
SEE : TEST 19 NO
Defective cluster. Replace.
Wiring diagram
8 8
AUTO DECEL. PRESS. SWITCH
3
4
CN-7 5 CD-7 CD-6
CN-56
6
7
8
9
7 7
1 1 CN-51
2 2
9 9
8 8
5 5 7
CN-57 CN-8
CN-50
6-55
2) TEST PROCEDURE
CN-50
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Ground
Multimeter
6-56
9. MALFUNCTION OF WARMING UP
Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES Defective cluster or Repair or
Check resistance CPU controller or Replace.
YES value between CN-
CD8(sensor)
57(3) - CD-8
Check resistance Poor connection Repair.
value between CN- SPEC : 0 NO
SEE : TEST 21 betweenCN-57(3) -
51(20) - CN-56(16)
CD-8.
SPEC : 0
SEE : TEST 20 Poor connection Repair.
NO
between CN-52(20)
- CN-56(16).
Wiring diagram
CN-56
3 6
CN-1
CN-57
6-57
2) TEST PROCEDURE
9 10111213141516
1 2 3 4 5 6 7 8
CN-52
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
Multimeter
12 11 10 9 8 7
6 5 4 3 2 1
Starting key OFF.
Remove cluster and disconnect CN-57 from
cluster.
Disconnect connector CD-8 of water temp
sensor at engine head. Cluster
Multimeter
6-58
10. MALFUNCTION OF OVERHEAT
Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective overheat Replace
switch
Check resistance
value between CD- YES
9 - GND. Defective CPU Replace
Check resistance controller
SPEC : value between CN-
Region NO 51(1) - CD-9
(Fig.) 0
SPEC : 0 Short circuit or poor Check or Repair
NO
SEE : TEST 22 SEE : TEST 23 connection between
CN-51(1) - CD-9.
coolant
temperature
110℃
Time
Region Ⅰ Region Ⅱ Region Ⅲ
Temperature curve
Wiring diagram
Overheat switch
1 3
CD-9
CN-51 CN-1
15 3
CN-56
CN-56
6-59
2) TEST PROCEDURE
Ground
Multimeter
CD-9
Overtheat switch
Multimeter
6-60
11. MALFUNCTION OF POWER MAX
Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Check only to H,S Defective power Replace
YES mode resistance max. sol. valve.
value between
CN-51(15) - CN-
88(1) and CN-51(2)
Check voltage - GND. NO Short circuit or poor Repair
between CN-88(2) - connection between
SPEC : 0 and power max button ON : 0
GND.
power max button OFF : CN-51(15) - CN-
SEE : TEST 25 88(1) and CS-29 -
SPEC : 24 1V
CN-51(2).
SEE : TEST 24
NO Short circuit or poor Repair
connection between
CN-88(2) - battery
relay(+).
Wiring diagram
CS-29
BATTERY
FUSE BOX
2 2 1 1 1
CN-36 CN-40 CN-5 CN-60 BATTERY RELAY
CN-88
2
1
2 8 POWER MAX.
2 2
15 1 SOLENOID VALVE
CN-51 CN-3 2
1
6-61
2) TEST PROCEDURE
Multimeter
(2) Test 25 : Check resistance value between Spec : 0 and power max. button ON : 0
connector (15) of CN-51-(1) of CN- power max. button OFF :
88 and GND-(2) of CN-51.
Power max. switch
Starting key OFF.
Remove CPU controller and disconnect
connector CN-51 from CPU controller. LH lever
Disconnect connector CN-88 from power
CN-51
max. solenoid valve. CPU
1 2 3 4 5 6 7 8 9
Check resistance value as Fig. CONTROLLER
10 11 12 13 14 15 16 17 18
CN53 CN52 CN51 CN-50
Multimeter
CN-88
Power max.
solenoid valve
CN-88
6-62