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95Z7B

93215-00730

SHOP MANUAL Operational Performance Test Troubleshooting

Printed in Japan (K) （アメリカ用）

93215-00730

January 2017

SHOP MANUAL WHEEL LOADER

95Z7B Operational Performance Test Troubleshooting

93215-00730

4 OPERATIONAL SECTION AND GROUP SECTION PERFORMANCE TEST CONTENTS Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Machine Performance Test SHOP MANUAL (Troubleshooting)

Group 5 Component Test Group 6 Adjustment

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 e-Service Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Air Conditioner

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

MEMO

INTRODUCTION To The Reader This manual is written for trained and skilled technicians to provide technical information needed to maintain and repair this machine.  Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References Please refer to the other materials (Operation and Maintenance Manual, parts catalog, engine technical material and Kawasaki Shop Manual, etc.) in addition to this manual.

Manual Composition  Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assembly / disassembly procedures.

This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.  Information included in the Technical Manual: Technical information needed for machine pre-delivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

 Information included in the Engine Manual: Technical information needed for machine pre-delivery and delivery and maintenance and repair of the engine, operation and activation of all devices and systems, troubleshooting and assembly / disassembly procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Shop Manual: T 1-3-5 T 1 3 5

 Workshop Manual: W 1-3-2-5 W 1 3 2 5

Technical Manual Section Number Group Number Consecutive Page Number for Each Group

IN-01

Workshop Manual (disassembly and reassembly) Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury or machine damage.

d CAUTION:

Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

d This is the safety alert symbol. When you see this

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

f NOTE:

Indicates supplementary technical information.

Units Used Example: 24.5 MPa (250 kgf/cm2, 3560 psi)

SI Units (International System of Units) are used in this manual. MKSA (Meter, Kilogram, Second, Ampere) system units and English units are also indicated in parentheses just behind SI units.

A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

0.03937

0.003281

Volume

US gal

0.2642

US qt

1.057

L 3

1.308

Weight

2.205

Force

kgf

0.10197

lbf

0.2248

N·m

kgf·m

Torque Pressure

0.10197 2

MPa

kgf/cm

10.197

MPa

psi

145.0

1.360

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

-1

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Power

Flow rate

fNOTE: The numerical value in this manual might be different from the above-mentioned table.

IN-02

Symbol and Abbreviation Symbol and Abbreviation Symbol / Abbreviation S/M T/C T/M MC

Name

Explanation

Shop Manual Torque Converter Transmission Main Controller

ECM

Engine Control Module

DCU

Dozing Control Unit

VGS VGT

Variable Geometry System controller Variable Geometry Turbo

CAN

Controller Area Network

A/C HVAC OP, OPT MPDr.

Air Conditioner Heating, Ventilation, and Air Conditioning Option Maintenance Pro Dr.

Shop Manual Torque Converter Transmission Main controller. MC controls the engine, pump, and valve according to the machine operating condition. Engine controller. ECM controls fuel injection amount according to the machine operating condition. DCU is the central control for the diesel exhaust fluid dosing system and handles the dosing activity, tank level sensing and tank temperature sensing. Variable turbo controller. VGS is an exhaust turbo charged system to supercharge the exhaust energy while running the engine at slow idle speed. VGS optimizes the turbine rotation, improves the performance at slow-speed torque and the acceleration, reduces fuel consumption, and reduces particulate matter (PM) by adjusting the nozzle opening of turbine housing. CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization). Air conditioner.

A/I, A/S ATT

Auto Idling-Stop Attachment

Optional component. MPDr. is software that troubleshooting, monitoring, and adjustment. Auto idling-stop function Front attachment, such as bucket

SY-1

Symbol and Abbreviation Symbol / Name Abbreviation SCR Selective Catalytic Reduction

DEF

Diesel Exhaust Fluid

DOC

Diesel Oxidation Catalyst

Particulate Matter

NOx

Oxides of Nitrogen

EGR

Exhaust Gas Recirculation

Explanation SCR technology is designed to permit NOx reduction reactions to take place in an oxidizing atmosphere. It is called "selective" because it reduces levels of NOx using ammonia as a reductant within a catalyst system (see DEF). DEF is a fluid that can have a slight ammonia smell, used with selective catalytic reduction (SCR) systems to convert NOx into nitrogen, small amount of CO2 and water. DEF is also commonly referred to as AdBlue™. Oxidation catalyst for the diesel engine. Diesel oxidation catalyst oxidizes unburned fuel and raises exhaust temperature. Particulate matter (PM) is a regulated diesel emission composed primarily of carbon soot and other combustion by-products. Oxides of nitrogen are a regulated gaseous emission which is a collective term for emissions composed of nitrogen and oxygen, which form when fuel is burned at high temperatures. The EGR control re-circulates a part of exhaust gas in the intake manifold and combines it with intake-air. Therefore, combustion temperature is lowered and generation of nitrogen oxides (NOx) is controlled.

SY-2

SECTION 4

OPERATIONAL PERFORMANCE TEST CONTENTS

Group 1 Introduction Operational Performance Tests...................................... T4-1-1 Preparation for Performance Tests ............................... T4-1-2

Group 2 Standard Operational Performance Standard Table ................. T4-2-1 Sensor Activating Range ................................................T4-2-10

Group 3 Engine Test Engine Speed ....................................................................... T4-3-1

Group 4 Machine Performance Test Travel Speed ......................................................................... T4-4-1 Service Brake Function Check ........................................ T4-4-4 Service Brake Wear Amount............................................ T4-4-6 Parking Brake Function Check ....................................... T4-4-7 Bucket Stopper, Lever (Bell Crank) Stopper Clearance .......................................................................... T4-4-8 Hydraulic Cylinder Cycle Time ......................................T4-4-10 Cylinder Drift Check .........................................................T4-4-12 Bucket Levelness ...............................................................T4-4-13 Control Lever Operating Force.....................................T4-4-14 Control Lever Stroke ........................................................T4-4-16

Group 5 Component Test Primary Pilot Pressure (Unloader Valve Setting Pressure) ........................... T4-5-1 Secondary Pilot Pressure .................................................. T4-5-3 Solenoid Valve Set Pressure ............................................ T4-5-4 Parallel/Tandem Switching Solenoid Valve .......... T4-5-4 Auto Brake Solenoid Valve ......................................... T4-5-5 Solenoid Valve Adjustment Procedure .................. T4-5-6 Main Pump Delivery Pressure......................................... T4-5-7 Loading Circuit Main Relief Set Pressure .................... T4-5-8 Main Relief Valve Pressure Adjustment Procedure .................................................................... T4-5-9 Steering Circuit Main Relief Set Pressure..................T4-5-10 Steering Relief Valve Pressure Adjustment Procedure ..................................................................T4-5-11 Steering Circuit Pilot Pressure ......................................T4-5-12 Loading/Steering Overload Relief Valve Set Pressure......................................................................T4-5-13 Service Brake Pressure (Front and Rear) ...................T4-5-16 Parking Brake Pressure ....................................................T4-5-18 Brake Accumulator Pressure ........................................T4-5-20 Accumulator Pressure ................................................T4-5-21 Number of Brake Pedal Applications ...................T4-5-21 Accumulator Charge Time........................................T4-5-21 Brake Warning Pressure (Pressure-Decreasing) .....T4-5-22 Brake Warning Pressure (Pressure-Increasing) .......T4-5-24 Transmission Clutch Pressure .......................................T4-5-26 Transmission Clutch Pack Combination ..............T4-5-27 Torque Converter Pressure ............................................T4-5-28

Group 6 Adjustment Rewrite of Aftertreatment Device Serial No. ............. T4-6-1

95Z7B Performance Test

(Blank)

95Z7B Performance Test

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Operational Performance Tests Use operational performance test procedure to quantitatively check all system and functions on the machine.

The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours.

Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values.

Definition of “Performance Standard”

2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.

1. Operation speed values and dimensions of the new machine.

3. To economically operate the machine under optimal conditions.

2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.

Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, and hydraulic cylinders. 2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves. Performance Standards “Performance Standard” is shown in tables to evaluate the performance test data. Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are. 2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions.

T4-1-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Preparation for Performance Tests Observe the following rules in order to carry out performance tests accurately and safely. THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. TEST AREA and TOOL 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 200 m (656 ft 2 in), and to make the steering operate. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. 4. Prepare the measuring instruments and tools. Use MPDr. if possible. PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail. 2. Operate the machine carefully and always give first priority to safety. 3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings. T105-06-01-003

4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings. MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance to obtain correct data. 2. Carry out tests under the exact test conditions prescribed for each test item. 3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

T4-1-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard The following switch positions shall be selected and the hydraulic oil temperature shall be maintained as indicated below as the preconditions of performance tests unless otherwise instructed in each performance test procedure:  Accelerator Pedal: Fully Applied  Power Mode Switch: ON  Hydraulic Oil Temperature: 55±5°C (131±9 °F)

Operational Performance Standard Table The standard Performance values are listed in the table below. Refer to the Group T4-3 to T4-5 for performance test procedures. Values indicated in parentheses are reference values. Performance Test Designation

Unit

Performance Standard

*Engine Speed Low Idle Speed (without load) High Idle Speed (without load) High Idle Speed (with torque converter stalled) High Idle Speed (with torque converter stalled and relieved) *Engine Speed Low Idle Speed (without load) High Idle Speed (without load) High Idle Speed (with torque converter stalled) High Idle Speed (with torque converter stalled and relieved) Engine Compression Pressure

min-1

MPa (kgf/cm2) (psi)

2.94 (30.0) (426)

Valve Clearance (In, Ex)

mm (in)

0.4 (0.0157)

850±50 1950±50 1700±100 1540±100

850±50 1950±50 1875±100 1540±100

Remarks

Power mode switch: OFF Value indicated on MPDr. Value indicated on MPDr. Second- speed forward, Value indicated on MPDr. Third- speed forward, Value indicated on MPDr. Power mode switch: ON T4-3-1 Value indicated on MPDr. Value indicated on MPDr. Second- speed forward, Value indicated on MPDr. Third- speed forward, Value indicated on MPDr. Engine speed: 200 min-1 Refer to Coolant temperature: 20°C Engine Manual (68°F) With the engine cold Refer to Engine Manual

fNOTE: *Engine speed should be tested under the following conditions. Refer to Group 3 Engine Test. Coolant temperature: 80°C (176°F) or higher Torque converter oil temperature: 60~80°C (140~176°F) Hydraulic oil temperature: 50°C (122°F) or higher Axle oil temperature: 60°C (140°F) or higher Fan revolution speed: Max. Parking brake: Applied (ON) Forward/Reverse Lever and Switch: Forward (F)

T4-2-1

Reference Page T4-3-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

*Travel Speed First Speed Second Speed Third Speed Fourth Speed (Forward Only) *Travel Speed First Speed Second Speed Third Speed Fourth Speed (Forward Only) Service Brake Function Check

km/h (mph)

Service Brake Wear Amount Brake Disc Brake Ring (t=7.0) Parking Brake Function Check Parking Brake Wear Amount Brake Disc Brake Plate Bucket Stopper Clearance Bell Crank (Lever) Stopper Clearance Front Pin Wear Amount Front Bushing Wear Amount Clearance Between Front Pin and Bushing

Performance Standard 6±1 (3.7±0.6) 11±1 (6.8±0.6) 19±2 (11.8±1.2) 35±4 (21.7±2.5)

km/h (mph)

m (yd)

6±1 (3.7±0.6) 11±1 (6.8±0.6) 19±2 (11.8±1.2) 35±4 (21.7±2.5) 12 (13) or less

mm (in)

mm (in)/5 min mm (in)

mm (in) mm (in) mm (in) mm (in) mm (in)

7.2 (0.28) 7.0 (0.27) 0 7.4 (0.291) 5.0 (0.197) 5±2 (0.2±0.08) 0 0.3 (0.01)

Remarks

Reference Page T4-4-1

Power mode switch: OFF Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Power mode switch: ON T4-4-1 Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Machine speed: 35±3 km/h T4-4-4 (21.7±1.9 mph) T4-4-6 Allowable limit: 6.1 (0.24) Allowable limit: 6.4 (0.25) T4-4-7 Allowable limit: 7.2 (0.283) Allowable limit: 4.8 (0.189) T4-4-8 T4-4-8 Allowable limit: -1.0 (-0.04) Allowable limit: -1.5 (-0.06) -

fNOTE: *Travel speed should be tested under the following conditions. Refer to Group 4 Machine Performance Test. Coolant temperature: 80°C (176°F) or higher Torque converter oil temperature: 60~80°C (140~176°F) Hydraulic oil temperature: 50°C (122°F) or higher Axle oil temperature: 60°C (140°F) or higher Fan revolution speed: Max.

T4-2-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Hydraulic Cylinder Cycle Time Lift Arm Raise Lift Arm Lower (Float) Bucket Dump Steering (engine: low idle speed) Steering (engine: high idle speed) Hydraulic Cylinder Cycle Time Lift Arm Raise Lift Arm Lower (Float) Bucket Dump Steering (engine: low idle speed) Steering (engine: high idle speed) Cylinder Drift Check Lift Arm Cylinder Bucket Cylinder Bucket Levelness

sec

Performance Standard

Remarks Power mode switch: OFF

Reference Page T4-4-10

6.8±0.3 4.5±0.3 1.2±0.3 3.6±0.3 3.0±0.4 sec 5.8±0.3 4.5±0.3 1.2±0.3 3.6±0.3 3.0±0.4 mm (in)/min

mm (in)

Power mode switch: ON Parking brake switch: ON Shift lever position: N

T4-4-10

T4-4-12 3 (0.12) or less 4 (0.16) or less 10 (0.4) or less

T4-2-3

T4-4-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Control Lever Operating Force Lift Arm Raise Lift Arm Raise (Detent) Lift Arm Raise (Detent Release) Lift Arm Lower Lift Arm Lower (Float) Lift Arm Lower (Float Release) Bucket Control Lever Roll Back Bucket Control Lever Roll Back (Detent) Bucket Control Lever Roll Back (Detent Release) Bucket Control Lever Dump Steering Forward/Reverse Lever

N (kgf ) (lbf )

Accelerator Pedal Brake Pedal (Right) Declutch Pedal (Left)

Performance Standard Remarks Two-lever 10 (1.0) (2.3) or less 16 (1.6) (3.6) or less 36 (3.6) (8.1) or less 10 (1.0) (2.3) or less 16 (1.6) (3.6) or less 36 (3.6) (8.1) or less 11 (1.1) (2.5) or less 16 (1.6) (3.6) or less 36 (3.6) (8.1) or less 16 (1.6) (3.6) or less 19.6 (2.0) (4.4) or less 12+3/-2 (1.2+0.3/-0.2) (2.7+0.7/-0.4) 40±2 (4.0±0.2) (9.0±0.4) 319+60/-40 (32.5+6.1/-4.1) (71.7+13.5/-9.0) 299+60/-40 (30.5+6.1/-4.1) (67.2+13.5/-9.0)

T4-2-4

Reference Page T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

N (kgf ) (lbf )

Accelerator Pedal Brake Pedal (Right) Declutch Pedal (Left)

Performance Standard

Remarks MF (Joystick type) lever

20 (2.0) (4.5) or less 40 (4.0) (9.0)or less 50 (5.0) (11.2) or less 20 (2.0) (4.5) or less 40 (4.0) (9.0) or less 50 (5.0) (11.2) or less 20 (2.0) (4.5) or less 40 (4.0) (9.0) or less 50 (5.0) (11.2) or less 30 (3.0) (6.7) or less 16 (1.6) (3.6) or less 12+3/-2 (1.2+0.3/-0.2) (2.7+0.7/-0.4) 40±2 (4.0±0.2) (9.0±0.4) 319+60/-40 (32.5+6.1/-4.1) (71.7+13.5/-9.0) 299+60/-40 (30.5+6.1/-4.1) (67.2+13.5/-9.0)

fNOTE: MF: Multi-Function

T4-2-5

Reference Page T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Control Lever Stroke Lift Arm Raise Lift Arm Raise (Detent) Lift Arm Lower Lift Arm Lower (Float) Bucket Control Lever Roll Back Bucket Control Lever Roll Back (Detent) Bucket Control Lever Dump Steering Wheel Rotation (Right Max. to Left Max.) Forward/Reverse Lever Steering Wheel Play Brake Pedal Application

mm (in)

Performance Standard

Remarks Two-lever

Reference Page T4-4-16

MF (Joystick type) lever

T4-4-16

42±5 (1.7±0.2) 65±5 (2.6±0.2) 32±5 (1.3±0.2) 55±5 (2.2±0.2) 42±5 (1.7±0.2) 65±5 (2.6±0.2) 55±5 (2.2±0.2) 4 to 5 (0.16 to 0.20) 50±5 (2.0±0.2) 5 to 15 (0.2 to 0.6) 41.7 to 51.7 (1.64 to 2.04) 58±10 (2.3±0.4) 79±10 (3.1±0.4) 58±10 (2.3±0.4) 79±10 (3.1±0.4) 58±10 (2.3±0.4) 79±10 (3.1±0.4) 79±10 (3.1±0.4) 4 to 5 (0.16 to 0.20) 50±5 (1.7±0.2) 5 to 15 (0.2 to 0.6) 41.7 to 51.7 (1.64 to 2.04)

fNOTE: MF: Multi-Function

T4-2-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Pedal Depressing Angle Accelerator Pedal Brake Pedal (Right) Declutch Pedal (Left) Electrolyte Density (Specification at 20°C (68°F)) Tire Inflation

deg.

Bias Tire Radial Tire

Performance Standard Remarks (without play) 18±1 20.6±0.5 17±0.5 1.28

Reference Page T4-4-16

kPa (kgf/cm2) (psi)

Front: 539 (5.5) (78) Rear: 441 (4.5) (64) Front: 490 (5.0) (71) Rear: 392 (4.0) (57)

T4-2-7

29.5-25-28PR 29.5R25

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Unloader Valve Setting Pressure (engine: low idle speed) Cut-out Pressure

MPa (kgf/cm2) (psi)

Cut-in Pressure Secondary Pilot Pressure Solenoid Valve Set Pressure

MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi)

Parallel/Tandem Switching Solenoid Valve Auto Brake Solenoid Valve Main Pump Delivery Pressure Loading Circuit Main Relief Set Pressure Relief Operation of Lift Arm

MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi)

Relief Operation of Bucket Steering Circuit Main Relief Set Pressure Steering Accumulator N2 Charging Pressure Steering Circuit Pilot Pressure Overload Relief Valve Set Pressure

MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi)

Lift Arm Lower Bucket Steering Service Brake Pressure (Front/Rear) Parking Brake Pressure

MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi)

Performance Standard

Remarks

11.8±0.5 (120±5) (1711±73) 6.9±0.5 (70±5) (1000±73) 3.5±0.5 (36±5) (508±73)

Reference Page T4-5-1

T4-5-3 T4-5-4

3.5±0.2 (36±2) (508±29) 0.63±0.1 (6.4±1) (91.4±15) 4.0+1.0/-0.5 (41+10/-5) (580+145/-73)

In neutral, Value indicated on MPDr.

T4-5-7 T4-5-8

31.4±0.5 (320±5) (4554±73) 31.4±0.5 (320±5) (4554±73) 27.4±0.5 (279±5) (3974±73) 5.0 (51) (725)

Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr.

3.5±0.5 (36±5) (508±73)

T4-5-12 Reference values at 50 L/ min

37.3±0.5 (380±5) (5410±73) 37.3±0.5 (380±5) (5410±73) 32.5±0.5 (331±5) (4714±73) 4.08±0.3 (41.6±3.1) (592±43.5) 3.0 to 3.7 (31 to 38) (435 to 537)

T4-2-8

T4-5-10

T4-5-13

T4-5-16 T4-5-18

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation Service Brake Accumulator Pressure Accumulator Pressure

Unit

Performance Standard

MPa (kgf/cm2) (psi) sec

11.8±0.5 (120±5) (1711±73) 15 or less at least 3 times

Accumulator Charge Time Number of Brake Pedal Applications Accumulator N2 Charging Pressure MPa (kgf/cm2) (psi) Brake Warning Pressure MPa (kgf/cm2) (psi) (Pressure-Decreasing) Brake Warning Pressure MPa (kgf/cm2) (psi) (Pressure-Increasing) Transmission Clutch Pressure MPa (kgf/cm2) (psi) 1st, Lock-up, H R, 2nd, 3rd, L Torque Converter Pressure Input Pressure Output Pressure

2.94±0.1 (30±1) (426±14) 3.9±0.5 (40±5) (566±73) 4.4±0.5 (45±5) (638±73)

Remarks

Reference Page T4-5-20

T4-5-22 T4-5-24 T4-5-26

2.3 to 2.7 (23.5 to 27.5) (336 to 392) 2.5 to 3.0 (25.5 to 30.6) (363 to 435)

MPa (kgf/cm2) (psi)

T4-5-28 0.8±0.1 (8±1) (116±14.5) 0.6±0.1 (6±1) (87±14.5)

T4-2-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Sensor Activating Range 1. Checking Method  Hydraulic Oil Temperature: 55±5 °C (131±9 °F)  Unless specified: Engine Speed High Idle Speed

Power Mode Switch ON

 Monitor each sensor by using MPDr.

2. Sensor Activating Range Item Pump Delivery Pressure

Operation Neutral Relieved

MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi)

Implement Pressure

Neutral Implement Lever: Relieved

MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi)

Parking Brake Pressure

Parking Brake Switch: ON Parking Brake Switch: OFF Brake Pedal: Neutral Brake Pedal: Fully Depressed

MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi) MPa (kgf/cm2) (psi)

Service Brake Pressure

T4-2-10

Specification 3.5 to 5.0 (36 to 51) (508 to 725) 30.9 to 31.9 (315 to 325) (4482 to 4627) 3.5 to 5.0 (36 to 51) (508 to 725) 30.9 to 31.9 (315 to 325) (4482 to 4627) 0 to 1.7 (0 to 17.3) (0 to 247) 2.0 to 3.7 (20.4 to 37.7) (290 to 537) 0 to 0.1 (0 to 1) (0 to 14.5) 3.8 to 4.4 (38.7 to 44.9) (551 to 638)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Engine Speed Summary: 1. Measure the engine speed by using the monitor unit or MPDr. 2. Measure the engine speeds in each mode.

fNOTE: If the engine speed is not adjusted correctly, all

other performance data will be unreliable. Consequently, measure the engine speed before performing all other tests in order to check that the engine speed meets specification.

Preparation: 1. Select the service menu of monitor (In case of using MPDr., install MPDr. first). 2. Warm up the machine until the following conditions are all satisied:  Coolant temperature is 80 °C (176 °F) or higher  Axle oil temperature 60 °C (140 °F) or higher  Hydraulic oil temperature 50 °C (122 °F) or higher  Transmission oil temperature falls within 60°C (140°F) to 80 °C (176 °F)

T4-3-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Measurement: 1. Measure the items as shown in the table below. 2. When measuring, set the switch and test condition as shown in the table below in response to the engine speed to be measured.

Forward/Reverse Lever, Shift Switch N

Accelerator Pedal

Parking Brake Switch Power Mode Switch

No depression

ON/OFF

Second speed/third speed forward Second speed forward

Full stroke

ON/OFF

Full stroke

OFF

ON/OFF

Third speed forward

Full stroke

OFF

ON/OFF

Declutch Position Switch OFF

Brake Pedal

High Idle Speed (with no load)

OFF

Full stroke

High Idle Speed (with torque converter stalled) High Idle Speed (with torque converter stalled and relieved)

OFF

Full stroke

OFF

Full stroke

Control Lever (Bucket) Transporting position, No control lever operation Transporting position, No control lever operation Transporting position, No control lever operation Transporting position, Bucket is rolled back and relieved.

Control Lever (Lift Arm (Boom)) Transporting position, No control lever operation Transporting position, No control lever operation Transporting position, No control lever operation In horizontal position or raised higher

Low Idle Speed (with no load) High Idle Speed (with no load) High Idle Speed (with torque converter stalled) High Idle Speed (with torque converter stalled and relieved)

Low Idle Speed (with no load)

Evaluation: Refer to Operational Performance Standard (p.T4-2-1). Remedy: Refer to Troubleshooting B. NOTE: Engine System Troubleshooting (T5-6-28).

T4-3-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Speed Summary: Measure the time required for the machine to travel a 50 m (164 ft) test track and check the performance of the travel drive system (torque converter to transmission).

fNOTE: The machine speed can be read on the MPDr or monitor. (Monitoring - Main (T/M) - Actual Vehicle Speed).

Preparation: a

1. Adjust air pressure of the tires in advance. c

 Radial Tire (29.5R25): Front: 471~490 kPa (4.8~5.0 kgf/cm2) (68~71 psi) Rear: 373~392 kPa (3.8~4.0 kgf/cm2) (54~57 psi)

e 95Z7BTT04-04-01

 Bias Tire (29.5-25-28PR): Front: 520~539 kPa (5.3~5.5 kgf/cm2) (75~78 psi) Rear 422~441 kPa (4.3~4.5 kgf/cm2) (61~64 psi)

abc-

2. Provide a flat, solid test track 50 m (164 ft) in length, with extra length of 70 m (230 ft) on both ends for machine acceleration and deceleration. (For measurement at fourth speed, a 300 m (984 ft) acceleration zone is needed.) 3. Empty the bucket and hold the lift arm with it floated 550 mm (1.8 ft) above the ground. 4. Maintain the hydraulic oil temperature at 55±5°C (131±9°F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicators of the coolant temperature monitor and the torque converter oil temperature monitor should rise above the horizontal position.

T4-4-1

550 mm (1.8 ft) Test Track Acceleration/Deceleration Zone

de-

End Start

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: Do not perform measurement in dCAUTION: reverse travel to avoid accident. 1. Measure in each mode (first speed to fourth speed). 2. Select the switches as follows. Shift Switch

Parking Brake Switch

Accelerator Pedal

Power Mode Switch

First Speed

OFF

Full Stroke

ON/OFF

Second Speed

OFF

Full Stroke

ON/OFF

Third Speed

OFF

Full Stroke

ON/OFF

Fourth Speed

OFF

Full Stroke

ON/OFF

3. Set the forward/reverse lever to the F (forward) position. Start traveling the machine in the acceleration zone with the accelerator pedal depressed to the stroke end. 4. Measure the travel speed (sec) of each travel mode. 5. Repeat the measurement three times and calculate the mean values. 6. Convert the measurement value to be expressed in km/h.

Measurement value (seconds) = S (sec) Converted value (hourly speed) = A (km/h) A = (50×3600)/(S×1000) Evaluation: Refer to Operational Performance Standard (p.T4-2-2).

Remedy: 1

Refer to Troubleshooting B. NOTE: Travel System Troubleshooting (p.T5-6-39)

95Z7BTT04-04-02 12-

T4-4-2

Machine Speed Sensor Machine Speed Sensor (Backup)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test (Blank)

T4-4-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Service Brake Function Check Summary: 1. Check the performance of the service brake. 2. The braking capability of the brake is an item of safety control. Be sure to conduct the performance test. Preparation: 1. Adjust air pressure of the tires evenly in advance.  Radial Tire (29.5R25): Front: 471~490 kPa (4.8~5.0 kgf/cm2) (68~71 psi) Rear: 373~392 kPa (3.8~4.0 kgf/cm2) (54~57 psi)  Bias Tire (29.5-25-28PR): Front: 520~539 kPa (5.3~5.5 kgf/cm2) (75~78 psi) Rear 422~441 kPa (4.3~4.5 kgf/cm2) (61~64 psi)

2. On a paved dry road, prepare a 150 m (492 ft) straight travel course (a 100 m (328 ft) of acceleration zone and a 50 m (164 ft) of test track) and set the brake starting point. 3. Empty the bucket and hold the lift arm with it floated 550 mm (1.8 ft) above the ground. 4. Maintain the hydraulic oil temperature at 55±5°C (131±9°F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicators of the coolant temperature monitor and the torque converter oil temperature monitor should rise above the horizontal position.

b c

d 95Z7BTT04-04-01

abcd-

T4-4-4

550 mm (1.8 ft) Braking Distance Stop Position Brake Starting Point

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: Do not perform measurement in dCAUTION: reverse travel to avoid accident. 1. Measure in high-speed mode. 2. Select the switches as follows. Shift Switch

Parking Brake Switch

Accelerator Pedal

Power Mode Switch

Declutch Position Switch

Fourth Speed

OFF

Full Stroke

OFF

3. Set the forward/reverse lever to the F (forward) position. Start traveling the machine in the acceleration zone with the accelerator pedal depressed to the stroke end and travel at 35 km/h (22 mph). 4. Release the accelerator pedal and step on the right service brake pedal at the brake starting point. Completely stop the machine. 5. Measure the distance from the brake starting point to the point where the front tire is contacting. 6. Repeat the measurement three times and calculate the mean values. Add traveling distance 0.97 m (3 ft 2 in) to the mean value. This is stopping distance. Evaluation: Stopping distance: 12 m (13 yard) or less

Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-42)

T4-4-5

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Service Brake Wear Amount Summary: Check the wear of the service brake discs in the axle by using slide calipers. Preparation: 1. Clean around inspection plug (1) of the axle and remove it. 7

Measurement: 1. Operate the service brake by stepping on the brake pedal.

2. Insert thickness gauge (2) into the clearance between separation discs (6). If it cannot be inserted, brake disc (7) should be worn. Check and replace brake discs (7).

5 5 2

Evaluation:

6 2

The limit of dimension A is 6.0 mm (0.24 in). Note that dimension A is 7 mm (0.28 in) when the brake discs (7) are new and unused.

95Z7BTT04-04-03 (Material: S45C) Unit: mm (in)

Thickness Gauge (2) 95Z7BTT04-04-05

1234-

T4-4-6

Plug (of Inspection Hole) Slide Calipers Axle Housing Brake Housing

567-

Piston Separation Disc Friction Disc

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Parking Brake Function Check Summary: 1. Measure the parking brake function on a specified slope. 2. The braking capability of the brake is an item of safety control. Be sure to conduct the performance test. Preparation: 1. Measure on a 1/5 slope (approx. 11.3°). 2. Empty the bucket and hold the bucket with it floated 550 mm (1.8 ft) above the ground. 3. Maintain the hydraulic oil temperature at 55±5°C (131±9°F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicators of the coolant temperature monitor and the torque converter oil temperature monitor should rise above the horizontal position.

95Z7BTT04-04-04

Measurement: 1. Climb the slope and set the parking brake switch to the ON position.

ab-

2. Stop the engine. 3. Put a mark (white line) on each tire and the road surface respectively. 4. After five minutes, measure the amount of movement between white lines of tire and road surface. 5. Repeat the measurement three times and calculate the mean values. Evaluation: No movement.

Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-42)

T4-4-7

550 mm (1.8 ft) 11.3° (20%)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Bucket Stopper Clearance, Lever (Bell Crank) Stopper Clearance Summary: Measure wear and deformation conditions of the bucket stopper (cross pipe side and roll back side) and the clearance between bucket dump stopper and lift arm. Preparation: 1. Stop the machine on a plane road surface and apply the parking brake. a

Measurement:

 Bucket Dump Stoppers (a, b) 1. Raise the lift arm to the highest lifting position and stop the engine. 2. Dump the bucket calmly with the engine stopped until the lever contacts cross pipe side stopper (b). At this time, measure strokes (A and B) of the bucket cylinder and the lift arm and dump angle (C) of the bucket. In addition, measure the clearance between bucket dump stopper (a) and the lift arm. 3. At the same time, measure the contact condition of bucket dump stopper (a) (left and right).  Bucket Roll Back Stopper (c) 1. Raise the lift arm until lift arm cylinder stroke (E) becomes the length of the standard dimension.

T4GB-04-04-008

2. Set the engine at idling speed and roll back the bucket calmly until it contacts bucket roll back stopper (c).

3. At this time, measure strokes (D and E) of the bucket cylinder and the lift arm cylinder and roll back angle (F) of the bucket. In addition, measure height (G) from the ground to the center of bucket hinge pin.

Bucket Dump Stopper

Cross Pipe Dump Stopper

4. At the same time, measure the contact condition of bucket roll back stopper (c) (left and right).

90T4GB-04-04-10 c-

T4-4-8

Bucket Roll Back Stopper

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Evaluation: 1. Bucket Dump Stopper

2. Bucket Roll Back Stopper

 Cylinder Strokes (A and B) (Reference)

 Cylinder Strokes (D and E) (Reference)

Bucket Cylinder (A) (mm (in))

Lift Arm Cylinder (B) (mm (in))

Bucket Cylinder (D) (mm (in))

Lift Arm Cylinder (E) (mm (in))

361±2 (14.2±0.08)

1285±2 (50.6±0.08)

791±2 (31.1±0.08)

294±2 (11.6±0.08)

 Bucket Dump Angle (C)

 Bucket Roll Back Angle (F)

C (deg.)

F (deg.)

47 to 50

39 to 41

 Clearance between Cross Pipe Dump Stopper and Lever (b) Standard

 Height from Ground to Bucket Hinge Pin (G) (With 29.5R25 tires)

Clearance between Stopper and Lever

G (mm (in))

0 (Even contact both sides)

270 (10.6)

 Clearance between Bucket Dump Stopper and Lift Arm (a)

 Clearance between Bucket Roll Back Stopper and Lift Arm (c)

Clearance between Stopper and Lift Arm Standard

Clearance between Stopper and Lift Arm

5±2 (0.2±0.08)

Standard

fNOTE:

Standard dimensions indicate those with new tires (standard) at the specified air pressure. When installing roll-back stoppers, the stoppers must have a smooth radius and must contact lift arm on both sides. The bucket cylinder must retain 3~5 mm of rod within the cylinders so the piston does not hit the cylinder head.

T4-4-9

0 (Even contact both sides)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Lift Arm Cylinder: (Raising)

Hydraulic Cylinder Cycle Time Summary: 1. Measure the operating time of cylinders for the lift arm, bucket, and steering and check the performance of the cylinder drive system (main pump to each cylinder). 2. The bucket should be empty.

T4GB-04-04-016

Preparation: 1. Measurement is made for the following positions.

(Lowering)

 Measurement of Lift Arm Cylinder (Raising) Fully roll back the bucket and lower the lift arm.  Measurement of Lift Arm Cylinder (Lowering) Lower the lift arm until the bucket bottom surface touches the ground horizontally.  Measurement of Bucket Cylinder Lift the lift arm to the highest position.  Measurement of Steering Cylinder Empty the bucket and take the travel forward position. 2. Maintain the hydraulic oil temperature at 55±5°C (131±9°F).

T487-04-03-005

Bucket Cylinder:

Select ground filled with sand or dCAUTION: something so that the bucket contacts the ground with buffer.

T487-04-03-006

Travel Position

A 95Z7BTT04-04-01 A-

T4-4-10

550 mm (1.8 ft)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Set the pedal, switches, and forward/reverse lever as follows. Accelerator Pedal

Parking Brake Forward/ Power Mode Switch Reverse Lever Switch

Lift Arm (Raising)

Full stroke (engine: high idle speed)

ON/OFF

Lift Arm (Lowering)

Neutral (engine: low idle speed)

ON/OFF

Bucket

Full stroke (engine: high idle speed)

ON/OFF

Steering

Full stroke (engine: high idle speed)

OFF

ON/OFF

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the steering area before starting the measurement. 2. Measure the cylinder cycle times as follows: (Cylinder full stroke includes cylinder cushioning zone.)  Measurement of Lift Arm Cylinder (Raising) Operate the lift arm control lever to the stroke end. Measure the time of movement of the lift arm from the lowest position to the highest position.  Measurement of Lift Arm Cylinder (Lowering) Lower the bucket onto the ground in the horizontal position and lift the lift arm to the highest position. Keep the lift arm control lever at the a float position. Measure the time of movement of the bucket reaching the ground.  Measurement of Bucket Cylinder Operate the bucket control lever to the stroke end. Measure the time of movement of the bucket from the full roll-back position to the full dump position.  Measurement of Steering Cylinder Operate the steering wheel to the stroke end. Measure the time of movement of the steering wheel from the right to the left stroke end and from the left to the right stroke end. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard (p.T4-2-3).

Remedy: Refer to Troubleshooting B. NOTE: Front Attachment System Troubleshooting (p.T56-33)

T4-4-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Cylinder Drift Check Summary: 1. Measure cylinder natural drift, which can be caused by oil leakage in lift arm cylinder, bucket cylinder, and the control valve, with the bucket loaded. 2. Measure in the standard front condition (standard bucket). 3. In case measurement is made immediately after the cylinder replacement, bleed air from the cylinder before measurement by operating the cylinders slowly to the stroke end several times. Preparation: 1. Load the bucket with either soil or a weight equivalent to the weight standard 9520 kg (20990 lb). Never allow any personnel to be dCAUTION: under the bucket. 2. In the front position, extend the lift arm to the maximum reach and hold the bucket at an angle of about 5 degrees declined forward from full tilting (rolling back). 3. Maintain the hydraulic oil temperature at 55±5°C (131±9°F). Measurement: 1. Stop the engine. 2. In 15 minutes after the engine has been stopped, measure the change in position of lift arm cylinder (2), bucket cylinder (1), and bottom of the bucket.

90T4GB-04-04-14

3. Repeat the measurement three times and calculate the mean values.

Drift Amount

Evaluation: Drift amount: Lfit arm: 3 mm (0.12 in) or less Bucket: 4 mm (0.16 in) or less

Remedy:

Refer to Troubleshooting B. NOTE: Front Attachment System Troubleshooting (p.T56-33)

T4-4-12

A T4GB-04-04-015

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Bucket Levelness Summary: 1. Check left and right inclinations of the bucket. Preparation: 1. Place the unloaded machine on a level platen on the ground. (In case a platen is not available, place it on a horizontal flat concrete on the ground. Deal with the measurement values as guide lines.) 2. Adjust the tire air pressure to the designated value all evenly. 3. Lower the bucket onto the ground in the horizontal position. 1

Measurement: Never put hands, feet, and measuring dCAUTION: instruments under the bucket. 1. Float the bucket bottom slightly above the platen. 2. Measure the vertical distance from the platen and the bottom surface of cutting edge (1) on the left and right ends, and confirm the difference. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Drift amount: 10 mm (0.4 in) or less

T4-4-13

T4GB-04-04-011

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Operating Force Summary: 1. Measure a play and operating condition of each control lever, pedal, and steering wheel, and measure operating force of them. 2. Measure maximum operating force of each control lever, pedal, and steering wheel. 3. Measure at the grip center of each control lever. Measure at 150 mm (6 in) from the pedal support of each pedal. A

Preparation:

95Z7BTT04-04-01

1. In the front position, empty the bucket in advance. A-

2. Maintain the hydraulic oil temperature at 55±5°C (131±9°F).

T4-4-14

550 mm (1.8 ft)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Measure for each control lever, pedal, and steering wheel. 2. Set the pedal, switches, and forward/reverse lever as follows. Accelerator Pedal

Parking Brake Switch

Neutral (engine: low ON idle speed)

Forward/ Reverse Lever N

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers

TNED-04-04-001

are out of the steering area before starting the measurement. 1

3. Attach a spring balance scale (tension type) onto each of the lift arm, bucket, and forward/reverse lever. Measure the maximum operating force by operating them to the stroke end. 4. In case of the pedals, attach a spring balance scale (compression type) or a load cell onto them. Measure the operating force when they are stepped slightly. 5. In case of the steering wheel, attach a spring balance scale (tension type) onto knob (1). Measure the maximum operating force when it is moved.

6. Repeat the measurement three times and calculate the mean values.

12-

Evaluation: Refer to Operational Performance Standard.  Two-lever: p.T4-2-4  MF (Joystick type) lever: p.T4-2-5

T4-4-15

Knob Accelerator Pedal

2 3-

Brake Pedal

MNEC-01-036

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Stroke Summary: 1. Measure a play and operating condition of each control lever, pedal, and steering wheel, and measure the stroke. 2. Measure at the grip tip of each control lever. Measure at the pedal top of each pedal. 3. In case lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes. Preparation: 1. Maintain the hydraulic oil temperature at 55±5°C (131±9°F). Measurement: 1. Measure as follows.  Measurement of Control Lever  Lower the bucket bottom onto the ground.  Stop the engine.  Measure each lever stroke from neutral to the stroke end of each control lever of lift arm, bucket, and forward/reverse at the grip top center.  Measurement of Pedal  Lower the bucket bottom onto the ground.  Stop the engine.  Measure the stroke from neutral to the stroke end of the pedal at the pedal top.  Measurement of Steering Wheel  Start the engine and run at low idle.  Float the bucket slightly above the ground.  Measure the number of times of rotation required for movement of the steering wheel from the right to the left stroke end and from the left to the right stroke end. 2. Measure the chord length from neutral to the stroke end. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard (p.T4-2-6).

T4-4-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure (Unloader Valve Setting Pressure) If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. (Refer to Troubleshooting B.)

IMPORTANT: Primary pilot pressure circuit delivers pressure oil from the accessory pump to the brake circuit when pressure in service brake accumulator (1) decreases, and accumulates pressure in service brake accumulator (1). Therefore, the brake circuit pressure is higher than the pilot circuit pressure. Use a pressure gauge capable of measuring 11.8 MPa (120 kgf/cm2) (1710 psi) or higher.

Summary: Measure the unloader valve set pressure at port (2) or (6) in reducing valve block (3). 95Z7BTT04-05-01

Preparation: 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. Remove plug (2) on the reducing valve (3). Install the pressure gauge to the port.

fNOTE: Plug (6) can also be used for the measurement. 6

4. Start the engine and keep the speed at low idle. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 55±5°C (131±9°F).

3 95Z7BTT04-05-02

1234-

T4-5-1

Brake Accumulators Plug (G1/4) Reducing Valve Block Reducing Valve (for Brake Oil Pressure)

56-

Pressure Sensor (for Brake Pressure Alarm) Plug (G3/8)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Select the following conditions: Accelerator Pedal

Power Mode Parking Switch Brake Switch

Forward/ Reverse Lever

Full stroke

2. Measure the pressure with no load. 3. Read and record the pressures when the pointer of the pressure gauge stops rising (cut-out pressure). 4. Keep the engine at low idle, and repeatedly depress and release the brake pedal to reduce the accumulator pressure. 5. Read and record the pressure when the pointer of the pressure gauge stops and then starts rising again (cut-in pressure). 6. Repeat the measurement three times and calculate the mean value.

fNOTE: When pressure in the service brake accumulator

decreases during measurement of primary pilot pressure, the measured value increases to around 11.8 MPa (120 kgf/cm2) (1710 psi) for several seconds.

Evaluation:  Cut-in Pressure:  Cut-out Pressure:

6.9±0.5 MPa (1000±73 PSI) 11.8±0.5 MPa (1711±73 PSI)

IMPORTANT: The cut-in/cut-out pressure levels are preset by the valve manufacturer. When it is out of the specified range, it is highly possible that the valve is defective. Replace the valve unit.

T4-5-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove plug (2) on the manifold block of combination valve (1). Install the pressure gauge to the port.

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 55±5°C (131±9°F). Measurement: 1. Select the following conditions: 95Z7BTT04-05-04

Accelerator Pedal

Power Mode Parking Switch Brake Switch

Forward/ Reverse Lever

Full stroke

2. Measure the pressure with no load. 3. Read and record the pressures on the pressure gauge.

4. Repeat the measurement three times and calculate the mean value. Evaluation: Standard. 3.5±0.5 MPa (508±73 PSI)

2 95Z7BTT04-05-03

Remedy: Refer to Troubleshooting A for any accompanied error code. Refer to Troubleshooting B for observed phenomena.

fNOTE: All Actuator System Troubleshooting (p.T5-6-30) Front Attachment System Troubleshooting (p.T5-6-33) Steering System Troubleshooting (p.T5-6-37) Brake System Troubleshooting (p.T5-6-42)

T4-5-3

Combination Valve (Manifold Block)

Plug (Z1) (G1/4)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 1

Solenoid Valve Set Pressure - Parallel/Tandem Switching Solenoid Valve (3) 2

Preparation: 1. Stop the engine. 2. Push air bleed valve (1) on top of hydraulic oil tank (2) and bleed air. 3. Connect MPDr. and select the monitoring function.

4. Disconnect the hose from the SJ port and install a pressure gauge to the port. Additional parts installation, such as hose, tee, or adapter, as shown is suggested for easier connection of the pressure gauge.

95Z7BTT04-05-04

5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 4

6. Maintain the hydraulic oil temperature at 55±5°C (131±9°F).

Measurement: SA

1. Set the following conditions: Accelerator Pedal Full stroke

Power Mode Switch ON

D 95Z7BTT04-05-05

2. Perform combined operation of lift arm raise and bucket fully roll back.

3. Read the values on both MPDr. and the pressure gauge.

4. Repeat the measurement three times and calculate the mean values. Evaluation: Standard: 3.5±0.2 MPa (508±29 PSI) 8

6 T157-05-04-002

1234-

T4-5-4

Air Bleeder Valve Hydraulic Oil Tank Solenoid Valve Unit (for Parallel/Tandem Switching) Solenoid Valve Unit (for Auto Brake)

5678-

Pressure Gauge Adapter Tee Adapter Hose

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test - Auto Brake Solenoid Valve (4)

Preparation: 1. Stop the engine.

2. Push air bleed valve (1) on top of hydraulic oil tank (2) and bleed air. 3. Connect MPDr. 4. Install a pressure gauge to the SA port. 5. Disconnect the solenoid harness from parallel/ tandem switching solenoid (9), and connect it to auto brake solenoid (10) to supply power to the auto brake solenoid. 6. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

95Z7BTT04-05-04

7. Maintain the hydraulic oil temperature at 55±5°C (131±9°F).

Measurement: P

1. Set the following conditions: Accelerator Pedal Full stroke

Power Mode Switch ON

SJ D

2. Perform combined operation of lift arm raise and bucket fully roll back.

95Z7BTT04-05-05

3. Read the value on the pressure gauge. 4. Repeat the measurement three times and calculate the mean value.

fNOTE:

124-

The pressure measured at the SA port maybe unstable in the beginning due to the circuit feature. Wait until it becomes stable. If the auto brake solenoid does not operate without the disconnection error, the MC may be defective .

Evaluation: Standard: 0.63±0.1 MPa (91.4±15 PSI)

T4-5-5

Air Bleeder Valve Hydraulic Oil Tank Solenoid Valve Unit (for Auto Brake)

Solenoid Connector (for Parallel/Tandem Switching) 10- Solenoid Connector (for Auto Brake)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Solenoid Valve Adjustment Procedure

IMPORTANT: As O-ring (11) is damaged and oil leakage may cause, do not loosen adjusting screw (12) excessively. Do not loosen adjusting screw (12) more than 2 turns.

1. Loosen lock nut (13). Turn adjusting screw (12) and adjust the set pressure. 2. After adjustment, tighten lock nut (13).

a b

j : 13 mm m : 5 N·m (0.5 kgf·m) (3.69 lbf·ft)

TDAA-04-05-013

0.663 mm (0.026 in)

l : 3 mm

2.0 mm (0.079 in)

3. After adjustment, check the set pressure. 4

fNOTE: Standard Change in Pressure (Reference) Screw Turns Change in Pressure

1/4 111

1/2 222

3/4 333

1 444

(kgf/cm2) (1.1)

(2.3)

(3.4)

(4.5)

kPa (psi)

P SA

(16.1) (32.2) (48.3) (64.4) D 95Z7BTT04-05-05

W107-02-05-129 c-

Pressure Increase

Solenoid Valve Unit (for Parallel/Tandem Switching) Solenoid Valve Unit (for Auto Brake)

11- Adjusting Screw 12- Lock Nut 13 O-Ring

T4-5-6

Pressure Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Pump Delivery Pressure 2

Summary:

Measure the main pump delivery pressure in neutral condition at test port (1).

fNOTE: Measure the pressure by using the monitor or MPDr. (Monitoring - Main (T/M) - Pump Delivery Pressure)

Preparation: 1

1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug (G1/4) from pressure check port (1). Install a pressure gauge with an adapter, hose, if needed. j : 19 mm

95Z7BTT04-05-06

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

12-

5. Maintain the hydraulic oil temperature at 55±5°C (131±9°F). Measurement: 1. Set the following conditions: Accelerator Pedal Full stroke

Power Mode Parking Forward/ Switch Brake Switch Reverse Lever ON ON N

2. Measure pressure with the control levers in neutral without load. 3. Repeat the measurement three times and calculate the mean value. Evaluation: Standard (neutral): 4.0+1.0/-0.5 MPa (580+145/-73 PSI)

Remedy: Refer to Troubleshooting A for any accompanied error code. Refer to Troubleshooting B for observed phenomena.

fNOTE: All Actuator System Troubleshooting (p.T5-6-30) Front Attachment System Troubleshooting (p.T5-6-33) Steering System Troubleshooting (p.T5-6-37)

T4-5-7

Check Port (G1/4) Multiple Control Valve

Main Pump

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Loading Circuit Main Relief Set Pressure Summary:

2 3

Measure the main relief set pressure at port (1) in the main pump delivery circuit.

fNOTE: Measure the pressure by using the monitor or MPDr. (Monitoring - Main (T/M) - Pump Delivery Pressure)

Preparation: 1. Stop the engine. 1

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug (G1/4) from pressure check port (1). Install an adapter, hose, and the pressure gauge. j : 19 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

95Z7BTT04-05-06

5. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

12-

Measurement: 1. Set the following conditions: Accelerator Pedal Full stroke

Power Mode Parking Forward/ Switch Brake Switch Reverse Lever ON ON N

2. Operate the bucket or lift arm control levers slowly, so as to operate each cylinder to the stroke end (both extend and retract), and relieve each function. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Standard (relief operation): 31.4±0.5 MPa (4554±73 PSI)

T4-5-8

Check Port (G1/4) Multiple Control Valve

Main Pump

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Valve Pressure Adjustment Procedure 1

IMPORTANT: Do not loosen screw (4). If erroneously loosened, refer to NOTE below. 1. Secure adjusting screw (2). Loosen lock nut (1). j : 32 mm 2. Turn adjusting screw (2) in order to adjust the relief pressure to the specification. Turning the screw clockwise (direction: a) increases the pressure.

95T4GB-04-05-10 12-

j : 27 mm

Lock Nut Adjusting Screw

34-

Lock Nut (Not Used) Adjusting Screw (Not Used)

3. Secure adjusting screw (2). Tighten lock nut (1). m : 47 to 61 N·m (4.8 to 6.2 kgf·m) (34.7 to 45.0 lbf·ft) 2

4. Check the relief set pressures. Standard Change in Pressure (Reference) Adjusting Screw (2) 1/4 Turns Change in MPa 3.23 2 Pressure (kgf/cm ) 32.9 (psi) 468

1/2

3/4

6.45 65.8 936

9.68 98.6 1403

12.9 131.5 1871

fNOTE: Do not loosen screw (4) for adjustment (not

T105-06-05-002 a-

necessary). If loosened, tighten it fully to the end and secure lock nut (3) with the following torque. j : Screw (4): 22 mm m : 38 to 50 N·m (3.9 to 5.0 kgf·m) (28 to 36 lbf·ft)

T4-5-9

Pressure Increase

Pressure Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 1, 3

Steering Circuit Main Relief Set Pressure Summary: Measure the steering relief valve set pressure at test ports (1) at steering cylinder (2) joint adapters to check performance of the steering relief valve.

fNOTE: Measure the pressure by using the monitor or MPDr. (Monitoring - Main (T/M) - Pump Delivery Pressure)

Preparation: 1. Stop the engine.

2 95Z7B-7-8-2

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug (G1/4) from test port (1) at the steering cylinder, and install a pressure gauge. Additional parts installation, such as hose, tee, or adapter, is suggested for easier connection of the pressure gauge.

l : 6 mm 1

fNOTE: North America equipped machines have fittings (3) at test ports (1).

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

95Z7-04-05-02

5. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

Measurement: 1. Set the following conditions: Accelerator Pedal Full stroke

Power Mode Parking Forward/ Switch Brake Switch Reverse Lever ON ON N

2. Install the articulation lock bar. Turn the steering wheel slowly but at 80 rpm or more to relieve the steering, and measure and record the pressure. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Standard: 27.4±0.5 MPa (3974±73 PSI)

T4-5-10

Steering Relief Pressure Check Port

23-

Steering Cylinders Fitting (USA only)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Steering Relief Valve (1) Pressure Adjustment Procedure 1. Loosen lock nut (2). j : 13 mm 2. Turn adjusting screw (3) to adjust the relief pressure. Turning the screw clockwise (direction: a) increases the pressure. l : 4 mm 3. Secure lock nut (2). 1

m : 17 to 19 N·m (1.7 to 1.9 kgf·m) (12.5 to 14 lbf·ft)

90T4GB-04-05-12

4. Check the relief set pressures.

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (3) 1/4 Turns Change in MPa 3.2 Pressure (kgf/cm2) (32.5) (psi) (464)

1/2

3/4

6.4 (65) (928)

9.6 12.8 (97.5) (130) (1392) (1856) 3 90T4GB-04-05-13 1-

Steering Relief Valve

23-

Lock Nut Adjusting Screw

T105-06-05-002 a-

T4-5-11

Pressure Increase

Pressure Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Steering Circuit Pilot Pressure Summary: 3

Measure the steering pilot pressure at ports of reducing valve to check performance of the steering pilot valve.

Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

90Z7B-04-05-10

3. Remove the plug (G1/4) from test port (A or B) at reducing valve (1) for the Orbitrol, and install a pressure gauge.

12-

Reducing Valve Stop Valve

l : 6 mm (0.24 in)

fNOTE: North America equipped machines have a fitting (3) at test port (A).

fNOTE: Either port A or B is usable for this test but port A maybe easier to access. Additional parts installation, such as hose, tee, or adapter, is suggested for easier connection of the pressure gauge.

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 55±5°C (131±9°F). Measurement: 1. Set the following conditions: Accelerator Pedal Full stroke

Power Mode Switch ON

Parking Brake Switch ON

Forward/Reverse Lever N

2. Install the articulation lock bar. Turn the steering wheel slowly and verify that the steering operation is normal. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard: 3.5±0.5 MPa (508±73 PSI)

T4-5-12

Bucket Empty

Fitting (USA only)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Loading/Steering Overload Relief Valve Set Pressure Summary: Since there is no method to measure the accurate overload relief valve pressure for the following reasons, it is recommended to measure the main relief pressure while releasing each front function respective to the measuring overload relief valve, when needed. The overload relief valve function can be assumed as correct if the obtained main relief pressure is within the specified value range. <Reasons> 1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable. 2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set pressure more than the overload valve setpressure is not a proper method. 3. Main relief valve may be designed to leak a small quantity of oil before reliving. In this case, its preleaking start pressure must be increased more than the overload relief valve set pressure. However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate. Some overload relief valves come in contact with the control valve body to block the oil passage. When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit.

T4-5-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Preparation:

2 3

1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Install a pressure gauge. (Loading Circuit) Remove the plug (G1/4) from pressure check port (1). Additional parts installation, such as hose, tee, or adapter, is suggested for easier connection of the pressure gauge.

l : 19 mm (Steering Circuit) Remove the plug (G1/4) from pressure check port (2).

fNOTE: North America equipped machines have fittings

95Z7BTT04-05-06

(3) at test ports (2).

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

Loading Circuit Main Relief Pressure Test Port (Pump Delivery Pressure Test Port)

23-

Multiple Control Valve Main Pump

5. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F). 3

2 95Z7-04-05-02 2-

T4-5-14

Steering Relief Pressure Check Port

Fitting (USA only)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Set the following conditions: Accelerator Pedal

Power Mode Parking Brake Switch Switch

Full stroke

Forward/ Reverse Lever N

2. For loading circuit, operate the bucket or lift arm control levers slowly, so as to operate each cylinder to the stroke end (both extend and retract), and relieve each function. For steering circuit, install the articulation lock bar. Turn the steering wheel slowly but at 80 rpm or more to relieve the steering. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Performance of the overload relief valves are normal if the measured pressure falls within the main relief normal pressure range. Standard: Loading circuit: 37.3±0.5 MPa (5410±73 PSI) Steering circuit: 32.5±0.5 MPa (4714±73 PSI)

fNOTE: The overload relief pressure values at each port are given for reference. Refer to page T4-5-12.

T4-5-15

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Service Brake Pressure (Front and Rear) If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. (Refer to Troubleshooting B.) Summary: Measure the pressure at the test port of axle assembly when brake pedal is depressed.

Preparation: Set blocks (1) at the front and rear dCAUTION: tires in order not to move the machine. Keep away from the front or back of the machine. 1. Stop the engine.

T4GB-04-05-017

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Depress brake pedal at least 50 strokes in order to decrease the accumulated pressure left in the brake circuit.

4. Remove air bleeder screw (2, 3) on the axle assembly and install a pressure gauge instead. Either of two ports in the front axle (2) is usable for the front wheel brake circuit pressure measurement, and ports in the rear axle (3) for the rear wheel brake circuit pressure.

Rear Axle

j : 19 mm m : 30 N·m (3.0 kgf·m) (22 lbf·ft) 2

5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. Front Axle

6. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

95Z7BTT04-05-11

T4-5-16

Air Bleeder Screw (Front Axle)

Air Bleeder Screw (Rear Axle)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Set the following conditions: Accelerator Pedal

Power Mode Switch

Full stroke

2. Measure the pressure when fully depressing the brake pedal at left side to the floor. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Standard: 4.08±0.3 MPa (592±43.5 PSI) Remedy: Refer to Troubleshooting B. Normally, the front and rear wheel brake pressures become equal. If not, malfunction of the brake valve and dirt caught in the valve are suspected. NOTE: Brake System Troubleshooting (p.T5-6-42)

T4-5-17

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Parking Brake Pressure If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. (Refer to Troubleshooting B.) Summary: Measure the parking brake release pressure in the parking brake release circuit. T4GB-04-05-017

Preparation: 1

Set blocks (1) at the front and rear dCAUTION: tires in order not to move the machine. Keep away from the front or back of the machine. 1. Stop the engine.

2. Push air bleed valve (2) on top of the hydraulic oil tank and bleed air. 3. Disconnect parking brake hose (3) and remove elbow fitting (4) from the combination valve. Install a pressure gauge to combination valve block (5) directly. 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

4 3

95Z7BTT04-05-07

234-

T4-5-18

Air Bleed Valve Parking Brake Hose Elbow Fitting

Combination Valve (Manifold Block)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Set the following condition: Accelerator Pedal Neutral 2. Release the parking brake and measure the pressure at this time. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Standard: 3.0 to 3.7 MPa (435 to 537 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-42)

T4-5-19

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Brake Accumulator Pressure If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. (Refer to Troubleshooting B.) Summary: Measure the accumulated brake pressure at the test port provided in the brake valve. The accumulated brake pressure varies according to operation of the brake. Record the maximum level. To assure the accumulator performance, the following two tests are recommended. - Number of brake pedal applications - Accumulator charge time

T4GB-04-05-017

Preparation: Set blocks (1) at the front and rear dCAUTION: tires in order not to move the machine. Keep away

4 A

from the front or back of the machine. 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. Depress the brake pedal at least 50 strokes in order to decrease the accumulated pressure left in the brake circuit. 4. Install a pressure gauge to brake accumulator (4) pressure measurement ports (G1/4) provided in fittings (2) mounted to brake valve (3). 3

5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

2 (PF)

6. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

2 (PR) Detail of A 95Z7BTT04-05-08 2-

T4-5-20

Fitting (at Pressure Measurement Port)

34-

Brake Valve Brake Accumulators

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Accumulator pressure:

Number of brake pedal applications:

1. Select the following conditions:

1. After running the engine at high idle for 1 minute, stop the engine. (Turn the key switch "ON" with engine off.)

Accelerator Pedal Full stroke

Power Mode Parking Forward/ Switch Brake Switch Reverse Lever ON ON N

2. Count and verify the number of stepping on the brake pedal is at least 3 times before the low pressure alarm indicator turns ON.

2. Measure the pressure when fully depressing the brake pedal at left side to the floor. 3. Repeat the measurement three times and calculate the mean values.

Accumulator charge time: 1. Run the engine at low idle. 2. Measure the time from the low pressure alarm indicator turns OFF until when the unloader valve set pressure reaches the cut-out pressure value (11.8±0.5 MPa (1711±73 PSI)).

Evaluation: Standard: 11.8±0.5 MPa (1711±73 PSI)

3. Verify the time period is 15 seconds or less.

Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-42)

f fNOTE: The maximum accumulated brake pressure

should equal to the unloader valve setting value (cutout). Refer to Primary Pilot Pressure (Unloader Valve Setting Pressure) measurement procedure (p.T4-5-1).

T4-5-21

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Brake Warning Pressure (PressureDecreasing) If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. (Refer to Troubleshooting B.) Summary: Measure the pressure at the accumulator output port when the buzzer sounds while decreasing the accumulated brake pressure. Preparation: Set blocks (1) at the front and rear dCAUTION: tires in order not to move the machine. Keep away

T4GB-04-05-017

from the front or back of the machine. 1. Stop the engine.

2. Push air bleed valve (2) on top of the hydraulic oil tank and bleed air. 3. Depress the brake pedal at least 50 strokes in order to decrease the accumulated pressure left in accumulator circuit.

4. Remove plug (3) on the manifold block of combination valve (4). Install a pressure gauge to the port. 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

6. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

4 23-

T4-5-22

Air Bleeder Valve Plug (Z1) (G1/4)

95Z7BTT04-05-09 Combination Valve (Manifold Block)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Set the following conditions: Forward/Reverse Lever N

Parking Brake Switch ON

2. Stop the engine. Set the key switch to the ON position. 3. Depress the brake pedal several times. Measure the pressure when the buzzer sounds. 4. Repeat the measurement three times and calculate the mean values. Evaluation: Standard: 3.9±0.5 MPa (566±73 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-42)

T4-5-23

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Brake Warning Pressure (PressureIncreasing) If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. (Refer to Troubleshooting B.) Summary: Measure the pressure at the accumulator output port when the buzzer stops sounding while increasing the accumulated brake pressure. Preparation: Set blocks (1) at the front and rear dCAUTION: tires in order not to move the machine. Keep away

T4GB-04-05-017

from the front or back of the machine. 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Depress the brake pedal at least 50 strokes in order to decrease the accumulated pressure left in accumulator (2) circuit.

4. Remove plug (3) on the manifold block of combination valve. Install the pressure gauge to the port. 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 3

6. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

4 23-

T4-5-24

Air Bleeder Valve Plug (Z1) (G1/4)

95Z7BTT04-05-09

Combination Valve (Manifold Block)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Set the following conditions: Forward/Reverse Lever N

Parking Brake Switch ON

2. Stop the engine. Set the key switch to the ON position. 3. Depress the brake pedal several times. Sound the buzzer. 4. Start the engine. Measure the pressure when the buzzer stops sounding. Notice that it is difficult to read the gauge as the pressure increases rapidly. 5. Repeat the measurement three times and calculate the mean value. Evaluation: Standard: 4.4±0.5 MPa (638±73 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-42)

T4-5-25

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Transmission Clutch Pressure Summary: Measure each operating pressure of the transmission clutch at each check port of the transmission control valve. NOTE: The pressure at the high clutch and lock-up clutch ports are not possible because they require machine running at the specified speed or higher.

Preparation: 1. Stop the engine. 2. Remove the plug from the check port. Install a hose, an adapter, and a pressure gauge. l : 6 mm m : 36 N·m (3.7 kgf/cm2) (26.6 lbf·ft)

fNOTE: Although the pressure can be measured by using one pressure gauge, all pressures can be measured by using seven pressure gauges at the same time.

3. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 4. Maintain the torque converter oil temperature at 80 to 95 °C (176 to 203 °F). Measurement:

T4GB-04-05-017

Set blocks (1) at the front and rear dCAUTION: tires in order not to move the machine. Keep away

from the front or back of the machine. 1. Set the following conditions: Accelerator Pedal Full stroke

Brake Pedal Full stroke

Power Mode Switch ON

Clutch Cut Position Switch OFF

2. Operate the forward/reverse lever and the shift switch. Measure each clutch pressure. (As for the combination of clutch pack, refer to the following page.) 3. Repeat the measurement three times and calculate the mean values. Evaluation: 1st, lock-up, H: 2.3~2.7 MPa (336~392 PSI) R, 2nd, 3rd, L: 2.5~3.0 MPa (363~435 PSI)

T4-5-26

Parking Brake Switch OFF

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test

L/U

1 3

95Z7BTT04-05-10

Transmission Clutch Pack Combination

Selected Speed Shift F1 F2 F2L F3 F3L F4 F4L R1 R2 R2L R3 R3L Neutral

Directional Control Clutch Pack Forward Low Forward Reverse (R) (L) High (H)  

First Speed (1) 

Speed Control Clutch Pack Second Third Speed Speed (2) (3) 

  



  

 

      

Lock Up (LU)

 

  

fNOTE:

In the neutral position, either clutch with an asterisk (*) is engaged. The operating pressure is applied to the clutch with the mark  when setting the forward/reverse lever and the shift switch to each selected speed shift.

T4-5-27

   *



SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Torque Converter Pressure Set blocks (1) at the front and rear dCAUTION: tires in order not to move the machine. Keep away from the front or back of the machine. Summary: Measure the torque converter input/output pressure at each sensor port.

T4GB-04-05-017

Preparation: 1. Stop the engine. 2. Remove the plug (G1/4) from the input pressure test port (2) and install a pressure gauge to the port. Remove the plug from the output pressure test port (3) and install a pressure gauge to the port. l : 5 mm m : 6 N·m (0.6 kgf/cm2) (4.4 lbf·ft) 3. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

4. Maintain the torque converter oil temperature at 80 to 95 °C (176 to 203 °F).

2 2-

Measurement:

Torque Converter Input Pressure Test Port

1. Set the following conditions: Accelerator Pedal Full stroke

Brake Pedal Full stroke

Power Mode Switch ON

Clutch Cut Position Switch OFF

2. Set the forward/reverse lever to F (Forward) and the shift switch to 4 (Fourth Speed). Measure the pressure. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Input Pressure: 0.8±0.1 MPa (116±14.5 PSI) Output Pressure: 0.6±0.1 MPa (87±14.5 PSI)

T4-5-28

Parking Brake Switch OFF

95Z7-04-05-03 3-

Torque Converter Output Pressure Test Port

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Rewrite of Aftertreatment Device Serial No. After replacing the aftertreatment device (DOC/SCR), rewrite their serial Nos. and upload the data to e-Service.

4. Input the following items of Oxidation Catalyst (DOC) and Front SCR (SCR Fr) and Rear SCR (SCR Fr).  ASM  SUB  Serial No.

1. Connect the Maintenance Pro Dr. (MPDr.) 2. Set the key switch to the ON position.

5. After inputting, select [F5] Set. 3. Select Functions - Engine - Aftertreatment Device No.

IMPORTANT: After finishing aftertreatment device serial No. input, upload the data to e-Service.

fNOTE: When the input data is uploaded to e-Service, the M-Find product specification and history will be updated.

: SCR Ft : SCR Rr : DOC

95Z7BTT04-06-01

T4-6-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment (Blank)

T4-6-2

SECTION 5

TROUBLESHOOTING CONTENTS

Group 1 Diagnosing Procedure Introduction .......................................................................... T5-1-1 Diagnosis Procedure .......................................................... T5-1-2 Electric System Inspection............................................... T5-1-5 Precautions for Inspection and Maintenance........... T5-1-6 Instructions for Disconnecting Connectors .............. T5-1-8 Fuse Inspection..................................................................T5-1-10 Fuse Box A/Fuse Box B ...............................................T5-1-11 Fusible Link Inspection ...................................................T5-1-12 Battery Voltage Check .....................................................T5-1-13 Alternator Check ...............................................................T5-1-14 Continuity Check...............................................................T5-1-15 Voltage and Current Measurement ............................T5-1-16 24-Volt Circuit ...............................................................T5-1-16 5-Volt Circuit ..................................................................T5-1-22 Check by False Signal ......................................................T5-1-23 Test Harness ........................................................................T5-1-24 Surge Voltage and Surge Suppression Diodes .......T5-1-26

Group 2 Monitor Outline .................................................................................... T5-2-1 Operating Procedures of Service Menu ...................... T5-2-2 How to display service menu .................................... T5-2-3 Troubleshooting .................................................................. T5-2-4 Monitoring ............................................................................ T5-2-6 List of Monitoring Item................................................ T5-2-8 Controller Version .............................................................T5-2-16 Issued Warning Record ...................................................T5-2-17 List of Alarm...................................................................T5-2-18 Communication Terminal Status .................................T5-2-22 List of Communication Terminal Status ..............T5-2-23 Machine Setting ................................................................T5-2-24 List of Machine Setting Item ...................................T5-2-25 Transmission Learning ...............................................T5-2-26 Lift Arm Angle Sensor Learning .............................T5-2-30 Digging Position Adjustment .................................T5-2-32 Engine Setting....................................................................T5-2-34 List of Engine Setting Item .......................................T5-2-35 Aftertreatment Device Manual Regeneration (Forcible) .........................................................................T5-2-36 Aftertreatment Device Auto Regeneration........T5-2-36 Aftertreatment Device Auto Regeneration Stop ..................................................................................T5-2-36 Air Bleeding from the Defrosting Piping ............T5-2-36 Fault Code Clear ...........................................................T5-2-36

Aftertreatment Device No. ............................................T5-2-37 Engine Output Restriction Suspend ..........................T5-2-38 Engine Tachometer ..........................................................T5-2-40 Transmission Oil Temperature Gauge and DEF/AdBlue Level Gauge ..........................................T5-2-41 Coolant Temperature Gauge ........................................T5-2-42

Group 3 e-Service Outline .................................................................................... T5-3-1 List of Operation Data ....................................................... T5-3-2 List of Daily Report Data ............................................. T5-3-2 List of Frequency Distribution Data ........................ T5-3-4 List of Total Operating Hours .................................... T5-3-5 Snapshot Data...................................................................... T5-3-6 Communication System ................................................... T5-3-7

Group 4 Component Layout Main Component (Overview) ......................................... T5-4-1 Electric Component Layout (Overview)...................... T5-4-4 Electrical System (Cab) ...................................................... T5-4-5 Controller and Relays ................................................... T5-4-6 Right Console.................................................................. T5-4-7 Multi-Function Monitor/ Air Conditioner Switch Panel .................................... T5-4-8 Joystick Steering Controls (Option) ........................ T5-4-8 Monitor and Switches .................................................. T5-4-9 Monitor Panel ...............................................................T5-4-10 Electrical System (Relays) ...............................................T5-4-11 Electrical System (Around Hydraulic Oil Tank)........T5-4-12 Electrical System (Around Fuel Tank) .........................T5-4-13 Engine ...................................................................................T5-4-14 Aftertreatment Device/Air Cleaner ............................T5-4-15 Hydraulic Pump .................................................................T5-4-16 Main Pump.....................................................................T5-4-16 Accessory Pump...........................................................T5-4-17 Transmission and Torque Converter Assembly ......T5-4-18 Multiple Control Valve .....................................................T5-4-19 Unloader Valve (Brake Charge Valve) .........................T5-4-20 Combination Valve (Brake Manifold Valve) ..............T5-4-20 Flow Regulator Valve .......................................................T5-4-21 Steering Valve.....................................................................T5-4-21 Ride Control Valve (Option) ...........................................T5-4-21 Secondary Steering Group (Option) ..........................T5-4-22 Secondary Steering Pump (Option)......................T5-4-22

95Z7B Troubleshooting

Group 5 Troubleshooting A Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure ............................................... T5-5-1 MPDr. Fault Code List......................................................... T5-5-3 MC Fault Code List ............................................................T5-5-12 SC Fault Code List .............................................................T5-5-26 Monitor Controller (Monitor) Fault Code List .........T5-5-37 Monitor Controller (Information) Fault Code List..T5-5-38 Column Display Controller Fault Code List ..............T5-5-38 JCU Fault Code List ...........................................................T5-5-40 Air Conditioner Controller Fault Code List ...............T5-5-46 ECM Fault Code List..........................................................T5-5-48 DCU Fault Code List..........................................................T5-5-76 MC Fault Codes 111000 to 111002 .............................T5-5-80 SC Fault Codes 111000 to 111002 ..............................T5-5-80 MC Fault Code 111003 ....................................................T5-5-80 SC Fault Code 111003......................................................T5-5-80 MC Fault Codes 111006, 111007, 111009, 111012 .............................................................................T5-5-83 SC Fault Codes 111015, 111017, 111019, 111024 .............................................................................T5-5-83 Monitor Controller (Monitor) Fault Codes 113002, 113003, 113005, 113010 ..........................T5-5-84 CAN1 Harness Check .......................................................T5-5-85 MC Fault Codes 111008, 111010, 111013, 111014, 111025 .............................................................................T5-5-88 SC Fault Codes 111016, 111018, 111020, 111021, 111026 .............................................................................T5-5-88 Monitor Controller (Monitor) Fault Codes 113004, 113006, 113007, 113011 ..........................T5-5-89 CAN2 Harness Check ......................................................T5-5-90 MC Fault Codes 111103, 111105, 111106 ................T5-5-93 CAN3 Harness Check ......................................................T5-5-94 CAN4 Harness Check ......................................................T5-5-97 SC Fault Codes 111205, 111207 ................................ T5-5-100 SC Fault Codes 111200, 111202, 111203 ............... T5-5-101 MC Fault Codes 111204, 111312 .............................. T5-5-102 SC Fault Codes 111206, 111217 ................................ T5-5-103 SC Fault Code 111208................................................... T5-5-104 MC Fault Code 111313 ................................................. T5-5-105 MC Fault Codes 111600 to 111602 .......................... T5-5-106 MC Fault Codes 111210 to 111212 .......................... T5-5-107 MC Fault Codes 111214, 111215 .............................. T5-5-108 SC Fault Codes 111309, 111310 ............................... T5-5-109 SC Fault Code 111407.................................................. T5-5-110 SC Fault Code 111410.................................................. T5-5-111 SC Fault Code 111411.................................................. T5-5-112 SC Fault Code 111412.................................................. T5-5-113 MC Fault Code 111413 ................................................ T5-5-114 MC Fault Code 111414 to 111421 ........................... T5-5-115 MC Fault Code 111408 ................................................. T5-5-117 SC Fault Code 111422.................................................. T5-5-118 SC Fault Code 111423.................................................. T5-5-119 MC Fault Codes 111502 to 111504, 111506, 111507 ......................................................................... T5-5-120 MC Fault Codes 111700 to 111704 .......................... T5-5-121

SC Fault Code 111900.................................................. T5-5-123 Specification of Transmission Oil Temperature Sensor .......................................... T5-5-123 SC Fault Code 111901................................................... T5-5-124 Specification of Hydraulic Oil Temperature Sensor .......................................... T5-5-124 MC Fault Code 111903 ................................................. T5-5-125 Specification of Transmission Oil Temperature Sensor ........................................... T5-5-125 SC Fault Code 111906, 111907.................................. T5-5-126 Specification of Axle Oil Temperature Sensor ...................................................................... T5-5-126 MC Fault Codes 120014, 120101 to 120104, 120106 .......................................................................... T5-5-127 SC Fault Codes 120000 to 120005 ........................... T5-5-128 Column Display Controller Fault Code 115001 ... T5-5-129 Monitor Controller (Monitor) Fault Code 120300 .......................................................................... T5-5-129 Monitor Controller (Information) Fault Code 113311 .......................................................................... T5-5-130 Fuel Level Sensor Specifications ......................... T5-5-131 Column Display Controller Fault Codes 120500 to 120507..................................................... T5-5-132 Air Conditioner Controller Fault Codes 11 to 22 ........................................................................ T5-5-133 Air Conditioner Controller Fault Codes 43 to 92 ....................................................................... T5-5-134

Group 6 Troubleshooting B Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure................. T5-6-1 Contents of Diagnosis.................................................. T5-6-2 Relationship between Machine Trouble Symptom and Related Parts ................................................................... T5-6-3 Correlation between Trouble Symptom and Part Failures ...................................................................T5-6-27 Engine System Troubleshooting ............................T5-6-28 All Actuator System Troubleshooting ..................T5-6-30 Front Attachment System Troubleshooting ......T5-6-33 Steering System Troubleshooting .........................T5-6-37 Travel System Troubleshooting ..............................T5-6-39 Brake System Troubleshooting...............................T5-6-42 Other System Troubleshooting ..............................T5-6-43 Engine System Troubleshooting .................................T5-6-47 All Actuator System Troubleshooting........................T5-6-54 Front Attachment System Troubleshooting............T5-6-59 Steering System Troubleshooting ..............................T5-6-69 Travel System Troubleshooting ...................................T5-6-73 Brake System Troubleshooting ....................................T5-6-83 Other System Troubleshooting....................................T5-6-87 Exchange Inspection .................................................... T5-6-101 Air Bleeding Procedures for Brake (Axle) ............... T5-6-102 Group 7 Air Conditioner Outline ................................................................................... T5-7-1 Component Layout...................................................... T5-7-2 Functions of Main Parts ................................................... T5-7-4 95Z7B Troubleshooting

Troubleshooting ................................................................. T5-7-9 Air Conditioner Controller Fault Code List .............. T5-7-10 Air Conditioner Controller Fault Codes 11 to 22....T5-7-11 Air Conditioner Controller Fault Codes 43 to 92... T5-7-12 Faulty cooling (1) ........................................................ T5-7-14 Faulty cooling (2) ........................................................ T5-7-16 Faulty cooling (3) ........................................................ T5-7-18 Faulty cooling (4) ........................................................ T5-7-20 Faulty cooling (5) ........................................................ T5-7-22 Faulty heating (1)........................................................ T5-7-24 Faulty heating (2)........................................................ T5-7-26 Others ............................................................................. T5-7-27 Blower motor does not operate. ........................... T5-7-30 Compressor clutch does not operate.................. T5-7-31 Cooling circuit check by using manifold gauge......................................................................... T5-7-32 Work after Replacing Components ........................... T5-7-34 Refill Compressor Oil ...................................................... T5-7-35 Charge Air Conditioner with Refrigerant ...........................................................T5-7-36 Necessity of Purging.................................................. T5-7-36 Procedures for charging air conditioner with refrigerant ...................................................... T5-7-37 Warm-up Operation .................................................. T5-7-42 Inspection ..................................................................... T5-7-42 Hose and Pipe Tightening Torque...............................T5-7-44

95Z7B Troubleshooting

(Blank)

95Z7B Troubleshooting

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Introduction Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to quickly find the cause of the machine trouble and solution. The troubleshooting section in this manual consists of seven groups; Diagnosing Procedure, Monitor, e-Service, Component Layout, Troubleshooting A (Base Machine Diagnosis By Using Fault Codes), Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom), and Air Conditioner.  Diagnosing Procedure This group explains procedures of troubleshooting and precautions and/or information for the electrical system inspection.

 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Refer to these procedures if any fault codes are displayed when each controller is diagnosed by using MPDr. (or the the service menu of monitor).

Example: Fuse Inspection  Monitor This group contains the display screen of monitor and the operating procedures of service menu.  Component Layout

IMPORTANT: The monitor controller receives and retains a record of the electrical signal system malfunction of each controller in the form of fault codes by using the CAN communication. In addition, the self-diagnosing function records the electrical signal system malfunction in the form of fault codes Example: Fault Code 111000-2: Abnormal EEPROM  Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Refer to troubleshooting B for diagnosis by using trouble symptom. Refer to these procedures when no fault codes are displayed after diagnosing the machine by using MPDr. (or the service menu of monitor). Example: Even if accelerator pedal is operated, engine speed does not change.  Air Conditioner This group contains system of the air conditioner, troubleshooting, and procedures for charging air conditioner with refrigerant.

T5-1-1

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Diagnosis Procedure These six basic steps are essential for efficient troubleshooting: 1. Study the system  Study the machine's technical manuals.  Know the system and how it works, and what the construction, functions and specifications of the system components are. (Construction and functions) 2. Ask the operator Before inspecting, get the full story of malfunctions from the operator below.  Operating condition: How is the machine being used? (Find out if the machine is being operated correctly.)  Trouble identification: When was the trouble noticed, and what types of work the machine doing at that time?  Trouble symptom: What are the details of the trouble? Did the trouble slowly get worse, or did it appear suddenly for the first time?  Trouble history: Did the machine have any other troubles previously? If so, which parts were repaired before? 3. Inspect the machine Before starting the troubleshooting procedure, check the machine's daily maintenance points, as shown in the operator's manual. Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine. If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result, wasting time. Check for blown fuses before troubleshooting. Even if a fuse looks normal by visual inspection, a fine crack is difficult to find. Always use a circuit tester when checking the fuses.

T107-07-01-001

T4GB-05-01-002

4. Operate the machine yourself Reproduce the trouble on the machine and make sure the actual phenomenon. If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses corresponding to the trouble. T4GB-05-01-003

T5-1-2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5. Perform troubleshooting Do not disconnect harnesses or dCAUTION: hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Stop the engine before disconnecting harnesses or hydraulic lines. Perform diagnosis by connecting MPDr. to the machine or by using the service menu of monitor. In case any fault code has been displayed by diagnosis by using MPDr. (the service menu of monitor), check the cause of the trouble by referring to Troubleshooting A in this section. In case any fault code has been displayed by diagnosis by using MPDr. (the service menu of monitor), write the fault code. Delete the fault code once and retry self-diagnosis again. If the fault code is displayed again, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code (displayed by the service menu of monitor) will be deleted. Therefore, in case the problems which are not easily re-predicable are encountered, check the fault code by using MPDr. In case the fault code is not displayed, check operating condition of each component by referring to Troubleshooting B in this section and by using MPDr. (the service menu of monitor).

fNOTE: Note that the fault codes displayed do not

necessarily indicate machine trouble. The controller stores even temporary electrical malfunctions, such as a drop in battery output voltage or disconnection of the switches, sensors, etc., for inspections. For this reason, the "RETRIAL" is required to erase the accumulated fault codes from the controller memory and to confirm if any fault codes are indicated after the "RETRIAL".

T5-1-3

TNED-05-01-001

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 6. Trace possible causes Before reaching a conclusion, check the most suspect causes again. Try to identify the actual cause of the trouble. Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions.

T4GB-05-01-006

T5-1-4

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Electric System Inspection The precautions and information for the electrical system inspection are explained here. The electrical system inspection contains as follows.  Precautions for Inspection and Maintenance  Instructions for Disconnecting Connectors  Fuse Inspection  Fusible Link Inspection  Battery Voltage Check  Alternator Check  Continuity Check  Voltage and Current Measurement  Check by False Signal  Test Harness

T5-1-5

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Precautions for Inspection and Maintenance 1. Disconnect the power source. Disconnect the harness from the negative terminal side in battery first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses and fusible links and, in some cases, cause fire due to short circuit. In addition, even when the key switch is turned OFF, the controller may be operated for a specified time. Therefore, disconnect the harness from the negative terminal side in battery after setting the key switch to the OFF position and waiting 5 minutes or more. 2. Color coding of wire harnesses. As for the color codes of wire harnesses in the electrical system, refer to the table. In cases on the design sheet where two colors are indicated for one wire, the left initial stands for base color, while the right initial stands for marking color. Code Color

R Red

W White

L Blue

G Green

Y Yellow

B Black

O Orange

Lg Light green

Br Brown

P Pink

fNOTE:

Gr Gray

V Violet

Code BW indicates a black base wire (1) with white fine-line marking (2). Wires with longitudinal stripes (3) printed on the harness do not indicate color code but wire type. 2 4 5 95Z7BTT05-01-01 12-

T5-1-6

Base Wire Fine-Line Marking (Color Code)

345-

Wire Type Stripped Wire (Conductor) Wire Insulation

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 3. Precautions for connecting and disconnecting terminal connectors.  When disconnecting the harnesses, grasp them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate connectors, if a lock is provided. (Refer to Instructions for Disconnecting Connector on T5-1-8.)  The water-resistant connectors keep water out. If water enters them, water will not easily drain from them. When checking the water-resistant connectors, take extra care not to allow water to enter the connectors. In case water should enter the connectors, reconnect only after the connectors are thoroughly dried.  Before connecting the terminal connectors, check that no terminals are bent (3) or coming off. In addition, as most connectors are made of brass, check that no terminals are rusting (2).  When connecting terminal connectors provided with a lock, insert them together until the lock "clicks."  Pull the harness near the connector in order to check if it is correctly connected.

TDAA-05-08-002

1 2 3

4 TDAA-05-08-003

12-

Correct Rust

34-

Incorrect (Deformation) Incorrect (Deformation)

4. Precaution for using a circuit tester.  Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity.  Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram. When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.  When checking the connector by using a circuit tester, insert a tester probe from the harness end of connector in order not to damage the terminal inside connector.

TDAA-05-08-004

T5-1-7

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Instructions for Disconnecting Connectors  Push Lock, Pull, and Separate Type  Push the lock, and pull connector.  Connectors will not be easily separated even if the lock is pushed while being pulled.  The lock is located on female side connector (harness end side).

T107-04-05-002

 Raise Lock, Pull, and Separate Type

T107-04-05-003

T5-1-8

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure  Pull Lock and Switch the Lever Type

TDAA-05-08-005

 Unlock, Move the Lever, Pull, and Separate Type NOTE: Securely unlock with one hand and slowly pull the lever with the other hand. Then, the connector will be separated.

T4GB-05-06-001

T4GB-05-06-002

 Rotate Lock, Pull, and Separate Type NOTE: Pick up the harness end connector with fingers and rotate it counterclockwise while pushing the projection part. Then, the connector will be separated.

T4GB-05-06-007

T5-1-9

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Inspection Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a circuit tester in order to correctly inspect fuse continuity. Use a circuit tester in order to correctly inspect fuse continuity by following the instructions described below. 1. Set the key switch to the ON position. When the key switch is in the ON position, current from key switch terminal M turns the battery relay ON so that electric power is supplied to all circuits. (Refer to the circuit diagram.)

2. Remove the fuse box cover. Set a circuit tester. (Measurement Range: 0 to 30 V) 3. Ground the negative probe of circuit tester to the body. Touch the terminals located (e) of fuse box one-by-one with the positive probe of circuit tester. When normal continuity of a fuse is intact, the circuit tester will indicate 20 to 25 V (battery voltage).

M178-07-034 d-

Terminals connected to the power source

Terminals connected to loads (accessories)

a, b

Front

11 12 13 14 15

1 2 3 4 5

16 17 18 19 20

6 7 8 9 10

90MNEC-01-47 ab-

Fuse Box A Fuse Box B

Relay Box

M178-07-034

T5-1-10

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Box A

Fuse Box B

Fuse No. Capacity Connected to 1 10 A MC (Sub) Solenoid (Power) 2 3

5A 20 A

Head Lamp (Right) 24 V Socket 12 V DC-DC Converter (JPN, EU) Revolving Flasher (Option)

4 5 6 7

15 A 20 A 5A 5A

Front Wiper/Washer Working Lamp (Front) Head Lamp (Left) Backup Lamp/Alarm

Fuse No. Capacity Connected to 1 5A Radio (EU, JPN) Power On DC-DC Converter (US) Power ON 2 10 A Lighting Switch 3 20 A Room Lamp Radio (EU, JPN) DC-DC Converter (US) Tachograph (Option) 4 OPT1 (Battery) 5 5A OPT CAN 6 10 A Horn 7 10 A Flasher Unit

Service Brake Lamp

10 A

9 10 11

10 A 5A 10 A

Air Conditioner Unit 1 Parking Brake Solenoid Radio (US)

9 10 11

10 A 30 A 5A

OPT2 (ACC)

13 14 15 16

15 A 10 A 20 A 20 A

Seat Heater (Option) Starter Key Switch Air Conditioner Unit 2 SCR Sensors

13 14 15 16

10 A 5A 10 A 5A

17 18 19 20

10 A 20 A -

ECM/DCU Startup Detection SCR DCU Power OPT3 (ACC2) OPT4 (Joystick Steering)

17 18 19 20

20 A 10 A 10 A 5A

T5-1-11

MC (Main), Monitor, DSZ Load Dump Relay Optional Control Unit GPS (Option), GSM (Option) MC (Sub) Power ECM Power Position 1 (Tail Lamp RH, Front Width Lamp LH) Position 2 (Tail Lamp LH, Front Width Lamp RH) Power ON Parking Brake Relay MC (Main) Solenoid Bucket Positioner Bucket Auto Leveller Loading Lever Safety Lock Solenoid Lift Arm (Boom) Kickout Hydraulic Coupler SW (Option) Working Lamp (Rear) Rear Wiper/Washer High Beam Secondary Steering (Option)

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fusible Link Inspection Inspection 1. Visually inspect fusible links (1, 2). Replacement 1. Disconnect the negative cable from the battery. 2. To replace a fusible link, remove 2 bolts and pull it up.

3. Connect the negative cable to the battery. Battery box

95Z7B-SlowBlow

90Z7-05-01-01 1234-

T5-1-12

Fusible Link (70 A x 2) Fusible Link (140 A x 2) Cover Fuse Element

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Battery Voltage Check 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the body (ground). Normal Voltage: 24 V

fNOTE: If voltage is abnormal, recharge or replace the battery.

2. Start the engine. Check voltage between the battery positive terminal and the body (ground). Normal Voltage: 26 to 28 V

fNOTE: If voltage is abnormal, check the charging

Machine Front

system.

95Z7BTT05-01-03

T5-1-13

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Alternator Check Generally, if the alternator has generated electricity, alternator alarm (1) will disappear. If discharge warning indicator (1) is displayed while the engine is running, the alternator might be defective. How to Check Alternator 1. Set the key switch to the ON position. Confirm that discharge warning indicator (1) is displayed. 2. Measure voltage between terminals B and E of alternator (2). If the measured voltage is around 24 V, the alternator circuit can be considered normal. If the measured voltage is low, a shortage in battery capacity or looseness of the wire connectors of alternator circuit might be the cause of the malfunction. When voltage is 0 V, the wiring between fuse box and alternator might be loose or disconnected. Also, the alternator cannot generate electricity if the ground line is disconnected.

1 MNEC-01-073

3. Next, start the engine and measure voltage generated while the alternator rotates. As described above, measure voltage between terminals B and E on the alternator side. If voltage is around 28 V, the alternator is operating normally. If the rated voltage is not being generated (around 24 V), there is some trouble with the alternator or the regulator.

Engine 95Z7-05-01-02

2 E

95Z7-05-01-01

T5-1-14

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Continuity Check IMPORTANT: Before continuity check, set the key switch to the OFF position.

 Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends:  If the ohm-meter reading is: ∞ Ω = Discontinuity  0 Ω = Continuity

 When the one end connector is far apart from the other, connect one end of connector (A) to the body by using a clip. Then, check continuity of the harness through the body as illustrated.  If the ohm-meter reading is: ∞ Ω = Discontinuity  0 Ω = Continuity A

 Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the body:  0 Ω = Short-circuit is present.  ∞ Ω = No short-circuit is present.

T107-07-05-003

Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the short-circuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c). By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c).  0 Ω = Line (B) - (b) has discontinuity.  ∞ Ω = Line (A) - (a) has discontinuity.

A B C

a b c

T107-07-05-004

A B C

a b c

 Multi-line short-circuit check Disconnect both end connectors of the harness, and check continuity between terminals (A) and (B) or (C).  0 Ω = Short-circuit exists between the lines.  ∞ Ω = No short-circuit exists between the lines. T107-07-05-005

T5-1-15

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Voltage and Current Measurement Turn key switch ON so that the specified voltage (current) is supplied to the location to be measured. Judge if the circuit is normal by evaluating whether the measured voltage (current) matches the specification. 24-Volt Circuit Start checking the circuit in order up to the location to be measured from either power source or actuator side. Thereby, the faulty location in the circuit will be found.  Black (negative) probe terminal of circuit tester: To ground to the body Red (Positive) probe terminal of circuit tester: To touch the location to be measured Engine Electric Power Circuit Stopped Stopped Stopped Stopped Stopped Stopped Preheating Circuit Stopped Stopped Charging Circuit Fast Speed Fast Speed Fast Speed Fast Speed Surge Voltage Prevention Circuit Idle Speed Idle Speed Idle Speed Idle Speed Accessory Circuit Stopped Stopped

Key Switch

Location to be Measured

OFF OFF OFF OFF OFF OFF

Between (2) and (1): Between (3) and (2): Between (3) and (1): Between (4) and Ground: Between (5) and Ground: Between (1) and Ground:

ON or START ON or START

Between (11) and Ground: Key Switch Between (7) and Ground: Glow Plug (Air Heater) *2

20 to 25 V 20 to 25 V

ON ON ON

26 to 30 V 26 to 30 V 26 to 30 V

Between (9) and Ground: Alternator (B)/Generating Voltage Between (8) and Ground: Battery Relay/Generating Voltage Between (17) and Ground: Fusible Link (140 A)/Generating Voltage Between (14) and Ground: Monitor Controller (A15)

ON ON ON ON

Between (9) and Ground: Between (13) and Ground: Between (10) and Ground: Between (6) and Ground:

26 to 30 V 26 to 30 V 26 to 30 V 26 to 30 V

ON ON

One Battery One Battery Two Batteries Battery Power Fusible Link Backup Current *1

Specification

Alternator (B) Key Switch ON Cut Relay (Option) Load Dump Relay Battery Relay

Between (12) and Ground: ACC Cut Relay (Option) Between (15) and Ground: Monitor Controller, Switch Panel, Air Conditioner Unit Stopped ON Between (18) and Ground: Radio Stopped ON Between (19) and Ground: Fusible Link (140 A) Stopped ON Between (6) and Ground: Battery Relay 1 * Before measurement, disconnect the negative cable from the battery. *2 The preheating circuit is operated for the preheating time according to the coolant temperature.

T5-1-16

10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V 20 mA or less

13 to 30 V

20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure c

a h

To MC (Main) (B17)

i f DSZ (D08)

d j

Starter

Radio (US)

Starter relay

DSZ (A17)

ECM (V82)

ECM main relay (C2)

ECM Monitor DSZ (A15)

b m

ECM (V91)

95Z7BTT05-01-04

abcde-

Battery Alternator Fusible Link Battery Relay Glow Plug

fghij-

Load Dump Relay Key Switch ACC Cut Relay (Option) Key Switch ON Cut Relay (Option) Fuse Box B

T5-1-17

k- Fuse Box A m- Fusible Link (140 A)

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Engine Starting Circuit Started Started Started Started Started Started Started Started Started Started Started Started Started Started

Key Switch START START START START START START START START START START START START START START

Location to be Measured Between (20) and Ground: Between (21) and Ground: Between (22) and Ground: Between (23) and Ground: Between (24) and Ground: Between (25) and Ground: Between (26) and Ground: Between (27) and Ground: Between (28) and Ground: Between (29) and Ground: Between (30) and Ground: Between (31) and Ground: Between (32) and Ground: Between (33) and Ground:

Battery Relay (Coil) Battery Relay (Switch) Starter (B) Starter Relay Starter Relay Starter Cut Relay Fuse Box B Key Switch Neutral Relay Monitor Controller (A17) (Key SW Start) Main Controller (MC) (E4) (Key ON) ECM (V82) ECM Main Relay ECM Main Relay

T5-1-18

Specification 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

e c

f h

95Z7BTT05-01-05

abc-

Starter Starter Relay Battery Relay

def-

Starter Cut Relay Key Switch Fuse Box B

ghi-

T5-1-19

Monitor Controller (DSZ) ECM Main Relay ECM

j k-

Main Controller (MC) Neutral Relay

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Engine Key Switch Location to be Measured Neutral Engine Start Circuit * Stopped ON Between (36) and Ground: Key Switch Stopped ON Between (37) and Ground: Key Switch ON Cut Relay (Option) Stopped ON Between (38) and Ground: Neutral Relay (Coil) Stopped ON Between (39) and Ground: Neutral Relay (Switch) * Before measurement, set the forward/ reverse lever to the neutral position.

T5-1-20

Specification

20 to 25 V 20 to 25 V 20 to 25 V 0V

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

b a

c 95Z7BTT05-01-06

ab-

Key Switch Key Switch ON Cut Relay (Option)

Neutral Relay

T5-1-21

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5-Volt Circuit  Voltage between terminal #1 and the body Disconnect the connector with the key switch OFF. Measure voltage between terminal #1 on the body harness end connector and the body (ground).

Two Polarities 1

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To ground to the body  Red (Positive) probe terminal of circuit tester: To terminal #1  Evaluation: If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 is normal.

T107-07-05-006

Three Polarities 1

T107-07-05-007

 Voltage between terminal #1 and the ground terminal Turn OFF the key switch, and disconnect the sensor connector. Measure the voltage between terminal #1 (5 V power supply) on the body harness end connector and the ground terminal (terminal #2 for two-polarities or terminal #3 for three-polarities connector) under the following conditions.  Key Switch: ON  Black (negative) probe terminal of circuit tester: To ground terminal (Terminal #2 or #3)  Red (Positive) probe terminal of circuit tester: To terminal #1  Evaluation: If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 or the ground terminal (terminal #2 or #3) is normal.

Two Polarities 1

T107-07-05-008

Three Polarities 1

T107-07-05-009

T5-1-22

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Check by False Signal Two Polarities

Turn the key switch OFF. Disconnect the sensor connector. Turn the key switch ON. Connect terminal #1 (power source) of the body harness end connector to terminal #2 (signal). (Power voltage is used as a false signal.) Check this state by using the monitor function of MPDr. When the maximum value is displayed, MC and the circuit up to the body harness end connector are normal. If "ON" is displayed, the pressure switch circuits are normal.

IMPORTANT: Do not connect terminal #1 or #2 to terminal #3 or to the body (ground) when checking a three-polarity connector.

T107-07-05-010

Three Polarities

fNOTE: Some kinds of sensors can be monitored by the

service menu of the monitor.

T107-07-05-011

T5-1-23

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Test Harness Prepare appropriate tools as shown. Install a test harness between connectors. Check the circuit condition depending on whether the test harness lamp lights or extinguishes during operation. Check Lamp

Check Lamp -

Use in order to check a single-line (discontinuity and/or voltage).

+ -

During Operation: Light is ON. +

GND T107-07-05-012

 Solenoid Check Lamp

Solenoid Check Lamp

Use in order to check the solenoid valve unit circuits. When the corresponding control lever or switch is operated: Light is ON.

To Solenoid Connector

T5-1-24

90T107-07-06-15

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure  Pressure Sensor Test Harness Connect a test harness to the harness end connector of pressure sensor. Check the state of pressure sensor circuit. Pressure Sensor Test Harness (Example)

3 TDAA-05-06-003

12-

Test Harness (Ground, Output, 5 V Lines) Dummy Connector

Harness Connector for Sensor Connection

1. Connect the male end connector of test harness (1) to harness end connector (3). 2. Connect a dummy sensor (2) to the female end connector of test harness (1). 3. Check the output voltage.

T5-1-25

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Surge Voltage and Surge Suppression Diodes

Electromagnetic field forms when switch closes. Coil Voltage Current Voltage [V] Current [A]

Battery

When a coil is energized, an electromagnetic field is formed.

Current direction

Some electrical parts such as solenoid valves are equipped with a coil.

Time [sec]

Load 95Z7BTT05-01-07

Voltage

Battery

Current

This can damage transistors, contacts, and other electronic parts. (See connection diagram.)

Coil

Voltage [V] Current [A]

When the solenoid coil is de-energized, the field collapses across the coil. The collapse of this electromagnetic field across the solenoid coil generates an unregulated voltage surge.

When the switch opens, the field collapses across the coil windings.

Surge voltage

Load

OFF

Time [sec] 95Z7BTT05-01-08

When the surge voltage was generated, it causes to increase wear on the switch points.

Surge suppression diode

During the coil is being activated by the transistor, when the excruciating high voltage is loaded on the transistor, the transistor may be broken. In order to absorb this surge voltage, connect the diode parallel to the coil in the reverse direction against the power supply.

Coil

Switch or transistor

When the switch is off, the same amount of electric current, that was flown till now, flows through the diode. This electric current is attenuated gradually and finally it reaches zero. That means no surge voltage is generated in the circuit. This diode is called as flywheel diode.

T5-1-26

95Z7BTT05-01-09

SECTION 5 TROUBLESHOOTING Group 2 Monitor Outline Basic Screen 1

18 5 17

20 16

95Z7B-05-02-01

1234567-

Engine Tachometer Economy (ECO) Indicator Speedometer Torque Converter Oil Temperature Gauge DEF/AdBlue® Level Gauge Air Conditioner Display Ride Control Indicator (Option)

8910111213-

Seat Belt Indicator Forward/Reverse Selector Switch Indicator Declutch Indicator Aftertreatment Device Indicator Power Mode Indicator Auto Idling-Stop Indicator

14- Dual Lift Arm Auto Leveler Indicator 15- Clock, Hour Meter, Odometer 16- Fan Reverse Rotation Indicator 17- Shift HOLD Display 18- Transmission Auto-shifting Indicator 19- F-N-R/Shift Position Indicator

T5-2-1

20- Auto Brake Indicator 21- Joystick Steering Indicator (Option) 22- Traction Control Indicator 23- Torque Converter Lock-Up Indicator

SECTION 5 TROUBLESHOOTING Group 2 Monitor Operating Procedures of Service Menu IMPORTANT: The service menu is provided only for maintenance activity. Do not explain this function to your customers. The following items can be displayed on the monitor without using Maintenance Pro Dr. (MPDr.)  Engine Output Restriction Suspend: Engine output restriction status can be temporarily canceled.  Troubleshooting: Fault code is displayed.  Monitoring: A part of monitor items for MPDr. is displayed.  Controller Version: The controller version is displayed.  Issued Warning Record: Ten alarms which were issued recently are displayed.  Communication Terminal Status: Information of the communication terminal is displayed.  Machine Setting: The learning and adjustment are performed.  Engine Setting: Some of the engine control are performed.  Aftertreatment Device No.: The manufacture number of aftertreatment device (DOC, SCR) are entered.

T5-2-2

SECTION 5 TROUBLESHOOTING Group 2 Monitor 1

How to display service menu 1. Push rotating select / confirm knob (3) while pushing return to previous screen switch (1) when the basic screen is displayed with the key switch set in the ON position or the engine running.

Then, Service Menu (4) is added to the Main Menu screen.

2. Turn select / confirm knob (3) and select Service Menu (4). MNEC-01-006

95TNED-05-02-14

3. Push select / confirm knob (3). The Service Menu screen appears.

95TNED-05-02-10

4. When pushing return to previous screen switch (1), the previous screen appears. 5. When pushing return to basic screen switch (2), the basic screen appears.

fNOTE: When the basic screen has appeared by using

return to previous screen switch (1) or return to basic screen switch (2), Service Menu (4) on the Main Menu screen is deleted. In order to display Service Menu (4), perform step 1 again.

T5-2-3

SECTION 5 TROUBLESHOOTING Group 2 Monitor Troubleshooting

1. Turn select / confirm knob (3) and select Troubleshooting (4) on Service Menu. 3

TNED-05-02-002

2. When pushing select / confirm knob (3), the Troubleshooting screen appears.

3. Turn select / set switch (3) and select the controller.

95TNED-05-02-10

fNOTE: The number in parentheses to the right of menu name indicates the number of listed fault codes for the menu.

4. When pushing select / confirm knob (3), the selfdiagnostic result of selected controller (fault code) is displayed. The past fault codes as well as the current ones are displayed at this time.

95TNED-05-02-24

fNOTE: Main (Sub) (5) is shown as an example here. 6

5. Turn select / confirm knob (3), select CLEAR (6), and push select / confirm knob (3). The past fault codes are deleted and only the current fault codes can be displayed.

95TNED-05-02-25

6. When pushing return to previous screen switch (1), the previous screen appears. 7. When pushing return to basic screen switch (2), the basic screen appears.

T5-2-4

95TNED-05-02-54

SECTION 5 TROUBLESHOOTING Group 2 Monitor (Blank)

T5-2-5

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring

1. Turn select / confirm knob (3) and select Monitoring (4) on Service Menu. 3

TNED-05-02-002

2. When pushing select / confirm knob (3), the Monitoring screen appears.

95TNED-05-02-10

3. Turn select / confirm knob (3) and select the controller for monitoring.

4. When pushing select / confirm knob (3), the monitoring items for selected controller are displayed.

fNOTE: Main Controller (Sub) (5) is selected as an example here.

95TNED-05-02-15

5. Turn select / confirm knob (3), select the item for monitoring, and push select / confirm knob (3). (Up to 8 items can be selected.)

6. Push return to previous screen switch (1) and the Monitoring screen appears.

95Z7B-05-02-16E

7. Turn select / confirm knob (3), select START (6), and push select / confirm knob (3).

fNOTE: START (6) and CLEAR (7) are displayed only when

one or more monitoring items are selected. START (6) and CLEAR (7) are not displayed when no monitoring item is selected.

6 7

95TNED-05-02-17

T5-2-6

SECTION 5 TROUBLESHOOTING Group 2 Monitor 8. The selected monitoring item is started monitoring.

fNOTE: Actual Engine Speed and Actual Vehicle Speed are selected as an example here.

95TNED-05-02-19

9. When pushing select / confirm knob (3) while monitoring, PAUSE (8) is displayed and the monitoring value can pause (be held). 3

10. When pushing select / confirm knob (3) again, pausing is stopped.

TNED-05-02-002

fNOTE: Even if the key switch is set to OFF position, the

selected monitoring item has been stored. In order to release the selected monitoring item, select CLEAR (7) on the Monitoring screen and push select / confirm knob (3) for a while until START (6) and CLEAR (7) disappear.

11. When pushing return to previous screen switch (1), the previous screen appears. 12. When pushing return to basic screen switch (2), the basic screen appears.

95TNED-05-02-18

6 7

95TNED-05-02-17

T5-2-7

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Monitoring Item Engine Controller (ECM) Item Fuel Filter Restriction Switch Load Dump Relay Output Engine Torque Actual Engine Speed Coolant Temperature Fuel Temperature Engine Oil Pressure Atmospheric Pressure Intake Air Temperature Boost Pressure Boost Temperature Target Fuel Injection Quantity Intercooler Inlet Temperature EGR Opening Amount 1 EGR Opening Amount 2 ITH Opening Amount Common Rail Pressure Actual Turbo Opening Amount DOC Outlet Exhaust Temperature DOC Inlet Exhaust Temperature Intake Air Temperature in Manifold Supply Pump Inlet Pressure ECM Battery Voltage Starter Switch Air Cleaner Restriction Switch Manual Regeneration Switch Engine Stop Switch Starter Cutoff Relay Signal Regeneration Status2

ESCAPE MODE Possible Urea Quality Alarm Light REFILL DEF/AdBlue Light NO POWER Light ESCAPE MODE Light

Unit Data OFF/ON Clogged fuel filter status OFF/ON Load dump relay ON/OFF status % Input signal from ECM Input signal from crank speed sensor and cam angle sensor min-1 °C Input signal from coolant temperature sensor °C Input signal from fuel temperature sensor kPa Input signal from engine oil pressure sensor kPa Input signal from atmospheric pressure sensor °C Input signal from intake-air temperature sensor kPa Input signal from boost pressure sensor °C Input signal from boost temperature sensor Input signal from ECM mm3/st °C Input signal from ECM % Input signal from ECM % Input signal from ECM % Input signal from ECM MPa Input signal from common rail pressure sensor % Input signal from ECM °C Input signal from exhaust temperature sensor (DOC outlet) °C Input signal from exhaust temperature sensor (DOC inlet) °C Input signal from intake manifold temperature sensor kPa Input signal from suction control valve V Input signal from ECM OFF/ON Key switch ON/OFF status OFF/ON Air cleaner restriction switch ON/OFF status OFF/ON Regeneration switch ON/OFF status OFF/ON Engine stop switch ON/OFF status OFF/ON Starter cutoff relay ON/OFF status 0: Normal Regeneration status of aftertreatment device 1: Regeneration end judging 4: Auto regeneration 5: Manual regeneration 0: Disabled Engine output restriction temporary release mode (ESCAPE 1: Enabled MODE) is disabled/enabled. 0: OFF Alarm ON/OFF status when urea SCR system is abnormal 1: ON (Abnormal DEF Quality) 0: OFF Alarm ON/OFF status when DEF is insufficient 1: ON 0: OFF Alarm ON/OFF status at engine output restriction (Level 3) 1: ON 0: OFF Alarm ON/OFF status when engine output restriction 1: ON temporary release mode (ESCAPE MODE) is activated

T5-2-8

SECTION 5 TROUBLESHOOTING Group 2 Monitor Engine Controller (ECM) Item Inducement Level

EXH FLUID Light EXH.SYSTEM Light Engine DERATE Light Repeat Offence Flag Regeneration Status1

DEF/AdBlue Level DEF/AdBlue S/M Temperature DEF/AdBlue Tank Temperature SCR Exhaust Temperature Upstream NOx Sensor Status Downstream NOx Sensor Status DEF/AdBlue Pressure DCU Battery Voltage Dosing Valve Status DEF/AdBlue Concentration Dosing Valve Opening DEF/AdBlue S/M Pump Opening CCV ON/OFF Reverting Valve ON/OFF Target Engine Speed Directed Engine Speed Common Rail Pressure DP EGR Cooler 1 Inlet Temperature EGR Cooler 2 Inlet Temperature

Unit Data 0: Normal Current engine output restriction status 1: Level 1 2: Level 2 3: Level 3 0: Lighting Alarm lighting/blinking status when urea SCR system is 1: Blinking abnormal 0: OFF Alarm ON/OFF status when urea SCR system is abnormal 1: ON 0: OFF Alarm ON/OFF status at engine output restriction (Level 2) 1: ON 0: Normal Status at monitoring of engine output restriction 1: Monitoring reappearance (REPEAT OFFENCE) Regeneration status of aftertreatment device 0: Normal 1: Regeneration 2: Required manual regeneration % Input signal from ECM °C Input signal from ECM (Temperature at supply module) °C Input signal from ECM °C Input signal from the SCR exhaust temperature sensor Input signal from NOx sensor (before DOC) Input signal from NOx sensor (after SCR) hPa Input signal from DEF/AdBlue pressure sensor V Input signal from DCU battery 0 to 255 Dosing module operating status % Input signal from ECM % Input signal from ECM % Input signal from ECM 0: OFF Coolant control valve ON/OFF status 1: ON 0: OFF Reverting valve ON/OFF status 1: ON rpm Input signal from ECM rpm Input signal from ECM MPa (Common rail differential pressure) °C Input signal from EGR sensor °C Input signal from EGR sensor

T5-2-9

SECTION 5 TROUBLESHOOTING Group 2 Monitor Main Controller (T/M) Item Demand Engine Speed Actual Engine Speed Accelerator Pedal 1 Transmission Oil Temperature Pump Delivery Pressure Torque Converter Output Speed Intermediate Gear Speed

Unit min-1 min-1 V °C MPa min-1 min-1

Transmission Output Speed Actual Vehicle Speed

min-1 km/h

Parking Brake Pressure Service Brake Secondary Pressure (For clutch Cut Off ) Torque Converter Speed Ratio

MPa MPa

Vehicle Speed Pulse Warning Buzzer

Forward Clutch Pressure Reverse Clutch Pressure 1st Clutch Pressure 2nd Clutch Pressure 3rd Clutch Pressure T/M Clutch Forward P/S Output T/M Clutch High P/S Output T/M Clutch Reverse P/S Output T/M Clutch 1st P/S Output T/M Clutch 2nd P/S Output T/M Clutch 3rd P/S Output T/M Clutch Lock Up P/S Output Pump Swash Angle P/S Output Auto Brake P/S Output T/M Clutch Forward P/S Output FB T/M Clutch High P/S Output FB T/M Clutch Reverse P/S Output FB T/M Clutch 1st P/S Output FB T/M Clutch 2nd P/S Output FB T/M Clutch 3rd P/S Output FB T/M Clutch Lock Up P/S Output FB Pump Swash Angle P/S Output FB Auto Brake P/S Output FB

% pulse 0: OFF 1: ON 2: ON 3: ON MPa MPa MPa MPa MPa mA mA mA mA mA mA mA MPa mA mA mA mA mA mA mA mA mA mA

Data Command value of engine speed from MC to ECM. Input signal from ECM Input signal from accelerator pedal sensor Input signal from transmission oil temperature sensor Input signal from pump delivery pressure sensor Input signal from torque converter output speed sensor Input signal from transmission intermediate gear shaft speed sensor (machine speed backup sensor) Input signal from transmission output speed sensor Converted signal from machine speed sensor into speed per hour Input signal from pressure sensor (parking brake) Input signal from pressure sensor (brake secondary pressure for declutch) Calculated signal from actual engine speed and torque converter output speed by MC (T/M) Actual transmission output speed pulse Auto idling-stop alarm ON/OFF status

Input signal from pressure sensor (forward clutch solenoid) Input signal from pressure sensor (reverse clutch solenoid) Input signal from pressure sensor (1st speed clutch solenoid) Input signal from pressure sensor (2nd speed clutch solenoid) Input signal from pressure sensor (3rd speed clutch solenoid) Control signal to transmission forward clutch solenoid valve Control signal to transmission high clutch solenoid valve Control signal to transmission reverse clutch solenoid valve Control signal to transmission 1st speed clutch solenoid valve Control signal to transmission 2nd speed clutch solenoid valve Control signal to transmission 3rd speed clutch solenoid valve Control signal to transmission lock up clutch solenoid valve Control signal to torque control solenoid valve Control signal to auto brake solenoid valve Feedback from transmission forward clutch solenoid valve Feedback from high clutch solenoid valve Feedback from reverse clutch solenoid valve Feedback from 1st speed clutch solenoid valve Feedback from 2nd speed clutch solenoid valve Feedback from 3rd speed clutch solenoid valve Feedback from lock up clutch solenoid valve Feedback from torque control solenoid valve output Feedback from auto brake solenoid valve output

T5-2-10

SECTION 5 TROUBLESHOOTING Group 2 Monitor Main Controller (T/M) Item Quick Power Switch Power Mode Switch DSS Switch Hold Switch Clutch Cut Off Position Switch

Travel Mode Selector Switch

Armrest Switch * U/D UP Button * U/D DOWN Button * Parking Brake Indicator Backup Light Relay Neutral Relay Forward/Reverse Lever

Unit OFF/ON OFF/ON OFF/ON OFF/ON 0: OFF 1: N Mode 2: D Mode 0: Manual Mode 1: AUTO_1 2: AUTO_2 OFF/ON OFF/ON OFF/ON

T/M Restriction Switch

OFF/ON OFF/ON OFF/ON 0: N 1: F 2: R 0: N 1: F 2: R 0: 1st speed 1: 2nd speed 2: 3rd speed 3: 4th speed OFF/ON

Auto Shut-Down Relay Bucket Angle Switch * Accelerator Pedal 2

OFF/ON OFF/ON V

Forward/Reverse Switch

Shift Switch

Data Quick power switch ON/OFF status Power mode switch ON/OFF status Downshift switch ON/OFF status Shift hold switch ON/OFF status Declutch mode status

Auto-shift mode status

Armrest switch ON/OFF status ON/OFF status of shift up button on the joystick steering lever ON/OFF status of shift down button on the joystick steering lever Parking brake indicator ON/OFF status Backup relay ON/OFF status Neutral relay ON/OFF status Forward/reverse lever selected position status

Forward/reverse switch selected position status

Shift switch selected speed range status

Transmission oil filter restriction (clog monitoring) switch ON/ OFF status Auto idling-stop relay ON/OFF status Bucket angle position detection switch ON/OFF status Input signal from accelerator pedal sensor 2

fNOTE: *: Option

T5-2-11

SECTION 5 TROUBLESHOOTING Group 2 Monitor Main Controller (Sub) Item Target Hydraulic Fan Speed

Unit min-1

Hydraulic Oil Temperature Torque Converter Oil Temperature Front Axle Oil Temperature Rear Axle Oil Temperature Lift Arm Angle Sensor Service Brake Primary Pressure (Front) Service Brake Primary Pressure (Rear) Hydraulic Fan Circuit Pressure Emergency Steering Pump Delivery Pressure * Air Conditioner Refrigerant Pressure Bucket Tilt Pilot Pressure Bucket Dump Pilot Pressure Lift Arm Raise Pilot Pressure Parallel/Tandem Control P/S Output Ride Control (Rod) P/S Output *

°C °C °C °C V MPa MPa MPa MPa MPa MPa MPa MPa MPa mA

Ride Control (Bottom) P/S Output *

Hyd Fan Reverse Rotation P/S Output Hyd Fan Speed Control P/S Output Lift Arm Speed Multiplication P/S Output

mA mA mA

Data Calculated signal from actual engine speed and control signal to fan control valve Input signal from hydraulic oil temperature sensor Input signal from torque converter oil temperature sensor Input signal from front axle oil temperature sensor Input signal from rear axle oil temperature sensor Input signal from lift arm (boom) angle sensor Input signal from pressure sensor (front brake primary pressure) Input signal from pressure sensor (rear brake primary pressure) Input signal from hydraulic fan circuit pressure sensor Input signal from secondary steering pump delivery pressure sensor Input signal from pressure sensor (refrigerant pressure) Input signal from pressure sensor (bucket roll back) Input signal from pressure sensor (bucket dump) Input signal from pressure sensor (lift arm raise) Control signal to parallel/tandem switching solenoid valve Control signal to ride control proportional solenoid valve (boom cylinder rod side) Control signal to ride control selector solenoid valve (boom cylinder bottom side) Control signal to fan reverse control solenoid valve Control signal to fan speed control solenoid valve Control signal to lift arm speed multiplication solenoid valve

fNOTE: *: Option

T5-2-12

SECTION 5 TROUBLESHOOTING Group 2 Monitor Main Controller (Sub) Item Unit Parallel/Tandem Control P/S Output FB mA Ride Control (Rod) P/S Output FB * mA Ride Control (Bottom) P/S Output FB *

Hyd Fan Reverse Rotation P/S Output FB Hyd Fan Speed Control P/S Output FB Lift Arm Speed Multiplication P/S Output FB Operation Lever Primary Pilot Pressure Steering Pressure Switch * Emergency Steering Check Switch * Fan Reversing Switch Fan Reversing Switch (Auto) * Ride Control Switch (Auto) * Ride Control Switch * Stick Steering Selector Switch * Emergency Steering Pump Relay * Low Steering Oil Pressure Indicator Low Brake Oil Pressure Indicator Lift Arm Auto Leveler Lower Kickout Lift Arm Auto Leveler Height Kickout Bucket Positioner Switch Axle Oil Cooler Relay * Lift Arm Bottom Pressure Lift Arm Rod Pressure

Data Feedback from parallel/tandem switching solenoid valve Feedback from ride control proportional solenoid valve (boom cylinder rod side) Feedback from ride control selector solenoid valve (boom cylinder bottom side) Feedback from fan reverse control solenoid valve

mA mA

Feedback from fan speed control solenoid valve Feedback from lift arm speed multiplication solenoid valve

MPa OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON ON/OFF ON/OFF MPa MPa

Input signal from pressure sensor (pilot valve primary pressure) Steering pressure switch ON/OFF status Secondary steering operation check switch ON/OFF status Fan reverse switch ON/OFF status Fan reverse auto switch ON/OFF status Ride control auto switch ON/OFF status Ride control switch ON/OFF status Stick steering selector switch ON/OFF status Secondary steering pump relay ON/OFF status Steering pressure warning indicator ON/OFF status Service brake warning indicator ON/OFF status Lower kickout detent ON/OFF status Height kickout detent ON/OFF status Bucket positioner (leveler) switch ON/OFF status Axle oil cooler relay ON/OFF status Input signal from pressure sensor (lift arm bottom pressure) Input signal from pressure sensor (lift arm rod pressure)

fNOTE: *:Optional

T5-2-13

SECTION 5 TROUBLESHOOTING Group 2 Monitor Column Display Controller Item Overheat Switch 1 Engine Oil Pressure Switch 1 Air Cleaner Restriction Switch Hydraulic Oil Level Switch Engine Trouble Switch Glow Switch Model Selector Switch 1 Model Selector Switch 2 Front Washer Switch Front Wiper Switch Light Switch Steering Pressure Switch Neutral Switch Digital Input 2 Digital Input 3 Front Wiper Relay 1 Output Front Wiper Relay 2 Output Buzzer Output Transmission Trouble Switch Service Brake Pressure Switch

Unit Data OFF/ON Overheat switch ON/OFF status OFF/ON Engine oil pressure switch ON/OFF status OFF/ON Air cleaner restriction (clog monitoring) switch ON/OFF status OFF/ON Hydraulic oil level switch ON/OFF status OFF/ON Engine trouble switch ON/OFF status OFF/ON Glow switch ON/OFF status OFF/ON Model selector switch 1 ON/OFF status OFF/ON Model selector switch 2 ON/OFF status OFF/ON Front washer switch ON/OFF status OFF/INT/LO/HI Front wiper switch selection status OFF/ON Light switch ON/OFF status OFF/ON Steering pressure switch ON/OFF status OFF/ON Main controller (T/M controller) neutral status OFF/ON OFF/ON OFF/ON Front wiper relay 1 ON/OFF status OFF/ON Front wiper relay 2 (fast speed) ON/OFF status OFF/ON Warning buzzer ON/OFF status OFF/ON Transmission trouble switch ON/OFF status OFF/ON Service brake pressure switch ON/OFF status

T5-2-14

SECTION 5 TROUBLESHOOTING Group 2 Monitor Air Conditioner Unit Item Compressor Operation Outdoor Air Temperature Indoor Air Temperature Amount of Insolation

Unit OFF/ON °C °C W/m2

Data Compressor operating status Input signal from ambient temperature sensor Input signal from air circulation sensor Input signal from solar radiation sensor

T5-2-15

SECTION 5 TROUBLESHOOTING Group 2 Monitor Controller Version

1. Turn select / confirm knob (3) and select Controller Version (4) on Service Menu. 3

TNED-05-02-002

2. When pushing select / confirm knob (3), the version of each controller appears.

3. When pushing return to previous screen switch (1), the previous screen appears. 4. When pushing return to basic screen switch (2), the basic screen appears.

T5-2-16

95TNED-05-02-10

95TNED-05-02-09

SECTION 5 TROUBLESHOOTING Group 2 Monitor Issued Warning Record

1. Turn select / confirm knob (3) and select Issued Warning Record (4) on Service Menu. 3

TNED-05-02-002

2. When pushing select / confirm knob (3), the Issued Warning Record screen appears. The symbol and trouble of maximum ten alarms which occurred and reported recently are displayed. (Refer To List of Alarm.)

3. Turn select / confirm knob (3) and select the displayed alarm. When pushing select / confirm knob (3), the time (ON / OFF) when the selected alarm has occurred / solved are displayed.

4. In case of currently occurring alarms, the resolving time (OFF) of the alarm is dashed (---).

95TNED-05-02-10

95Z7B-05-02-21E

95Z7B-05-02-22E

fNOTE: The display of date and time depends on the setting. (Refer to the operator’s manual.)

5. When pushing return to previous screen switch (1), the previous screen appears. 6. When pushing return to basic screen switch (2), the basic screen appears.

T5-2-17

95Z7B-05-02-23E

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Alarm Symbol

Alarm Brake Oil Pressure Alarm

Monitor Message Brake Oil Pressure Is Low. Safely Park The Machine And Stop The Engine Immediately. Check Hydraulic Oil Level And Brake System For Damages And Leaks

Remedy Refer to Troubleshooting A.

Steering Oil Pressure Alarm

Steering Oil Pressure Is Low. Safely Park The Machine And Stop The Engine Immediately. Check Hydraulic Oil Level And Auto-Brake System For Damages And Leaks.

Refer to Troubleshooting A.

Secondary Steering Alarm (Blinking)

Safely Park The Machine And Stop The Engine Immediately. Check Hydraulic Oil Level And Secondary Steering System For Damages And Leaks.

Refer to Troubleshooting A.

Hydraulic Oil Level Alarm

Hydraulic Oil Level Is Low. Safely Park The Machine And Stop The Engine Immediately. Check Hydraulic Oil Level And System For Damages And Leaks.

Refer to Troubleshooting A.

Aftertreatment Device Alarm (Blinking) (Red)

Aftertreatment Device Is Abnormal. Safely Park The Machine And Stop The Engine Immediately. Contact Your Nearest Authorized Dealer.

Follow Trouble Screen on the monitor.

* Aftertreatment Device Aftertreatment Device Needs Immediate Regeneration To Regeneration Request Prevent Damage To The Filter. (Blinking) (Yellow) Safely Park The Machine With The Engine Running . Turn The Aftertreatment Device Switch To "Regeneration" MDAA-01-026 Following The Instruction On Monitor. * Aftertreatment Device Aftertreatment Device Regeneration Operation Is Inhibited. Regeneration Inhibit Safely Park The Machine And Manually Perform Alarm Regeneration. (Lighting) (Yellow)

Follow Trouble Screen on the monitor.

M4GB-01-013

M4GB-01-016

M4GB-01-015

M4GF-01-004

MDAA-01-025

Follow Trouble Screen on the monitor.

MDAA-01-027

* Aftertreatment Device Auto Aftertreatment Device Regeneration Is Deactivated. Auto Regeneration Safely Park The Machine And Manually Perform Inhibit Alarm Regeneration. (Lighting) (Yellow) MDAA-01-027

fNOTE: *: These alarms are not displayed on the Issued Warning Record screen.

T5-2-18

Follow Trouble Screen on the monitor.

SECTION 5 TROUBLESHOOTING Group 2 Monitor Symbol

Alarm Monitor Message * Aftertreatment Device Hydraulic Oil Temperature Is Too High For Manual Regeneration Alarm Aftertreatment Device Regeneration. (Lighting) (Yellow) Safely Park The Machine With The Engine Running At Slow Idle Speed. Regenerate After Hydraulic Oil Temperature Cools. MDAA-01-027

Remedy Follow Trouble Screen on the monitor.

Overheat Alarm

Coolant Temperature Is Abnormally High. Stop Operation. Run The Engine At Slow Idle To Cool Coolant Temperature.

Follow Trouble Screen on the monitor.

Hydraulic Oil Overheat Alarm

Hydraulic Oil Temperature Is Abnormally High. Stop Machine Operation. Run The Engine At Slow Idle Speed To Lower The Oil Temperature.

Refer to Troubleshooting A.

Axle Oil Temperature Alarm

Axle Oil Temperature Is Abnormally High. Check If The Service Brake Is Daggled. If The Brake Pedal Is Continuously Stepped On, An Increase Of The Axle Oil Temperature May Result.

Follow Trouble Screen on the monitor.

Transmission Oil Overheat Alarm

Transmission Oil Temperature Is Abnormally High. Stop Machine Operation. Run The Engine At Slow Idle Speed To Lower The Oil Temperature.

Refer to Troubleshooting A.

Engine Trouble Alarm

Engine Or Accessory Are Abnormal. Safely Park The Machine And Stop The Engine Immediately. Contact Your Nearest Authorized Dealer.

Refer to Engine Troubleshooting Manual.

Transmission Warning Alarm

Transmission Or accessory Is Abnormal. Safely Park The Machine And Stop The Engine Immediately. Contact Your Nearest Authorized Dealer.

Refer to Troubleshooting A.

Transmission Oil Pressure Alarm

Transmission oil pressure is too low. Safely park the machine. Check transmission oil level and check for leaks.

Refer to Troubleshooting A.

Engine Oil Pressure Alarm

Engine Oil Pressure Is Low. Immediately Stop The Engine. Check The Engine Oil System And Oil Level.

Refer to Troubleshooting A.

MDAA-01-067

MDAA-01-068

M4GF-01-005

M4GB-01-027

MDAA-01-069

M4GB-01-024

M183-01-073

M4GB-01-021

fNOTE: *: These alarms are not displayed on the Issued Warning Record screen.

T5-2-19

SECTION 5 TROUBLESHOOTING Group 2 Monitor Symbol

Alarm Boost Temperature Rise Alarm

Monitor Message Intake air temperature is abnormally high. Stop operation. Check intercooler for clogging and intake air piping connections.

Auto Brake Warning Alarm

Auto brake system is abnormal. Safely park the machine and stop the engine immediately. Check hydraulic oil level and auto brake system for damages and leaks.

Transmission Filter Clogging

Remedy Refer to Troubleshooting A.

MDAA-01-029

95Z7-AutoBrakeAlarm

95Z7-TM-clog

Main Pump Oil Pressure Main Pump Oil Pressure Is Too Low. Alarm Safely Park The Machine. Check For Leaks Especially At Front Attachment Piping.

Refer to Troubleshooting A.

MNEC-01-009

Exhaust Temperature Rise Alarm

Exhaust temperature is abnormally high. Stop machine operation, apply parking brake, and check the exhaust lines.

Intake Air Temperature Rise Alarm

Intake air temperature is abnormally high. Stop machine operation and apply parking brake. Check for any abnormality such as disconnected intake air piping.

Urea System Alarm

Aftertreatment Device Is Abnormal. Contact Your Nearest Authorized Dealer.

Refer to Troubleshooting A.

Battery Charge Alarm

Electrical System Is Abnormal. Safely Park The Machine And Stop The Engine. Check Alternator And Battery Systems. Contact Your Nearest Authorized Dealer.

Refer to Troubleshooting A.

M183-01-074

MDAA-01-031

MDAA-01-071

M183-01-071

fNOTE: In case of Exhaust Filter Abnormal, the exhaust filter is not abnormal, but the circuit corresponding to exhaust filter regeneration is abnormal.

T5-2-20

SECTION 5 TROUBLESHOOTING Group 2 Monitor Symbol

Alarm Monitor Message Fuel Temperature Alarm Fuel temperature is abnormally high. Stop machine operation and apply parking brake. Run the engine at slow idle speed to lower the fuel temperature.

Remedy

Air Cleaner Clogging

Air Cleaner Elements Are Clogged. Clean Or Replace Air Cleaner Element Following The Instruction In The Operator's Manual. Serious Engine Damage Will Occur If Ignored.

Follow Trouble Screen on the monitor.

Fuel Filter Restriction Alarm

Fuel filter is clogged. Replace fuel filter element.

EGR Gas Temperature Alarm

EGR gas temperature is abnormally high. Stop operation, apply parking brake, and check EGR cooler, EGR cooler coolant circulation circuit, coolant level and intake air and exhaust piping for any abnormality.

Water Separator Alarm (Option)

Water Separator Is Full. Drain Water.

Follow Trouble Screen on the monitor.

System Failure Alarm

Machine Network System Is Abnormal. Contact Your Nearest Authorized Dealer.

Refer to Troubleshooting A.

MDAA-01-032

M183-01-067

M1U1-01-116

MDAA-01-035

MNEC-01-010

MDDA-01-034

T5-2-21

SECTION 5 TROUBLESHOOTING Group 2 Monitor Communication Terminal Status 1

1. Turn select / set switch (3) and select Communication Terminal Status (4) on Service Menu.

TNED-05-02-002

2. When pushing select / set switch (3), the Communication Terminal Status screen appears.

3. Each data of the communication terminals is displayed. (Refer To List of Communication Terminal Status.)

TNED-05-02-010EN

4. When pushing back switch (1), the previous screen appears. 5. When pushing return to basic screen switch (2), the basic screen appears. TNED-05-02-034EN

T5-2-22

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Communication Terminal Status Item

Unit

GPS Status

0 to 2

Radio Wave Intensity

0 to 3, 250, 254

Data Transmission Status

0, 1

Communication Module Status

0, 1

Portable Antenna Signal

0 to 31, 99

GPRS Ntwk Conn Status

0, 1

Frequency Band

0 to 3

Data Portable Terminal (Option) 0: Uncoupled Connection 1: Incomplete Positioning 2: Positioning State 0: Reception Level: 0 1: Reception Level: 1 2: Reception Level: 2 3: Reception Level: 3 250: Out of range 254: Not detected 0: Uncoupled Connection 1: Connection 0: Correct 1: Incorrect 0 to 1: Out of range 2 to 8: Reception Level: 0 9 to 12: Reception Level: 1 13 to 17: Reception Level: 2 18 to 31: Reception Level: 3 99: Not detected 0: Failure 1: Success 0 to 3

fNOTE: The detail data of radio wave intensity are displayed for Antenna Signal.

T5-2-23

Satellite Terminal (Option) 0: Uncoupled Connection 1: Incomplete Positioning 2: Positioning State 0: Communication not available 1: Communication available

SECTION 5 TROUBLESHOOTING Group 2 Monitor Machine Setting

 Learning/Adjustment 1. Turn select / confirm knob (3) and select Machine Setting (4) on Service Menu.

TNED-05-02-002

95Z7B-05-02-11E

2. When pushing select / confirm knob (3), the Machine Setting screen appears. (Refer to List of Machine Setting Item.)

fNOTE: Items of learning/adjustment are as follows.  Transmission Learning  Lift Arm Angle Sensor Learning  Digging Position Adjustment 95TNED-05-02-61

T5-2-24

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Machine Setting Item Item Transmission Learning Lift Arm Angle Sensor Learning Digging Position Adjustment

Unit -

Details Performance of learning (calibration) Performance of learning Adjustment of position

T5-2-25

SECTION 5 TROUBLESHOOTING Group 2 Monitor Transmission Learning IMPORTANT: When transmission or transmission control valve has been repaired/replaced, and Main Controller (MC) has been replaced, perform transmission learning. Preparation: 1. Start the engine. 2. Select Service Menu screen on the monitor and Machine Setting/Transmission Learning screen appears. (Refer to Monitor Operation) 3. Stall the transmission with the following machine conditions. Stall Condition:  Declutch Position Switch: OFF  Travel Mode: Manual Mode  Shift Switch: 4th  Parking Brake Switch: OFF  Brake Pedal: Fully Applied  Accelerator Pedal: Fully Applied  Forward/Reverse Lever: Forward Position 4. Raise transmission oil temperature (7) up to 60°C (140°F) but not to exceed 115°C (239°F) by operating the accelerator pedal moderately. 5. When transmission oil temperature (7) reaches 60°C (140°F), stop transmission stalling, and set the machine in the following conditions. Learning Start Condition:  Accelerator Pedal: Not Applied  Forward/Reverse Lever: Neutral Position  Parking Brake Switch: ON  Brake Pedal: Not Applied

T5-2-26

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitor Operation: 1

IMPORTANT: Do not operate control levers and other switches when learning is performed. 1. Turn select / confirm knob (3) and select Machine Setting (4) on Service Menu.

TNED-05-02-002

95Z7B-05-02-11E

2. When pushing select / confirm knob (3), the Machine Setting screen appears.

3. Turn select / confirm knob (3) and select Transmission Learning (5).

95TNED-05-02-61

T5-2-27

SECTION 5 TROUBLESHOOTING Group 2 Monitor 4. When pushing select / confirm knob (3), Transmission Learning (5) screen appears.

5. When transmission oil temperature (7) is 50 to 60°C (122 to 140°F), "Start" (6) appears on the monitor display. 6. Push select / confirm knob (3) to start learning.

95TNED-05-02-71

fNOTE: While transmission learning is in process, the

learning progress (8) and the transmission oil temperature are displayed. F1~F3: Forward clutch R1~R3: Reverse clutch 11~13: 1st speed clutch 21~23: 2nd speed clutch 31~33: 3rd speed clutch

fNOTE: While transmission learning is in process, input

signal to return to previous screen switch (1) and return to basic screen switch (2) is invalid.

95Z7BTT05-02-01E

7. When learning is completed, the Learning End screen appears. 8. Set the key switch to the OFF position, and finish the learning.

95Z7BTT05-02-02E

T5-2-28

SECTION 5 TROUBLESHOOTING Group 2 Monitor Transmission Learning Error: 9

 Learning failed to start If the transmission learning failed to start, the error number is indicated (9). Solve the problem and restart transmission learning. Error Description Number 2 Forward/reverse lever and/or switch is not in "Neutral" position. 3 Parking brake switch is not "ON". 4 Machine is in running status. 5 Transmission Oil temperature is too low. 6 Transmission Oil temperature is too high. 7 Engine speed is too low. 8 Engine speed is too high.  Learning cancelled If the transmission learning is aborted, the error number is indicated (10). Solve the problem and restart transmission learning.

95Z7BTT05-02-03E

Error Description Number 108 Starter key switch was turned "OFF". 208

Engine speed fell out of the specified range.

308

Parking brake switch was turned OFF.

408

Machine was made in running status.

508

Forward/reverse lever and/or switch was operated.

109 209 309 110 210 310 111 211 311 113 213 313 114 214 314

95Z7BTT05-02-04E

Calibration of 1st speed clutch failed.

Calibration of 2nd speed clutch failed.

Calibration of 3rd speed clutch failed.

Calibration of forward clutch failed.

Calibration of reverse clutch failed.

fNOTE: When the machine is in deactivation condition

while learning, learning is stopped. Turn the start key to OFF, wait for 10 seconds, and turn the key ON. Perform the learning again.

T5-2-29

SECTION 5 TROUBLESHOOTING Group 2 Monitor Lift Arm Angle Sensor Learning IMPORTANT: When lift arm angle sensor has been replaced, perform lift arm angle sensor learning.

Preparation: 1. Start the engine.

2. Set front control lever lock switch (1) to UNLOCK Position (3).

3. Raise lift arms to the highest level by lift arm raise operation. MNEC-01-041

4. Set front control lever lock switch (1) to LOCK Position (2). 1

5. Set the key switch to the OFF position.

3 MNEC-01-015 2-

T5-2-30

LOCK

UNLOCK

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitor Operation: 1

IMPORTANT: The learning can not be performed when the value of lift arm angle sensor is out of range from 3.3 V to 4.3 V. 3

1. Set the key switch to the ON position. 2. Turn select / confirm knob (3) and select Machine Setting (4) on Service Menu.

TNED-05-02-002

95Z7B-05-02-11E

3. When pushing select / confirm knob (3), the Machine Setting screen appears. 4. Turn select / confirm knob (3) and select Lift Arm Angle Sensor Learning (5).

95TNED-05-02-61

5. When pushing select / confirm knob (3), the Lift Arm Angle Sensor Learning (5) screen appears. 6. When pushing select / confirm knob (3), the learning starts.

95TNED-05-02-72

7. When learning is completed, the Learning End screen appears. 8. Set the key switch to the OFF position, and finish the learning.

fNOTE: When the learning is performed, input signal to return to previous screen switch (1) and return to basic screen switch (2) is invalid.

95TNED-05-02-84

T5-2-31

SECTION 5 TROUBLESHOOTING Group 2 Monitor Digging Position Adjustment 1

IMPORTANT: When lift arm angle sensor has been replaced, perform the digging position adjustment after performing the lift arm angle sensor learning. Preparation: 1. Start the engine. 2. Set front control lever lock switch (1) to UNLOCK Position (3). 3. Lower the lift arms and set the bucket on the ground horizontally.

MNEC-01-041

3 MNEC-01-015 2-

T5-2-32

LOCK

UNLOCK

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitor Operation: 1

1. Turn select / confirm knob (3) and select Machine Setting (4) on Service Menu. 3

TNED-05-02-002

2. Push select / confirm knob (3) and turn it to select Machine Setting - Digging Position Adjustment (7) menu.

3. When pushing select / confirm knob (3), the Digging Position Adjustment screen appears.

4. Turn select / confirm knob (3) and select the check mark. When pushing select / confirm knob (3), the setting has been completed.

5. When the digging position has been changed, the digging position and lift arm angle position settings are changed.

95Z7B-05-02-11E

6. When pushing return to previous screen switch (1), the previous screen appears. 95TNED-05-02-61

7. When pushing return to basic screen switch (2), the basic screen appears.

95TNED-05-02-73

95TNED-05-02-85

T5-2-33

SECTION 5 TROUBLESHOOTING Group 2 Monitor Engine Setting

1. Turn select / confirm knob (3) and select Engine Setting (4) on Service Menu. 3

TNED-05-02-002

2. When pushing select / confirm knob (3), the Engine Setting screen appears.

95Z7B-05-02-11E

3. Turn select / confirm knob (3) and select a desired item to set. (Refer to List of Engine Setting Item.)

4. Rotate and press selector knob (3) to highlight the check mark on each screen to start the operation. (See the following page.)

T5-2-34

95Z7B-03-11-13

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Engine Setting Item Item Aftertreatment Device Manual Regeneration (Forcible) Aftertreatment Device Auto Regeneration

Details Runs aftertreatment device manual regeneration process . Runs aftertreatment device auto regeneration process.

Aftertreatment Device Auto Regeneration Stop

Disables aftertreatment device auto regeneration function

Air Bleeding from the Defrosting Piping

Opens the coolant control valve to remove air in the DEF heating line. Deletes the error code history in the ECM and DCU.

Fault Code Clear

T5-2-35

SECTION 5 TROUBLESHOOTING Group 2 Monitor Aftertreatment Device Manual Regeneration (Forcible) This function overloads and dCAUTION: deteriorates the aftertreatment device if used on the clean device. Runs aftertreatment device manual regeneration process when regeneration is not required to check if it works. The coolant temperature is monitored. 95Z7B-05-02-17E

Aftertreatment Device Auto Regeneration Runs aftertreatment device auto regeneration process to check if it works. The coolant temperature is monitored.

Aftertreatment Device Auto Regeneration Stop Disables aftertreatment device auto regeneration function 95Z7B-05-02-18E

Air Bleeding from the Defrosting Piping Opens the coolant control valve to remove air in the DEF heating line.

fNOTE: The coolant control valve remains open during this countdown. Refer to F&S S/M T3-11-10 for the procedures.

95Z7B-03-11-14

Fault Code Clear Deletes the error code history in the ECM and DCU.

95Z7B-05-02-19E

T5-2-36

SECTION 5 TROUBLESHOOTING Group 2 Monitor Aftertreatment Device No.

1. Turn select / confirm knob (3) and select Aftertreatment Device No. (4) on Service Menu. 3

TNED-05-02-002

95Z7B-05-02-11E

2. When pushing select / confirm knob (3), the Aftertreatment Device screen appears. 3. The manufacturing number (S/N) of aftertreatment device (DOC, SCR) is displayed.

95Z7BTT05-02-05E

4. When pushing return to previous screen switch (1), the previous screen appears. 5. When pushing return to basic screen switch (2), the basic screen appears.

T5-2-37

SECTION 5 TROUBLESHOOTING Group 2 Monitor Engine Output Restriction Suspend When DEF/AdBlue level becomes low, or malfunction occurs in the urea SCR system, alarms (1) are reported on the monitor and the engine output restriction function gradually decreases the engine torque and speed. In case the machine must be moved or operated after this engine output restriction starts, normal power can be temporarily available as follows.

95Z7BT02-03-05E

IMPORTANT:  Engine output restriction function can be canceled only once during a restricted period.  Engine output restriction function is to provide temporary power. Supply DEF/AdBlue or solve the malfunction promptly. 95Z7BT02-03-10E

1. Turn select/confirm knob (2) and select Engine Output Restriction Suspend (3) on Service Menu.

fNOTE: Engine Output Restriction Suspend menu

appears only when it is required (Inducement Final Stage). TNED-05-02-002

90Z7B-05-02-10E

T5-2-38

SECTION 5 TROUBLESHOOTING Group 2 Monitor [A]

2. When pushing select/confirm knob (2), the Engine Output Restriction Suspend screen (A) appears.

95Z7B-05-02-01E [B]

3. Turn select/confirm knob (2) and select the check mark. When pushing select/confirm knob (2), Engine Output Restriction Suspend screen (B) appears.

95Z7B-05-02-02E

[C]

4. Select the check mark and push select/confirm knob (2) again. Escape Mode screen (C) appears.

95Z7B-05-02-03E

NOTE: Engine output restriction can be canceled for several minutes. After the period, the engine output will be restricted again.

fNOTE: When the machine is stopped or in the neutral

condition, a message appears on the monitor indicating that the engine output restriction is being temporarily canceled.

T5-2-39

SECTION 5 TROUBLESHOOTING Group 2 Monitor Engine Tachometer Engine Tachometer

No.

B A

Engine Tachometer Scale 0 1

B C

2 3 4 5 6 7 8 9

10 11

TNED-02-05-080

fNOTE: Engine tachometer scales are 200 min step. -1

T5-2-40

Engine Speed (Unit: min-1) Less than 600 More than 600, less than 830 (Low Idle: 800) More than 830, less than 1030 More than 1030, less than 1200 More than 1200, less than 1400 More than 1400, less than 1600 More than 1600, less than 1800 More than 1800, less than 2000 More than 2000, less than 2200 More than 2200, less than 2400 (High Idle: 2350) More than 2400, less than 2600 More than 2600, less than 2800

SECTION 5 TROUBLESHOOTING Group 2 Monitor Transmission Oil Temperature Gauge and DEF/AdBlue Level Gauge Transmission Oil Temperature Gauge

No. A B C A D TNED-02-05-081 E E D C B

Gauge Scale 0 1 2 3 4 5 6 7 8 9 10

Torque Converter Oil Temperature (Unit: °C (°F) ) Less than 40 (104) More than 40 (104), less than 45 (113) More than 45 (113), less than 50 (122) More than 50 (122), less than 55 (131) More than 55 (131), less than 60 (140) More than 60 (140), less than 80 (176) More than 80 (176), less than 100 (212) More than 100 (212), less than 115 (239) More than 115 (239), less than 120 (248) More than 120 (248), less than 125 (257) More than 125 (257)

Gauge Scale 10 9 8 7 6 5 4 3 2 1 1 0

Gauge DEF/AdBlue Remaining Level Color (Unit: %) Green 90 or more Green More than 80, less than 90 Green More than 70, less than 80 Green More than 60, less than 70 Green More than 50, less than 60 Green More than 40, less than 50 Green More than 30, less than 40 Green More than 20, less than 30 Green More than 10, less than 20 Yellow More than 5, less than 10 Red More than 0, less than 5 Red (Frame) Less than 0

fNOTE: When the oil temperature is more than scale "D", the alarm mark and the service indicator appear on the basic screen.

DEF/AdBlue Level Gauge

No. D C C B B A A 90Z7B-05-02-DEF A A D

fNOTE: When the DEF/AdBlue amount becomes level "A", the alarm mark and the service indicator appear on the basic screen.

T5-2-41

SECTION 5 TROUBLESHOOTING Group 2 Monitor Coolant Temperature Gauge Coolant Temperature Gauge

No. A B C D E

E D

Coolant Temperature (ºC (ºF)) 25 (77) 40 (104) 95 (203) 105 (221) (120) (248)

TNED-05-02-003

TNED-05-02-004 1-

T5-2-42

Coolant Temperature Gauge

SECTION 5 TROUBLESHOOTING Group 3 e-Service Outline Controller saves the input signals from various sensors and switches of the machine as data. Various input signals are recorded as Operation Data and Snapshot Data in information controller. The recorded data is able to be downloaded to the personal computer and uploaded to the center server via LAN, so that the data can be used as “e-Service” (option). The machine equipped with the optional communication terminal sends the data to the center server by using the communication terminal. (As for the communication system, refer to T5-3-7.)

T5-3-1

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Operation Data List of Daily Report Data Item Date Time Fuel Level Fuel Usage Amount Machine Hour Meter Machine Travel Distance Engine Power Mode OFF and Operating TCS OFF Hours Hours Power Mode ON and TCS OFF Hours Power Mode OFF and TCS ON Hours Power Mode ON and TCS ON Hours Idling Hours

Details Date of daily report data. Last time when the engine is operated during a day. The value of the final remained fuel during a day. (Value is recorded by fuel sensor data from information controller.) The value of fuel used during a day. (Value is calculated and recorded by accumulated fuel usage amount from ECM.) Hour meter cumulative hours. (Hours are recorded by hour meter from information controller.) Travel distance during a day. Total hours of power mode (OFF) and TCS (OFF) with engine running during a day. (Hours are recorded by the information from MC.) Total hours of power mode (ON) and TCS (OFF) with engine running during a day. (Hours are recorded by the information from MC.) Total hours of power mode (OFF) and TCS (ON) with engine running during a day. (Hours are recorded by the information from MC.) Total hours of power mode (ON) and TCS (ON) with engine running during a day. (Hours are recorded by the information from MC.) Total hours when setting forward/reverse lever and forward/reverse switch (OPT) in (N) position and running engine at less than 950 min-1 during a day.

T5-3-2

SECTION 5 TROUBLESHOOTING Group 3 e-Service

Item Engine Operating Hour Distribution Data Latitude Longitude

Details Engine operating hour distribution during a day. (Engine ON state is recorded when engine is running for more than 5 minutes at each range of engine operating hour distribution.) Signal from GPS antenna. Signal from GPS antenna.

fNOTE: The daily operation in this table is equivalent to the hours between 0:00 and 23:59:59 counted by the monitor controller built-in clock. In case the engine is kept operated beyond 0:00, such data are recorded as those for the following day.

T5-3-3

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Frequency Distribution Data Item Radiator Coolant Temperature (79 °C or less) Radiator Coolant Temperature (80 to 93 °C) Radiator Coolant Temperature (94 to 104 °C) Radiator Coolant Temperature (105 °C or more) Hydraulic Oil Temperature (49 °C or less) Hydraulic Oil Temperature (50 to 89 °C) Hydraulic Oil Temperature (90 to 99 °C) Hydraulic Oil Temperature (100 °C or more)

Details Total hours when coolant temperature is less than 80 °C (176 °F) during a day. Total hours when coolant temperature is 80 °C (176 °F) or more and less than 94 °C (201.2 °F) during a day. Total hours when coolant temperature is 94 °C (201.2 °F) or more and less than 105 °C (221 °F) during a day. Total hours when coolant temperature is 105 °C (221 °F) or more during a day. Total hours when hydraulic oil temperature is less than 50 °C (122 °F) during a day. Total hours when hydraulic oil temperature is 50 °C (122 °F) or more and less than 90 °C (194 °F) during a day. Total hours when hydraulic oil temperature is 90 °C (194 °F) or more and less than 100 °C (212 °F) during a day. Total hours when hydraulic oil temperature is 100 °C (212 °F) or more during a day.

T5-3-4

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Total Operating Hours Item Hour Meter End Travel Distance Engine Power Mode OFF and Operating TCS OFF Hours Hours Power Mode ON and TCS OFF Hours Power Mode OFF and TCS ON Hours Power Mode ON and TCS ON Hours Consumed Fuel Quantity Idling Hours

Details Hour meter’s value accumulated in machine’s monitor Odometer’s value accumulated in machine’s monitor Total engine operating hours selecting power mode (OFF) and TCS (OFF) Total engine operating hours selecting power mode (ON) and TCS (OFF) Total engine operating hours selecting power mode (OFF) and TCS (ON) Total engine operating hours selecting power mode (ON) and TCS (ON) Total amount of fuel usage amount Total operating hours when setting forward/reverse lever and forward/reverse switch (OPT) in (N) position and running engine at less than 950 min-1

T5-3-5

SECTION 5 TROUBLESHOOTING Group 3 e-Service Snapshot Data Item Serial No. Snapshot

Model 1 Model 2 DTC Code Priority Hour Meter Occurrence: Year Occurrence: Date Occurrence: Time SA SPN Version

Details Machine serial no. Difference of large-sized crawler, middle-sized crawler, wheeled excavator, and wheel loader Detail difference on model 1 Fault code and frequency of occurrence Machine’s hour meter at a time when trouble occurred Year at a time when trouble occurred Date at a time when trouble occurred Time at a time when trouble occurred 001: Version 1 010: Version 2 011: Version 3 100: Version 4 111: Missing version

fNOTE: The data on machine body system including MC are

downloaded as for Snapshot Data Download (Hitachi). The data on engine system including ECM are downloaded as for Snapshot Data Download (Isuzu).

T5-3-6

SECTION 5 TROUBLESHOOTING Group 3 e-Service Communication System The communication system is used for maintenance of the machine, “e-Service” by transmitting various data of the machine regularly via the communication terminal.

fNOTE: Depending on the circumstances of the machine

(ex. in the constructions, in the tunnel, affected by the surrounding building and affected of noise), the data transfer rate may become slower, or the communication might not be established. The communication system transmits digital data through the radio wave. If there is excessively noise or use of electrical equipment which causes noise near the machine, they cause reduces data transfer rate or communication might not be established at worst.

The communication system consists of communication terminal, GPS antenna and communication antenna. The functions of each equipment are as follows.  Communication Terminal: Receives the data from information controller and GPS antenna, and sends the data to the communication antenna.  GPS Antenna: Receives positional information of the machine.  Communication Antenna: Communicates the data.

T5-3-7

SECTION 5 TROUBLESHOOTING Group 3 e-Service (Blank)

T5-3-8

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Main Component (Overview) 5

3 2 10

9 95Z7B-01-02-01

6 9

11 7

95Z7B-01-02-02

123-

Bucket Bell Crank (Lever) Bucket Cylinder

56-

Front Combination Light (Headlight, Turn Signal Light, Clearance Light, Hazard Light) Front Working Light Rear Working Light

T5-4-1

Rear Combination Light (Turn Signal Light, Hazard Light, Tail Light, Brake Light, Backup Light) Lift Arm (Boom) Cylinder

9- Lift Arm (Boom) 10- Bucket Link 11- Hydraulic Tank

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Main Component

15 12

8 6 5 A

7 4 3

22 37

2 19

28 20

10 36

24 26

23 31 20

Arrow View A

95Z7B-01-02-03

12345678910-

Fan Motor Radiator Inter Charge Air Cooler Coolant Level and Surge Tank Aftertreatment Device (DOC) Aftertreatment Device (SCR) Air Cleaner Service Brake Accumulator Brake Charge (Unloader) Valve Manifold Valve

11121314151617181920-

Brake Valve Steering Pilot Valve (Orbitrol) Pilot Valve Steering Valve Loading Control Valve Stop Valve Flow Regulator Valve Fuel Pre-Filter T/M Oil Filter Engine

2122232425262728-

Fuel Filter Torque Converter Cooler Hydraulic Oil Cooler Steering Accumulator Reducing Valve Fan Control Valve Priority Valve (for Fan Motor) Ride Control Accumulator (Option) 29- Ride Control Valve (Option)

T5-4-2

30- Parallel/Tandem Switching Solenoid Valve 31- Fuel Cooler 32- Reducing Valve (for Brake Oil Pressure) 33- DEF/AdBlue® Tank 34- DEF/AdBlue® Supply Module 35- DEF Sensor Unit 36- Engine Oil Filter 37- Coolant Control Valve Assy

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Main Component

8 4 5 8 6

1 2

3 7 9 95Z7B-01-02-04

123-

Front Axle Propeller Shaft (Front) Steering Cylinder

456-

Hydraulic Pump Transmission Rear Axle

789-

T5-4-3

Propeller Shaft (Rear) Axle Oil Temperature Sensor Fuel Tank

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Electric Component Layout (Overview)

13 6

9 11

10 95Z7B-01-02-05

1234-

Bucket Auto Leveler Bucket Angle Switch Lift Arm Angle Sensor Components Related with Cab (Refer to T5-4-5)

67-

Components Related with Hydraulic Tank (Refer to T54-12) Components Related with Engine (Refer to T5-4-14) Backup Alarm

89-

Battery Components Related with Fuel Tank (Refer to T5-4-13) 10- Components Related with Hydraulic Pump (Refer to T5-4-16)

T5-4-4

11- Secondary Steering Pump (Option) 12- Rear View Camera 13- ECM (Engine Control Module)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Electrical System (Cab)

2 3

8 11 6

CAB Bottom View 95Z7B-01-02-18 1234-

Radio Upper Switch Panel (Option) Speaker Rear Wiper Motor

56-

95TNED-01-02-29

Components Related with Right Console (Refer to T5-4-7) Components Related with Controllers and Relays (Refer to T5-4-6)

789-

T5-4-5

Brake Lamp Switch Front Wiper Motor

10- Components Related with Monitor and Switches (Refer to T5-4-9) 11- Outside Temperature Sensor

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Controller and Relays

3 4 2 5 1 11 10 9

16 15 14 13 12

21 20 19 18 17 26 25 24 23 22 31 29

28 27

95Z7B-01-02-17

12345678910-

Monitor Controller Flasher Relay Air Conditioner Controller MC (Main Controller) (Main) MPDr. Connector MC (Main Controller) (Sub) Head Light Relay (Left) Head Light Relay (Right) High-Beam Relay Bucket Leveler Relay

111213141516-

Back Lamp and Alarm Relay Work Light Relay (Front) Work Light Relay (Rear) Right Turn Signal Light Relay Horn Relay Bucket Angle Position Sensor Relay 17- Parking Brake Relay 1 18- Parking Brake Relay 2 19- Pilot Shut-Off Relay

20212223242526272829-

T5-4-6

Brake Light Relay Load Dump Relay Neutral Relay Left Turn Signal Light Relay Front Washer Relay Rear Wiper Relay Rear Washer Relay Starter Cut Relay Engine ECM Main Relay Cab Working Light (Rear) Relay

30- Fuse Box A 31- Fuse Box B 32- Tech2 (Engine Diagnostic Tool) Connector

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Right Console

Fingertip Control Type 4 5 3

6 7 8

9 10

11 12

1 22 19

13 14 15 MNEC-01-042 MNEC-01-041

Multi-Function Joystick Type 22

6 7 8

2310 11

25 24

12 26 27

13 14 15 MNEC-01-044 MNEC-01-043

12345678-

Auxiliary Control Lever (Option) Bucket Control Lever Lift Arm Control Lever Forward/Reverse Switch Control Lever Lock Switch Declutch Position Switch Travel Mode Selector Switch Power Mode Switch

910111213-

Forward/Reverse Selector Switch Fan Reverse Rotation Switch Hydraulic Coupler Switch (Option) Auxiliary Secondary Steering Operation Check Switch (Option)

14- Aftertreatment Device Regeneration Switch 15- Auxiliary 16- Auxiliary 17- Ride Control Switch (Option) 18- Hold Switch 19- Right Console Slide Lever 20- DSS (Down Shift Switch) 21- Horn Switch

T5-4-7

22- Quick Power Switch 23- Forward/Reverse Selector Switch 24- Forward/Reverse Switch 25- Multi-Function Joystick Lever 26- Hold Switch (Under the Lever) 27- Horn Switch (Under the Lever)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Multi-Function Monitor/Air Conditioner Switch Panel

1234-

Select / Confirm Knob Return to Previous Screen Return to Basic Screen Blower / Air Conditioner AUTO Switch Air Conditioner ON / OFF Switch

678-

Temperature / Mode Switch Defroster Switch Circulation / Fresh Air Switch

MNEC-01-006

Joystick Steering Controls (Option) 7

1 2

8 9

6 115Z7-01-02-06

123-

Forward / Reverse Switch Quick Power Switch Down Shift Switch (DSS)

45-

Joystick Steering System Switch Armrest Adjust Handle

678-

T5-4-8

Armrest Lock Release Button Armrest Switch (Micro Switch) Hold Switch

Horn Switch

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Monitor and Switches

90TNED-01-02-29a

3 4

MNEC-01-037

1234-

Front/Rear Wiper Switch Hazard Switch Work Light Switch Parking Brake Switch

56-

Forward/Reverse Lever/Shift Switch Monitor Panel (Refer to T54-10)

MNEC-01-038

78-

T5-4-9

Turn Signal Lever/Light Switch/High-Low Beam Switch Multi-Function Monitor/Air Conditioner Switch Panel (Refer to T5-4-8)

Key Switch

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Monitor Panel

7 8 9

11 16

12 13

123456-

Left Turn Signal Indicator High Beam Indicator Work Light Indicator Right Turn Signal Indicator Parking Brake Indicator Brake Oil Low Pressure Indicator

78-

Hydraulic Oil Level Indicator Low Steering Oil Pressure Indicator (Option) 9- Transmission Warning Indicator 10- Control Lever Lock Indicator 11- Low Fuel Level Indicator

12131415-

Discharge Warning Indicator Fuel Gauge Multi Function Monitor Communication System Error Indicator 16- Coolant Temperature Gauge 17- Overheat Indicator

T5-4-10

MNEC-01-001

18- Engine Warning Indicator 19- Engine Oil Low Pressure Indicator 20- Preheat Indicator 21- Air Filter Restriction Indicator 22- Clearance Light Indicator

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Electrical System (Relays)

A 5 7

1 View A

6 95Z7B-01-02-06

12-

Battery Relay Fusible Link (70A) x 2

34-

Fusible Link (140A) x 2 Glow Relay

56-

T5-4-11

Starter Relay Battery

Battery Disconnect Switch (Option)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Electrical System (Around Hydraulic Oil Tank) 5

4 3

95Z7B-01-02-07

12-

Hydraulic Oil Level Sensor Hydraulic Tank

34-

Hydraulic Oil Temperature Sensor Window Washer Pump

T5-4-12

Combination Valve (Refer to T5-4-20.)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Electrical System (Around Fuel Tank)

1 5

Hydraulic Fan Circuit Pressure Sensor

23-

95Z7B-01-02-08

Fan Motor Control Valve Fuel Tank

45-

T5-4-13

Fuel Level Sensor DCU (Dosing Control Unit)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Engine 17

2 17

7 6

9 14

3 12 1234567-

EGR Valve Turbocharger Supply Pump Intake Throttle Valve MAF (Mass Air Flow) Sensor Fuel Filter Overheat Switch

Boost Temperature/Pressure Sensor 9- CMP (Camshaft Position) Sensor 10- Coolant Temperature Sensor 11- Fuel Rail Pressure Sensor 12- Fuel Temperature Sensor

13- CKP (Crankshaft Position) Sensor 14- Engine Oil Pressure Sensor 15- EGR Cooler Gas Temperature Sensor 1 (In Temp. 1) 16- EGR Cooler Gas Temperature Sensor 2 (Out Temp. 1)

fNOTE: Refer to T2-3-4 for the engine sensor locations. Refer to the 6WG1 engine shop manuals.

T5-4-14

95Z7B-01-02-16

17- EGR Cooler Gas Temperature Sensor 3 (In Temp. 2) 18- EGR Cooler Gas Temperature Sensor 4 (Out Temp. 2) 19- IMT (Intake Manifold Temperature) Sensor 20- Oil Separator

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Aftertreatment Device/Air Cleaner 8

95Z7B-01-02-09

7 6

3 9

95Z7B-01-02-10

12-

Selective Catalytic Reduction (SCR) Unit* Diesel Oxidation Catalyst (DOC) Unit*

34-

DOC Unit Temperature Sensor (Inlet)* DOC Unit Temperature Sensor (Outlet)*

567-

fNOTE *: Engine accessory parts T5-4-15

DOC Unit NOx Sensor (Outlet)* SCR Unit Temperature Sensor (Inlet)* SCR Unit NOx Sensor (Outlet)*

8- Air Cleaner Assy 9- Air Cleaner Clogging Sensor 10- MAF (Mass Air Flow) Sensor*

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Hydraulic Pump Main Pump

1 95TNED-01-02-11

12-

Steering and Loading Pump Proportional Reducing Valve

34-

Regulator 1 Regulator 2

T5-4-16

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Accessory Pump

95TNED-01-02-12

Pilot, Fan and Brake Pump

T5-4-17

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Transmission and Torque Converter Assembly

View A

14 1 12

13 2

11 12345-

Air Breather Transmission Control Valve Machine Speed Sensor Proportional Solenoid Valve (For Low Clutch Proportional Solenoid Valve (For High Clutch)

678-

Proportional Solenoid Valve (For Reverse Clutch) Proportional Solenoid Valve (For 1st Speed Clutch) Proportional Solenoid Valve (For 2nd Speed Clutch)

Proportional Solenoid Valve (For 3rd Speed Clutch) 10- Proportional Solenoid Valve (For Lock-Up Clutch) 11- Transmission Oil Temperature Sensor

T5-4-18

95Z7B-01-02-11

12- Torque Converter Oil Temperature Sensor 13- Torque Converter Output Speed Sensor 14- Machine Speed Sensor (Backup)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Multiple Control Valve

95TNED-01-02-14

12-

Main Relief Valve Overload Relief Valve (Bucket: Rod Side)

34-

Overload Relief Valve (Bucket: Bottom Side) Overload Relief Valve (Lift Arm: Rod Side)

56-

T5-4-19

Solenoid Valve (for Ride Control) (Option) Bleed-off Compensation Valve

Load Sensing Control (Negative Control) Relief Valve

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Unloader Valve (Brake Charge Valve) 4

2 1 95Z7B-01-02-12

12-

Unloader Valve (Brake Charge Valve) Brake Accumulator

Reducing Valve (for Brake Oil Pressure)

Brake Primary Pressure Sensor (Service Brake Pressure Alarm)

Combination Valve (Brake Manifold Valve) 3 4

2 1

6 95Z7B-01-02-13

12-

Safety Lock Solenoid Valve Parking Brake Solenoid Valve

Pressure Sensor (Loading Pilot Pressure)

45-

T5-4-20

Pressure Sensor (Parking Brake Lamp) Reducing Valve

Parallel/Tandem Switching Solenoid Valve

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Flow Regulator Valve

Ride Control Valve (Option)

1 90TNED-01-02-22

12-

Pressure Sensor (Bucket Roll Back) Pressure Sensor (Bucket Dump)

Pressure Sensor (Lift Arm (Boom) Raise)

90Z7-01-02-RC

Steering Valve 2

1 90T4GB-01-02-20

12-

Main Relief Valve Overload Relief Valve

T5-4-21

Solenoid Valve

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Secondary Steering Group (Option)

Steering Valve

95Z7B-01-02-14 12-

Secondary Steering Pump (Option) Pressure Sensor (Secondary Steering) (Option)

34-

Secondary Steering Pump (Option)

1 3

2 90TNED-01-02-19

123-

Electric Motor Gear Pump Relief Valve

T5-4-22

Pressure Switch (Secondary Steering) (Option) Pressure Sensor (Main Pump)

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing by using MPDr. or the service menu of the monitor.

fNOTE: The engine controller (ECM) judges the engine

 Diagnosis Procedure  The diagnosis procedures for the displayed fault codes are explained in this group.  In case more than one fault code are displayed at the same time, Main Controller (MC) may be faulty or the power/ground of the sensor system may be faulty.  When the MC fault code is displayed with other fault code, replace MC.  When fault code 111003-3 (Abnormal Sensor Voltage) is displayed with other fault code, diagnose for fault code 111003-3 first.  In case more than one fault code other than those described above are displayed at the same time, diagnose for each fault code.  It may be required that the machine is operated or the test harness is connected at inspection. Check the items of preparation and perform inspection according to the procedures when diagnosing.

fNOTE: Harness end connector viewed from the open end side by the all connectors image shown in this section.

1 2

T6L4-05-03-001

Harness End Connector

Harness

T5-5-1

malfunction. After the engine is repaired, select Fault Code Clear on Engine Setting. Then, delete the fault code of engine controller (ECM) on Troubleshooting. (Refer to TROUBLESHOOTING / Monitor.)

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Contents of Diagnosis

Fault Code

Preparation Tools for a diagnosis and contents needing inspection beforehand are explained.

How to Read Table Fault Code Trouble or MP Inspection Dr. Message Method (A) (B) (C) (F)     

A: B: C, D, E,

Evaluation

Cause

(D) (G)

(E) (H)

Fault code Trouble details or message displayed on the Maintenance Pro Dr. F: Inspection method for trouble cause G: Evaluation specification of check results H: Trouble cause for the fault code

Procedure: 1. Check an applicable line depending on displayed fault cord (A). 2. After checking or measuring on Inspection Method (C), refer to Evaluation (D) and judge the results. 3. In case the results are satisfied with Evaluation (D), the trouble cause becomes Cause (E). In case the results are not satisfied with Evaluation (D), go to the next procedure, Inspection Method (F). Circuit Diagram of Test Harness A connection point of the test harness and a point to check are explained. (Only Pressure Sensor System Troubleshooting)

T5-5-2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code List Fault Code 111000-2 111001-2 111002-2 111003-3 111006-2 111007-2 111008-2 111009-2 111010-2 111012-2 111013-2 111014-2 111015-2 111016-2 111017-2 111018-2 111019-2 111020-2 111021-2 111024-2 111025-2 111026-2 111033-2 111034-2 111103-3 111103-4 111105-3 111106-3 111106-4 111107-2 111200-3 111200-4 111202-3 111202-4 111203-3 111203-4 111204-3 111204-4

MPDr. Message Abnormal EEPROM Abnormal RAM Abnormal A/D Converter Abnormal Sensor Voltage (MC) Engine Controller Communication Error (MC) Information Controller Communication Error 1 (MC) Information Controller Communication Error 2 (MC) Monitor Controller Communication Error 1 (MC) Monitor Controller Communication Error 2 (MC) Sub-Controller Communication Error 1 (MC) Sub-Controller Communication Error 2 (MC) Air Conditioner Controller Communication Error (SC) Information Controller Communication Error 1 (SC) Information Controller Communication Error 2 (SC) Monitor Controller Communication Error 1 (SC) Monitor Controller Communication Error 2 (SC) MC Controller Communication Error 1 (SC) MC Controller Communication Error 2 (SC) Air Conditioner Controller Communication Error (SC) Engine Controller Communication Error (MC) Column Monitor Controller Communication Error (SC) Column Monitor Controller Communication Error (Main Controller) Joystick Steering Controller Communication Error (Sub Controller) Joystick Steering Controller Communication Error Accelerator Pedal Position Sensor 1 High Input Accelerator Pedal Position Sensor 1 Low Input Abnormal Engine Speed Sensor Accelerator Pedal Position Sensor 2 High Input Accelerator Pedal Position Sensor 2 Low Input Accelerator Pedal Position Sensor 1-2 Correlation Lift Arm Raise Pilot Pressure Sensor Circuit High Input Lift Arm Raise Pilot Pressure Sensor Circuit Low Input Bucket Tilt Pilot Pressure Sensor Circuit High Input Bucket Tilt Pilot Pressure Sensor Circuit Low Input Bucket Dump Pilot Pressure Sensor Circuit High Input Bucket Dump Pilot Pressure Sensor Circuit Low Input Pump Delivery Pressure Sensor Circuit High Input Pump Delivery Pressure Sensor Circuit Low Input

T5-5-3

Category MC, SC MC, SC MC, SC MC, SC MC MC MC MC MC MC MC MC SC SC SC SC SC SC SC SC MC SC MC

Reference 1 T5-5-12, T5-5-26 T5-5-12, T5-5-26 T5-5-12, T5-5-26 T5-5-12, T5-5-26 T5-5-13 T5-5-13 T5-5-13 T5-5-13 T5-5-13 T5-5-13 T5-5-13 T5-5-13 T5-5-27 T5-5-27 T5-5-27 T5-5-27 T5-5-27 T5-5-27 T5-5-27 T5-5-27 T5-5-13 T5-5-27 T5-5-13

Reference 2 T5-5-80 T5-5-80 T5-5-80 T5-5-80 T5-5-83 T5-5-83 T5-5-88 T5-5-83 T5-5-88 T5-5-83 T5-5-88 T5-5-88 T5-5-83 T5-5-88 T5-5-83 T5-5-88 T5-5-83 T5-5-88 T5-5-88 T5-5-83 T5-5-88 T5-5-88 -

T5-5-27

MC MC SC MC MC MC SC SC SC SC SC SC MC MC

T5-5-14 T5-5-14 T5-5-26 T5-5-14 T5-5-14 T5-5-14 T5-5-29 T5-5-29 T5-5-29 T5-5-29 T5-5-29 T5-5-29 T5-5-15 T5-5-15

T5-5-93 T5-5-93 T5-5-93 T5-5-93 T5-5-93 T5-5-101 T5-5-101 T5-5-101 T5-5-101 T5-5-101 T5-5-101 T5-5-102 T5-5-102

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code List (Continued) Fault Code 111205-3 111205-4 111206-3 111206-4 111207-3 111207-4 111208-3 111208-4 111210-3 111210-4 111211-3 111211-4 111212-3 111212-4 111214-3 111214-4 111215-3 111215-4 111217-3 111217-4 111309-3 111309-4 111310-3 111310-4 111312-3 111312-4 111313-3 111313-4 111407-2 111407-3 111407-4 111408-2 111408-3 111408-4

MPDr. Message Lift Arm Angle Sensor Circuit High Input Lift Arm Angle Sensor Circuit Low Input Hyd. Fan Circuit Pressure Sensor Circuit High Input Hyd. Fan Circuit Pressure Sensor Circuit Low Input Refrigerant Pressure Sensor Circuit High Input Refrigerant Pressure Sensor Circuit Low Input Emergency Steering Check Pressure Sensor Circuit High Input Emergency Steering Check Pressure Sensor Circuit High Input Clutch Pressure_1st Circuit High Input Clutch Pressure_1st Circuit Low Input Clutch Pressure_2nd Circuit High Input Clutch Pressure_2nd Circuit Low Input Clutch Pressure_2nd Circuit High Input Clutch Pressure_2nd Circuit Low Input Clutch Pressure_F Circuit High Input Clutch Pressure_F Circuit Low Input Clutch Pressure_R Circuit High Input Clutch Pressure_R Circuit Low Input Pilot Pressure Sensor Circuit High Input Pilot Pressure Sensor Circuit Low Input Service Brake Pressure (Front) Sensor Circuit High Input Service Brake Pressure (Front) Sensor Circuit Low Input Service Brake Pressure (Rear) Sensor Circuit High Input Service Brake Pressure (Rear) Sensor Circuit Low Input Service Brake Secondary Pressure Sensor Circuit High Input Service Brake Secondary Pressure Sensor Circuit Low Input Parking Brake Pressure Sensor Circuit High Input Parking Brake Pressure Sensor Circuit Low Input Lift Speed Increase P/S Valve Abnormal FB Lift Speed Increase P/S Valve FB High Current Lift Speed Increase P/S Valve Low Current Auto Brake P/S Valve Abnormal FB Auto Brake P/S Valve FB High Current Auto Brake P/S Valve FB Low Current

T5-5-4

Category SC SC SC SC SC SC SC

Reference 1 T5-5-35 T5-5-35 T5-5-28 T5-5-28 T5-5-35 T5-5-35 T5-5-28

Reference 2 T5-5-100 T5-5-100 T5-5-103 T5-5-103 T5-5-100 T5-5-100 T5-5-104

T5-5-28

T5-5-104

MC MC MC MC MC MC MC MC MC MC SC SC SC SC SC SC MC

T5-5-15 T5-5-15 T5-5-15 T5-5-15 T5-5-15 T5-5-15 T5-5-16 T5-5-16 T5-5-16 T5-5-16 T5-5-30 T5-5-30 T5-5-30 T5-5-30 T5-5-30 T5-5-30 T5-5-17

T5-5-107 T5-5-107 T5-5-107 T5-5-107 T5-5-107 T5-5-107 T5-5-108 T5-5-108 T5-5-108 T5-5-108 T5-5-103 T5-5-103 T5-5-109 T5-5-109 T5-5-109 T5-5-109 T5-5-102

T5-5-17

T5-5-102

MC MC SC SC SC MC MC MC

T5-5-17 T5-5-17 T5-5-31 T5-5-31 T5-5-31 T5-5-21 T5-5-21 T5-5-21

T5-5-105 T5-5-105 T5-5-110 T5-5-110 T5-5-110 T5-5-117 T5-5-117 T5-5-117

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code List (Continued) Fault Code 111410-2 111410-3 111410-4 111411-2 111411-3 111411-4 111412-2 111412-3 111412-4 111413-2 111413-3 111413-4 111414-2 111414-3 111414-4 111415-2 111415-3 111415-4 111416-2 111416-3 111416-4 111418-2 111418-3 111418-4 111419-2 111419-3 111419-4 111420-2 111420-3 111420-4 111421-2 111421-3 111421-4 111422-2 111422-3 111422-4 111423-2 111423-3 111423-4

MPDr. Message Category Parallel/Tandem Control P/S Valve Abnormal FB SC Parallel/Tandem Control P/S Valve FB High Current SC Parallel/Tandem Control P/S Valve FB Low Current SC Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB SC Hydraulic Fan Reverse Rotation P/S Valve FB High SC Current Hydraulic Fan Reverse Rotation P/S Valve FB Low Current SC Hyd. Fan P/S Valve Abnormal Feedback SC Hyd. Fan P/S Valve Feedback High Current SC Hyd. Fan P/S Valve Feedback Low Current SC Pump Swash Angle P/S Valve Abnormal FB MC Pump Swash Angle P/S Valve FB High Current MC Pump Swash Angle P/S Valve FB Low Current MC T/M Clutch 1st P/S Valve Abnormal FB MC T/M Clutch 1st P/S Valve FB High Current MC T/M Clutch 1st P/S Valve FB Low Current MC T/M Clutch 2nd P/S Valve Abnormal FB MC T/M Clutch 2nd P/S Valve FB High Current MC T/M Clutch 2nd P/S Valve FB Low Current MC T/M Clutch 3rd P/S Valve Abnormal FB MC T/M Clutch 3rd P/S Valve FB High Current MC T/M Clutch 3rd P/S Valve FB Low Current MC T/M Clutch Forward P/S Valve Abnormal FB MC T/M Clutch Forward P/S Valve FB High Current MC T/M Clutch Forward P/S Valve FB Low Current MC T/M Clutch Reverse P/S Valve Abnormal FB MC T/M Clutch Reverse P/S Valve FB High Current MC T/M Clutch Reverse P/S Valve FB Low Current MC T/M Clutch Fast P/S Valve Abnormal FB MC T/M Clutch Fast P/S Valve FB High Current MC T/M Clutch Fast P/S Valve FB Low Current MC Lockup P/S Valve Abnormal FB MC Lockup P/S Valve FB High Current MC Lockup P/S Valve FB Low Current MC Ride Control (Bottom) P/S Valve Abnormal FB SC Ride Control (Bottom) P/S Valve FB High Current SC Ride Control (Bottom) P/S Valve FB Low Current SC Ride Control (Rod) P/S Valve Abnormal FB SC Ride Control (Rod) P/S Valve FB High Current SC Ride Control (Rod) P/S Valve FB Low Current SC

T5-5-5

Reference 1 T5-5-31 T5-5-31 T5-5-31 T5-5-32 T5-5-32

Reference 2 T5-5-111 T5-5-111 T5-5-111 T5-5-112 T5-5-112

T5-5-32 T5-5-32 T5-5-32 T5-5-32 T5-5-18 T5-5-18 T5-5-18 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-20 T5-5-20 T5-5-20 T5-5-20 T5-5-20 T5-5-20 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-33 T5-5-33 T5-5-33 T5-5-33 T5-5-33 T5-5-33

T5-5-112 T5-5-113 T5-5-113 T5-5-113 T5-5-114 T5-5-114 T5-5-114 T5-5-115 T5-5-115 T5-5-116 T5-5-115 T5-5-115 T5-5-116 T5-5-115 T5-5-115 T5-5-116 T5-5-115 T5-5-115 T5-5-116 T5-5-115 T5-5-115 T5-5-116 T5-5-115 T5-5-115 T5-5-116 T5-5-115 T5-5-115 T5-5-116 T5-5-118 T5-5-118 T5-5-118 T5-5-119 T5-5-119 T5-5-119

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code List (Continued) Fault Code 111502-2 111503-2 111504-2 111506-2 111507-2 111600-3 111600-4 111601-3 111602-3 111700-xx 111700-31 111701-xx 111701-31 111702-xx 111702-31 111703-xx 111703-31 111704-31 111720-2 111900-3 111900-4 111901-3 111901-4 111903-3 111903-4 111904-2 111905-2 111906-3 111906-4 111907-3 111907-4

MPDr. Message T/M Clutch Pressure Decreased (1-speed) when Engaging the Clutch T/M Clutch Pressure Decreased (2-speed) when Engaging the Clutch T/M Clutch Pressure Decreased (3-speed) when Engaging the Clutch T/M Clutch Pressure Decreased (F) when Engaging the Clutch T/M Clutch Pressure Decreased (R) when Engaging the Clutch T/M Output Speed Sensor Failure T/M Out Speed Sensor Circuit Low Input Torque Converter Output Speed Sensor Failure Intermediate Shaft Speed Sensor Failure Calibration Abort Forward Calibration Abort Forward: Un-Calibration Calibration Abort Reverse Calibration Abort Reverse: Un-Calibration Calibration Abort 1st Calibration Abort 1st: Un-Calibration Calibration Abort 2nd Calibration Abort 2nd: Un-Calibration Calibration Abort 3rd: Un-Calibration Lift arm angle sensor is uncalibrated. Torque Converter Oil Temperature Sensor Circuit High Input Torque Converter Oil Temperature Sensor Circuit Low Input Hyd. Oil Temp Sensor Circuit High Input Hyd. Oil Temp Sensor Circuit Low Input T/M Oil Temp Sensor Circuit High Input T/M Oil Temp Sensor Circuit Low Input Column FNR SW Failure Implement FNR SW Failure F Axle Oil Temperature Sensor Circuit High Input F Axle Oil Temperature Sensor Circuit Low Input R Axle Oil Temperature Sensor Circuit High Input R Axle Oil Temperature Sensor Circuit Low Input

T5-5-6

Category MC

Reference 1 T5-5-16

Reference 2 T5-5-120

T5-5-16

T5-5-120

T5-5-16

T5-5-120

T5-5-16

T5-5-120

T5-5-16

T5-5-120

MC MC MC MC MC MC MC MC MC MC MC MC MC SC SC

T5-5-22 T5-5-22 T5-5-22 T5-5-22 T5-5-24 T5-5-24 T5-5-24 T5-5-24 T5-5-24 T5-5-24 T5-5-24 T5-5-24 T5-5-24 T5-5-35 T5-5-34

T5-5-106 T5-5-106 T5-5-106 T5-5-106 T5-5-121, 122 T5-5-121, 122 T5-5-121, 122 T5-5-121, 122 T5-5-121, 122 T5-5-121, 122 T5-5-121, 122 T5-5-121, 122 T5-5-121, 122 T5-5-123

T5-5-34

T5-5-123

SC SC MC MC MC MC MC MC MC MC

T5-5-34 T5-5-34 T5-5-23 T5-5-23 T5-5-24 T5-5-24 T5-5-23 T5-5-23 T5-5-23 T5-5-23

T5-5-124 T5-5-124 T5-5-125 T5-5-125 T5-5-126 T5-5-126 T5-5-126 T5-5-126

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code List (Continued) Fault Code 113002-2 113003-2 113004-2 113005-2 113006-2 113007-2 113010-2 113011-2 113311-3 113311-4 115001-2 115002-2 115003-2 115018-2

MPDr. Message (Monitor Controller) Engine Controller Communication Error (Monitor Controller) Main Controller Communication Error 1 (Monitor Controller) Main Controller Communication Error 2 (Monitor Controller) ICF Communication Error 1 (Monitor Controller) ICF Communication Error 2 (Monitor Controller) Column Controller Communication Error (Monitor Controller) Sub-Controller Communication Error 1 (Monitor Controller) Sub-Controller Communication Error 2 Fuel Level Sensor Circuit High Input Fuel Level Sensor Circuit Low Input Abnormal REG input H level CAN Communication Error 2 Abnormal EEPROM Abnormal 24V Output

T5-5-7

Category Monitor

Reference 1 T5-5-37

Reference 2 T5-5-84

Monitor

T5-5-37

T5-5-84

Monitor

T5-5-37

T5-5-89

Monitor Monitor Monitor

T5-5-37 T5-5-37 T5-5-37

T5-5-84 T5-5-89 T5-5-89

Monitor

T5-5-37

T5-5-84

Monitor

T5-5-37

T5-5-89

Information Information Column Display Column Display Column Display Column Display

T5-5-38 T5-5-38 T5-5-38 T5-5-38 T5-5-38 T5-5-38

T5-5-130 T5-5-130 T5-5-129 -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code List (Continued) Fault Code 116000-2 116001-2 116002-3 116002-4 116003-3 116003-4 116004-3 116004-4 116005-2 116006-3 116006-4 116007-3 116007-4 116008-3 116008-4 116010-2 116013-2

MPDr. Message (Joystick Steering Controller) Abnormal Power Source (Engine Speed) (Joystick Steering Controller) Abnormal Solenoid Pilot Source Pressure (Joystick Steering Controller) Controller Source Voltage Abnormally High (Joystick Steering Controller) Controller Source Voltage Abnormally Low (Joystick Steering Controller) Joystick Signal 1 Voltage Abnormally High (Joystick Steering Controller) Joystick Signal 1 Voltage Abnormally Low (Joystick Steering Controller) Joystick Signal 2 Voltage Abnormally High (Joystick Steering Controller) Joystick Signal 2 Voltage Abnormally Low (Joystick Steering Controller) Joystick Signal Correlative Diagnosis Error (Joystick Steering Controller) Right Steering Solenoid Valve Pressure Sensor Voltage Abnormally High (Joystick Steering Controller) Right Steering Solenoid Valve Pressure Sensor Voltage Abnormally Low (Joystick Steering Controller) Left Steering Solenoid Valve Pressure Sensor Voltage Abnormally High (Joystick Steering Controller) Left Steering Solenoid Valve Pressure Sensor Voltage Abnormally Low (Joystick Steering Controller) Solenoid Valve Source Pressure: Pressure Sensor Voltage Abnormally High (Joystick Steering Controller) Solenoid Valve Source Pressure: Pressure Sensor Voltage Abnormally Low (Joystick Steering Controller) Main Controller Communication Error (Joystick Steering Controller) Monitor Controller Communication Error

T5-5-8

Category JCU

Reference 1 T5-5-40

Reference 2 -

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-40

JCU

T5-5-41

JCU

T5-5-41

JCU

T5-5-41

JCU

T5-5-41

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code List (Continued) Fault Code 116118-2 116118-3 116118-4 116119-2 116119-3 116119-4

MPDr. Message (Joystick Steering Controller) Right Steering Solenoid Valve Abnormal Feedback (Joystick Steering Controller) Right Steering Solenoid Valve Feedback Current Abnormally High (Joystick Steering Controller) Right Steering Solenoid Valve Feedback Current Abnormally Low (Joystick Steering Controller) Left Steering Solenoid Valve Feedback Abnormal (Joystick Steering Controller) Left Steering Solenoid Valve Feedback Current Abnormally High (Joystick Steering Controller) Left Steering Solenoid Valve Feedback Current Abnormally Low

T5-5-9

Category JCU

Reference 1 T5-5-42

Reference 2 -

JCU

T5-5-42

JCU

T5-5-42

JCU

T5-5-42

JCU

T5-5-42

JCU

T5-5-42

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code List (Continued) Fault Code 120000-2

MPDr. Message Hydraulic Oil Overheat Alarm

Category SC

Reference 1 T5-5-36

Reference 2 T5-5-128

120001-2

Main Pump Pressure Alarm

T5-5-36

T5-5-128

120002-2

Axle Oil Temperature Alarm

T5-5-36

T5-5-128

120003-2

Emergency Steering Activated

T5-5-36

T5-5-128

120004-2

Emergency Steering Activated Pressure Alarm

T5-5-36

T5-5-128

120005-2

Transmission Oil Temperature Overheat Alarm

T5-5-36

T5-5-128

120006-2

Transmission Oil Pressure Alarm

T5-5-36

120007-2

Transmission Filter Restriction Alarm

T5-5-36

120013-2

Brake Oil Pressure Alarm

T5-5-36

120014-2

Overrun Alarm

T5-5-25

T5-5-127

120016-2

Auto Brake Alarm

T5-5-25

120101-2

Exhaust Temperature Alarm

T5-5-25

T5-5-127

120102-2

Intake Air Temperature Alarm

T5-5-25

T5-5-127

120103-2

Boost Temperature Increase Alarm

T5-5-25

T5-5-127

120104-2

Fuel Temperature Increase Alarm

T5-5-25

T5-5-127

120105-2

Overrun Alarm

T5-5-25

T5-5-127

120106-2

EGR Gas Temperature Alarm

T5-5-25

T5-5-127

120300-2

System Failure Alarm

Monitor

T5-5-37

T5-5-129

120500-2

Overheat Alarm

Column Display

T5-5-39

T5-5-132

120501-2

Engine Error

Column Display

T5-5-39

T5-5-132

120502-2

Engine Oil Pressure Alarm

Column Display

T5-5-39

T5-5-132

120503-2

Air Cleaner Restriction Alarm

Column Display

T5-5-39

T5-5-132

120504-2

Hydraulic Oil Level Alarm

Column Display

T5-5-39

T5-5-132

120505-2

Brake Pressure Alarm

Column Display

T5-5-39

T5-5-132

120506-2

Steering Oil Pressure Alarm

Column Display

T5-5-39

T5-5-132

120507-2

T/M Malfunction

Column Display

T5-5-39

T5-5-132

T5-5-10

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code List (Continued) Fault Code 120600-2 120601-2 120602-2 120603-2 120604-2 120605-2 120606-2 120607-2 120608-2 120609-2 120610-2 120611-2 120612-2 120613-2 120614-2 120615-2 120616-2 120617-2 120618-2

MPDr. Message (Joystick Steering Controller) Abnormal Joystick Function (Joystick Function Enabled 1) (Joystick Steering Controller) Abnormal Joystick Function (Joystick Function Disabled) (Joystick Steering Controller) Abnormal Joystick Function (Joystick Function can not be enabled.) (Joystick Steering Controller) Abnormal Joystick Function (Joystick Function can not be disabled.) (Joystick Steering Controller) Abnormal Joystick Function (Joystick Function Enabled 2) (Joystick Steering Controller) Abnormal Joystick Function (Right Steering Pressure 1) (Joystick Steering Controller) Abnormal Joystick Function (Right Steering Pressure 2) (Joystick Steering Controller) Abnormal Joystick Function (Left Steering Pressure 1) (Joystick Steering Controller) Abnormal Joystick Function (Left Steering Pressure 2) (Joystick Steering Controller) Abnormal FNR (Switch FNR Function enabled 1) (Joystick Steering Controller) Abnormal FNR (Switch FNR Function disabled) (Joystick Steering Controller) Abnormal FNR (Switch FNR Function can not be enabled.) (Joystick Steering Controller) Abnormal FNR (Switch FNR Function can not be disabled.) (Joystick Steering Controller) Abnormal FNR (Switch FNR Function enabled 2) (Joystick Steering Controller) Abnormal Switch (FNR Switching: OFF operation) (Joystick Steering Controller) Abnormal Switch (Joystick Function: OFF operation) (Joystick Steering Controller) Abnormal Switch (Arm Rest Switch) (Joystick Steering Controller) Abnormal Switch (FNR Switch) (Joystick Steering Controller) Abnormal Switch (Joystick FNR Switch)

fNOTE:

Refer to page T5-5-46 for the air conditioner controller fault code list. Refer to page T5-5-48 for the ECM fault code list. Refer to page T5-5-76 for the DCU fault code list.

T5-5-11

Category JCU

Reference 1 T5-5-42

Reference 2 -

JCU

T5-5-43

JCU

T5-5-43

JCU

T5-5-43

JCU

T5-5-43

JCU

T5-5-43

JCU

T5-5-43

JCU

T5-5-43

JCU

T5-5-43

JCU

T5-5-44

JCU

T5-5-44

JCU

T5-5-44

JCU

T5-5-44

JCU

T5-5-44

JCU

T5-5-44

JCU

T5-5-44

JCU

T5-5-45

JCU

T5-5-45

JCU

T5-5-45

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code List Controller Hardware Failure Fault Code Trouble or MP Dr. Message

Cause

111000-2 111001-2 111002-2

Faulty MC Faulty MC Faulty MC

111003-3

Abnormal EEPROM Abnormal RAM Abnormal A/D Converter Abnormal Sensor Voltage

Faulty MC Faulty sensor Faulty harness

Symptoms in Machine Operation When Trouble Occurs. -

Remedy

Replace MC. Replace MC. Replace MC.

Although the accelerator Check the sensor connected pedal is operated, the engine to MC. speed does not change. Check the harness. Replace MC.

fNOTE: MC here refers to the Main Controller (Main). These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-12

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN Data Reception Failure Fault Code Trouble or MP Dr. Cause Message 111006-2 (MC) Engine Controller Faulty harness Communication Error

111007-2

111008-2

111009-2

111010-2

111012-2

(MC) Information Controller Communication Error 1 (MC) Information Controller Communication Error 2 (MC) Monitor Controller Communication Error 1 (MC) Monitor Controller Communication Error 2 (MC) Sub-Controller Communication Error 1

111013-2

(MC) Sub-Controller Communication Error 2

111014-2

(MC) Air Conditioner Controller Communication Error

111025-2

(MC) Column Monitor Controller Communication Error

111033-2

(Main Controller) Joystick Steering Controller Communication Error

Faulty monitor controller Faulty CAN1 harness

Symptoms in Machine Operation When Trouble Occurs. Even if accelerator pedal is operated, engine speed does not change. The manual regeneration of aftertreatment device cannot be performed. Nothing observed.

Faulty monitor controller Faulty CAN2 harness

Nothing observed.

Faulty monitor controller Faulty CAN1 harness

Nothing observed.

Faulty monitor controller Faulty CAN2 harness

Nothing observed.

Faulty main controller (sub) Faulty CAN1 or CAN2 harness Faulty main controller (sub) Faulty CAN1 or CAN2 harness Faulty air conditioner controller Faulty CAN2 harness

Nothing observed.

Check the harness.

Check the CAN1 harness. Replace monitor controller. Check the CAN2 harness. Replace monitor controller. Check the CAN1 harness. Replace monitor controller. Check the CAN2 harness. Replace monitor controller. Check the CAN harness.

Check the CAN harness.

Check the CAN2 harness. Replace the air conditioner controller. Faulty column display The transmission warning Check the CAN2 controller indicator on column display harness. Faulty CAN2 harness controller do not light. Replace column Overrun alarm control is disabled. display controller. Faulty joystick The joystick steering does not Check the CAN2 steering controller work. harness. Faulty CAN2 harness Replace the joystick steering controller.

fNOTE: MC here refers to the Main Controller (Main). These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-13

The air conditioner does not work.

Remedy

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Engine Failure Fault Code

Trouble or MP Dr. Message

111103-3

Accelerator Pedal Position Sensor 1 High Input

111103-4

Accelerator Pedal Position Sensor 1 Low Input

111106-3

Accelerator Pedal Position Sensor 2 High Input

111106-4

Accelerator Pedal Position Sensor 2 Low Input

111107-2

Accelerator Pedal Position Sensor 1-2 Correlation

Cause

Symptoms in Machine Operation When Trouble Occurs. Voltage: more than The engine speed is fixed to 4.74 V 1100 min-1. Although the accelerator pedal is operated, aftertreatment device manual regeneration control cannot be deactivated. Voltage: less than The engine speed is fixed to 0.25 V 1100 min-1. Although the accelerator pedal is operated, aftertreatment device manual regeneration control cannot be deactivated. Voltage: more than The engine speed is fixed to 4.74 V 1100 min-1. Although the accelerator pedal is operated, aftertreatment device manual regeneration control cannot be deactivated. Voltage: less than The engine speed is fixed to 0.25 V 1100 min-1. Although the accelerator pedal is operated, aftertreatment device manual regeneration control cannot be deactivated. Voltage difference The engine speed is fixed to between accelerator 1100 min-1. Although the accelerator pedals 1 and 2: pedal is operated, more than 0.625 V aftertreatment device manual regeneration control cannot be deactivated.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-14

Remedy

Check the harness. Replace the accelerator pedal sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pump Failure Fault Code 111204-3

111204-4

Trouble or MP Dr. Message Pump Delivery Pressure Sensor Circuit High Input Pump Delivery Pressure Sensor Circuit Low Input

Cause

Symptoms in Machine Operation When Trouble Occurs. Voltage: 4.75 V Engine speed regulator for or more digging is deactivated. Voltage: less than 0.25 V

Engine speed regulator for digging is deactivated.

Transmission Clutch Pressure Failure Fault Code Trouble or MP Dr. Cause Message 111210-3 Clutch Pressure_1st Voltage: 4.75 V Circuit High Input or more

111210-4

111211-3

111211-4

111212-3

111212-4

Symptoms in Machine Operation When Trouble Occurs. Transmission warning indicator on the monitor panel turns ON. The shift change to the 1st range feels worse. Transmission warning indicator on Clutch Pressure_1st Voltage: less Circuit Low Input than 0.25 V the monitor panel turns ON. The shift change to the 1st range feels worse. Clutch Pressure_2nd Voltage: 4.75 V Transmission warning indicator on Circuit High Input or more the monitor panel turns ON. The shift change to the 2nd range feels worse. Clutch Pressure_2nd Voltage: less Transmission warning indicator on Circuit Low Input than 0.25 V the monitor panel turns ON. The shift change to the 2nd range feels worse. Clutch Pressure_3rd Voltage: 4.75 V Transmission warning indicator on Circuit High Input or more the monitor panel turns ON. The shift change to the 3rd range feels worse. Clutch Pressure_3rd Voltage: less Transmission warning indicator on Circuit Low Input than 0.25 V the monitor panel turns ON. The shift change to the 3rd range feels worse.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-15

Remedy Check the harness. Replace the pump delivery pressure sensor. Check the harness. Replace the pump delivery pressure sensor.

Remedy Check the harness. Replace the 1st clutch pressure sensor. Check the harness. Replace the 1st clutch pressure sensor. Check the harness. Replace the 2nd clutch pressure sensor. Check the harness. Replace the 2nd clutch pressure sensor. Check the harness. Replace the 3rd clutch pressure sensor. Check the harness. Replace the 3rd clutch pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Transmission Clutch Pressure Failure Fault Code Trouble or MP Dr. Message 111214-3 Clutch Pressure_F Circuit High Input

111214-4

111215-3

111215-4

111502-2

111503-2

111504-2

111506-2

111507-2

Cause

Symptoms in Machine Operation When Trouble Occurs. Voltage: 4.75 V Transmission warning indicator on or more the monitor panel turns ON. The machine direction change to forward feels worse. Clutch Pressure_F Voltage: less Transmission warning indicator on Circuit Low Input than 0.25 V the monitor panel turns ON. The machine direction change to forward feels worse. Clutch Pressure_R Voltage: 4.75 V Transmission warning indicator on Circuit High Input or more the monitor panel turns ON. The machine direction change to reverse feels worse. Clutch Pressure_R Voltage: less Transmission warning indicator on Circuit Low Input than 0.25 V the monitor panel turns ON. The machine direction change to reverse feels worse. T/M Clutch Pressure Pressure: less Transmission warning indicator on the monitor panel turns ON. Decreased (1-speed) than 2 MPa Transmission oil pressure alarm when Engaging the (290 PSI) appears on the monitor display. Clutch T/M Clutch Pressure Pressure: less Transmission warning indicator on Decreased (2-speed) than 2.2 MPa the monitor panel turns ON. when Engaging the (320 PSI) Transmission oil pressure alarm Clutch appears on the monitor display. T/M Clutch Pressure Pressure: less Transmission warning indicator on Decreased (3-speed) than 2.2 MPa the monitor panel turns ON. when Engaging the (320 PSI) Transmission oil pressure alarm Clutch appears on the monitor display. T/M Clutch Pressure Pressure: less Transmission warning indicator on Decreased (F) when than 2.2 MPa the monitor panel turns ON. Engaging the Clutch (320 PSI) Transmission oil pressure alarm appears on the monitor display. T/M Clutch Pressure Pressure: less Transmission warning indicator on Decreased (R) when than 2.2 MPa the monitor panel turns ON. Engaging the Clutch (320 PSI) Transmission oil pressure alarm appears on the monitor display.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-16

Remedy Check the harness. Replace the forward clutch pressure sensor. Check the harness. Replace the forward clutch pressure sensor. Check the harness. Replace the reverse clutch pressure sensor. Check the harness. Replace the reverse clutch pressure sensor. Check the harness. Replace the 1st clutch pressure sensor. Check the harness. Replace the 2nd clutch pressure sensor. Check the harness. Replace the 3rd clutch pressure sensor. Check the harness. Replace the forward clutch pressure sensor. Check the harness. Replace the reverse clutch pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pilot Failure Fault Code 111312-3

111312-4

111313-3

111313-4

Trouble or MP Dr. Cause Message Service Brake Voltage: 4.75 V Secondary Pressure or more Sensor Circuit High Input

Symptoms in Machine Operation When Trouble Occurs. The declutch control becomes ineffective. The declutch is impossible. The speed shift does not automatically downshift to first speed with the travel mode set in AUTO 1 mode. Service Brake Voltage: less The declutch control becomes Secondary Pressure than 0.25 V ineffective. The declutch is Sensor Circuit Low impossible. The speed shift does not Input automatically downshift to first speed with the travel mode set in AUTO 1 mode. Parking Brake Voltage: 4.75 V Although the parking brake Pressure Sensor or more is applied, the parking brake Circuit High Input indicator is not ON. (The parking brake signal is forcibly fixed to the Release side.) Parking Brake Voltage: less Although the parking brake Pressure Sensor than 0.25 V is applied, the parking brake Circuit Low Input indicator is not ON. (The parking brake signal is forcibly fixed to the Release side.)

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-17

Remedy Check the harness. Replace the pressure sensor (brake secondary pressure).

Check the harness. Replace the pressure sensor (brake secondary pressure).

Check the harness. Replace the pressure sensor (parking brake).

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Cause Message 111413-2 Pump Swash Angle P/S Solenoid valve Valve Abnormal FB output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) 111413-3 Pump Swash Angle P/S Current: more than Valve FB High Current 920 mA 111413-4

Pump Swash Angle P/S Current: less than Valve FB Low Current 70 mA

Symptoms in Machine Operation Remedy When Trouble Occurs. Engine speed regulator for digging Check the harness. is deactivated.

Check the harness. The engine stalls is remarkable at high loaded. In addition, the engine lug-down is remarkable. Engine speed regulator for digging Check the harness. is deactivated.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-18

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Message 111414-2 T/M Clutch 1st P/S Valve Abnormal FB

Cause

111414-3

T/M Clutch 1st P/S Valve FB High Current

Solenoid valve output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) Current: more than 920 mA

111414-4

T/M Clutch 1st P/S Valve FB Low Current

Current: less than 70 mA

111415-2

T/M Clutch 2nd P/S Valve Abnormal FB

111415-3

T/M Clutch 2nd P/S Valve FB High Current

Solenoid valve output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) Current: more than 920 mA

111415-4

T/M Clutch 2nd P/S Valve FB Low Current

Current: less than 70 mA

111416-2

T/M Clutch 3rd P/S Valve Abnormal FB

111416-3

T/M Clutch 3rd P/S Valve FB High Current

Solenoid valve output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) Current: more than 920 mA

111416-4

T/M Clutch 3rd P/S Valve FB Low Current

Current: less than 70 mA

Symptoms in Machine Operation Remedy When Trouble Occurs. 1st speed clutch gear engagement Check the harness. is not possible. If 1st speed range is selected, 2nd speed clutch gear is engaged.

1st speed clutch gear engagement Check the harness. is not possible. If 1st speed range is selected, 2nd speed clutch gear is engaged. 1st speed clutch gear engagement Check the harness. is not possible. If 1st speed range is selected, 2nd speed clutch gear is engaged. Check the harness. 2nd speed clutch gear engagement is not possible. If 2nd speed range is selected, 1st speed clutch gear is engaged.

2nd speed clutch gear Check the harness. engagement is not possible. If 2nd speed range is selected, 1st speed clutch gear is engaged 2nd speed clutch gear Check the harness. engagement is not possible. If 2nd speed range is selected, 1st speed clutch gear is engaged 3rd speed clutch gear engagement Check the harness. is not possible. If 3rd speed range is selected, 2nd speed clutch gear is engaged.

3rd speed clutch gear engagement Check the harness. is not possible. If 3rd speed range is selected, 2nd speed clutch gear is engaged. 3rd speed clutch gear engagement Check the harness. is not possible. If 3rd speed range is selected, 2nd speed clutch gear is engaged.

fNOTE: MC here refers to the Main Controller (Main). These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-19

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Cause Message 111418-2 T/M Clutch Forward Solenoid valve P/S Valve Abnormal FB output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) 111418-3 T/M Clutch Forward Current: more than P/S Valve FB High 920 mA Current 111418-4

T/M Clutch Forward P/S Valve FB Low Current

111419-2

T/M Clutch Reverse P/S Solenoid valve Valve Abnormal FB output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) T/M Clutch Reverse P/S Current: more than Valve FB High Current 920 mA

111419-3

111419-4

Current: less than 70 mA

T/M Clutch Reverse P/S Current: less than Valve FB Low Current 70 mA

Symptoms in Machine Operation Remedy When Trouble Occurs. Low clutch gear engagement is not Check the harness. possible. If forward is selected, T/M is in the neutral status.

Low clutch gear engagement is not Check the harness. possible. If forward is selected, T/M is in the neutral status. Low clutch gear engagement is not Check the harness. possible. If forward is selected, T/M is in the neutral status. Reverse clutch gear engagement is Check the harness. not possible. If reverse is selected, T/M is in the neutral status.

Reverse clutch gear engagement is Check the harness. not possible. If reverse is selected, T/M is in the neutral status. Reverse clutch gear engagement is Check the harness. not possible. If reverse is selected, T/M is in the neutral status.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-20

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Message 111420-2 T/M Clutch Fast P/S Valve Abnormal FB

Cause

111420-3

T/M Clutch Fast P/S Valve FB High Current

Solenoid valve output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) Current: more than 920 mA

111420-4

T/M Clutch Fast P/S Valve FB Low Current

Current: less than 70 mA

111421-2

Lockup P/S Valve Abnormal FB

111421-3

Lockup P/S Valve FB High Current

Solenoid valve output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) Current: more than 920 mA

111421-4

Lockup P/S Valve FB Low Current

Current: less than 70 mA

111408-2

Auto Brake P/S Valve Abnormal FB

111408-3

Auto Brake P/S Valve FB High Current

Solenoid valve output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) Current: more than 920 mA

111408-4

Auto Brake P/S Valve FB Low Current

Current: less than 70 mA

Symptoms in Machine Operation When Trouble Occurs. High clutch gear engagement is not possible. If forward is selected, T/M is in the neutral status.

Remedy

High clutch gear engagement is not possible. If forward is selected, T/M is in the neutral status.

Check the harness.

High clutch gear engagement is Check the harness. not possible. If forward is selected, T/M is in the neutral status. Lockup clutch gear engagement is Check the harness. not possible. Lockup shift range is not available.

Lockup clutch gear engagement is Check the harness. not possible. Lockup shift range is not available. Lockup clutch gear engagement is Check the harness. not possible. Lockup shift range is not available. Auto brake does not work. Check the harness. Auto brake warning alarm appears on the monitor display.

Auto brake does not work. Check the harness. Auto brake warning alarm appears on the monitor display. Auto brake does not work. Check the harness. Auto brake warning alarm appears on the monitor display.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-21

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Sensor Failure Fault Code

111600-3

111600-4

111601-3

111602-3

Trouble or MP Dr. Message

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs. Abnormal shift down Check the harness. T/M Output Speed (At starter key turns ON) Replace the T/M Sensor Failure Harness disconnection detected feeling. Selected speed range is output revolution and voltage is 1.8 V or more. not correctly indicated at sensor (machine (While engine is running) speed sensor). When forward or reverse clutch is shift change. Measure clutch engaged, T/M output revolution Machine cannot move due to clutch slippage. pressures. = 0 min-1, and T/M intermediate shaft revolution > 200 min-1 or T/C output revolution > 500 min-1. T/M Out Speed Harness disconnection detected Abnormal shift down Check the harness. Sensor Circuit Low at starter key turns ON and feeling. Replace the T/M Input voltage is 1.1 V or less. Selected speed range is output revolution not correctly indicated at sensor (machine shift change. speed sensor). Controls monitoring Check the harness. Torque Converter When forward or reverse clutch T/C speed ratio are Replace the T/C is engaged, and T/M output Output Speed deactivated as it cannot output revolution revolution = 0 min-1, Sensor Failure T/M intermediate shaft revolution be calculated. sensor. > 300 min-1, or T/M output revolution > 300 min-1. Service indicator turns on. Check the harness. Intermediate Shaft When forward or reverse clutch If Transmission Output Replace the T/M Speed Sensor is engaged, and T/M output Revolution Sensor Error intermediate shaft Failure revolution = 0 min-1, T/M intermediate shaft revolution (111600-3) occurs at revolution sensor > 200 min-1, or T/C output the same time, machine (machine speed revolution > 500 min-1. speed is not displayed. backup sensor)

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (T/M) screen.

T5-5-22

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Temperature Sensor Failures Fault Code Trouble or MP Dr. Message 111903-3 T/M Oil Temp Sensor Circuit High Input 111903-4 T/M Oil Temp Sensor Circuit Low Input 111906-3 F Axle Oil Temperature Sensor Circuit High Input 111906-4 F Axle Oil Temperature Sensor Circuit Low Input 111907-3 R Axle Oil Temperature Sensor Circuit High Input 111907-4 R Axle Oil Temperature Sensor Circuit Low Input

Cause Voltage: 4.75 V or more Voltage: less than 0.25 V Voltage: more than 4.75 V Voltage: less than 0.1 V Voltage: more than 4.75 V Voltage: less than 0.1 V

Symptoms in Machine Operation When Trouble Occurs. Abnormal shift change feeling.

Remedy

Abnormal shift change feeling.

Check the harness.

Nothing observed.

Check the harness.

Nothing observed.

Check the harness.

Nothing observed.

Check the harness.

Nothing observed.

Check the harness.

fNOTE: MC here refers to the Main Controller (Main). These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-23

Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Learning Failure Fault Code Trouble or MP Dr. Message 111700-xx Calibration Abort Forward 111700-31 Calibration Abort Forward: UnCalibration 111701-xx Calibration Abort Reverse 111701-31 Calibration Abort Reverse: UnCalibration 111702-xx Calibration Abort 1st 111702-31 111703-xx 111703-31 111704-xx 111704-31

Switch Failure Fault Code 111904-2 111905-2

Cause

Symptoms in Machine Operation When Trouble Occurs Transmission learning Direction changing to forward may failed. not be smooth. Transmission learning Direction changing to forward may was not done. not be smooth.

Remedy

Transmission learning failed. Transmission learning was not done.

Perform T/M learning. See pp.T5-5-121, 122. Perform T/M learning. See p.T5-5-122.

Transmission learning failed. Transmission learning Calibration Abort was not done. 1st: Un-Calibration Calibration Abort Transmission learning 2nd failed. Transmission learning Calibration Abort 2nd: Un-Calibration was not done. Calibration Abort 3rd Transmission learning failed. Transmission learning Calibration Abort 3rd: Un-Calibration was not done.

Direction changing to reverse may not be smooth. Direction changing to reverse may not be smooth.

Perform T/M learning. See pp.T5-5-121, 122. Perform T/M learning. See p.T5-5-122.

Speed shifting to the 1st range may Perform T/M learning. not be smooth. See pp.T5-5-121, 122. Speed shifting to the 1st range may Perform T/M learning. not be smooth. See p.T5-5-122. Speed shifting to the 2nd range Perform T/M learning. may not be smooth. See pp.T5-5-121, 122. Speed shifting to the 2nd range Perform T/M learning. may not be smooth. See p.T5-5-122. Speed shifting to the 3rd range may Perform T/M learning. not be smooth. See pp.T5-5-121, 122. Speed shifting to the 3rd range may Perform T/M learning. not be smooth. See p.T5-5-122.

Trouble or MP Dr. Cause Message Column FNR SW Shift lever F & R contact Failure ON at the same time. Implement FNR SW Shift switch F & R contact Failure ON at the same time.

fNOTE: These error codes are observed on the Service Menu - Troubleshooting - Main (T/M) screen.

T5-5-24

Symptoms in Machine Operation Remedy When Trouble Occurs. Transmission is in the neutral Check the harness. condition. Replace the switch. Transmission is in the neutral Check the harness. condition. Replace the switch.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Alarms on Monitor Fault Code Trouble or MP Dr. Message 120014-2

120016-2

120101-2

120102-2

120103-2

120104-2

120105-2

120106-2

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs. Overrun Alarm MC judges the The buzzer sounds. Check the harness. machine speed is Replace the machine speed beyond the upper sensor. limit. Auto Brake Alarm Faulty auto brake The alarm is displayed Check the harness. solenoid. on the monitor. Replace the auto brake solenoid valve. Exhaust Temperature Exhaust Check the harness. Alarm temperature Check if any ECM fault code is around the accompanied. muffler is high. Replace the exhaust temperature sensor. Intake Air Temperature Intake air Check the harness. Alarm temperature Check if any ECM fault code is increases. accompanied. Replace the intake-air temperature sensor. Boost Temperature Boost Check the harness. Increase Alarm temperature Check if any ECM fault code is increases. accompanied. Replace the boost temperature sensor. Fuel Temperature Fuel temperature Check the harness. Increase Alarm increases. Check if any ECM fault code is accompanied. Replace the fuel temperature sensor. Overrun Alarm ECM judged the The buzzer sounds. Check the harness. engine revolution Replace the engine revolution sensor speed is sensor. beyond the upper limit. EGR Gas Temperature EGR gas Check the harness. Alarm temperature Check if any ECM fault code is increases. accompanied. Replace the intake manifold temperature sensor.

fNOTE: These error codes are observed on the Service Menu - Troubleshooting - Main (T/M) screen.

T5-5-25

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code List Controller Hardware Failure Fault Code Trouble or MP Dr. Message

Cause

111000-2 111001-2 111002-2

Abnormal EEPROM Abnormal RAM Abnormal A/D Converter Abnormal Sensor Voltage

Faulty SC Faulty SC Faulty SC Faulty SC Faulty sensor Faulty harness

Although the accelerator Check the sensor connected pedal is operated, the engine to SC. speed does not change. Check the harness. Replace SC.

Trouble or MP Dr. Message

Cause

Abnormal Engine Speed Sensor

Torque converter input speed sensor = 0 min-1 and Engine speed sent from ECM (CAN) > 500 min-1

Symptoms in Machine Operation When Trouble Occurs. Although the accelerator pedal is operated, aftertreatment device manual regeneration control cannot be deactivated.

111003-3

Engine Failure Fault Code

111105-3

Symptoms in Machine Operation When Trouble Occurs. -

fNOTE: SC (Sub-Controller) refers to the Main Controller

(Sub). These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-26

Remedy

Replace SC. Replace SC. Replace SC.

Remedy

Check the harness. Check and adjust the engine speed sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN Data Reception Failure Fault Code Trouble or MP Dr. Cause Message 111015-2 (SC) Information Faulty monitor Controller controller Communication Error Faulty CAN1 1 harness 111016-2 (SC) Information Faulty monitor Controller controller Communication Error Faulty CAN2 harness 2 111017-2 (SC) Monitor Controller Faulty monitor Communication Error controller Faulty CAN1 1 harness 111018-2 (SC) Monitor Controller Faulty monitor Communication Error controller 2 Faulty CAN2 harness 111019-2 (SC) MC Controller Faulty main Communication Error controller (main) 1 Faulty CAN1 harness 111020-2 (SC) MC Controller Faulty main Communication Error controller (main) 2 Faulty CAN2 harness 111021-2 (SC) Air Conditioner Faulty air Controller conditioner Communication Error controller Faulty CAN2 harness 111024-2 (SC) Engine Controller Faulty harness Communication Error 111026-2

(SC) Column Monitor Controller Communication Error

111033-2

(Sub Controller) Joystick Steering Controller Communication Error

Symptoms in Machine Operation When Trouble Occurs. Nothing observed.

Nothing observed.

Remedy Check the CAN1 harness. Replace monitor controller. Check the CAN2 harness. Replace monitor controller. Check the CAN1 harness. Replace monitor controller. Check the CAN2 harness. Replace monitor controller. Check the CAN harness.

The manual regeneration of exhaust filter cannot be performed.

Check the CAN harness.

The air conditioner does not work.

Check the CAN2 harness. Replace the air conditioner controller. Check the harness.

Even if accelerator pedal is operated, engine speed does not change.

Faulty column The control lever lock indicator on the display controller column display controller does not Faulty CAN2 light. harness Faulty joystick The joystick steering does not work. steering controller Faulty CAN2 harness

fNOTE: MC refers to the Main Controller (Main) and SC (SubController) refers to the Main Controller (Sub). These error codes are observed on the Service Menu - Troubleshooting Main (Sub) screen.

T5-5-27

Check the CAN2 harness. Replace column display controller. Check the CAN2 harness. Replace the joystick steering controller.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pump Failure Fault Code 111206-3

111206-4

111208-3

111208-4

Trouble or MP Dr. Cause Message Hyd. Fan Circuit Voltage: 4.75 V Pressure Sensor or more Circuit High Input Hyd. Fan Circuit Voltage: less Pressure Sensor than 0.25 V Circuit Low Input Emergency Steering Voltage: 4.75 V Check Pressure or more Sensor Circuit High Input

Emergency Steering Voltage: less than 0.25 V Check Pressure Sensor Circuit Low Input

Symptoms in Machine Operation When Trouble Occurs. Fan rotation direction (in normal / reverse) cannot change manually or automatically. Fan rotation direction (in normal / reverse) cannot change manually or automatically. The initial automatic check for secondary steering operation cannot be performed. (When the engine starts) Secondary steering indicator on monitor blinks. The initial automatic check for secondary steering operation cannot be performed. (When the engine starts) Secondary steering indicator on monitor blinks.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-28

Remedy Check the harness. Replace the fan pump delivery pressure sensor. Check the harness. Replace the fan pump delivery pressure sensor. Check the harness. Replace the secondary steering pump delivery pressure sensor.

Check the harness. Replace the secondary steering pump delivery pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pilot Failure Fault Code 111200-3

Trouble or MP Dr. Message Lift Arm Raise Pilot Pressure Sensor Circuit High Input

111200-4

Lift Arm Raise Pilot Pressure Sensor Circuit Low Input

111202-3

Bucket Tilt Pilot Pressure Sensor Circuit High Input Bucket Tilt Pilot Pressure Sensor Circuit Low Input Bucket Dump Pilot Pressure Sensor Circuit High Input

111202-4

111203-3

111203-4

Bucket Dump Pilot Pressure Sensor Circuit Low Input

Cause

Symptoms in Machine Operation When Trouble Occurs. Voltage: 4.75 V Bucket speed is slow during or more combined operation of lift arm and bucket. Ride control is not activated. Speed shift delay control is always delayed at AUTO 2 mode. Voltage: less Bucket speed is slow during than 0.25 V combined operation of lift arm and bucket. Ride control is not activated. Speed shift delay control is always delayed at AUTO 2 mode. Voltage: 4.75 V Bucket speed is slow during or more combined operation of lift arm and bucket. Voltage: less Bucket speed is slow during than 0.25 V combined operation of lift arm and bucket. Voltage: 4.75 V Bucket speed is slow during or more combined operation of lift arm and bucket. Speed shift delay control is always delayed at AUTO 2 mode. Voltage: less Bucket speed is slow during than 0.25 V combined operation of lift arm and bucket. Speed shift delay control is always delayed at AUTO 2 mode.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-29

Remedy Check the harness. Replace the pressure sensor (lift arm raise).

Check the harness. Replace the pressure sensor (lift arm raise).

Check the harness. Replace the pressure sensor (bucket tilt (roll back)). Check the harness. Replace the pressure sensor (bucket tilt (roll back)). Check the harness. Replace the pressure sensor (bucket dump).

Check the harness. Replace the pressure sensor (bucket dump).

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pilot Failure Fault Code 111217-3

Trouble or MP Dr. Message Pilot Pressure Sensor Circuit High Input

111217-4

Pilot Pressure Sensor Circuit Low Input

111309-3

Service Brake Pressure (Front) Sensor Circuit High Input

111309-4

Service Brake Pressure (Front) Sensor Circuit Low Input

111310-3

Service Brake Pressure (Rear) Sensor Circuit High Input

111310-4

Service Brake Pressure (Rear) Sensor Circuit Low Input

Cause

Symptoms in Machine Operation Remedy When Trouble Occurs. Voltage: 4.75 V Front control lever lock indicator Check the harness. or more on monitor is always OFF. Replace the pressure sensor Exhaust filter manual regeneration (loading pilot pressure). control is not deactivated although front control lever lock is released. Check the harness. Voltage: less Front control lever lock indicator Replace the pressure sensor than 0.25 V on monitor is always OFF. Exhaust filter manual regeneration (loading pilot pressure). control is not deactivated although front control lever lock is released. Check the harness. Voltage: 4.75 V The low brake oil pressure Replace the pressure sensor or more indicator is always ON. (brake primary pressure) Although the service brake is in the front service brake applied, the brake oil pressure circuit. gauge points at the minimum value, zero. Voltage: less The low brake oil pressure Check the harness. than 0.25 V indicator is always ON. Replace the pressure sensor Although the service brake is (brake primary pressure) applied, the brake oil pressure in the front service brake gauge points at the minimum circuit. value, zero. Voltage: 4.75 V The low brake oil pressure Check the harness. or more indicator is always ON. Replace the pressure sensor Although the service brake is (brake primary pressure) in applied, the brake oil pressure the rear service brake circuit. gauge points at the minimum value, zero. Voltage: less The low brake oil pressure Check the harness. than 0.25 V indicator is always ON. Replace the pressure sensor Although the service brake is (brake primary pressure) in applied, the brake oil pressure the rear service brake circuit. gauge points at the minimum value, zero.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-30

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Cause Symptoms in Machine Operation Remedy Message When Trouble Occurs. 111407-2 Lift Speed Increase P/S Solenoid valve Lift arm speed multiplication control Check the harness. Valve Abnormal FB output: 140 mA or is disabled. more, and Feedback current: more than 920 mA or less than 70 mA (both detected) 111407-3 Lift Speed Increase P/S Current: more Lift arm speed multiplication control Check the harness. Valve FB High Current than 920 mA is always activated. 111407-4 Lift Speed Increase P/S Current: less than Lift arm speed multiplication control Check the harness. Valve Low Current 70 mA is always deactivated. 111410-2 Parallel/Tandem Solenoid valve Bucket speed is slow during Check the parallel/ tandem switching Control P/S Valve output: 140 mA or combined operation of lift arm and bucket. solenoid valve Abnormal FB more, and Check the harness. Feedback current: more than 920 mA or less than 70 mA (both detected) 111410-3 Parallel/Tandem Current: more Lift arm raise speed becomes slow Check the parallel/ Control P/S Valve FB than 920 mA during combined operation of lift arm tandem switching High Current and bucket. solenoid valve Check the harness. 111410-4 Parallel/Tandem Current: less than Bucket speed is slow during Check the parallel/ Control P/S Valve FB 70 mA combined operation of lift arm and tandem switching Low Current bucket. solenoid valve Check the harness.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-31

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Message 111411-2 Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB

111411-3

111411-4

111412-2

111412-3 111412-4

Hydraulic Fan Reverse Rotation P/S Valve FB High Current Hydraulic Fan Reverse Rotation P/S Valve FB Low Current Hyd. Fan P/S Valve Abnormal Feedback

Cause

Symptoms in Machine Operation Remedy When Trouble Occurs. Solenoid valve The fan reverse rotation control Check the harness. output: 140 mA or becomes ineffective. more, and Fan rotation direction (in normal / Feedback current: reverse) cannot change manually nor more than 920 automatically. mA or less than 70 mA (both detected) Current: more Fan rotation direction is fixed in Check the harness. than 920 mA reverse.

Current: less than Fan rotation direction (in normal / 70 mA reverse) cannot change manually and automatically. The fan speed is fixed to the Solenoid valve output: 140 mA or maximum. more, and Feedback current: more than 920 mA or less than 70 mA (both detected) Hyd. Fan P/S Valve Current: more The fan speed is fixed to the Feedback High Current than 920 mA minimum. Hyd. Fan P/S Valve Current: less than The fan speed is fixed to the Feedback Low Current 70 mA maximum.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-32

Check the harness.

Check the harness. Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Cause Symptoms in Machine Operation Remedy Message When Trouble Occurs. 111422-2 Ride Control (Bottom) Solenoid valve Ride control selector solenoid valve Check the harness. P/S Valve Abnormal FB output: 140 mA or (boom cylinder bottom side) control more, and is disabled. Feedback current: more than 920 mA or less than 70 mA (both detected) Check the harness. 111422-3 Ride Control (Bottom) Current: more Ride control selector solenoid valve P/S Valve FB High than 920 mA (boom cylinder bottom side) control is always activated. Current 111422-4 Ride Control (Bottom) Current: less than Ride control selector solenoid valve Check the harness. P/S Valve FB Low 70 mA (boom cylinder bottom side) control Current is always deactivated. Ride control proportional solenoid Check the harness. 111423-2 Ride Control (Rod) P/S Solenoid valve Valve Abnormal FB output: 140 mA or valve (boom cylinder rod side) control is disabled. more, and Feedback current: more than 920 mA or less than 70 mA (both detected) 111423-3 Ride Control (Rod) P/S Current: more Ride control proportional solenoid Check the harness. Valve FB High Current than 920 mA valve (boom cylinder rod side) control is always activated. 111423-4 Ride Control (Rod) P/S Current: less than Ride control proportional solenoid Check the harness. Valve FB Low Current 70 mA valve (boom cylinder rod side) control is always deactivated.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-33

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Temperature Sensor Failures Fault Code Trouble or MP Dr. Message 111900-3 Torque Converter Oil Temperature Sensor Circuit High Input

111900-4

Torque Converter Oil Temperature Sensor Circuit Low Input

111901-3

Hyd. Oil Temp Sensor Circuit High Input

111901-4

Hyd. Oil Temp Sensor Circuit Low Input

Cause

Symptoms in Machine Operation Remedy When Trouble Occurs. Voltage: more The fan speed is always fixed to the Check the harness. than 4.75 V maximum. Fan reverse rotation control is disabled. Lift arm speed multiplication control is disabled. Auto idling stop is disabled. Voltage: less than The fan speed is always fixed to the Check the harness. 0.25 V maximum. Fan reverse rotation control is disabled. Lift arm speed multiplication control is disabled. Auto idling stop is disabled. Voltage: more When hydraulic oil temperature is less Check the harness. than 4.35 V than 0 °C, the auto-warm up control is not effective. Regeneration may not complete as the load cannot be applied during manual or auto regeneration of the exhaust filter. The fan speed is always fixed to the maximum. The fan reverse rotation control is not activated. Voltage: less than When hydraulic oil temperature is less Check the harness. 0.1 V than 0 °C, the auto-warm up control is not effective. Regeneration may not complete as the load cannot be applied during manual or auto regeneration of the exhaust filter. The fan speed is always fixed to the maximum. The fan reverse rotation control is not activated.

fNOTE: MC here refers to the Main Controller (Main). These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-34

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Learning Failure Fault Code Trouble or MP Dr. Cause Message 111720-2 Lift arm angle sensor is The lift arm angle uncalibrated. sensor calibration is not performed. Or, it fails.

Other Sensor Failures Fault Code Trouble or MP Dr. Message 111205-3 Lift Arm Angle Sensor Circuit High Input

111205-4

Lift Arm Angle Sensor Circuit Low Input

111207-3

Refrigerant Pressure Sensor Circuit High Input

111207-4

Refrigerant Pressure Sensor Circuit Low Input

Symptoms in Machine Operation When Trouble Occurs. Dual lift arm auto leveler cannot be set.

Cause

Symptoms in Machine Operation When Trouble Occurs. Voltage: 4.75 V or Dual lift arm auto leveler operation is more not effective. Speed shift delay control is always delayed at 2nd speed. Voltage: less than Dual lift arm auto leveler operation is 0.25 V not effective. Speed shift delay control is always delayed at 2nd speed. Voltage: more The fan speed is always fixed to the than 4.74 V maximum.

Voltage: less than The fan speed is always fixed to the 0.25 V maximum.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-35

Remedy Perform lift arm angle sensor calibration.

Remedy Check the harness. Replace the lift arm angle sensor. Check the harness. Replace the lift arm angle sensor. Check the harness. Replace the refrigerant pressure sensor. Check the harness. Replace the refrigerant pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Alarms on Monitor Fault Code Trouble or MP Dr. Message 120000-2

120001-2

120002-2

120003-2

120004-2

120005-2

120006-2

120007-2

120013-2

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs. Hydraulic Oil Overheat Hydraulic oil temperature The alarm is displayed on Check the harness. Alarm is high. the monitor. Replace the hydraulic oil temperature sensor. Main Pump Pressure Main pump oil pressure The alarm is displayed on Check the harness. Alarm is high. the monitor. Replace the main pump oil pressure sensor. Axle Oil Temperature Axle oil temperature is The alarm is displayed on Check the harness. Alarm high. the monitor. Replace the axle oil temperature sensor. Emergency Steering Steering oil pressure is The alarm is displayed on Check the harness. Activated low. the monitor. Check/replace the steering pressure switch. Emergency Steering Secondary steering The alarm is displayed on Check the harness. Activated Pressure pump delivery pressure the monitor. Replace the pressure Alarm does not increase up sensor. to the specified value. (When the engine starts) Transmission Oil Transmission oil The alarm is displayed on Check the harness. Temperature Overheat temperature is high. the monitor. Replace the torque Alarm converter oil temperature sensor. Transmission Oil Transmission oil pressure The alarm is displayed on Check the transmission Pressure Alarm is low. the monitor. clutch pressure sensors, and replace if necessary. Check the clutch solenoid hydraulic circuit. Transmission Filter Transmission oil filter is The alarm is displayed on Disconnect the Restriction Alarm clogged. the monitor. transmission filter clog detection switch connector. Check the harness between the clog switch and MC. Brake Oil Pressure Brake oil pressure is low. The alarm is displayed on Check the harness. Alarm the monitor. Check/replace the brake oil pressure sensor.

fNOTE: These error codes are observed on the Service Menu Troubleshooting - Main (Sub) screen.

T5-5-36

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Monitor) Fault Code List Fault Code 113002-2 113003-2

113004-2

113005-2 113006-2 113007-2 113010-2

113011-2

Trouble or MP Dr. Message (Monitor Controller) Engine Controller Communication Error (Monitor Controller) Main Controller Communication Error 1 (Monitor Controller) Main Controller Communication Error 2 (Monitor Controller) ICF Communication Error 1 (Monitor Controller) ICF Communication Error 2 (Monitor Controller) Column Controller Communication Error (Monitor Controller) SubController Communication Error 1 (Monitor Controller) SubController Communication Error 2

Fault Code

Trouble or MP Dr. Message

120300-2

System Failure Alarm

Cause Faulty monitor controller Faulty CAN1 harness Faulty monitor controller Faulty CAN1 harness

Remedy Check the CAN1 harness. Replace the monitor controller. Check the CAN1 harness. Replace the monitor controller.

Faulty monitor controller Faulty CAN2 harness

Check the CAN2 harness. Replace the monitor controller.

Faulty monitor controller Faulty CAN1 harness Faulty monitor controller Faulty CAN2 harness Faulty monitor controller Faulty CAN2 harness Faulty monitor controller Faulty CAN1 harness

Check the CAN1 harness. Replace the monitor controller. Check the CAN2 harness. Replace the monitor controller. Check the CAN2 harness. Replace the monitor controller. Check the CAN1 harness. Replace the monitor controller.

Faulty monitor controller Faulty CAN2 harness

Check the CAN2 harness. Replace the monitor controller.

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs Faulty CAN System failure alarm Check the CAN harness. communication bus line. appears on the monitor display.

T5-5-37

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Information) Fault Code List Fault Code 113311-3 113311-4

Trouble or MP Dr. Message Fuel Level Sensor Circuit High Input Fuel Level Sensor Circuit Low Input

Cause 131±5 Ω or less continues for 5 seconds. 4±2 Ω or less continues for 5 seconds.

Remedy Check the harness. Replace the fuel level sensor. Check the harness. Replace the fuel level sensor.

Column Display Controller Fault Code List Fault Code

115001-2

115002-2

115003-2 115018-2

Trouble or MP Dr. Message

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs. Alternator generating The alternator Check the harness. Abnormal REG input H level voltage: 33.5 V or more indicator is ON. Check the battery. Check the alternator. CAN Communication Faulty column display Alarm lamps and Check the harness. Error 2 controller indicators do not light Replace the column display controller. Faulty CAN2 harness correctly. Abnormal EEPROM Faulty column display Replace the column controller. display controller. Abnormal 24V Output Faulty column display Check the harness. controller. Replace the column display controller.

T5-5-38

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code 120500-2 120501-2 120502-2 120503-2 120504-2 120505-2

120506-2 120507-2

Trouble or MP Dr. Message Overheat Alarm Engine Error Engine Oil Pressure Alarm Air Cleaner Restriction Alarm Hydraulic Oil Level Alarm Brake Pressure Alarm Steering Oil Pressure Alarm T/M Malfunction

Cause

Remedy

Coolant temperature is high while Check the harness. the engine runs. Replace the overheat switch. Faulty engine system Refer to ECM fault code list. Engine oil pressure is reduced. Check the harness. Replace the engine oil pressure switch. Clogged air cleaner. Check the harness. Replace the air cleaner restriction switch. Hydraulic oil level is lowered. Check the harness. Replace the hydraulic oil level switch. Brake oil pressure decreases. Check the harness. Replace the pressure sensor (brake primary pressure). Faulty steering pressure switch Check the harness. (Optional) Replace the steering pressure switch. Faulty transmission system Refer to the accompanied T/M related fault code.

T5-5-39

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A JCU Fault Code List Fault Code

116000-2

116001-2

116002-3

116002-4 116003-3 116003-4 116004-3 116004-4 116005-2

116006-3

116006-4

116007-3

116007-4

Trouble or MP Dr. Message

Cause

Symptoms in Machine Operation When Trouble Occurs. Abnormal Power Source The engine stops after After detecting a failure, (Engine Speed) starting. the joystick steering can not be enabled. After detecting a failure, Abnormal Solenoid Pilot Pilot pump delivery Source Pressure pressure decreases after the joystick steering can starting the engine. not be enabled. Controller Source Power voltage is 32 V or Forced Disabling the Voltage Abnormally higher. Joystick Steering High Controller Source Power voltage is 20 V or Forced Disabling the Voltage Abnormally Low lower. Joystick Steering Joystick Signal 1 Voltage Voltage is 4.75 V or Forced Disabling the Abnormally High higher. Joystick Steering Joystick Signal 1 Voltage Voltage is 0.25 V or Forced Disabling the Abnormally Low lower. Joystick Steering Joystick Signal 2 Voltage Voltage is 4.75 V or Forced Disabling the Abnormally High higher. Joystick Steering Joystick Signal 2 Voltage Voltage is 0.25 V or Forced Disabling the Abnormally Low lower. Joystick Steering Joystick Signal Joystick signals 1, 2: Forced Disabling the Correlative Diagnosis Signal error (mismatch) Joystick Steering Error Right Steering Solenoid Voltage is 4.75 V or After detecting a failure, Valve Pressure Sensor higher. the joystick steering can Voltage Abnormally not be enabled. High Right Steering Solenoid Voltage is 0.25 V or After detecting a failure, Valve Pressure Sensor lower. the joystick steering can Voltage Abnormally Low not be enabled. Left Steering Solenoid Voltage is 4.75 V or After detecting a failure, Valve Pressure Sensor higher. the joystick steering can Voltage Abnormally not be enabled. High Left Steering Solenoid Voltage is 0.25 V or After detecting a failure, the joystick steering can Valve Pressure Sensor lower. not be enabled. Voltage Abnormally Low

T5-5-40

Remedy

Check the hydraulic circuit. Check the harness.

Check the harness. Check the harness and joystick signal. Check the harness and joystick signal. Check the harness and joystick signal. Check the harness and joystick signal. Check the harness and joystick signal. Check the harness and sensor.

Check the harness and sensor. Check the harness and sensor.

Check the harness and sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A JCU Fault Code List Fault Code Trouble or MP Dr. Message Cause

116008-3

116008-4

116010-2

116013-2

Solenoid Valve Source Pressure: Pressure Sensor Voltage Abnormally High Solenoid Valve Source Pressure: Pressure Sensor Voltage Abnormally Low Main Controller Communication Error

Symptoms in Machine Operation When Trouble Occurs. Voltage is 4.75 V or higher. After detecting a failure, the joystick steering can not be enabled. Voltage is 0.25 V or lower. After detecting a failure, the joystick steering can not be enabled. Faulty harness, Faulty main Forced Disabling the controller Joystick Steering

Monitor Controller Communication Error

Faulty harness, Faulty monitor controller

T5-5-41

Forced Disabling the Joystick Steering

Remedy

Check the harness and sensor. Check the harness and sensor. Check the harness, Check the main controller Check the harness, Check the main controller

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A JCU Fault Code List Fault Code Trouble or MP Dr. Message 116118-2

116118-3

116118-4

116119-2

116119-3

116119-4

120600-2

Cause

Symptoms in Machine Operation When Trouble Occurs. Forced Disabling the Joystick Steering

Right Steering Solenoid Feedback current: Both Valve Abnormal Feedback more than 920 mA and less than 70 mA are detected Right Steering Solenoid Feedback current: more Forced Disabling the than 920 mA Joystick Steering Valve Feedback Current Abnormally High Right Steering Solenoid Feedback current: less Forced Disabling the Valve Feedback Current than 70 mA Joystick Steering Abnormally Low Left Steering Solenoid Feedback current: Both Forced Disabling the Valve Feedback Abnormal more than 920 mA and Joystick Steering less than 70 mA are detected Left Steering Solenoid Feedback current: more Forced Disabling the Valve Feedback Current than 920 mA Joystick Steering Abnormally High Left Steering Solenoid Feedback current: less Forced Disabling the Valve Feedback Current than 70 mA Joystick Steering Abnormally Low Abnormal Joystick Joystick steering is After detecting a failure, Function (Joystick enabled without enabling the joystick steering can Function Enabled 1) it. not be enabled.

T5-5-42

Remedy

Check the harness.

Check the harness and enabling/ disabling switch.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A JCU Fault Code List Fault Code Trouble or MP Dr. Message Cause

120601-2

120602-2

120603-2

120604-2

Abnormal Joystick Function (Joystick Function Disabled) Abnormal Joystick Function (Joystick Function can not be enabled.) Abnormal Joystick Function (Joystick Function can not be disabled.) Abnormal Joystick Function (Joystick Function Enabled 2)

120605-2

Abnormal Joystick Function (Right Steering Pressure 1)

120606-2

Abnormal Joystick Function (Right Steering Pressure 2)

120607-2

Abnormal Joystick Function (Left Steering Pressure 1)

120608-2

Abnormal Joystick Function (Left Steering Pressure 2)

Symptoms in Machine Operation When Trouble Occurs. Joystick steering is After detecting a failure, disabled without disabling the joystick steering can it. not be enabled. Joystick steering is not After detecting a failure, enabled after enabling it. the joystick steering can not be enabled.

Remedy

Joystick steering is not The joystick steering can disabled after disabling it. not be disabled.

Check the harness and enabling/ disabling switch.

After detecting a failure, the joystick steering can not be enabled.

Check the harness and enabling/ disabling switch.

Forced Disabling the Joystick Steering

Check the harness and hydraulic circuit.

Forced Disabling the Joystick Steering

Check the harness and hydraulic circuit.

Forced Disabling the Joystick Steering

Check the harness and hydraulic circuit.

Forced Disabling the Joystick Steering

Check the harness and hydraulic circuit.

Joystick steering is enabled though enabling conditions are not satisfied. Command signal and actual pressure are mismatching. Pressure does not increase although it is commanded to increase. Command signal and actual pressure are mismatching. Pressure increases although it is commanded not to increase. Command signal and actual pressure are mismatching. Pressure does not increase although it is commanded to increase. Command signal and actual pressure are mismatching. Pressure increases although it is commanded not to increase.

T5-5-43

Check the harness and enabling/ disabling switch. Check the harness and enabling/ disabling switch.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A JCU Fault Code List Fault Code Trouble or MP Dr. Message 120609-2

120610-2

120611-2

120612-2

120613-2

120614-2

120615-2

Cause

Symptoms in Machine Operation When Trouble Occurs.

Abnormal FNR (Switch FNR Function enabled 1)

Forward/Reverse switch After detecting a failure, (right) is enabled without the forward/reverse enabling it. switch (right) can not be enabled. Abnormal FNR (Switch Forward/Reverse switch After detecting a failure, FNR Function disabled) (right) is disabled without the forward/reverse disabling it. switch (right) can not be enabled. Abnormal FNR (Switch Forward/Reverse switch After detecting a failure, FNR Function can not be (right) is not enabled after the forward/reverse enabled.) enabling it. switch (right) can not be enabled. Abnormal FNR (Switch Forward/Reverse switch The forward/reverse FNR Function can not be (right) is not disabled switch (right) can not be disabled.) after disabling it. disabled. Abnormal FNR (Switch Forward/Reverse switch After detecting a failure, FNR Function enabled 2) (right) is enabled though the forward/reverse enabling conditions are switch (right) can not be enabled. not satisfied. Abnormal Switch (FNR Two lines of switch signal After detecting a failure, Switching: OFF operation) errors that detect OFF the forward/reverse operation switch (right) can not be enabled. Abnormal Switch (Joystick Two lines of switch signal After detecting a failure, Function: OFF operation) errors that detect OFF the joystick steering can operation not be enabled.

T5-5-44

Remedy

Check the harness and enabling/ disabling switch. Check the harness and enabling/ disabling switch. Check the harness and enabling/ disabling switch. Check the harness and enabling/ disabling switch. Check the harness and enabling/ disabling switch. Check the harness and enabling/ disabling switch. Check the harness and enabling/ disabling switch.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A JCU Fault Code List Fault Code Trouble or MP Dr. Message

Cause

Symptoms in Machine Operation When Trouble Occurs.

Remedy

Error of two lines of switch signals that detect raise operation of the left armrest. Signal error of Forward/ Reverse switch (right)

After detecting a failure, the joystick steering can not be enabled.

Check the harness and armrest limit switch.

After detecting a failure, the forward/reverse switch (right) can not be enabled.

Check the harness. Check the combination of signals at each F-N-R position of the forward/reverse switch. Check the harness. Check the combination of signals at each F-N-R position of the forward/reverse switch.

120616-2

Abnormal Switch (Arm Rest Switch)

120617-2

Abnormal Switch (FNR Switch)

120618-2

Abnormal Switch (Joystick Signal error of Forward/ FNR Switch) Reverse switch (left)

T5-5-45

After detecting a failure, the forward/reverse switch (right) can not be enabled.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Code List Fault Code

Trouble or MP Dr. Message

Symptoms in Machine Operation When Trouble Occurs. Open circuit in air Voltage: more than 4.95 V Operation is controlled under circulation sensor such circumstance as no air circulation sensor is provided. Shorted circuit in air Voltage: less than 0.3 V Operation is controlled under circulation sensor such circumstance as no air circulation sensor is provided. Open circuit in fresh Voltage: more than 4.88 V Operation is controlled under air sensor such circumstance as no fresh air sensor is provided. Shorted circuit in Voltage: less than 0.096 V Operation is controlled under fresh air sensor such circumstance as no fresh air sensor is provided. Open circuit in solar Operation is controlled under radiation sensor such circumstance as no solar radiation sensor is provided. Shorted circuit in solar Voltage: more than 5.04 V Operation is controlled under radiation sensor such circumstance as no solar radiation sensor is provided. Open circuit in Voltage: more than 4.79 V The compressor clutch is evaporator sensor disengaged. (The compressor stops.) Shorted circuit in Voltage: less than 0.096 V The compressor clutch is evaporator sensor disengaged. (The compressor stops.) Abnormal air vent Shorted circuit: Voltage: 0 V Air vent damper servo motor damper Open circuit: Voltage: more becomes inoperable. than 5 V Abnormal air mix Shorted circuit: Voltage: Air mix damper servo motor damper less than 0.2 V becomes inoperable. Open circuit: Voltage: more than 4.8 V Abnormal high/low Voltage: 0 V The compressor clutch is refrigerant pressure disengaged. (The compressor stops.) CAN communication Faulty CAN1 harness Air conditioner stops. error between monitor controller and air conditioner controller CAN bus off error

Cause

Faulty air conditioner controller Faulty CAN1 harness

T5-5-46

Air conditioner stops.

Remedy

Check the harness. Replace the air circulation sensor. Check the harness. Replace the air circulation sensor. Check the harness. Replace the fresh air sensor. Check the harness. Replace the fresh air sensor. Check the harness. Replace the solar radiation sensor. Check the harness. Replace the solar radiation sensor. Check the harness. Replace the evaporator sensor. Check the harness. Replace the evaporator sensor. Check the harness. Replace the air vent damper servo motor. Check the harness. Replace the air vent damper servo motor. Check the harness. Replace the high/ low pressure switch. Check the CAN1 harness. Replace air conditioner controller. Check the CAN1 harness. Replace air conditioner controller.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-47

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List

fNOTE: Refer to 6WG1 Technical Manual for details. Fault Code ISUZU MPDr. P0523 100-3

Trouble

Cause

Engine Oil Pressure Sensor Circuit High Input

P0522

100-4

Engine Oil Pressure Sensor Circuit Low Input

P0234

102-0

Over Boost-Pressure

Voltage at the engine oil pressure sensor is more than 4.85 V. Voltage at the engine oil pressure sensor is less than 0.1 V. Boost pressure is more than 300 kPa.

P0238

102-3

Boost Pressure Sensor Circuit High Input

P0237

102-4

Boost Pressure Sensor Circuit Low Input

P1098

105-3

P1097

105-4

P2229

108-3

P2228

108-4

P0217

110-0

Boost Temperature Sensor (Intercooler Outlet) High Input Boost Temperature Sensor (Intercooler Outlet) Low Input Abnormal Atmospheric Pressure Sensor Circuit (High Input) Abnormal Atmospheric Pressure Sensor Circuit (Low Input) Overheat

P0118

110-3

Engine Coolant Temperature Circuit High Input

P0117

110-4

Engine Coolant Temperature Circuit Low Input

P0103

132-3

Air Flow Sensor Circuit High Input

P0102

132-4

Voltage at the air flow sensor is less than 1.5 V.

P0193

157-3

Abnormal Mass Air Flow Sensor (Abnormal Low Input or Abnormally Decrease in the Air Flow) Common Rail Pressure Sensor Circuit High Input

P0192

157-4

P0089

157-15

P0563

158-3

Abnormally High Battery System Voltage

IG-KEY voltage is more than 32 V.

Voltage at the boost pressure sensor is more than 4.9 V. Voltage at the boost pressure sensor is less than 0.1 V. Voltage at the boost temperature sensor is more than 4.94 V. Voltage at the boost temperature sensor is less than 0.1 V. Voltage at the atmospheric pressure sensor is more than 4.9 V. Voltage at the atmospheric pressure sensor is less than 0.1 V. Coolant temperature is more than 101 °C. Voltage at the coolant temperature sensor is more than 4.85 V. Voltage at the coolant temperature sensor is less than 0.1 V. Voltage at the air flow sensor is more than 4.9 V.

Voltage at the common rail pressure sensor is more than 4.8 V. Common Rail Pressure Sensor Circuit Low Input Voltage at the common rail pressure sensor is less than 0.7 V. Abnormal Common Rail Pressure (Over Pumping) Actual rail pressure is more than 40 MPa higher than the target rail pressure.

T5-5-48

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

Nothing special.

Engine oil pressure is 120 kPa.

Nothing special.

Engine oil pressure is 120 kPa.

The output power decreases.

Malfunction of VGS turbo

The output power decreases.

Boost pressure is 100 kPa.

The output power decreases.

Boost pressure is 100 kPa.

Nothing special.

Boost temperature is 50 °C.

Nothing special.

Boost temperature is 50 °C.

The output power decreases.

Atmospheric pressure is 95 kPa.

The output power decreases.

Atmospheric pressure is 95 kPa.

There is no influence when operating the machine.

Injection amount is regulated by overheat protection.

The output power decreases.

When starting: Coolant temperature is -20 °C. When operating: Coolant temperature is 90 °C. When starting: Coolant temperature is -20 °C. When operating: Coolant temperature is 90 °C. The MAF sensor value is 250 g/sec.

The output power decreases.

The MAF sensor value is 250 g/sec.

The engine may be stalled. The output power decreases.

Rail pressure is 80 MPa.

The output power decreases.

Rail pressure is 80 MPa.

Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large. The battery may be faulty.

Prevent fuel leaks.

The output power decreases.

T5-5-49

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P0523 100-3

Trouble

Influence to Engine Performance (Presumption) The output power does not decrease.

Rotation speed is limited, the output power decreases.

P0522

100-4

P0234

102-0

Engine Oil Pressure Sensor Circuit High Input Engine Oil Pressure Sensor Circuit Low Input Over Boost-Pressure

P0238

102-3

Boost Pressure Sensor Circuit High Input

The output power decreases.

P0237

102-4

Boost Pressure Sensor Circuit Low Input

The output power decreases.

P1113

105-3

The output power does not decrease.

P1112

105-4

P2229

108-3

P2228

108-4

P0217

110-0

P0118

110-3

Engine Coolant Temperature Circuit High The output power decreases. Input

P0117

110-4

Engine Coolant Temperature Circuit Low Input

The output power decreases.

P0103

132-3

Air Flow Sensor Circuit High Input

The output power decreases.

P0102

132-4

P0193

157-3

P0192

157-4

P0089

157-15

P0563

158-3

Abnormal Mass Air Flow Sensor The output power decreases. (Abnormal Low Input or Abnormally Decrease in the Air Flow) Common Rail Pressure Sensor Circuit The output power decreases. High Input Common Rail Pressure Sensor Circuit Low The output power decreases. Input Abnormal Common Rail Pressure (Over The output power decreases. Pumping) Abnormally High Battery System Voltage The output power does not change.

The output power does not decrease.

The output power does not decrease. The output power decreases. The output power decreases. Rotation speed is limited, the output power decreases.

T5-5-50

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B 

Remark C

  



The boost pressure is reduced due to turbo control and the output power decreases. The boost pressure is reduced due to turbo control and the output power decreases. Boost temperature alarm stops.



Boost temperature alarm stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



The indicator does not light due to overheat switch alarm in the same way as Tier 3. Send the CAN fault code. Limit Q is performed as regeneration stops. The boost pressure is reduced due to turbo control and the output power decreases. Limit Q is performed as regeneration stops. The boost pressure is reduced due to turbo control and the output power decreases. Limit Q is performed just in case as regeneration evaluation stops. Limit Q is performed just in case as regeneration evaluation stops.



 

  

Limit Q is performed as rail pressure cannot be controlled and regeneration stops. Limit Q is performed as rail pressure cannot be controlled and regeneration stops. Limit Q is performed as regeneration stops.



Operating Rank A: Digging / travel is operable. B: Machine can travel on a level ground and a downhill. C: The engine only runs. (Travel and operation are impossible even in light load.) D: The engine cannot stop / start.

T5-5-51

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P0113 172-3

Trouble

Cause

Intake Air Temperature Sensor Circuit High Input

P0112

172-4

Intake Air Temperature Sensor Circuit Low Input

P0428

173-3

DOC Outlet Exhaust Temperature Sensor High Input

Voltage at the intake-air temperature sensor is more than 4.85 V. Voltage at the intake-air temperature sensor is less than 0.1 V. Voltage at exhaust temperature sensor 1 is more than 4.85 V.

P0427

173-4

DOC Outlet Exhaust Temperature Sensor Low Input

P0183

174-3

Fuel Temperature Sensor Circuit High Input

P0182

174-4

Fuel Temperature Sensor Circuit Low Input

P0219

190-0

Engine Overrun

P040D

412-3

P040C

412-4

P0601

628-2

EGR Cooler 2 Outlet Temperature Sensor High Input EGR Cooler 2 Outlet Temperature Sensor Low Input Abnormal ROM

Voltage at exhaust temperature sensor 1 is less than 0.1 V. (Exhaust temperature is equivalent to 1000 °C.) Voltage at the fuel temperature sensor is more than 4.85 V. Voltage at the fuel temperature sensor is less than 0.1 V. Engine speed is more than specification (2300 min-1). EGR gas temperature sensor 4 signal voltage is 4.9 V or more for 10 seconds. EGR gas temperature sensor 4 signal voltage is 0.1 V or less for 10 seconds. Check sum is NG.

P0087

633-7

Pressure Limiter Open

It is judged by rail pressure change pattern.

P0340

636-2

Camshaft Position Sensor Malfunction

Engine speed: 90 min-1 or more, the signal from cam sensor is not present.

P0016

636-7

Phase Difference between Cam and Sensor

The correct cam pulse is not present at the gap in the crank.

U0101

639-2

Abnormal CAN Time-out

TSC1 message from SA=228 is not received.

U0073

639-19

Abnormal CAN Bus

The bus line OFF is detected.

T5-5-52

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

The output power decreases.

Intake-air temperature is -10 °C.

The output power decreases.

Intake-air temperature is -10 °C.

The output power decreases.

Exhaust temperature sensor 2 is substituted for aftertreatment device regeneration evaluation temperature. Exhaust temperature 1 is 0 °C. Exhaust temperature sensor 2 is substituted for aftertreatment device regeneration evaluation temperature. Exhaust temperature 1 is 0 °C. When starting: Coolant temperature is -20 °C. When operating: Coolant temperature is 50 °C. When starting: Coolant temperature is -20 °C. When operating: Coolant temperature is 50 °C. Protect the engine.

The output power decreases.

Nothing special. Nothing special. Engine speed may not increase 2800 min-1 or more.

Nothing special.

Engine speed is more than 1500 min-1. Coolant temperature is 79 °C (-20 °F) or higher. -

The engine cannot start.

Malfunction of ROM

The output power decreases.

Limiter open status

While the engine runs, there is nothing abnormal with machine operation. After the engine is stalled, the re-start is impossible. While the engine runs, there is nothing abnormal with machine operation. After the engine is stalled, the re-start is impossible. The engine speed is fixed to 1100 min-1.

While the engine runs, operate according to standard of the crank sensor. When the engine stops, the start is impossible. While the engine runs, operate according to standard of the crank sensor. When the engine stops, the start is impossible. CAN communication is impossible.

The engine runs at idle speed.

CAN communication is impossible.

Nothing special.

T5-5-53

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P0113 172-3

Trouble

Influence to Engine Performance (Presumption)

Intake Air Temperature Sensor Circuit High Input

The output power decreases.

P0112

172-4

Intake Air Temperature Sensor Circuit Low Input

The output power decreases.

P0428

173-3

The output power decreases.

P0427

173-4

P0183

174-3

DOC Outlet Exhaust Temperature Sensor High Input DOC Outlet Exhaust Temperature Sensor Low Input Fuel Temperature Sensor Circuit High Input

P0182

174-4

Fuel Temperature Sensor Circuit Low Input

The output power does not decrease.

P0219

190-0

Engine Overrun

P040D

412-3

P040C

412-4

P0601

628-2

EGR Cooler 2 Outlet Temperature Sensor High Input EGR Cooler 2 Outlet Temperature Sensor Low Input Abnormal ROM

Engine speed maybe limited to specification (2300 min-1) for engine protection. Nothing special.

P0087

633-7

Pressure Limiter Open

The output power decreases.

P0340

636-2

Camshaft Position Sensor Malfunction

P0016

636-7

Phase Difference between Cam and Sensor

U0101

639-2

Abnormal CAN Time-out

No influence during operation. After stopping, the re-start is impossible. No influence during operation. After stopping, the re-start is impossible. Engine speed is fixed.

U0073

639-19

Abnormal CAN Bus

Idle speed

T5-5-54

The output power decreases. The output power does not decrease.

Nothing special. The engine cannot start.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B 

Remark C



The boost pressure is reduced due to turbo control and the output power decreases. The boost pressure is reduced due to turbo control and the output power decreases. Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



  

The indicator does not light as the repair is not required in particular. The past fault codes are kept just in case.

   

Limit Q is performed as regeneration stops.



  

T5-5-55

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P0201 651-5

Trouble

Cause

Cylinder 1 Injector Circuit Open

No input signal of injector 1 monitor.

P0202

652-5

Cylinder 2 Injector Circuit Open

No input signal of injector 2 monitor.

P0203

653-5

Cylinder 3 Injector Circuit Open

No input signal of injector 3 monitor.

P0204

654-5

Cylinder 4 Injector Circuit Open

No input signal of injector 4 monitor.

P0205

655-5

Cylinder 5 Injector Circuit Open

No input signal of injector 5 monitor.

P0206

656-5

Cylinder 6 Injector Circuit Open

No input signal of injector 6 monitor.

P0335

723-2

Crank Sensor Malfunction (No Signal)

Engine speed: 90 min-1 or more, even if the cam signal is present, the crank signal is not present.

P0336

723-8

Crank Sensor Malfunction (Abnormal Signal)

Engine speed: 750 min-1 or more, the pulse of crank signal is not matched.

P0606

1077-2

Abnormal CPU

P06A6

1079-2

Abnormal 5V-Electric Power Circuit #1

P06A7

1080-2

Abnormal 5V-Electric Power Circuit #2

P0098

1131-3

Manifold Temperature Sensor Circuit High Input

P0097

1131-4

Manifold Temperature Sensor Circuit Low Input

P1093

1239-1 1239-17

Pressure Decline in Common Rail (Lack of Pumping Pressure or Fuel Filter Restriction)

Failure of main CPU is detected by sub CPU. (Sub CPU resets CPU.) Voltage of 5 V1 or 5 V5 power source is 5.5 V or more or 4.5 V or less. Voltage of 5 V2 or 5 V6 power source is 5.5 V or more or 4.5 V or less. Voltage at the manifold temperature sensor is more than 4.94 V. Voltage at the manifold temperature sensor is less than 0.1 V. Actual rail pressure is lower than the target rail pressure by 50 MPa or more for 5 seconds or more.

P3093

1239-31

Pressure Decline in Common Rail (Lack of Pumping Pressure or Fuel Filter Restriction) (Fuel Temperature Less Than 5 deg. C)

T5-5-56

Actual rail pressure is lower than the target rail pressure by 50 MPa or more for 5 seconds or more. Fuel temperature is 5 °C or lower.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. The output power may decrease, white smoke may occur and vibration may occur, the engine may be stalled. (If the cam senor is normal, the engine can re-start.) The output power may decrease, white smoke may occur and vibration may occur, the engine may be stalled. (If the cam senor is normal, the engine can re-start.) The output power decreases.

The injector cannot be controlled.

The output power decreases.

Nothing special.

Manifold temperature is 60 °C.

Nothing special.

Manifold temperature is 60 °C.

Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large. Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large.

The injector cannot be controlled.

The engine is operated according to the cam sensor standard. The engine is operated according to the cam sensor standard. Malfunction of CPU

Coolant temperature is 60°C (140°F) or more.

T5-5-57

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P0201 651-5

Trouble

Influence to Engine Performance (Presumption)

Cylinder 1 Injector Circuit Open

P0202

652-5

Cylinder 2 Injector Circuit Open

P0203

653-5

Cylinder 3 Injector Circuit Open

P0204

654-5

Cylinder 4 Injector Circuit Open

P0205

655-5

Cylinder 5 Injector Circuit Open

P0206

656-5

Cylinder 6 Injector Circuit Open

P0335

723-2

Crank Sensor Malfunction (No Signal)

The output power decreases. Five cylinders in operation The output power decreases. Five cylinders in operation The output power decreases. Five cylinders in operation The output power decreases. Five cylinders in operation The output power decreases. Five cylinders in operation The output power decreases. Five cylinders in operation The output power decreases.

P0336

723-8

Crank Sensor Malfunction (Abnormal Signal)

The output power decreases.

P0606

1077-2

Abnormal CPU

P06A6

1079-2

Abnormal 5V-Electric Power Circuit #1

Rotation speed limit control, the output power decreases. The output power decreases.

P06A7

1080-2

Abnormal 5V-Electric Power Circuit #2

The output power decreases.

P0098

1131-3

Manifold Temperature Sensor Circuit High Input

The output power does not decrease.

P0097

1131-4

Manifold Temperature Sensor Circuit Low Input

The output power does not decrease.

P1093

1239-1 1239-17 1239-31

Pressure Decline in Common Rail (Lack of Pumping Pressure or Fuel Filter Restriction) Pressure Decline in Common Rail (Lack of Pumping Pressure or Fuel Filter Restriction) (Fuel Temperature Less Than 5 deg. C)

Stop the engine.

P3093

T5-5-58

The fuel injection quantity is limited. The fuel flow rate is limited. SCR purging is stopped.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B 

Remark C

D Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.

   

EGR cannot be controlled.

T5-5-59

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P0092 1347-3

Trouble

Cause

SCV or PCV1 Drive System + B Short Circuit

SCV current is 2400 mA or more or difference between SCV current and target current is 1000 mA or more. Abnormal PCV1 drive signal (fixed to H) SCV current is 50 mA or less or difference between SCV current and target current is 1000 mA or more. Abnormal PCV1 drive signal (fixed to L) ECM detects a malfunction in the regeneration circuit of the PCV 1 drive circuit. When PCV 2 is ON, PCV 2 drive voltage is abnormal for approximately 4 seconds or more. When PCV 2 is OFF, PCV 2 drive voltage is abnormal for approximately 4 seconds or more. ECM detects a malfunction in the regeneration circuit of the PCV 2 drive circuit. Voltage at the restriction sensor is more than 4.9 V. Voltage at the restriction sensor is less than 0.1 V. Voltage in the main relay system is 1 V or less with the main relay coil output ON. Even if the main relay coil output is turned OFF, the main relay is kept ON. ECM detects a MAF difference that is less than expected. DCU detects an abnormal urea fluid concentration for 10 minutes or more. Difference between the temperatures detected by EGR gas temperature sensor 3 and those detected by EGR gas temperature sensor 4 is lower than the calculated value for 10 seconds. Difference between the temperatures detected by charge air cooler temperature sensor 1 and those detected by the boost temperature sensor is lower than the calculated value for 10 seconds. The condition which the output signal of EGR position sensor cannot be present in. Zero-point calibration value is beyond the specification. Difference between the target valve lift and actual position is more than 20 %.

P0091

1347-4

SCV or PCV1 Drive System + B Open Circuit or Short Circuit to GND

P1062

1347-12

Abnormal PCV1 FB

P2296

1348-3

PCV2 Drive Circuit + Short Circuit B

P2295

1348-4

P1063

1348-12

PCV2 Drive Circuit Open or Short Circuited to GND Abnormal PCV2 FB

P20E0

1381-3

Fuel Filter Restriction Sensor Circuit High Input

P20DF

1381-4

Fuel Filter Restriction Sensor Circuit Low Input

P0685

1485-5

Abnormal Main Relay Circuit (Inactivation)

P0687

1485-6

Abnormal Main Relay Circuit (Kept closed)

P0401

2791-2

EGR Flow Failure

P207F

4332-12

Abnormal DEF/AdBlue Quality

P2457

5260-1

Degradation of EGR Cooler 2

P1236

5285-1

Decrease in Inter Cooler Performance

P0409

10001-2

EGR Position Error (Brushless Type)

P1404

10001-13 Abnormal EGR Zero-point Calibration

P0404

10002-2

Abnormal EGR Valve Control Circuit

T5-5-60

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

The output power decreases, there is influence to exhaust gas.

The supply pump can not be controlled.

The output power decreases, there is influence to exhaust gas, the supply pump can not be controlled, the engine may increase the rotation speed automatically and abnormally. The output power decreases.

The supply pump can not be controlled.  Prevent the engine from increasing the rotation speed automatically and abnormally. (The engine is protected from damage.) -

The output power decreases.

Nothing special.

Fuel pressure is 0 kPa.

Nothing special.

Fuel pressure is 0 kPa.

The engine cannot start.

Electrical power is kept supplying to the machine.

Engine power decreases. Engine speed decreases. SCR purging is stopped.

Malfunction of EGR system. Urea SCR cannot be controlled.

Nothing special.

The output power decreases.

EGR opening amount is not certain.

The output power decreases.

EGR cannot be controlled.

The output power decreases.

EGR cannot be controlled.

T5-5-61

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P0092 1347-3

Trouble

Influence to Engine Performance (Presumption)

SCV or PCV1 Drive System + B Short Circuit

The output power decreases. The output power decreases.

P0091

1347-4

P1062

1347-12

SCV or PCV1 Drive System + B Open Circuit or Short Circuit to GND Abnormal PCV1 FB

P2296

1348-3

PCV2 Drive Circuit + Short Circuit B

P2295

1348-4

P1063

1348-12

PCV2 Drive Circuit Open or Short Circuited to GND Abnormal PCV2 FB

P20E0

1381-3

Fuel Filter Restriction Sensor Circuit High Input

The fuel injection quantity is limited. SCR purging is stopped. The fuel injection quantity is limited. SCR purging is stopped. The fuel injection quantity is limited. SCR purging is stopped. The fuel injection quantity is limited. SCR purging is stopped. The output power does not decrease.

P20DF

1381-4

Fuel Filter Restriction Sensor Circuit Low Input

The output power does not decrease.

P0685

1485-5

Abnormal Main Relay Circuit (Inactivation)

The engine stops.

P0687

1485-6

Abnormal Main Relay Circuit (Kept closed)

The output power does not change.

P0401

2791-2

EGR Flow Failure

The output power decreases.

P207F

4332-12

Abnormal DEF/AdBlue Quality

The output power decreases.

P2457

5260-1

Degradation of EGR Cooler 2

Nothing special.

P1236

5285-1

Decrease in Inter Cooler Performance

Nothing special.

P0409

10001-2

EGR Position Error (Brushless Type)

The output power decreases.

P1404

10001-13 Abnormal EGR Zero-point Calibration

The output power decreases.

P0404

10002-2

The output power decreases.

Abnormal EGR Valve Control Circuit

T5-5-62

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B 

Remark C

D Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



EGR cannot be controlled.



EGR cannot be controlled.



EGR cannot be controlled.



EGR cannot be controlled.

   

The battery may run out.  

Engine output power and speed are restricted in a phased manner. Engine output power and speed are restricted in a phased manner.

  

Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.

T5-5-63

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P2146 10003-2

Trouble

Cause

Abnormal Injector Common 1 Circuit

No monitor input signal of injectors 1, 2, and 3.

P2149

10004-2

Abnormal Injector Common 2 Circuit

No monitor input signal of injectors 4, 5, and 6.

P1261

10005-2

Abnormal Charge Circuit (Bank 1)

Voltage at bank 1 of charge circuit in ECM is low.

P1262

10006-2

Abnormal Charge Circuit (Bank 2)

Voltage at bank 2 of charge circuit in ECM is low.

P060A

10007-2

Abnormal CPU Monitor IC

No change of RUN-SUB pulse in 20 msec.

P060C

10008-2

Abnormal A/D Converter

A/D conversion cannot be done.

P06A8

10009-2

Abnormal 5V-Electric Power Circuit #3

P06A9

10010-2

Abnormal 5V-Electric Power Circuit #4

P06D5

10011-2

Abnormal 5V-Electric Power Circuit #5

P0560

10012-2

Abnormal 12V Circuit

P1622

10013-2

Abnormal EEPROM

Voltage of 5 V power supply circuit 3 or 8 is 4.5 V or less, or 5.5 V or more, for 0.4 seconds or more. Voltage of 5 V power supply circuit 4 or 9 is 4.5 V or less, or 5.5 V or more, for 0.4 seconds or more. Voltage of 5 V power supply circuit 5 or 10 is 4.5 V or less, or 5.5 V or more, for 0.4 seconds or more. Voltage of 12 V power source is 19 V or more or 7 V or less. Abnormal EEPROM is detected.

P041D

10014-3

P041C

10014-4

EGR Cooler 1 Outlet Temperature Sensor High Input EGR Cooler 1 Outlet Temperature Sensor Low Input

P045B

10020-2

Abnormal EGR 2 Valve Control

P140B

10021-2

EGR 2 Position Error

P140C

10021-13 Abnormal EGR 2 Zero-point Calibration

P0638

10022-2

Abnormal Intake Throttle Control Circuit

P0123

10022-3

P0122

10022-4

Intake Throttle Position Sensor Circuit High Input Intake Throttle Position Sensor Circuit Low Input

T5-5-64

EGR gas temperature sensor 2 signal voltage is 4.9 V or more for 10 seconds. EGR gas temperature sensor 2 signal voltage is 0.1 V or less for 10 seconds. (Exhaust temperature is equivalent to 250 °C.) Difference between the actual and desired EGR2 valve positions is 20% or more for 10 seconds or more. Signals from the EGR valve position sensor are stuck in a low or high state for 5 seconds or more. EGR learned closed position is not within the predetermined range when the ignition switch is turned OFF. Difference between the target valve lift and actual position is more than 40 %. Voltage at the intake throttle position sensor is more than 4.9 V. Voltage at the intake throttle position sensor is less than 0.3 V.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled. Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled. Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled. Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled. The output power decreases.

The injector cannot be controlled.

The output power decreases, dark smoke occurs.

All analogue sensor cannot be used.

The output power decreases.

Nothing special.

Learning value and correction value cannot be used.

The injector cannot be controlled.

Malfunction of sub CPU

Nothing special. Nothing special.

The output power decreases. Engine speed decreases. SCR purging is stopped. The output power decreases. Engine speed decreases. SCR purging is stopped. The output power decreases. Engine speed decreases. SCR purging is stopped. The output power decreases.

EGR cannot be controlled.

ITH cannot be controlled.

The output power decreases.

The intake throttle opening amount is not certain.

The output power decreases.

The intake throttle opening amount is not certain.

EGR cannot be controlled.

T5-5-65

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P2146 10003-2

Trouble

Influence to Engine Performance (Presumption)

Abnormal Injector Common 1 Circuit

Three cylinders in operation

P2149

10004-2

Abnormal Injector Common 2 Circuit

Three cylinders in operation

P1261

10005-2

Abnormal Charge Circuit (Bank 1)

Three cylinders in operation

P1262

10006-2

Abnormal Charge Circuit (Bank 2)

Three cylinders in operation

P060A

10007-2

Abnormal CPU Monitor IC

The output power decreases.

P060C

10008-2

Abnormal A/D Converter

The output power decreases.

P06A8

10009-2

Abnormal 5V-Electric Power Circuit #3

The output power decreases.

P06A9

10010-2

Abnormal 5V-Electric Power Circuit #4

The output power decreases.

P06D5

10011-2

Abnormal 5V-Electric Power Circuit #5

The output power decreases.

P0560

10012-2

Abnormal 12V Circuit

The output power decreases.

P1622

10013-2

Abnormal EEPROM

The output power does not change.

P041D

10014-3

Nothing special

P041C

10014-4

P045B

10020-2

EGR Cooler 1 Outlet Temperature Sensor High Input EGR Cooler 1 Outlet Temperature Sensor Low Input Abnormal EGR 2 Valve Control

P140B

10021-2

EGR 2 Position Error

The output power decreases.

P140C

10021-13 Abnormal EGR 2 Zero-point Calibration

The output power decreases.

P0638

10022-2

Abnormal Intake Throttle Control Circuit

The output power decreases.

P0123

10022-3

The output power decreases.

P0122

10022-4

Intake Throttle Position Sensor Circuit High Input Intake Throttle Position Sensor Circuit Low Input

T5-5-66

Nothing special The output power decreases.

The output power decreases.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B

Remark C    

D Although regeneration stops, limit Q is not performed as the output power decreases too much. Although regeneration stops, limit Q is not performed as the output power decreases too much. Although regeneration stops, limit Q is not performed as the output power decreases too much. Although regeneration stops, limit Q is not performed as the output power decreases too much.

 

Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.

    



Engine output power and speed are restricted in a phased manner. Engine output power and speed are restricted in a phased manner. Engine output power and speed are restricted in a phased manner. Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.

 

T5-5-67

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. U0110 10023-2 P0045

Trouble

Cause

Abnormal CAN VNT Time-Out

Message from turbo controller is not received.

P0602

Abnormal message from turbo controller has been received. 10023-19 VNT Communication Error Rotation speed limit control, the output power decreases. 10024-3 DOC Inlet Exhaust Temperature Sensor High Voltage at exhaust temperature sensor 2 is more Input than 4.85 V. 10024-4 DOC Inlet Exhaust Temperature Sensor Low Input Voltage at exhaust temperature sensor 2 is less than 0.1 V. (Exhaust temperature is equivalent to 1000 °C.) 10025-5 Abnormal Manual Regeneration Switch Lamp No manual regeneration switch lamp monitor signal. 10029-0 Aftertreatment Device Regeneration In case regeneration time out is continuously Overfrequent three times 10032-2 QR Code Error QR code and Q adjust have not been written.

P0604

10033-2

Abnormal RAM

Abnormal RAM is detected.

U0001

10040-19 Abnormal ISO-CAN Bus

Bus line OFF is detected.

U010E

10041-2

P2BAA

10042-12 Abnormal Urea SCR System (with Engine Output Restriction/Regeneration Inhibition) 10043-2 Abnormal Urea SCR System (without Engine Output Restriction) 10044-1 Abnormal Urea SCR System (with Engine Output Restriction) 10045-2 ADIC Failure

CAN messages from the DCU are not received for 5 seconds or more. ECM receives an error message from the DCU. ECM receives an error message from the DCU.

U0411 P042D P042C

P1669 P2458

P204F P20C9 P160B

10023-12 Abnormal VNT Turbo

DCU Communication Error

T5-5-68

ECM receives an error message from the DCU. ECM receives an error message from the DCU. ECM detects a malfunction in the signal from the AD-IC.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

The output power decreases.

The information from turbo controller cannot be received.

The output power decreases.

Turbo controller performs fail- safe control and the boost pressure decreases. Turbo controller performs fail- safe control and the boost pressure decreases. Exhaust temperature 2 is 0 °C.

The output power decreases.

Exhaust temperature 2 is 0 °C.

There is no influence when operating the machine.

The output power decreases.

Regenerative control is impossible.

Combustion sound may change.

The injector cannot be corrected.

The engine cannot start.

Malfunction of RAM

The output power decreases.

Turbo controller performs fail- safe control and the boost pressure decreases.

The output power decreases.

Refer to DCU Fault Code List.

Nothing special.

Refer to DCU Fault Code List.

The output power decreases.

Refer to DCU Fault Code List.

The output power decreases.

T5-5-69

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. U0110 10023-2

Trouble

Influence to Engine Performance (Presumption)

Abnormal CAN VNT Time-Out

Rotation speed limit control, the output power decreases. Rotation speed limit control, the output power decreases. Rotation speed limit control, the output power decreases. The output power decreases.

P0045

10023-12 Abnormal VNT Turbo

U0411

10023-19 VNT Communication Error

P042D

10024-3

P042C

10024-4

DOC Inlet Exhaust Temperature Sensor High Input DOC Inlet Exhaust Temperature Sensor Low Input The output power decreases.

P1669

10025-5

Abnormal Manual Regeneration Switch Lamp

The output power does not change.

P2458

10029-0

The output power decreases.

P0602

10032-2

Aftertreatment Device Regeneration Overfrequent QR Code Error

The output power does not change.

P0604

10033-2

Abnormal RAM

The engine cannot start.

U0001

10040-19 Abnormal ISO-CAN Bus

U010E

10041-2

P2BAA

P204F P20C9 P160B

DCU Communication Error

Rotation speed control, the output power decreases. The output power decreases. Engine speed decreases. The output power decreases. Nothing special. The output power decreases. The output power decreases.

IMPORTANT: In case fault code 10029-0 is displayed, delete it once. Measure exhaust temperature of diesel oxidation catalyst (DOC) and filter (CSF) under the following conditions. Then, when difference between two exhaust temperature is beyond 35 °C (95 °F), the temperature sensor at lower-temperature side may be faulty. Condition:  Condition after warming-up  Power mode: ON  Parking brake: ON  Forward/reverse lever: F  Bucket relief operation  Engine runs at fast idle speed without load for six minutes.

Normal value of exhaust temperature (reference)

T5-5-70

Temperature (°C)

420 (788 °F)

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B 

Remark C

          

Engine output power and speed are restricted in a phased manner. Engine output power and speed are restricted in a phased manner.

 

Engine output power and speed are restricted in a phased manner.



T5-5-71

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P1606 10046-2

Trouble

Cause

SWIC-1 Failure

ECM detects an internal SW-IC1 malfunction.

P1606

10047-2

SWIC-2 Failure

ECM detects an internal SW-IC2 malfunction.

P1606

10048-2

SWIC-1 Communication Failure

P1606

P06AF

P1077 P1076 P0546 P0545 P2457

P0549 P0548 P160C P06AF P06AF

SW-IC1 communication malfunction. The ECM detects a communication error with the internal SW-IC1. 10049-2 SWIC-2 Communication Failure SW-IC2 communication malfunction. The ECM detects a communication error with the internal SW-IC2. 10050-2 INJ-IC Failure ECM detects a malfunction in the injector drive custom IC for 2 seconds. ECM detects an error in the injector drive custom IC communication circuit for 3 seconds. The calculated checksum does not match the ROM internal registered checksum for 3 seconds. 10051-3 Inter Cooler Inlet Temperature Sensor Failure Charge air cooler temperature sensor 1 signal (High Input) voltage is 4.9 V or more for 10 seconds. 10051-4 Inter Cooler Inlet Temperature Sensor Failure Intercooler temperature sensor signal voltage is (Low Input) 0.1 V or less for 10 seconds. 10053-3 EGR Cooler 1 Inlet Temperature Sensor High Input EGR gas temperature sensor 1 signal voltage is 4.9 V or more for 10 seconds. 10053-4 EGR Cooler 1 Inlet Temperature Sensor Low Input EGR gas temperature sensor 1 signal voltage is 0.1 V or less for 10 seconds. 10054-17 Degradation of EGR Cooler 1 The difference between the temperatures detected by EGR gas temperature sensor 1 and those detected by EGR gas temperature sensor 2 is lower than the calculated value for 10 seconds. 10055-3 EGR Cooler 2 Inlet Temperature Sensor High Input EGR gas temperature sensor 3 signal voltage is 4.9 V or more for 10 seconds. 10055-4 EGR Cooler 2 Inlet Temperature Sensor Low Input EGR gas temperature sensor 3 signal voltage is 0.1 V or less for 10 seconds. 10078-12 ADIC 2 Failure ECM detects a malfunction in the signal from the AD-IC2 for 2 seconds. 10082-2 INJ-IC Communication Failure ECM detects an error in the injector drive custom IC communication circuit for 3 seconds. 10083-2 INJ-IC Checksum Failure The calculated checksum does not match the ROM internal registered checksum for 3 seconds.

T5-5-72

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

Nothing special. Nothing special. Nothing special.

Nothing special.

The engine cannot start.

Nothing special. Nothing special. Nothing special. Nothing special. Nothing special.

T5-5-73

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU MPDr. P1606 10046-2

Trouble

Influence to Engine Performance (Presumption)

SWIC-1 Failure

Nothing special.

P1606

10047-2

SWIC-2 Failure

Nothing special.

P1606

10048-2

SWIC-1 Communication Failure

Nothing special.

P1606

10049-2

SWIC-2 Communication Failure

Nothing special.

P06AF

10050-2

INJ-IC Failure

The engine cannot start.

P1077

10051-3

P1076

10051-4

P0546

10053-3

Inter Cooler Inlet Temperature Sensor Failure Nothing special. (High Input) Inter Cooler Inlet Temperature Sensor Failure Nothing special. (Low Input) EGR Cooler 1 Inlet Temperature Sensor High Input Nothing special.

P0545

10053-4

EGR Cooler 1 Inlet Temperature Sensor Low Input Nothing special.

P2457

10054-17 Degradation of EGR Cooler 1

P0549

10055-3

EGR Cooler 2 Inlet Temperature Sensor High Input Nothing special.

P0548

10055-4

EGR Cooler 2 Inlet Temperature Sensor Low Input Nothing special.

P160C

10078-12 ADIC 2 Failure

Nothing special.

P06AF

10082-2

INJ-IC Communication Failure

Nothing special.

P06AF

10083-2

INJ-IC Checksum Failure

Nothing special.

T5-5-74

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B 

Remark C

              Operating Rank A: Digging / travel is operable. B: Machine can travel on a level ground and a downhill. C: The engine only runs. (Travel and operation are impossible even in light load.) D: The engine cannot stop / start.

T5-5-75

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A DCU Fault Code List The following fault codes are accompanied by DCU fault code(s) indicating malfunction of urea SCR system. SPN-FMI

Description

4332-12

Abnormal DEF/AdBlue Quality Abnormal Urea SCR System (with Engine Output Restriction/Regeneration Inhibition) Abnormal Urea SCR System (without Engine Output Restriction) Abnormal Urea SCR System (with Engine Output Restriction)

10042-12 10043-2 10044-1

Engine output power and speed are restricted in a phased manner (Inducement). Finally operation is limited to light load and engine can only run. Refer to the Engine Manual for DCU Fault Codes. SPN-FMI 4332-12

10042-12

Failure Code

Description

Cause

10523-12

P207F

Abnormal DEF/AdBlue Quality (Concentration Reduction)

DEF concentration value is low.

10514-12

P0607

Abnormal DCU (DCU Internal Failure such as EEPROM)

Faulty DCU

10500-12

P2048

10500-12

P2049

10501-12

P208E

10507-12

P20B1

10507-12

P20B3

10507-12

P20B4

Short circuit between control circuit and battery or ignition power source.

10508-12

P208A

Open circuit of pump control circuit.

10508-12

P208C

10508-12

P208D

10509-12

P208B

10511-12

P204C

10511-12

P204D

Open circuit or short circuit to GND. Abnormal Dosing Module (Open or Short Circuit at Battery or GND Side)

Abnormal Dosing Module (Dosing Valve Stuck)

Short circuit between dosing module circuit and battery or ignition power source. Circuit current is lower than the specified value and it continues for the specified time. Open circuit of control circuit.

Abnormal Coolant Control Valve (Open or Short Circuit at Battery or GND Side)

Abnormal DEF/AdBlue Supply Module (Open or Short Circuit at Battery or GND Side)

Short-circuit between control circuit and GND

Short circuit between pump control circuit and GND. Short circuit between pump control circuit and battery or ignition power source.

Abnormal DEF/AdBlue Supply Module (Comparison Error Between Target Speed and Actual Speed)

Difference between actual and target speed of DEF pump motor is larger than certain value.

DEF/AdBlue Pressure Sensor Error (High or Low Input)

Voltage: less than 0.25V or lower.

T5-5-76

Voltage: more than 4.75V or higher.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

SPN-FMI

Failure Code

10512-12

P204B

10514-12

P0641

Description

Cause

DEF/AdBlue Pressure Sensor Error (Abnormal DEF/AdBlue Pressure after Stopping DEF/AdBlue Pump)

Pressure is less than -50 kPa or over 50 kPa while stopping DEF pump.

Abnormal DCU (DCU Internal Failure such as EEPROM)

DEF pressure sensor 5 V power source circuit voltage exceeds the specification.

10514-12

P060B

10514-12

P062F

Faulty DCU

10515-12

P0641

DEF pressure sensor 5 V power source circuit voltage exceeds the specification.

Abnormal DCU (Short Circuit of Supply Module (S/M) and Coolant Control Valve (CCV))

Faulty DCU

Voltage of the battery voltage supply circuit is low.

10515-12

P0658

10515-12

P0659

10520-12

P20FE

10525-12

U0002

10525-12

U0100

10526-12

P1462

10529-12

P206A

10529-12

P206C

10529-12

P206D

10530-12

P20E9

Abnormal DEF/AdBlue Pressure (High Pressure Error 1050kPa)

Pressure: 1050 kPa or more.

10532-12

P205D

Abnormal DEF/AdBlue Sensor Unit (Abnormal DEF/AdBlue Tank Temperature Sensor (Open or Short Circuit))

Signal voltage is high.

10533-12

P20E8

Abnormal DEF/AdBlue Pressure (Low Pressure: 650 kPa or less Pressure in Normal Condition)

10536-12

P20A2

Abnormal Reverting Valve (Short Circuit at GND Side)

10042-12

Voltage of the battery voltage supply circuit is high. Pressure does not increase beyond Abnormal DEF/AdBlue Pressure (Low 650 kPa for 250 seconds or longer Pressure after Start-Up) with the start-up control. CAN Communication Error (between DCU and ECM, ISO-CAN BUS discontinuation) CAN Communication Error (between DCU and DEF/AdBlue Sensor Unit)

CAN Bus message is not send to ECM. Communication to ECM is disconnected. CAN Bus message is not received from the DEF sensor unit. Internal malfunction of DEF quality sensor.

Abnormal DEF/AdBlue Sensor Unit (Abnormal DEF/AdBlue Quality Sensor (Open or Short Circuit))

Short circuit of DEF quality sensor circuit. Open circuit of DEF quality sensor circuit.

T5-5-77

Short circuit between control circuit and GND.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

SPN-FMI

Failure Code

10502-12

P242C

10502-12

P242D

10503-12

P242B

10504-12

P2206

10504-12

P2207

Description

Cause

SCR Exhaust Temperature Sensor Error (High or Low Input)

Voltage: 0.2 V or less

SCR Exhaust Temperature Sensor Error (Properness Diagnostic Error)

Voltage: 4.6 V or more The state that SCR exhaust gas temperature is higher than DOC outlet exhaust temperature beyond the specified value for the specified time. Open circuit in NOx sensor circuit

Abnormal Upstream NOx Sensor (Open or Short Circuit)

Short circuit in NOx sensor circuit

P2201

NOx Sensor Error (Properness Diagnostic Error)

NOx concentration data is extremely low or high.

10513-12

P20AC

Abnormal DEF/AdBlue Supply Module (Abnormal Temperature Sensor Signal or Communication Error)

Input signal is not exist.

10522-12

P203B

DEF/AdBlue Tank Level Sensor Error (Level Sensor Stuck)

Change of DEF tank level is smaller than estimated DEF consumption.

10524-12

U029D

CAN Communication Error (between Data sent from NOx sensor can not DCU and Upstream NOx Sensor) be received.

10527-12

U029D

CAN Communication Error (J1939 CAN BUS Discontinuation)

CAN Bus message hasnot been recieved from NOx sensor.

10531-12

P203D

Abnormal DEF/AdBlue Sensor Unit (Abnormal DEF/AdBlue Tank Level Sensor (Open or Short Circuit))

Signal voltage is high.

10540-12

P2210

10540-12

P2211

10505-12

10044-1

Abnormal Downstream NOx Sensor (Open or Short Circuit)

Open circuit in NOx sensor circuit Short circuit in NOx sensor circuit

10541-12

U029E

CAN Communication Error (between Data sent to NOx sensor can not be DCU and Downstream NOx Sensor) received.

10542-12

P2000

NOx Purification Rate Error

T5-5-78

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A When the following failure code is reported, there is no influence to the engine performance. Machine operation is available. SPN-FMI

Failure Code

Cause Open circuit in reverting valve control circuit.

10510-12

P20A0

10510-12

P20A3

10521-12

P149D

Abnormal DEF/AdBlue Tank Temperature (High)

Temperature exceeds 70 °C

10528-12

P1464

Abnormal DCU (Main Relay Stuck)

Main relay state is not the directed state.

P205B

Abnormal DEF/AdBlue Tank DEF temperature is extremely low Temperature (Properness Diagnostic or high while comparing with the Error of DEF/AdBlue Tank and Inlet intake air temperature. Air Temperature)

10516-12

P20AD

DEF/AdBlue Supply Module Temperature Sensor Error (Properness Diagnostic Error)

10517-12

P1468

10517-12

P1493

10518-12

P1491

Abnormal DEF/AdBlue Pressure (High Pressure Error 1250 kPa)

Pressure: 1250 kPa or higher.

10519-12

P149C

Abnormal DEF/AdBlue Pressure (Abnormal Remaining Pressure after Key Switch OFF)

DEF pressure does not decrease 40 kPa or lower within the specified period of time at DEF pressure decrease control.

10534-12

P1464

10043-2

10506-12

Description

10534-12

P20EA

10535-12

P206B

Abnormal Reverting Valve (Open or Short Circuit at Battery Side)

Abnormal DCU (Abnormal DCU Internal Circuit Temperature)

After Run Non-Completion (DCU Failure or DCU Power OFF before Completion of After Run)

DEF/AdBlue Sensor Unit Error (Controller High Temperature)

T5-5-79

Short circuit between control circuit and battery or ignition power source.

Temperature in the supply module does not rise within the specified period of time while coolant control valve is ON. Abnormal high temperature inside of DCU. Abnormal high temperature of internal actuator driving circuit.

Main relay is turned OFF while operating DCU, or main relay is stuck to ON after the after-run control. DEF pressure does not decrease the specified pressure or lower within the specified period of time at DEF pressure decrease control. Controller temperature is high.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111000 to 111002 SC Fault Codes 111000 to 111002 Fault Code 111000-2 111001-2 111002-2

Trouble or MP Dr. Message Abnormal EEPROM Abnormal RAM Abnormal A/D Converter

Cause Faulty Main Controller (Main or Sub) Faulty Main Controller (Main or Sub) Faulty Main Controller (Main or Sub)

fNOTE: Even if the engine and the machine is operated normally with the fault code displayed after retrial, the machine can be operated as it is.

MC Fault Code 111003 SC Fault Code 111003 IMPORTANT: When fault code 111003-3 (Abnormal Sensor Voltage) is displayed with other fault code, diagnose on fault code 111003-3 first. Fault Code 111003-3

Trouble or MP Dr. Message Abnormal Sensor Voltage

Inspection Method

Evaluation

Cause

Disconnect connectors from all sensors and accelerator pedal sensor. Retry the troubleshooting by using MPDr. Measure voltage between sensor harness end #1 and chassis. Check shorted circuit in harness between sensor harness end #1 and #3. -

Fault code 111003-3 is not displayed.

Faulty sensor

T5-5-80

Voltage: less than 0.25 V Open circuit in harness #1. 0Ω

Shorted circuit in harness #1 and #3.

Normal in above check.

Faulty Main Controller (Main or Sub)

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Accelerator Pedal Sensor Pump Delivery Pressure Sensor F Clutch Pressure Sensor r Clutch Pressure Sensor 1st Clutch Pressure Sensor 2nd Clutch Pressure Sensor T/M Output Shaft Speed Sensor (Machine Speed Sensor)

T/C Output Speed Sensor T/M Intermediate Gear Speed Sensor (Machine Speed Backup Sensor)

ECM (128) E/G Speed Sensor E/G Speed Sensor (GND) Load Computer (45V) 3rd Clutch Pressure Sensor Parking Brake Pressure Sensor Service Brake Secondary Pressure Sensor (for Declutch) T/M Oil Temperature Sensor Load Computer (-)

Lift Arm Raise Pilot Pressure Sensor Bucket Roll Back Pilot Pressure Sensor Bucket Dump Pilot Pressure Sensor Lift Arm Angle Sensor Front Axle Oil Temperature Sensor Secondary Steering Pressure Switch (Opt)

2 Hydraulic Fan Circuit Pressure Sensor Service Brake Primary Pressure Sensor (ACC2) Service Brake Primary Pressure Sensor (ACC1) Air Conditioner Refrigerant Pressure Sensor Secondary Steering Check Pressure Sensor (Opt) Loading Lever Primary Pilot Pressure Sensor Hydraulic Oil Temperature Sensor T/C Oil Temperature Sensor Rear Axle Oil Temperature Sensor

12-

Main Controller (Main ) Main Controller (Sub )

95Z7BTT05-05-01

T5-5-81

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Harness end of connector viewed from the open end side)  Lift Arm Angle Sensor  Pressure Sensor (Lift Arm Raise Piot)  Pressure Sensor (Bucket Dump Pilot)  Pressure Sensor (Bucket Roll Back Pilot)  Pressure Sensor (Brake Secondary Pressure)  Pressure Sensor (Primary Pilot)  Pressure Sensor (Parking Brake)  Pressure Sensor (F, R, 1st 2nd, 3rd Clutch Pressure)

90Z7-05-CN04

 Pressure Sensor (Refrigerant Pressure)

90Z7-05-CN01

90Z7-05-CN05

 Accelerator Pedal Sensor  Steering Pressure Switch

S2 90Z7-05-CN06 90Z7-05-CN02

fNOTE: P: 5 V or 24 V power supply  Pump Delivery Pressure Sensor  Hydraulic Fan Circuit Pressure Sensor  Secondary Steering Pump Delivery Pressure Sensor (Option)  Pressure Sensor (Brake Primary Pressure) (Front, Rear)

S: Signal G: Ground (chassis) (S2: Signal 2)

 T/M Oil Temperature Sensor  T/C Oil Temperature Sensor  Hydraulic Oil Temperature Sensor

90Z7-05-CN03

G  T/M Output Shaft Speed Sensor (Machine Speed Sensor)  T/C Output Speed Sensor  T/M Intermediate Gear Speed Sensor (Machine Speed Backup Sensor)

90Z7-05-CN11

 Rear Axle Oil Temperature Sensor

G G

S 90Z7-05-CN12 95Z7BTT05-05-02

T5-5-82

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111006, 111007, 111009, 111012 SC Fault Codes 111015, 111017, 111019, 111024 Preparation  Disconnect the connectors from each controller.  Check the wiring connections first.  Check the CAN1 harness between the controllers. (Refer to CAN1 Harness Check on T5-5-85 to 87.) Fault Code

Trouble or MP Dr. Message

Inspection Method

Cause

111006-2

(MC) Engine Controller Communication Error

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

111007-2

111009-2

111012-2

111015-2

111017-2

111019-2

111024-2

(MC) Information Controller Communication Error 1

(MC) Monitor Controller Communication Error 1

(MC) Sub-Controller Communication Error 1

(SC) Information Controller Communication Error 1

(SC) Monitor Controller Communication Error 1

(SC) MC Controller Communication Error 1

(SC) Engine Controller Communication Error

T5-5-83

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Monitor) Fault Codes 113002, 113003, 113005, 113010 Preparation  Disconnect the connectors from each controller.  Check the wiring connections first.  Check the CAN1 harness between the controllers. (Refer to CAN1 Harness Check on T5-5-85 to 87.) Fault Code

Trouble or MP Dr. Message

Inspection Method

Cause

113002-2

(Monitor Controller) Engine Controller Communication Error

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(Monitor Controller) Main Controller Communication Error 1

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(Monitor Controller) ICF Communication Error 1

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

113003-2

113005-2

113010-2

(Monitor Controller) SubController Communication Error 1

T5-5-84

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN1 Harness Check Preparation  Before continuity check, set the key switch to the OFF position. Evaluation

Continuity check (open circuit) Discontinuity check (shorted circuit)

Continuity (0 Ω) Correct

Discontinuity (∞ Ω) Discontinuity

Shorted circuit

Correct

Inspection

CAN Harness

ECM

Monitor Controller

Continuity check between Main Controller (MC) and each controller Discontinuity check between CAN circuit and ground circuit in each controller

High side Low side

#D2 #D3

#V60 #V77

#A24 #A23

Column Display Controller #1 - 6 #1 - 7

High side

#D2 - #E1 #D2 - #E2 #D2 - #F4 #D2 - #F5 #D2 - #F6 #D3 - #E1 #D3 - #E2 #D3 - #F4 #D3 - #F5 #D3 - #F6 -

#V60 - #V2 #V60 - #V4 #V60 - #V6 #V60 - #V41 #V60 - #V42 #V60 - #V75 #V77 - #V2 #V77 - #V4 #V77 - #V6 #V77 - #V41 #V77 - #V42 #V77 - #V75

#A24 - #B36 #A23 - #B36 -

#1-6 - #1-19 #1-7 - #1-19 -

Low side

T5-5-85

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN1 Harness Check Inspection

CAN Harness

ECM

Monitor Controller

Discontinuity check between CAN circuit and power circuit in each controller

High side

#D2 - #E5 #D2 - #E6 #D2 - #F1 #D2 - #F2 #D2 - #F3 #D3 - #E5 #D3 - #E6 #D3 - #F1 #D3 - #F2 #D3 - #F3 #D2 - #E4

#V60 - #V1 #V60 - #V3 #V60 - #V5 #V77 - #V1 #V77 - #V3 #V77 - #V5 #V60 - #V76

#A24 - #B18 #A23 - #B18 #A24 - #B17

Column Display Controller #1-6 - #2-1 #1-7 - #2-1 #1-6 - #2-2

#D3 - #E4

#V60 - #V76

#A23 - #B17

#1-7 - #2-2

#D2 - #D3

#V60 - #V77

#A24 - #A23

#1-6 - #1-7

Low side

Discontinuity check High side between CAN circuit and key signal circuit Low side in each controller Discontinuity check between CAN (High side) circuit and CAN (Low side) circuit in each controller

T5-5-86

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Harness end)  MC-D Connector

 Monitor Controller-A Connector

TNED-05-05-011

TNED-05-05-005

 MC-E Connector

 Monitor Controller-B Connector

TNED-05-05-006

 MC-F Connector

TNED-05-05-012

 Column Display Controller 1 Connector

TNED-05-05-007

TNED-05-05-004

 Column Display Controller 2 Connector

TNED-05-05-013

 Central Connector (ECM) (E)

95Z7BTT05-05-05

 Central Connector (ECM) (V)

95Z7BTT05-05-06

T5-5-87

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111008, 111010, 111013, 111014, 111025 SC Fault Codes 111016, 111018, 111020, 111021, 111026 Preparation  Disconnect the connectors from each controller.  Check the wiring connections first.  Check the CAN2 harness between the controllers. (Refer to CAN2 Harness Check on T5-5-90 to 92.) Fault Code

Trouble or MP Dr. Message

Inspection Method

Cause

111008-2

(MC) Information Controller Communication Error 2

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

111010-2

111013-2

111014-2

111016-2

111018-2

111020-2

111021-2

111025-2

111026-2

(MC) Monitor Controller Communication Error 2 (MC) Sub-Controller Communication Error 2

(MC) Air Conditioner Controller Continuity check (open circuit) Communication Error Discontinuity check (shorted circuit) (SC) Information Controller Communication Error 2 (SC) Monitor Controller Communication Error 2 (SC) MC Controller Communication Error 2

(SC) Column Monitor Controller Communication Error

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(SC) Air Conditioner Controller Continuity check (open circuit) Communication Error Discontinuity check (shorted circuit) (MC) Column Monitor Communication Error

Open circuit in harness.

Open circuit in harness. Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

T5-5-88

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Monitor) Fault Codes 113004, 113006, 113007, 113011 Preparation  Disconnect the connectors from each controller.  Check the wiring connections first.  Check the CAN2 harness between the controllers. (Refer to CAN2 Harness Check on T5-5-90 to 92.) Fault Code

Trouble or MP Dr. Message

Inspection Method

Cause

113004-2

(Monitor Controller) Main Controller Communication Error 2

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(Monitor Controller) ICF Communication Error 2

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(Monitor Controller) Column Controller Communication Error

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(Monitor Controller) SubController Communication Error 2

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

113006-2

113007-2

113011-2

T5-5-89

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN2 Harness Check Preparation  Before continuity check, set the key switch to the OFF position. Evaluation

Continuity check (open circuit) Discontinuity check (shorted circuit) Inspection

Continuity (0 Ω) Correct

Discontinuity (∞ Ω) Open circuit

Shorted circuit

Correct

CAN Harness

Continuity check High side between MC and each Low side controller Discontinuity check High side between CAN circuit and ground circuit in each controller

Low side

MC #D4 #D5

Monitor Controller #A26 #A25

Column Display Controller #1 - 8 #1 - 9

#A10(A/C2) #A11(A/C2)

#D4 - #E1 #D4 - #E2 #D4 - #F4 #D4 - #F5 #D4 - #F6 #D5 - #E1 #D5 - #E2 #D5 - #F4 #D5 - #F5 #D5 - #F6

#A26 - #B36 #A25 - #B36 -

#1-8 - #1-19 #1-9 - #1-19 -

#A10(A/C2)-#A05(A/C1) #A11(A/C2)-#A05(A/C1) -

T5-5-90

A/C

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Inspection

CAN Harness

Discontinuity check between CAN circuit and power circuit in each controller

High side

Monitor Controller #A26 - #B18 #A25 - #B18 #A26 - #B17

Column Display Controller #1-8 - #2-1 #1-9 - #2-1 #1-8 - #2-2

A/C #A10(A/C2) - #A01(A/C1) #A10(A/C2) - S#A41(A/C1) #A11(A/C2) - #A01(A/C1) #A11(A/C2) - #A41(A/C1) #A10(A/C2) - #A17(A/C1)

Discontinuity check between CAN circuit and key signal circuit in each controller

High side

#D4 - #E5 #D4 - #E6 #D4 - #F1 #D4 - #F2 #D4 - #F3 #D5 - #E5 #D5 - #E6 #D5 - #F1 #D5 - #F2 #D5 - #F3 #D4 - #E4

Low side

#D5 - #E4

#A25 - #B17

#1-9 - #2-2

#A11(A/C2) - #A17(A/C1)

Discontinuity check between CAN (High side) circuit and CAN (Low side) circuit in each controller

#D4 - #D5

#A26 - #A25

#1-8 - #1-9

#A10(A/C2) - #A11(A/C2)

Low side

T5-5-91

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Harness end)  MC-D Connector

 Column Display Controller 1 Connector

TNED-05-05-005

 MC-E Connector

TNED-05-05-004

 Column Display Controller 2 Connector

TNED-05-05-006

 MC-F Connector

TNED-05-05-013

 A/C1 Connector

TNED-05-05-007 TNED-05-05-018

 Monitor Controller-A Connector

 A/C2 Connector

TNED-05-05-011 TNED-05-05-019

 Monitor Controller-B Connector

TNED-05-05-012

T5-5-92

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111103, 111105, 111106 Preparation  Check the wiring connections first. Fault Code 111103-3

111103-4

111105-3

111106-3

111106-4

Trouble or MP Dr. Inspection Method Message Accelerator Pedal Circuit Measure resistance High Input between accelerator pedal sensor end #1 and #2. Accelerator Pedal Circuit Measure voltage between Low Input accelerator pedal sensor harness end #2 and #6. Measure voltage between accelerator pedal sensor harness end #1 and #6. --Abnormal Engine Speed Torque converter input Sensor speed sensor = 0 min-1 and Engine speed sent from ECM (CAN) > 500 min-1 Accelerator Pedal Measure resistance Position Sensor 2 High between accelerator pedal Input sensor end #1 and #25 Accelerator Pedal Position Sensor 2 Low Input

Measure voltage between accelerator pedal sensor harness end #2 and #6. Measure voltage between accelerator pedal sensor harness end #5 and #6. ---

Evaluation

Cause

0Ω

Shorted circuit in harness #1 and #2.

Normal in above check. Voltage: less than 0.25 V

Open circuit accelerator pedal sensor. Open circuit in harness #2.

Voltage: less than 0.25 V

Open circuit in harness #1.

Normal in above check.

Faulty accelerator pedal sensor. Faulty engine speed sensor

0Ω

Shorted circuit in harness #1 and #5

Normal in above check. Voltage: less than 0.25 V

Open circuit accelerator pedal sensor. Open circuit in rear console harness #2 (power supply line). Open circuit in rear console harness #5 (signal 2 line). Faulty accelerator pedal sensor.

Voltage: less than 0.25 V Normal in above check.

Accelerator pedal sensor (limit switch)

Connector (Harness end)  Accelerator Pedal Sensor Connector (Rear Console Cable Assy)

S2 90Z7-05-CN06

fNOTE: P: 5 V or 24 V power supply S: Signal G: Ground (chassis) S2: Signal 2

90Z7-05-05-04

T5-5-93

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN3 Harness Check Preparation  Before continuity check, set the key switch to the OFF position. Evaluation

Continuity check (open circuit) Discontinuity check (shorted circuit) Inspection Continuity check between MC and each controller Discontinuity check between CAN circuit and ground circuit in each controller

Continuity (0 Ω) Correct

Discontinuity (∞ Ω) Open circuit

Shorted circuit

Correct

CAN Harness High side Low side

ECM #V64 #V81

DCU #211 #212

VGS Turbo Unit #A3 #A4)

High side

#V64 - #V2 #V64 - #V4 #V64 - #V6 #V64 - #V41 #V64 - #V42 #V64 - #V75 #V81 - #V2 #V81 - #V4 #V81 - #V6 #V81 - #V41 #V81 - #V42 #V81 - #V75

#211 - #201 #211 - #202 #211 - #203 #211 - #204 #211 - #205 #212 - #201 #212 - #202 #212 - #203 #212 - #204 #212 - #205 -

#A3 - #2 -

Low side

T5-5-94

#A4 - #2 -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Inspection Discontinuity check between CAN circuit and power circuit in each controller

CAN Harness High side

Discontinuity check between CAN circuit and key signal circuit in each controller

High side

ECM #V64 - #V1 #V64 - #V3 #V64 - #V5 #V81 - #V1 #V81 - #V3 #V81 - #V5 #V64 - #V76

Low side

#V81 - #V76

#212 - #252

Discontinuity check between CAN (High side) circuit and CAN (Low side) circuit in each controller

#V64 - #V81

#211 - #212

#3 - #A4

Low side

T5-5-95

DCU #211 - #206 #211 - #207 #211 - #208 #211 - #209 #212 - #206 #212 - #207 #212 - #208 #212 - #209 #211 - #252

VGS Turbo Unit #A3 - #1 #A4 - #1 -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A  Central Connector (ECM) (E)

95Z7BTT05-05-07

 Central Connector (ECM) (V)

95Z7BTT05-05-08

 Central Connector (DCU) (86-poles)

95Z7BTT05-05-09

 Central Connector (Turbo Controller)

 Central Connector (DCU) (53-poles)

95Z7BTT05-05-10

T5-5-96

95Z7BTT05-05-11

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN4 Harness Check Preparation  Before continuity check, set the key switch to the OFF position. Evaluation

Continuity (0 Ω) Correct

Discontinuity (∞ Ω) Open circuit

Shorted circuit

Correct

CAN Harness High side Low side

DCU #214 #215

Urea Sensor #2 #1

NOx Sensor (SCR In) #4 #3

NOx Sensor (SCR Out) #4 #3

High side

#214 - #201 #214 - #202 #214 - #203 #214 - #204 #214 - #205 #215 - #201 #215 - #202 #215 - #203 #215 - #204 #215 - #205

#2 - #4 #1 - #4 -

#4 - #2 #3 - #2 -

Low side

T5-5-97

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Inspection Discontinuity check between CAN circuit and power circuit in each controller

CAN Harness High side

Discontinuity check between CAN circuit and key signal circuit in each controller

High side

DCU #214 - #206 #214 - #207 #214 - #208 #214 - #209 #215 - #206 #215 - #207 #215 - #208 #215 - #209 #214 - #252

Low side

#215 - #252

Discontinuity check between CAN (High side) circuit and CAN (Low side) circuit in each controller

#214 - #215

#2 - #1

#4 - #3

Low side

Urea Sensor #2 - #3 #1 - #3 -

NOx Sensor (SCR In) #4 - #1 #3 - #1 -

NOx Sensor (SCR Out) #4 - #1 #3 - #1 -

T5-5-98

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A  Central Connector (DCU) (86-poles)

95Z7BTT05-05-09

 Central Connector (DCU) (53-poles)

95Z7BTT05-05-10

 Urea Sensor Connector

 NOx Sensor Connector

95Z7BTT05-05-12

T5-5-99

95Z7BTT05-05-13

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Codes 111205, 111207 Preparation  Check the wiring connections first. Fault Code 111205-3

111205-4

111207-3

111207-4

Trouble or MP Dr. Message Lift Arm Angle Sensor Circuit High Input

Inspection Method

Evaluation

Cause

Measure resistance between lift arm angle sensor end #1 and #2. -

0Ω

Shorted circuit in harness #1 and #2.

Normal in above check. Voltage: less than 0.25 V

Open circuit lift arm angle sensor. Open circuit in harness #1.

Lift Arm Angle Sensor Circuit Low Input

Measure voltage between lift arm angle sensor harness end #1 and chassis. Measure voltage between Voltage: less than lift arm angle sensor 0.25 V harness end #1 and #3. Normal in above check. 0Ω Refrigerant Pressure Measure resistance Circuit High Input between refrigerant pressure sensor end #1 and #2. Normal in above check. Refrigerant Pressure Measure voltage between Voltage: less than Sensor Circuit Low Input refrigerant pressure sensor 0.25 V harness end #1 and chassis. Measure voltage between Voltage: less than refrigerant pressure sensor 0.25 V harness end #1 and #3. Normal in above check.

Open circuit in harness #3.

Faulty lift arm angle sensor. Shorted circuit in harness #1 and #2.

Open circuit refrigerant pressure sensor. Open circuit in harness #1.

Open circuit in harness #3.

Faulty refrigerant pressure sensor.

Connector (Harness end)  Lift Arm Angle Sensor

 Refrigerant Pressure Sensor

90Z7-05-CN04

90Z7-05-CN05

fNOTE: P: 5 V or 24 V power supply S: Signal G: Ground (chassis)

T5-5-100

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Codes 111200, 111202, 111203 Preparation  Before inspection, set the key switch to the ON position.

 Check the wiring connections first.  Connect the test harness and dummy sensor. Fault Code Trouble or MP Dr. Message 111200-3 Lift Arm Raise Pilot Pressure Sensor Circuit High Input 111200-4

Lift Arm Raise Pilot Pressure Sensor Circuit Low Input

111202-3

Bucket Tilt Pilot Pressure Sensor Circuit High Input

111202-4

Bucket Tilt Pilot Pressure Sensor Circuit Low Input

111203-3

Bucket Dump Pilot Pressure Sensor Circuit High Input

111203-4

Bucket Dump Pilot Pressure Sensor Circuit Low Input

Inspection Method

Evaluation

Retry by using MPDr. Un-displayed fault code Measure voltage between B Voltage: 4.75 V or more and chassis. Retry by using MPDr. Un-displayed fault code Measure voltage between A Voltage: less than 0.25 V and chassis. Measure voltage between A Voltage: less than 0.25 V and C (GND). Normal in above check. Retry by using MPDr. Un-displayed fault code Measure voltage between B Voltage: 4.75 V or more and chassis. Retry by using MPDr. Un-displayed fault code Measure voltage between A Voltage: less than 0.25 V and chassis. Measure voltage between A Voltage: less than 0.25 V and C (GND). Normal in above check. Retry by using MPDr. Un-displayed fault code Measure voltage between B Voltage: 4.75 V or more and chassis. Retry by using MPDr. Un-displayed fault code Measure voltage between A Voltage: less than 0.25 V and chassis. Measure voltage between A Voltage: less than 0.25 V and C (GND). Normal in above check. C

Cause Faulty sensor. Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1. Open circuit in harness #3. Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1. Open circuit in harness #3. Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1. Open circuit in harness #3. Open circuit in harness #2.

TDAA-05-06-003

T5-5-101

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111204, 111312 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111204-3

111204-4

111312-3

111312-4

Trouble or MP Dr. Inspection Method Evaluation Message Pump Delivery Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit High Input code Measure voltage between B Voltage: 4.75 V or and chassis. more Pump Delivery Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit Low Input code Measure voltage between A Voltage: less than and chassis. 0.25 V Measure voltage between A Voltage: less than and C (GND). 0.25 V Normal in above check. Service Brake Secondary Retry by using MPDr. Un-displayed fault Pressure Sensor Circuit code High Input Measure voltage between B Voltage: 4.75 V or and chassis. more Service Brake Secondary Retry by using MPDr. Un-displayed fault Pressure Sensor Circuit code Low Input Measure voltage between A Voltage: less than and chassis. 0.25 V Measure voltage between A Voltage: less than and C (GND). 0.25 V Normal in above check. C

TDAA-05-06-003

T5-5-102

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Codes 111206, 111217 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111206-3

111206-4

111217-3

111217-4

Trouble or MP Dr. Inspection Method Evaluation Message Hyd. Fan Circuit Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit High Input code Measure voltage between B Voltage: 4.75 V or and chassis. more Hyd. Fan Circuit Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit Low Input code Measure voltage between A Voltage: less than and chassis. 0.25 V Measure voltage between A Voltage: less than and C (GND). 0.25 V Normal in above check. Pilot Pressure Sensor Retry by using MPDr. Un-displayed fault Circuit High Input code Measure voltage between B Voltage: 4.75 V or and chassis. more Pilot Pressure Sensor Retry by using MPDr. Un-displayed fault Circuit Low Input code Measure voltage between A Voltage: less than and chassis. 0.25 V Measure voltage between A Voltage: less than and C (GND). 0.25 V Normal in above check. C

TDAA-05-06-003

T5-5-103

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code 111208 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111208-3

111208-4

Trouble or MP Dr. Message Emergency Steering Check Pressure Sensor Circuit High Input Emergency Steering Check Pressure Sensor Circuit Low Input

Inspection Method

Evaluation

Retry by using MPDr.

Un-displayed fault code Measure voltage between B Voltage: 4.75 V or and chassis. more Retry by using MPDr. Un-displayed fault code Measure voltage between A Voltage: less than and chassis. 0.25 V Measure voltage between A Voltage: less than and C (GND). 0.25 V Normal in above check. C

Cause Faulty sensor. Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1. Open circuit in harness #3. Open circuit in harness #2.

TDAA-05-06-003

T5-5-104

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111313 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111313-3

111313-4

Trouble or MP Dr. Inspection Method Message Parking Brake Pressure Retry by using MPDr. Sensor Circuit High Input Measure voltage between B and chassis. Parking Brake Pressure Retry by using MPDr. Sensor Circuit Low Input Measure voltage between A and chassis. Measure voltage between A and C (GND). -

Evaluation

Cause

Un-displayed fault code

Faulty sensor.

Voltage: 4.75 V or more

Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1. Open circuit in harness #3. Open circuit in harness #2

Un-displayed fault code Voltage: less than 0.25 V Voltage: less than 0.25 V Normal in above check.

TDAA-05-06-003

T5-5-105

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111600 to 111602 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111600-3 111600-4 111601-3 111602-3

Trouble or MP Dr. Message T/M Output Speed Sensor Failure T/M Out Speed Sensor Circuit Low Input Torque Converter Output Speed Sensor Failure Intermediate Shaft Speed Sensor Failure

Inspection Method Check if the sensor is loosen or tightened too much Measure resistance between sensor #1 and #2. -

fNOTE: Refer to p. T5-4-17 for each sensor. IMPORTANT: If clearance "A" between the sensor and the detected object is too large or too small, the sensor doesn't work correctly.

90Z7B-05-05-03

T5-5-106

Evaluation Abnormal

Cause Abnormal sensor mounting condition.

0/∞Ω

Faulty sensor.

Normal in harness check

Abnormal harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111210 to 111212 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111210-3

111210-4

Trouble or MP Dr. Message Clutch Pressure_1st Circuit High Input

Clutch Pressure_1st Circuit Low Input

111211-3

Clutch Pressure_2nd Circuit High Input

111211-4

Clutch Pressure_2nd Circuit Low Input

111212-3

Clutch Pressure_3rd Circuit High Input

111212-4

Clutch Pressure_3rd Circuit Low Input

Inspection Method

Evaluation

Cause

Retry by using MPDr.

Un-displayed fault code

Faulty sensor.

Measure voltage between B and chassis. Retry by using MPDr. Measure voltage between A and chassis. Measure voltage between A and C (GND). -

Voltage: 4.75 V or more

Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1. Open circuit in harness #3. Open circuit in harness #2 Faulty sensor. Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1. Open circuit in harness #3. Open circuit in harness #2 Faulty sensor. Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1. Open circuit in harness #3. Open circuit in harness #2.

Un-displayed fault code Voltage: less than 0.25 V Voltage: less than 0.25 V Normal in above check.

Retry by using MPDr. Measure voltage between B and chassis. Retry by using MPDr. Measure voltage between A and chassis. Measure voltage between A and C (GND). -

Un-displayed fault code Voltage: 4.75 V or more

Retry by using MPDr. Measure voltage between B and chassis. Retry by using MPDr. Measure voltage between A and chassis. Measure voltage between A and C (GND). -

Un-displayed fault code Voltage: 4.75 V or more

Un-displayed fault code Voltage: less than 0.25 V Voltage: less than 0.25 V Normal in above check.

TDAA-05-06-003

T5-5-107

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111214, 111215 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111214-3

111214-4

111215-3

111215-4

Trouble or MP Dr. Inspection Method Message Clutch Pressure_F Circuit Retry by using MPDr. High Input Measure voltage between B and chassis. Clutch Pressure_F Circuit Retry by using MPDr. Low Input Measure voltage between A and chassis. Measure voltage between A and C (GND). -

Evaluation

Cause

Un-displayed fault code

Faulty sensor.

Voltage: 4.75 V or more

Clutch Pressure_R Circuit Retry by using MPDr. High Input Measure voltage between B and chassis. Clutch Pressure_R Circuit Retry by using MPDr. Low Input Measure voltage between A and chassis. Measure voltage between A and C (GND). -

Un-displayed fault code Voltage: 4.75 V or more

Un-displayed fault code Voltage: less than 0.25 V Voltage: less than 0.25 V Normal in above check.

TDAA-05-06-003

T5-5-108

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Codes 111309, 111310 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111309-3

111309-4

111310-3

111310-4

Trouble or MP Dr. Message Service Brake Pressure (Front) Sensor Circuit High Input Service Brake Pressure (Front) Sensor Circuit Low Input

Inspection Method

Evaluation

Cause

Retry by using MPDr.

Un-displayed fault code

Faulty sensor.

Measure voltage between B and chassis. Retry by using MPDr. Measure voltage between A and chassis. Measure voltage between A and C (GND). -

Voltage: 4.75 V or more

Service Brake Pressure (Rear) Sensor Circuit High Input

Retry by using MPDr. Measure voltage between B and chassis. Service Brake Pressure Retry by using MPDr. (Rear) Sensor Circuit Low Measure voltage between A Input and chassis. Measure voltage between A and C (GND). -

Un-displayed fault code Voltage: less than 0.25 V Voltage: less than 0.25 V Normal in above check. Un-displayed fault code Voltage: 4.75 V or more Un-displayed fault code Voltage: less than 0.25 V Voltage: less than 0.25 V Normal in above check.

TDAA-05-06-003

T5-5-109

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code 111407 Preparation  Check the wiring connections first. Fault Code 111407-2

111407-3

111407-4

Trouble or MP Dr. Message Lift Speed Increase P/S Valve Abnormal FB

Lift Speed Increase P/S Valve FB High Current

Lift Speed Increase P/S Valve Low Current

Inspection Method

Evaluation

Cause

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Lift speed increase P/S FB -

0/∞Ω (Normal value: 34.3±2.4 Ω) 0V

Faulty solenoid valve.

0 mA Normal in above check. 0/∞Ω (Normal value: 34.3±2.4 Ω) Normal in above check. 0/∞Ω (Normal value: 34.3±2.4 Ω) 0V

Open circuit in harness #2. Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Lift speed increase P/S FB

Connector (Harness end)  Solenoid Valve Connector

90Z7-05-CN10

T5-5-110

0 mA

Open circuit in harness #1.

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Open circuit in harness #1.

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code 111410 Preparation  Check the wiring connections first. Fault Code 111410-2

111410-3

111410-4

Trouble or MP Dr. Message Parallel/Tandem Control P/S Valve Abnormal FB

Parallel/Tandem Control P/S Valve FB High Current

Inspection Method

Evaluation

Cause

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Parallel/Tandem Switch P/S FB -

0/∞Ω (Normal value: 22±0.4 Ω) 0V

Faulty solenoid valve.

0 mA

Open circuit in harness #2.

Normal in above check. 0Ω (Normal value: 22±0.4 Ω) Normal in above check. ∞Ω (Normal value: 22±0.4 Ω) 0V

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Measure resistance between solenoid valve #1 and #2. -

Parallel/Tandem Control Measure resistance P/S Valve FB Low Current between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Parallel/Tandem Switch P/S 0 mA FB

Connector (Harness end)  Solenoid Valve Connector

90Z7B-05-05-20

T5-5-111

Open circuit in harness #1.

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Open circuit in harness #1.

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code 111411 Preparation  Check the wiring connections first. Fault Code 111411-2

111411-3

111411-4

Trouble or MP Dr. Message Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB

Hydraulic Fan Reverse Rotation P/S Valve FB High Current

Hydraulic Fan Reverse Rotation P/S Valve FB Low Current

Inspection Method

Evaluation

Cause

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Oil Pressure Driving Fan Reverse P/S FB -

0/∞Ω (Normal value: 30 Ω) 0V

Faulty solenoid valve.

0 mA

Open circuit in harness #2.

Normal in above check. 0Ω (Normal value: 30 Ω) Normal in above check. ∞Ω (Normal value: 30 Ω) 0V

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Oil Pressure Driving Fan Reverse P/S FB

Connector (Harness end)  Solenoid Valve Connector

90Z7-05-CN10

T5-5-112

0 mA

Open circuit in harness #1.

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Open circuit in harness #1.

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code 111412 Preparation  Check the wiring connections first. Fault Code 111412-2

111412-3

111412-4

Trouble or MP Dr. Message Hyd. Fan P/S Valve Abnormal Feedback

Hyd. Fan P/S Valve Feedback High Current

Hyd. Fan P/S Valve Feedback Low Current

Inspection Method

Evaluation

Cause

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Oil Pressure Driving Fan Control P/S FB -

0/∞Ω (Normal value: 30 Ω) 0V

Faulty solenoid valve.

0 mA

Open circuit in harness #2.

Normal in above check. 0Ω (Normal value: 30 Ω) Normal in above check. ∞Ω (Normal value: 30 Ω) 0V

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Connector (Harness end)  Solenoid Valve Connector

90Z7-05-CN10

T5-5-113

0 mA

Open circuit in harness #1.

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Open circuit in harness #1.

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111413 Preparation  Check the wiring connections first. Fault Code 111413-2

111413-3

111413-4

Trouble or MP Dr. Message Pump Swash Angle P/S Valve Abnormal FB

Pump Swash Angle P/S Valve FB High Current

Pump Swash Angle P/S Valve FB Low Current

Inspection Method

Evaluation

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Monitor Pump Torque Control P/S Valve Output FB. -

0/∞Ω Faulty solenoid valve. (Normal value: 17.5 Ω) 0V Open circuit in harness #1.

Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Monitor Pump Torque Control P/S Valve Output FB.

Connector (Harness end)  Solenoid Valve Connector

90Z7-05-CN11

T5-5-114

Cause

0 mA

Open circuit in harness #2.

Normal in above check. 0Ω (Normal value: 17.5 Ω) Normal in above check. ∞Ω (Normal value: 17.5 Ω) 0V

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

0 mA

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Open circuit in harness #1.

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111414 to 111421 Preparation  Check the wiring connections first. Fault Code 111414-2 111415-2 111416-2 111418-2 111419-2 111420-2 111421-2 111414-3 111415-3 111416-3 111418-3 111419-3 111420-3 111421-3

Trouble or MP Dr. Inspection Method Message T/M Clutch 1st P/S Valve Measure resistance Abnormal FB between solenoid valve #1 T/M Clutch 2nd P/S Valve and #2. Abnormal FB Measure voltage between T/M Clutch 3rd P/S Valve solenoid valve harness end Abnormal FB #1 and chassis. T/M Clutch Forward P/S Monitor each clutch P/S FB Valve Abnormal FB T/M Clutch Reverse P/S Valve Abnormal FB T/M Clutch Fast P/S Valve Abnormal FB Lockup P/S Valve Abnormal FB T/M Clutch 1st P/S Valve Measure resistance FB High Current between solenoid valve #1 T/M Clutch 2nd P/S Valve and #2. FB High Current T/M Clutch 3rd P/S Valve FB High Current T/M Clutch Forward P/S Valve FB High Current T/M Clutch Reverse P/S Valve FB High Current T/M Clutch Fast P/S Valve FB High Current Lockup P/S Valve FB High Current

Connector (Harness end)  Solenoid Valve Connector

90Z7-05-CN10

T5-5-115

Evaluation

Cause

0/∞Ω (Normal voltage: 17.5 Ω) 0V

Faulty solenoid valve.

0 mA

Open circuit in harness #2.

Normal in above check.

Shorted circuit in harness #1 and #2.

0Ω (Normal voltage: 17.5 Ω)

Faulty solenoid valve.

Normal in above check.

Shorted circuit in harness #1 and #2.

Open circuit in harness #1.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code 111414-4 111415-4 111416-4 111418-4 111419-4 111420-4 111421-4

Trouble or MP Dr. Inspection Method Message T/M Clutch 1st P/S Valve Measure resistance FB Low Current between solenoid valve #1 T/M Clutch 2nd P/S Valve and #2. FB Low Current T/M Clutch 3rd P/S Valve Measure voltage between FB Low Current solenoid valve harness end T/M Clutch Forward P/S #1 and chassis. Valve FB Low Current T/M Clutch Reverse P/S Monitor each clutch P/S FB Valve FB Low Current T/M Clutch Fast P/S Valve FB Low Current Lockup P/S Valve FB Low Current

Connector (Harness end)  Solenoid Valve Connector

90Z7-05-CN10

T5-5-116

Evaluation

Cause

∞Ω (Normal voltage: 17.5 Ω)

Faulty solenoid valve.

Open circuit in harness #1.

0 mA

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111408 Preparation  Check the wiring connections first. Fault Code 111408-2

111408-3

111408-4

Trouble or MP Dr. Message Auto Brake P/S Valve Abnormal FB

Auto Brake P/S Valve FB High Current

Auto Brake P/S Valve FB Low Current

Inspection Method

Evaluation

Cause

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Monitor auto brake P/S FB -

0/∞Ω (Normal value: 22±0.4 Ω) 0V

Faulty solenoid valve.

0 mA Normal in above check. 0Ω (Normal value: 22±0.4 Ω) Normal in above check. ∞Ω (Normal value: 22±0.4 Ω) 0V

Open circuit in harness #2. Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Monitor auto brake P/S FB

Connector (Harness end)  Solenoid Valve Connector

90Z7B-05-05-20

T5-5-117

0 mA

Open circuit in harness #1.

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Open circuit in harness #1.

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code 111422 Preparation  Check the wiring connections first. Fault Code 111422-2

111422-3

111422-4

Trouble or MP Dr. Message Ride Control (Bottom) P/S Valve Abnormal FB

Ride Control (Bottom) P/S Valve FB High Current

Inspection Method

Evaluation

Cause

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Ride Control P/S FB -

0/∞Ω (Normal voltage: 17.5 Ω) 0V

Faulty solenoid valve.

0 mA Normal in above check. 0Ω (Normal voltage: 17.5 Ω) Normal in above check. ∞Ω (Normal voltage: 17.5 Ω) 0V

Open circuit in harness #2. Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Measure resistance between solenoid valve #1 and #2. -

Ride Control (Bottom) Measure resistance P/S Valve FB Low Current between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Ride Control P/S FB

Connector (Harness end)  Solenoid Valve Connector

90Z7-05-CN10

T5-5-118

0 mA

Open circuit in harness #1.

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Open circuit in harness #1.

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code 111423 Preparation  Check the wiring connections first. Fault Code 111423-2

111423-3

111423-4

Trouble or MP Dr. Message Ride Control (Rod) P/S Valve Abnormal FB

Ride Control (Rod) P/S Valve FB High Current

Ride Control (Rod) P/S Valve FB Low Current

Inspection Method

Evaluation

Cause

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Ride Control P/S FB -

0/∞Ω (Normal voltage: 26.2±1.3 Ω) 0V

Faulty solenoid valve.

0 mA Normal in above check. 0Ω (Normal voltage: 26.2±1.3 Ω) Normal in above check. ∞Ω (Normal voltage: 26.2±1.3 Ω) 0V

Open circuit in harness #2. Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Ride Control P/S FB

Connector (Harness end)  Solenoid Valve Connector

90Z7-05-CN10

T5-5-119

0 mA

Open circuit in harness #1.

Shorted circuit in harness #1 and #2. Faulty solenoid valve.

Open circuit in harness #1.

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111502 to 111504, 111506, 111507 Preparation  Check the pressure sensor connections first. Fault Code 111502-2

111503-2

111504-2

111506-2

111507-2

Trouble or MP Dr. Message T/M Clutch Pressure Decreased (1-speed) when Engaging the Clutch T/M Clutch Pressure Decreased (2-speed) when Engaging the Clutch T/M Clutch Pressure Decreased (3-speed) when Engaging the Clutch T/M Clutch Pressure Decreased (F) when Engaging the Clutch T/M Clutch Pressure Decreased (R) when Engaging the Clutch

Inspection Method Measure pressure at the 1st clutch

Evaluation Pressure: less than 2 MPa (290 PSI)

Measure pressure at the 2nd clutch

Pressure: less than 2.2 Faulty 2nd clutch MPa (320 PSI) pressure sensor.

Measure pressure at the 3rd clutch

Pressure: less than 2.2 Faulty 3rd clutch MPa (320 PSI) pressure sensor.

Measure pressure at the low clutch

Pressure: less than 2.2 Faulty low clutch MPa (320 PSI) pressure sensor.

Measure pressure at the reverse clutch

Pressure: less than 2.2 Faulty reverse clutch MPa (320 PSI) pressure sensor.

fNOTE: Refer to page T4-5-26 for the transmission clutch pressure measurement.

T5-5-120

Cause Faulty 1st clutch pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111700 to 111704 Fault Code

Trouble or MP Dr. Message

111700-6 111701-6 111702-6 111703-6 111704-6 111700-7 111701-7 111702-7 111703-7 111704-7 111700-8

Calibration Abort Forward: Key-off Calibration Abort Reverse: Key-off Calibration Abort 1st: Key-off Calibration Abort 2nd: Key-off Calibration Abort 3rd: Key-off Calibration Abort Forward: Stop Order from MPDr. Calibration Abort Reverse: Stop Order from MPDr. Calibration Abort 1st: Stop Order from MPDr. Calibration Abort 2nd: Stop Order from MPDr. Calibration Abort 3rd: Stop Order from MPDr. Calibration Abort Forward: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort Reverse: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort 1st: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort 2nd: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort 3rd: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort Forward: Parking Brakelight Off Calibration Abort Reverse: Parking Brakelight Off Calibration Abort 1st: Parking Brakelight Off Calibration Abort 2nd: Parking Brakelight Off Calibration Abort 3rd: Parking Brakelight Off Calibration Abort Forward: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort Reverse: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort 1st: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort 2nd: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort 3rd: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort Forward: Travel Speed != 0 km/h Calibration Abort Reverse: Travel Speed != 0 km/h Calibration Abort 1st: Travel Speed != 0 km/h Calibration Abort 2nd: Travel Speed != 0 km/h Calibration Abort 3rd: Travel Speed != 0 km/h Calibration Abort Forward: FNR != N Calibration Abort Reverse: FNR != N Calibration Abort 1st: FNR != N Calibration Abort 2nd: FNR != N Calibration Abort 3rd: FNR != N

111701-8 111702-8 111703-8 111704-8 111700-9 111701-9 111702-9 111703-9 111704-9 111700-10 111701-10 111702-10 111703-10 111704-10 111700-11 111701-11 111702-11 111703-11 111704-11 111700-12 111701-12 111702-12 111703-12 111704-12

T5-5-121

Symptoms in Machine Remedy Operation When Trouble Occurs Transmission learning Perform T/M learning. failed. Refer to T5-2-28. Shifting may not be smooth. Transmission learning failed. Shifting may not be smooth.

Perform T/M learning. Refer to T5-2-28.

Transmission learning failed. Shifting may not be smooth.

Start engine and perform T/M learning. Refer to T5-2-28.

Transmission learning failed. Shifting may not be smooth.

Apply parking brake and perform T/M learning. Refer to T5-2-28.

Transmission learning failed. Shifting may not be smooth.

Check and wait until the T/C oil temperature becomes normal. Perform T/M learning. Refer to T5-2-28.

Transmission learning failed. Shifting may not be smooth.

Apply parking brake and perform T/M learning. Refer to T5-2-28.

Transmission learning failed. Shifting may not be smooth.

Set FNR lever to neutral position and perform T/M learning. Refer to T5-2-26.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble or MP Dr. Message

111700-22 111701-22 111702-22 111703-22 111704-22

Calibration Abort Forward: Calibration Abort Reverse: Calibration Abort 1st: Calibration Abort 2nd: Calibration Abort 3rd: The difference between the inspection current pressure conversion value and the real clutch pressure is great. Calibration Abort Forward: Calibration Abort Reverse: Calibration Abort 1st: Calibration Abort 2nd: Calibration Abort 3rd: The filling was not able to be completed by the inspection current. Calibration Abort Forward: Calibration Abort Reverse: Calibration Abort 1st: Calibration Abort 2nd: Calibration Abort 3rd: The measurement after it corrects it is great the difference with the real clutch pressure. Calibration Abort Forward: Calibration Abort Reverse: Calibration Abort 1st: Calibration Abort 2nd: Calibration Abort 3rd: Un-Calibration

111700-23 111701-23 111702-23 111703-23 111704-23

111700-24 111701-24 111702-24 111703-24 111704-24

111700-31 111701-31 111702-31 111703-31 111704-31

T5-5-122

Symptoms in Machine Operation When Trouble Occurs Transmission learning failed. Shifting may not be smooth.

Remedy

Transmission learning failed. Shifting may not be smooth.

Perform T/M learning. Refer to T5-2-26. Check harness.

Transmission learning failed. Shifting may not be smooth.

Perform T/M learning. Refer to T5-2-26. Check harness.

Shifting may not be smooth.

Perform T/M learning. Refer to T5-2-26.

Perform T/M learning. Refer to T5-2-26. Check harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code 111900 Preparation  Check the wiring connections first. Fault Code 111900-4

111900-3

Trouble or MP Dr. Message Torque Converter Oil Temperature Sensor Circuit Low Input

Inspection Method

Evaluation

Cause

Measure resistance between sensor #1 and #2. -

Refer to the table.

Faulty sensor.

Torque Converter Oil Temperature Sensor Circuit High Input

Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. -

Normal in above check. Refer to the table.

Shorted circuit in harness #1. Faulty sensor.

Open circuit in harness #1.

Normal in above check.

Open circuit in harness #2.

Specification of Transmission Oil Temperature Sensor Transmission Oil Resistance (kΩ) Temperature (°C (°F)) -30 (-22) -20 (-4) 77.0 -10 (14) 47.4 0 (32) 30.0 10 (50) 19.5 20 (68) 13.0 30 (86) 8.9 40 (104) 6.2 50 (122) 4.0 60 (140) 3.1 70 (158) 2.3 80 (176) 1.8 90 (194) 1.3 100 (212) 1 110 (230) 0.8 120 (248) 0.6

Connector (Harness end)  T/M Oil Temperature Sensor

90Z7-05-CN11

T5-5-123

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Code 111901 Preparation  Check the wiring connections first. Fault Code 111901-4

111901-3

Trouble or MP Dr. Message Hyd. Oil Temp Sensor Circuit Low Input

Hyd. Oil Temp Sensor Circuit High Input

Inspection Method

Evaluation

Cause

Measure resistance between sensor #1 and #2. -

Refer to the table.

Faulty sensor.

Normal in above check. Refer to the table.

Shorted circuit in harness #1. Faulty sensor.

Open circuit in harness #1.

Normal in above check.

Open circuit in harness #2.

Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. -

Specification of Hydraulic Oil Temperature Sensor Hydraulic Oil Resistance (kΩ) Temperature (°C (°F)) -30 (-22) 25.4 -20 (-4) 15.0 -10 (14) 9.16 0 (32) 5.74 10 (50) 3.7 20 (68) 2.45 30 (86) 1.66 40 (104) 1.15 50 (122) 0.811 60 (140) 0.584 70 (158) 0.428 80 (176) 0.318 90 (194) 0.24 100 (212) 0.1836 110 (230) 0.1417 120 (248) 0.1108

2 3

95Z7-05-05-02 12-

Hydraulic Oil Tank Hydraulic Oil Temperature Sensor

Hydraulic Oil Level Switch

Connector (Harness end)  Hydraulic Oil Temperature Sensor

35829-60160

90Z7-05-CN11

T5-5-124

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111903 Preparation  Check the wiring connections first. Fault Code 111903-3

111903-4

Trouble or MP Dr. Message T/M Oil Temp Sensor Circuit High Input

T/M Oil Temp Sensor Circuit Low Input

Inspection Method

Evaluation

Cause

Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. -

Refer to the table.

Faulty sensor.

Open circuit in harness #1.

Normal in above check. Refer to the table.

Open circuit in harness #2. Faulty sensor.

Normal in above check.

Shorted circuit in harness #1.

Measure resistance between sensor #1 and #2. -

Connector (Harness end)  Transmission Oil Temperature Sensor

90Z7-05-CN11

T5-5-125

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111906, 111907 Preparation  Check the wiring connections first. Fault Code 111906-3

111906-4

111907-3

111907-4

Trouble or MP Dr. Message F Axle Oil Temperature Sensor Circuit High Input

F Axle Oil Temperature Sensor Circuit Low Input R Axle Oil Temperature Sensor Circuit High Input

R Axle Oil Temperature Sensor Circuit Low Input

Inspection Method

Evaluation

Cause

Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. Measure resistance between sensor #1 and #2. -

Refer to the table.

Faulty sensor.

Open circuit in harness #1.

Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. Measure resistance between sensor #1 and #2. -

Specification of Axle Oil Temperature Sensor Axle Oil Temperature (°C (°F)) Resistance (kΩ) -30 (-22) 112.5 -20 (-4) 67.9 -10 (14) 42.4 0 (32) 27.2 10 (50) 17.9 20 (68) 12.1 25 (77) 10 30 (86) 8.3 40 (104) 5.8 50 (122) 4.2 60 (140) 3.1 70 (158) 2.3 80 (176) 1.7 90 (194) 1.3 100 (212) 1.0

Normal in above check. Open circuit in harness #2. Refer to the table. Faulty sensor. Normal in above check. Shorted circuit in harness #1. Refer to the table. Faulty sensor. 0V

Open circuit in harness #1.

Normal in above check. Open circuit in harness #2. Refer to the table. Faulty sensor. Normal in above check. Shorted circuit in harness #1.

Axle Oil Temperature (°C (°F)) Resistance (kΩ) 110 (230) 0.78 120 (248) 0.62 130 (266) 0.49 140 (284) 0.39 150 (302) 0.32 160 (320) 0.27 170 (338) 0.22 180 (356) 0.18 Connector (Harness end)  Axle Oil Temperature Sensor

90Z7-05-CN12

T5-5-126

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 120014, 120101 to 120104, 120106 Fault Code 120014-2

120101-2 120102-2 120103-2 120104-2 120106-2

Trouble or MP Dr. Message Inspection Method Overrun Alarm Disconnect the connector from the machine speed sensor. Retry by using MPDr. Exhaust Temperature Diagnose on fault codes of ECM. Alarm Intake Air Temperature Diagnose on fault codes of ECM. Alarm Boost Temperature Diagnose on fault codes of ECM. Increase Alarm Fuel Temperature Increase Diagnose on fault codes of ECM. Alarm EGR Gas Temperature Diagnose on fault codes of ECM. Alarm

T5-5-127

Evaluation -

Cause -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A SC Fault Codes 120000 to 120005 Fault Code 120000-2

120001-2

120002-2

Trouble or MP Dr. Message Inspection Method Hydraulic Oil Overheat Disconnect the connector Alarm from the hydraulic oil temperature sensor. Retry by using MPDr. Main Pump Pressure Alarm Disconnect the connector from the main pump oil pressure sensor. Retry by using MPDr. Axle Oil Temperature Alarm

120003-2

Emergency Steering Activated

120004-2

Emergency Steering Activated Pressure Alarm

120005-2

Transmission Oil Temperature Overheat Alarm

Disconnect the connector from the axle oil temperature sensor. Retry by using MPDr. Disconnect the connector from the steering oil pressure switch. Retry by using MPDr. Disconnect the connector from the steering oil pressure switch. Retry by using MPDr. Disconnect the connector from the transmission oil temperature sensor. Retry by using MPDr.

fNOTE: SC (Sub-Controller) refers to the Main Controller (Sub).

T5-5-128

Evaluation Displayed fault code Un-displayed fault code Displayed fault code Un-displayed fault code Displayed fault code Un-displayed fault code Correct Incorrect

Displayed fault code Un-displayed fault code Displayed fault code Un-displayed fault code

Cause Faulty SC or shorted circuit in harness. Faulty hydraulic oil temperature sensor. Faulty MC or shorted circuit in harness. Faulty main pump oil pressure sensor. Faulty SC or shorted circuit in harness. Faulty axle oil temperature sensor. Faulty harness. Faulty secondary steering check switch. Faulty SC or shorted circuit in harness. Faulty transmission oil temperature sensor. Faulty MC or shorted circuit in harness. Faulty transmission oil temperature sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display Controller Fault Code 115001 Fault Code 115001-2

Trouble or MP Dr. Message Inspection Method Abnormal REG input H Measurement of voltage level between monitor controller harness end #A15 and chassis Measurement of voltage at alternator terminal L -

Evaluation 13 to 33.5 V

Cause Faulty monitor controller.

13 to 33.5 V

Open circuit in harness. Faulty alternator.

Normal in above check

Connector (Harness end)  Monitor Controller-A Connector

TNED-05-05-011

Monitor Controller (Monitor) Fault Code 120300 Fault Code 120300-2

Trouble or MP Dr. Message Inspection Method System Failure Alarm Check CAN harness.

T5-5-129

Evaluation -

Cause Faulty CAN harness

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Information) Fault Code 113311 Fault Code 113311-3

113311-4

Trouble or MP Dr. Message Inspection Method Fuel Level Sensor Circuit Measure resistance High Input between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. Fuel Level Sensor Circuit Low Input

Fuel Gauge

Cause Faulty sensor.

Open circuit in harness #1.

Normal in above check. Refer to the table.

Open circuit in harness #2. Faulty sensor.

Measure resistance between sensor #1 and #2. Normal in above check. No. A B C

Evaluation Refer to the table.

Fuel Level (%) 100 (FULL) 50 0 (EMPTY)

C TNED-05-05-008

Connector (Harness end)  Fuel Sensor

90Z7-05-CN11

T5-5-130

Shorted circuit in harness #1 and #2.

Fuel Sensor (Ω) 10 (+0/-4) 34±5 90 (+10/-0)

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

78.5±10 mm (3.09±0.4 in)

Fuel Level Sensor Specifications

1/2

R205 mm (8.1 in)

Float

RES

401.5±10 mm (15.8±0.4 in)

347.7 mm (13.69 in)

235.4 mm (9.27 in)

Float

E 35828-60580

 Fuel Sensor Harness Connector

 Fuel Sensor Circuit

Gauge Unit (Blue)

GND (Black) DC12V

Unit

35828-60470

35828-60470C1

fNOTE: Refer to the table on the previous page for the resistance.

T5-5-131

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display Controller Fault Codes 120500 to 120507 Fault Code 120500-2

Trouble or MP Dr. Message Inspection Method Overheat Alarm Disconnect a connector from the overheat switch. Retry by using MPDr.

120501-2

Engine Error

120502-2

Engine Oil Pressure Alarm

120503-2

Air Cleaner Restriction Alarm

120504-2

Hydraulic Oil Level Alarm

120505-2

Brake Pressure Alarm

120506-2

120507-2

Evaluation Displayed fault code

Un-displayed fault code Diagnose on fault codes of ECM. Diagnose on fault codes of ECM. Disconnect a connector Displayed fault code from air filter restriction switch. Retry by using MPDr. Un-displayed fault code Disconnect a connector Displayed fault code from the hydraulic oil level switch. Retry by using MPDr. Un-displayed fault code

Displayed fault code Disconnect a connector from the brake oil pressure sensor. Retry by using MPDr. Un-displayed fault code Steering Oil Pressure Alarm Disconnect a connector Displayed fault code from the steering oil pressure switch. Retry by using MPDr. Un-displayed fault code Transmission Malfunction Check the accompanied T/M solenoid or revolution sensor error, and check for the error.

Connector (Harness end)  Column Display Controller 1 Connector

TNED-05-05-004

T5-5-132

Cause Faulty column display controller or shorted circuit in harness. Faulty overheat switch. Faulty column display controller or shorted circuit in harness. Faulty air filter restriction switch. Faulty column display controller or shorted circuit in harness. Faulty hydraulic oil level switch. Faulty column display controller or shorted circuit in harness. Faulty brake oil pressure sensor. Faulty column display controller or shorted circuit in harness. Faulty steering oil pressure switch. -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Codes 11 to 22 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 11

Trouble or MP Dr. Message Open circuit in recirculated air sensor

Shorted circuit in recirculated air sensor

Open circuit in outdoor ambient temperature sensor

Inspection Method

Evaluation

Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. -

∞ Ω (Normal value: Faulty sensor. 300 to 430 kΩ) 0V Open circuit in harness #1.

Measure resistance between sensor #1 and #2. Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. -

Shorted circuit in outdoor ambient temperature sensor

Measure resistance between sensor #1 and #2. -

Shorted circuit in solar radiation sensor

Check continuity between sensor harness end #1 and #2. -

Open circuit in frost sensor

Shorted circuit in frost sensor

Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. Measure resistance between sensor #1 and #2. -

T5-5-133

Normal in above check. 0 Ω (Normal value: 300 to 430 kΩ) Normal in above check. ∞ Ω (Normal value: 100 to 210 kΩ) 0V

Normal in above check. 0 Ω (Normal value: 100 to 210 kΩ) Normal in above check. 0Ω

Cause

Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1.

Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2. Shorted circuit in harness #1 and #2.

Normal in above Faulty sensor. check. ∞ Ω (Normal value: Faulty sensor. 100 to 115 kΩ) 0V Open circuit in harness #1.

Normal in above check. 0 Ω (Normal value: 100 to 115 kΩ) Normal in above check.

Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Codes 43 to 92 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 43

Trouble or MP Dr. Message Abnormal air vent damper servo motor

Abnormal air mix damper servo motor

Abnormal refrigerant pressure high and low.

CAN communication error

CAN bus off error

Inspection Method

Evaluation

Cause

Measure voltage between 0V air vent damper servo motor harness end 7C and chassis. (AUTO/OFF switch / blower switch: ON) Measure voltage between 0V air vent damper servo motor harness end 7C and 25D. (AUTO/ OFF switch / blower switch: ON) Normal in above check. Measure voltage between 0V air mix damper servo motor harness end 7D and chassis. (AUTO/OFF switch / blower switch: ON) 0V Measure voltage between air mix damper servo motor harness end 7D and 25E. (AUTO/ OFF switch / blower switch: ON) Normal in above check. Measure voltage between High 0 V and low pressure switch harness end A21 and A05. (AUTO/OFF switch / blower switch: ON) Normal in above check. Check continuity in CAN1 Normal harness. Abnormal

Faulty air mix damper servo motor. Faulty controller or open circuit in harness between controller and High and low pressure switch. Faulty High and low pressure switch. Faulty controller. Faulty CAN1 harness.

Check continuity in CAN1 harness.

Faulty controller. Faulty CAN1 harness.

T5-5-134

Normal Abnormal

Faulty controller or open circuit in harness between controller and air vent damper servo motor. Faulty controller or open circuit in harness between controller and air vent damper servo motor. Faulty air vent damper servo motor. Faulty controller or open circuit in harness between controller and air mix damper servo motor.

Faulty controller or open circuit in harness between controller and air mix damper servo motor.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure Refer to troubleshooting B procedures for diagnosis by using trouble symptom when no fault codes are displayed.  Diagnosis Procedure  Perform diagnosis by using MPDr. or the service menu of monitor first.  In case any fault code has not been displayed by diagnosis, perform inspection according to the procedures when diagnosing.  When the fault code is displayed, refer to the troubleshooting A group and diagnose.  On the front section pages of this group, there are the tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if failed. Start the troubleshooting with more probable causes selected by referring to these tables.

fNOTE: Harness end connector viewed from the open end side by the all connectors image shown in this section.

1 2

T6L4-05-03-001 1-

Harness End Connector

Harness

T5-6-1

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Contents of Diagnosis

Trouble Symptom Preparation Viewpoints for a diagnosis and contents needing inspection beforehand are explained.

How to Read Table Procedure (A) (F)

Inspection Method (B) (G)

Condition

Evaluation

Cause

(D) (I)

(E) (J)

 A, F: Inspection order  B, G: Inspection method for trouble cause  C, H: Conditions for inspection  D, I: Evaluation specification of check results  E, J: Trouble cause for trouble symptom

Procedure: 1. Perform inspection according to Inspection Method (B) and Condition (C) of Procedure (A). 2. In case the results are applied to Evaluation (D), the trouble cause becomes Cause (E). In case the results are not applied to Evaluation (D), go to the next procedure, Procedure (F).

T5-6-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Relationship between Machine Trouble Symptoms and Related Parts This table indicates the relationship between machine trouble symptoms and the potential problem parts, which may cause trouble if failed, and the evaluation methods of these components. Parts MC: Main Controller (Main) SC: Main Controller (Sub)

Accelerator Pedal (Accelerator Pedal Sensor)

Item Function

Controls engine, pump, and valve Instructs target engine speed operation. according to accelerator pedal depressing amount. Symptoms Depending on trouble situations, MC holds engine speed in 1100 in control control system malfunction may min-1. system when differ. (The following symptoms trouble occurs in machine operation indicates that MC logic circuit has failed.) The engine speed is fixed to 1100 Although the accelerator pedal is Symptoms operated during aftertreatment min-1. in machine As pump displacement is held at device manual regeneration, operation when trouble minimum, all actuator speeds are hydraulic load is not released. slow. occurs Evaluation by 111000, 111001, 111002, 111003 111103, 111106 Fault Code Evaluation by MC: Demand Engine Speed Monitoring ECM: Actual Engine Speed Evaluation by using Test Harness Note Descriptions T2-2 T2-2 of Control (Operational Principle Section in S/M)

T5-6-3

Travel Mode Selector Switch

Shifts the travel mode into AUTO 1, AUTO 2, and Manual modes. MC holds the travel mode in Manual mode.

Open circuit: Travel mode is always Manual mode. Shorted circuit: Travel mode is always AUTO 1/ AUTO 2 mode. MC: Travel Mode Selector Switch -

T2-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Power Mode Switch Item Function

Turns power mode ON/OFF.

Symptoms Same as shown below. in control system when trouble occurs Symptoms Power mode (ON/OFF) can not in machine change. operation The power mode indicator on when trouble monitor is not shifted. occurs Evaluation by Fault Code Evaluation by MC: Power Mode Switch Monitoring Evaluation by using Test Harness Note -

Descriptions of Control (Operational Principle Section in S/M)

T2-2

Quick Power Switch

Declutch Position Switch

Turns power mode ON/OFF.

Activates or deactivates the declutch control. Declutch control is not activated.

Same as shown below.

Functions of power mode switch become effective.

Although declutch position switch is turned ON, the declutch indicator on monitor is not ON.

MC: Quick Power Switch

MC: Delutch Position Switch

When quick power mode control Brake Pedal Depressing Amount: is effective. Two modes, Fully and Lightly (Quick power mode is not with the declutch position switch activated when travel is in neutral set in the ON position or the travel load is light.) T2-2 T2-2

T5-6-4

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Fan Reverse Rotation Switch Item Function

Forward/Reverse Lever

Shifts fan reverse rotation control Shifts forward clutch solenoid solenoid valve of fan valve. valve, and reverse clutch solenoid valve of transmission. Same as shown below. MC holds the travel in neutral.

Symptoms in control system when trouble occurs Symptoms Cooling fan does not rotate in in machine reverse. operation The fan reverse rotation indicator when trouble on monitor is not ON. (The occurs indicator does not blink when shifting.) Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-2, 2-4 of Control (Operational Principle Section in S/M)

Although forward/reverse lever is operated, machine does not travel forward/reverse. The FNR indication on monitor is not shifted. 111904 (F/R input at the same time) MC: Forward/Reverse Lever (F)/ (N)/(R) -

T2-2, T2-5

T5-6-5

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Forward/Reverse Selector Switch Forward/Reverse Switch Item Function

Selects forward/reverse lever or Shifts forward clutch solenoid forward/reverse switch operation valve, and reverse clutch solenoid valve of transmission. MC makes forward/reverse switch MC makes forward/reverse lever operation effective. operation effective.

Symptoms in control system when trouble occurs Symptoms Functions of forward/reverse in machine lever become effective. operation when trouble occurs Evaluation by Fault Code Evaluation by MC: Forward/Reverse Selector Monitoring Switch Evaluation by using Test Harness Note The operation is effective with forward/reverse lever and forward/reverse switch set in the neutral position. Descriptions of Control (Operational Principle Section in S/M)

T2-2, T2-5

Functions of forward/reverse lever become effective.

111905 (F/R simultaneous input) MC: Forward/Reverse Switch (F)/ (N)/(R) -

When forward/reverse lever is operated, forward/reverse selector switch operation becomes ineffective. (forward/ reverse lever has priority) T2-2, T2-5

T5-6-6

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Shift Switch Item Function

Downshift Switch (DSS)

Hold Switch

Shifts speed shift solenoid valves Shifts speed shift solenoid valves (1, 2, and 3) of transmission. of transmission and shifts down the speed shift during automatic speed shift. MC holds the speed shift in Same as shown below. second speed.

Shifts speed shift solenoid valves of transmission and holds the speed shift during automatic speed shift. Same as shown below.

The speed shift is not shifted down although downshift switch (DSS) is turned ON during automatic speed shift. The shift indication on monitor is not shifted. -

The speed shift is not held although hold switch is turned ON during automatic speed shift. The hold indication on monitor is not shifted. -

MC: DSS Switch

MC: Shift Hold Switch

T2-2

Symptoms in control system when trouble occurs Symptoms The speed shift is held in second in machine speed with travel mode set in operation Manual mode or AUTO 2 mode. when trouble The speed shift is automatically occurs changed to first speed from second speed in AUTO 1 mode. Evaluation by Fault Code Evaluation by MC: Shift Switch Monitoring Evaluation by using Test Harness Note Descriptions T2-2, T2-5 of Control (Operational Principle Section in S/M)

T5-6-7

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Aftertreatment Regeneration Switch

Ride Control Switch, Ride Control Switch (AUTO) (Option)

Shifts aftertreatment device regeneration control solenoid valve and performs manual regeneration of the aftertreatment device. Same as shown below.

Shifts ride control solenoid valves (rod side and bottom side) and activates or deactivates the ride control.

Symptoms in control system when trouble occurs Symptoms Although aftertreatment device in machine manual regeneration switch is operation turned ON, regeneration of the when trouble aftertreatment device is not performed. occurs The aftertreatment device indicator on monitor is not ON. Evaluation by Fault Code Evaluation by ECM: Muf/Fltr Switch Monitoring Evaluation by using Test Harness Note When aftertreatment device manual regeneration is required Descriptions T2-2 of Control (Operational Principle Section in S/M)

Same as shown below.

Open circuit: Ride control switch is always OFF. Although ride control switch is turned ON, the ride control is not activated. Shorted circuit: Ride control switch is always ON. SC: Ride Control Switch, Ride Control Switch (AUTO) -

T2-2, T2-4

T5-6-8

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Parking Brake Switch Item Function

Front Control Lever Lock Switch

Pilot Shut-Off Solenoid Valve

Shifts parking brake solenoid valve. Same as shown below.

Shifts pilot shut-off solenoid valve. Same as shown below.

Opens and closes the front pilot circuit. Same as shown below.

When closed: The lift arm and bucket are not operated. (Pilot pressure oil is not supplied to pilot valve.) When open: Pilot pressure oil is always supplied to pilot valve.

Open circuit: Front control lever lock switch is always OFF. Pilot shut-off solenoid valve is not shifted. The lift arm and bucket are not operated although the control lever is operated with the front control lever lock switch set in UNLOCK position. Shorted circuit: Front control lever lock switch is always ON. -

SC: Pilot Primary Pressure

Symptoms in control system when trouble occurs Symptoms Although the parking brake in machine switch is turned ON/OFF, the operation parking brake is not released/ when trouble applied with the engine running. occurs

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

Descriptions of Control (Operational Principle Section in S/M)

Column Display Controller: Parking Brake Signal Output -

Although the parking brake is turned OFF, the parking brake is applied with the engine stopped. T2-2, T2-5 T2-4

The pilot shut-off solenoid valve can be manually turned ON/OFF. T2-5

T5-6-9

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor Item Function

Monitors hydraulic oil temperature. Symptoms SC (Main Controller (Sub)) in control recognizes that hydraulic oil system when temperature is 120°C (248°F) trouble occurs when open circuit occurs. (Hydraulic oil temperature: 120°C (248°F) is not displayed on monitoring.) Symptoms When hydraulic oil temperature in machine is 0°C (32°F) or less when starting operation engine, auto-warming up control when trouble is not operated. occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in S/M)

111901 SC: Hydraulic Oil Temperature

T/M Oil Temperature Sensor

Monitors torque converter oil temperature. SC recognizes that torque converter oil temperature is 120°C (248°F) when open circuit occurs.

Monitors transmission oil temperature. MC recognizes that transmission oil temperature is 120°C (248°F) when open circuit occurs.

The color of transmission oil temperature on monitor is red. The buzzer sounds and the indicator is displayed. Fan speed control becomes abnormal. 111900, 120005

Shift change becomes unsmooth.

111903

SC: Torque Converter Oil Temperature -

MC: Transmission Oil Temperature -

T2-2

fNOTE: The T/M oil temperature sensor value is used only in the Service Menu-Monitoring, and Transmission Learning programs. The others are value from the torque converter oil temperature sensor.

T5-6-10

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pump Delivery Pressure Sensor Item Function

Detects pump delivery pressure.

Hyd. Fan Circuit Pressure Sensor

Detects hydraulic fan circuit pressure. When output is 0 V or 5 V, the following symptoms occur.

Symptoms When output is 0 V or 5 V, the in control following symptoms occur. system when trouble occurs Symptoms Matching control while digging is Although fan reverse rotation in machine not activated. switch is operated, fan rotation operation direction can not change. when trouble occurs Evaluation by 111204 111206 Fault Code Evaluation by MC: Pump Delivery Pressure SC: Hydraulic Fan Circuit Pressure Monitoring Evaluation by using Test Harness Refer to p. T5-5-103. Note Refer to p. T5-5-102. Possible to judge if sensor or Possible to judge if sensor or harness is faulty by switching harness is faulty by switching pressure sensor with other pressure sensor with other pressure sensor. pressure sensor. Descriptions T2-2 T2-2 of Control (Operational Principle Section in S/M)

T5-6-11

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Steering Pressure Switch (Option) Secondary Steering Pump Delivery Pressure Sensor (Option) Item Function

Detects steering circuit pressure.

Detects secondary steering pump delivery pressure. When output is 0 V or 5 V, the following symptoms occur.

Symptoms Open circuit: Secondary steering in control operation condition: Steering system when pressure decreases. trouble occurs Symptoms Secondary steering pump is The secondary steering pump is operated normally. (When the in machine operated when the harness is engine starts) operation disconnected while traveling. when trouble The low steering oil pressure occurs indicator is always ON. Evaluation by 111208 Fault Code Evaluation by MC: Steering Pressure Switch SC: Secondary Steering Pump Monitoring Delivery Pressure Evaluation by using Test Harness Refer to p. T5-5-104. Note Refer to p. T5-4-22 for the Possible to judge if sensor or pressure switch location. harness is faulty by switching Possible to judge if pressure sensor is faulty or port is clogged pressure sensor with other by switching pressure switch with pressure sensor. pump delivery pressure switch. Descriptions T2-2 T2-2 of Control (Operational Principle Section in S/M)

T5-6-12

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pressure Sensor (Parking Brake Pressure)

Pressure Sensor (Brake Primary Pressure)

Pressure Sensor (Brake Secondary Pressure)

Item Function Detects parking brake pressure. Detects brake pressure. Detects front brake pressure. Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the in control following symptoms occur. following symptoms occur. following symptoms occur. system when trouble occurs The low brake oil pressure The speed shift does not Symptoms Although the parking brake indicator is always ON. automatically downshift to first in machine is applied, the parking brake speed with the travel mode set in operation indicator is not ON. AUTO 1 mode. when trouble The machine may not accelerate by possible parking brake The declutch control is not occurs dragging because parking brake activated. ON/OFF cannot be judged. Evaluation by 111313 111309, 111310 111312 Fault Code Evaluation by MC: Parking Brake Pressure MC: Service Brake Primary MC: Service Brake Secondary Monitoring Pressure Pressure (For Declutch) Evaluation by using Test Harness Refer to p. T5-5-109. Refer to p. T5-5-102. Note Refer to p. T5-5-105. Possible to judge if pressure Possible to judge if pressure sensor is faulty or port is clogged sensor is faulty or port is clogged by switching pressure sensor with by switching pressure sensor with other pressure sensor. other pressure sensor. Descriptions T2-2, T2-4 T2-2, T2-4 T2-2 of Control (Operational Principle Section in S/M)

T5-6-13

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Lift Arm Angle Sensor Item Function

Pressure Sensor (Lift Arm Raise)

Detects operating angle of the lift arm. When output is 0 V or 5 V, the following symptoms occur.

Detects lift arm raise pilot pressure. When output is 0 V or 5 V, the following symptoms occur.

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

111205

Front attachment operation circuit selection control is not activated during combined operation of lift arm and bucket dump. The ride control is not activated. 111200

SC: Lift Arm Angle Sensor

SC: Lift Arm Raise Pilot Pressure

Refer to p. T5-4-100.

Descriptions of Control (Operational Principle Section in S/M)

T2-2

Refer to p. T5-5-101. Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2, T2-4

Symptoms in control system when trouble occurs Symptoms The lift arm auto leveler lower in machine kickout control is not activated. operation The lift arm auto leveler height when trouble kickout control is not activated. occurs

T5-6-14

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pressure Sensor (Bucket Dump) Item Function

Detects bucket dump pilot pressure. When output is 0 V or 5 V, the following symptoms occur.

Symptoms in control system when trouble occurs Symptoms Front attachment operation in machine circuit selection control is not operation activated during combined when trouble operation of lift arm and bucket. occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

Descriptions of Control (Operational Principle Section in S/M)

Pressure Sensor (Bucket Roll Back)

Pressure Sensor (Primary Pilot Pressure)

Detects bucket roll back (tilt) pilot Detects primary pilot pressure. pressure. When output is 0 V or 5 V, the When output is 0 V or 5 V, the following symptoms occur. following symptoms occur.

Front attachment operation circuit selection control is not activated during combined operation of lift arm and bucket.

111203

111202

Although front control lever lock solenoid valve is operated with front control lever lock switch set in the OFF (Lock) position, front control lever lock indicator is not ON. 111217

SC: Bucket Dump Pilot Pressure

SC: Bucket Tilt Pilot Pressure

SC: Pilot Pressure Sensor

Refer to p. T5-5-101. Refer to p. T5-5-103. Refer to p. T5-5-101. Possible to judge if pressure Possible to judge if pressure Possible to judge if pressure sensor is faulty or port is clogged sensor is faulty or port is clogged sensor is faulty or port is clogged by switching pressure sensor with by switching pressure sensor with by switching pressure sensor with other pressure sensor. other pressure sensor. other pressure sensor. T2-2, T2-4 T2-2, T2-4 T2-2, T2-4

T5-6-15

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Forward/Reverse/1st/2nd/3rd Clutch Pressure Sensors Item Function

Detects clutch solenoid pressure

Torque Converter Output Speed Sensor

Transmission Intermediate Shaft Speed Sensor

Detects torque converter output shaft speed. When abnormality is detected, the following symptoms occur.

Detects transmission intermediate shaft speed. When abnormality is detected, the following symptoms occur.

Symptoms When output is 0 V or 5 V, the in control following symptoms occur. system when trouble occurs Symptoms Transmission Oil Pressure Alarm is The speed change feeling in machine reported. becomes bad extremely during operation The gear shift to the selected automatic speed shift. when trouble range may feel worse. Possible to judge if sensor is faulty by switching sensor with occurs other sensor. Evaluation by MC: 111210, 111211, 111212, 111101-3 Fault Code 111214, 111215 Evaluation by MC: Transmission Clutch Oil Torque Converter Output Speed Monitoring Pressure Sensor Evaluation by using Test Harness Note Possible to judge if pressure Possible to judge if speed sensor sensor is faulty by switching is faulty by switching pressure sensor with other speed sensor. a sensor with other pressure sensor. Descriptions T2-2 T2-2 of Control (Operational Principle Section in S/M)

fNOTE: Refer to p. T5-4-18 for the sensors.

T5-6-16

Nothing special.

111602-3 -

Possible to judge if speed sensor is faulty by switching pressure sensor with other speed sensor. T2-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Vehicle Speed Sensor Item Function

Detects transmission output shaft speed. When abnormality is detected, the following symptoms occur.

Symptoms in control system when trouble occurs Symptoms The speed meter continues to in machine display 0 km/h. operation The overrun alarm control is not when trouble effective. occurs The ride control is not effective. Evaluation by 111600 Fault Code Evaluation by MC: Machine Speed Pulse Monitoring Evaluation by using Test Harness Note Refer to p. T5-4-18 for the sensor location. Possible to judge if speed sensor is faulty by switching pressure sensor with other speed sensor. Descriptions T2-2 of Control (Operational Principle Section in S/M)

Pressure Sensor (Refrigerant Pressure) Detects air conditioner refrigerant pressure. When output is 0 V or 5 V, the following symptoms occur.

The fan speed is fixed to the maximum. The fan reverse rotation control is not activated.

111207 SC: Air Conditioner Refrigerant Pressure -

Refer to p. T5-5-100.

T2-2

T5-6-17

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Ride Control Solenoid Valves (Rod Parallel/Tandem Switching Side and Bottom Side) Solenoid Valve Item Function

Shifts ride control main spool in control valve. Connects the rod side circuit to the tank.

Same as shown below. Symptoms in control system when trouble occurs Symptoms High current: The ride control is in machine always activated. operation Low current: The ride control is when trouble not effective. occurs

Evaluation by 111422, 111423 Fault Code Evaluation by SC: Ride Control (Rod) P/S Monitoring Output, Ride Control (Rod) P/S Output FB, Ride Control (Bottom) P/S Output, Ride Control (Bottom) P/S Output FB Evaluation Install light harness tool. by using Test Check output signals from SC Harness (Main Controller (Sub)) and harness condition. Note Descriptions T2-2, 2-4 of Control (Operational Principle Section in S/M)

Shifts selector valve in lift arm flow rate control valve. Limits flow rate to lift arm during combined operation of lift arm raise and bucket. Same as shown below.

High current: Lift arm speed becomes slow as the lift arm flow rate control valve (selector valve) is always restricted. Low current: The operation combined with the lift arm is not smooth as the lift arm flow rate control valve (selector valve) is always opened. 111410 SC: Parallel/Tandem Control P/S Output, Parallel/Tandem Switch P/S Output FB

Install light harness tool. Check output signals from SC (Main Controller (Sub)) and harness condition. T2-2, 2-4

T5-6-18

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Parking Brake Solenoid Valve Item Function

Applies and releases parking brake by using pilot pressure oil. Same as shown below.

Symptoms in control system when trouble occurs Symptoms When closed: The parking brake in machine is not released. (Pilot pressure oil operation is not supplied to parking brake.) when trouble When open: The parking brake occurs is applied. (Pilot pressure oil is supplied to parking brake.)

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

Descriptions of Control (Operational Principle Section in S/M)

This solenoid valve can be manually turned ON/OFF. Refer to p. T5-4-18 for the solenoid valve location. T2-2, 2-4

Pump Swash Plate Tilt Solenoid Valve (Pump Torque Control Solenoid) Supplies control pressure to main pump. Same as shown below.

The aftertreatment device alarm is displayed on the monitor. High current: Pump torque of main pump is kept minimum. The loading movement becomes slow. Low current: Engine speed regulation for digging is deactivated. 111413 SC: Pump Swash Angle P/S Output, Pump Swash Angle P/S Output FB -

Refer to p. T5-5-413.

T2-2

T5-6-19

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Hyd. Fan Speed Control Solenoid Hyd. Fan Reverse Rotation Valve Control Solenoid Valve Item Function

Control hydraulic fan rotation speed. Same as shown below.

Symptoms in control system when trouble occurs Symptoms High current: The fan speed is in machine fixed to the minimum. operation Low current: The fan speed is when trouble fixed to the maximum. occurs Evaluation by 111412 Fault Code Evaluation by SC: Hyd Fan Speed Control P/S Monitoring Output, Hyd Fan Speed Control P/S Output FB Evaluation by using Test Harness Note Refer to p. T5-5-113. Descriptions T2-2, 2-4 of Control (Operational Principle Section in S/M)

Shifts hydraulic fan reverse rotation spool of fan valve. Same as shown below.

High current: The fan always rotates in reverse. Low current: The fan does not rotate in reverse. 111411 SC: Hyd Fan Reverses Rotation P/S Output, Hyd Fan Reverses Rotation P/S Output FB -

Refer to p. T5-5-112. T2-2, 2-4

T5-6-20

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Forward/Reverse/High/Lockup Clutch Solenoid Valves Item Function

Shifts forward spool, and reverse spool of transmission control valve. Same as shown below.

Symptoms in control system when trouble occurs Symptoms Defective clutch gears cannot in machine engage. operation when trouble occurs Evaluation by MC: 111418, 111419, 111420, Fault Code 111421 Evaluation by T/M Clutch Forward P/S Valve Monitoring Output T/M Clutch Forward P/S Valve FB T/M Clutch Reverse P/S Valve Output T/M Clutch Reverse P/S Valve FB T/M Clutch Fast P/S Valve Output T/M Clutch Fast P/S Valve FB T/M Clutch Lockup P/S Valve Output T/M Clutch Lockup P/S Valve FB Evaluation by using Test Harness Note Refer to p. T5-5-115. Descriptions T2-2 of Control (Operational Principle Section in S/M)

Speed Shift Solenoid Valves (1, 2, and 3) Shifts spools in speed shift solenoid valves (1, 2, and 3) of transmission control valve. Same as shown below.

Defective clutch gears cannot engage.

MC: 111414, 111415, 111416, T/M Clutch 1st P/S Valve Output T/M Clutch 1st P/S Valve FB T/M Clutch 2nd P/S Valve Output T/M Clutch 2nd P/S Valve FB T/M Clutch 3rd P/S Valve Output T/M Clutch 3rd P/S Valve FB

Refer to p. T5-5-115. T2-2

fNOTE: Refer to pp. T5-5-19, 20 for the detailed machine operation when trouble occurs.

T5-6-21

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Lift Speed Increase Solenoid Valve Item Function

Shifts spools in lift arm speed multiplication solenoid valve of priority hammer valve. Same as shown below.

Symptoms in control system when trouble occurs Symptoms Oil flow to increase lift arm in machine raising speed cannot be directed operation as expected. when trouble occurs Evaluation by MC: 111407 Fault Code Evaluation by Lift Speed Increase P/S Valve Monitoring Output Lift Speed Increase P/S Valve FB

Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in S/M)

Auto Brake Solenoid Valve

Shifts spools in auto brake solenoid valve. Same as shown below.

Auto brake does not work. Auto brake warning alarm appears on the monitor display.

MC: 111408 Auto Brake P/S Valve Output Auto Brake P/S Valve FB

Refer to p. T5-5-110. T2-2

Refer to p. T5-5-117. T2-2

T5-6-22

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Main Relief Valve for Main Pump Item Function

Prevents pressure in main pump circuit from exceeding the set pressure when a control lever is operated. Same as shown below.

Symptoms in control system when trouble occurs Symptoms If stuck in fully closed position, in machine hose of front attachment may be operation damaged. when trouble If stuck in fully open position, occurs power is weak during digging operation. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Operational Principle Section in S/M)

Overload Relief Valve

Prevents actuator circuit pressure generated by external force from exceeding the set pressure with a control lever set in neutral. Same as shown below.

If stuck in fully closed position, hose of front attachment may be damaged by external force. If stuck in fully open position, power is weak during digging operation. -

T2-4

fNOTE: Refer to p. T5-6-57 and F&S S/M Section T3-2 Control Valve for each valve.

T5-6-23

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Lift Arm Flow Rate Control Valve Item Function

Is shifted by pilot pressure from lift arm flow rate control solenoid valve. Restricts lift arm circuit and keeps bucket speed during combined operation of lift arm and bucket. Same as shown below.

Symptoms in control system when trouble occurs Symptoms If poppet valve or selector valve in machine is stuck in fully closed position, operation boom operation is not smooth. when trouble If poppet valve or selector valve is stuck in fully open occurs position, bucket tilt operation is not smooth during combined operation of lift arm lower and bucket roll back. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Operational Principle Section in S/M)

Pump Control Valve

Supplies pressure oil from the main pump to the regulator of pump device and increases/ decreases the pump delivery flow rate. Same as shown below.

Load is applied to the pump as the pump delivery flow rate does not decrease with the front attachment control lever set in neutral. As pump torque increases, acceleration is not smooth when staring the engine. Machine speed does not increase. -

T2-4

fNOTE: Refer to F&S S/M Section T3-2 Control Valve for each valve.

T5-6-24

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Ride Control Valve Main Spool (Optional Ride Control Valve) Item Function

Is shifted by pilot pressure from ride control solenoid valve. Connects the accumulator to lift arm cylinder circuit and increases/decreases the lift arm cylinder bottom pressure.

Symptoms Same as shown below. in control system when trouble occurs Symptoms If stuck in neutral position, the ride control is not activated. in machine If stuck in ride control operating operation when trouble position, digging operation is not smooth. occurs

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in S/M)

Bleed-Off Compensation Spool (Control Valve)

Fan Reversing Spool (Fan Valve)

Is shifted by main pump pressure Is shifted by pilot pressure sent by activated exhaust filter from fan reverse rotation regeneration solenoid valve. control solenoid valve in fan Sends more pressurized oil to the valve. Changes the fan rotation steering circuit or forcibly relieves direction (in normal / reverse). the main circuit pressure to increase hydraulic load in order to raise exhaust temperature. Same as shown below. Same as shown below.

If stuck in neutral position, steering is not smooth. If stuck in steering position, front attachment operating power is lack and moves slower. If stuck in exhaust filter regeneration position, loading operation becomes impossible. Overheating occurs easily. -

T2-4

T5-6-25

If stuck in normal direction position, the fan always rotates in normal direction. If stuck in reverse direction position, the fan always rotates in reverse direction. Overheating occurs easily.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-26

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Correlation between Trouble Symptoms and Part Failures This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed. The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom. The marks / in this table indicate the influence to trouble symptom. : Related, required to check : Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.

T5-6-27

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting Trouble Symptom E-1 Starter does not rotate.

E-2 Even if starter rotates, engine does not start.

Parts Main Controller Engine Control Module (ECM) Monitor Controller Monitor Column Display Controller MPDr. Key Switch Accelerator Pedal Sensor Forward/Reverse Lever Forward/Reverse Selector Switch Forward/Reverse Switch Battery Battery Relay Fuse Box A Fuse Box B Neutral Relay Starter Cut Relay Starter Relay ECM Main Relay Starter Engine Unit Coolant Temperature Sensor Glow Plug (Heater) Relay Glow Plug Pump Delivery Pressure Sensor

: Check required







E-3 Engine starts with forward/ reverse lever set in the positions except N.



 (Neutral) 

 (Neutral) 

 (Neutral)    (#14)  (#10, #133)     

 (Neutral)

 (#17)  (#10)

 

: Related

T5-6-28

 (#13) 

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting

Parts

Trouble Symptom E-4 Power mode is not shifted down when pushing power mode switch.

Main Controller (Main) Engine Control Module (ECM) Monitor Controller Monitor Column Display Controller MPDr. Key Switch Accelerator Pedal Sensor Power Mode Switch Parking Brake Switch Forward/Reverse Lever Forward/Reverse Selector Switch Forward/Reverse Switch Exhaust Filter Switch Battery Battery Relay Fuse Box A Fuse Box B Key Switch ON Cut Relay ACC Cut Relay Auto Shut-Down Relay Starter Relay ECM Main Relay Starter Engine Unit Coolant Temperature Sensor Pump Delivery Pressure Sensor Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor Pressure Sensor (Parking Brake)

: Check required



E-5 Even if key switch is turned OFF, engine does not stop.

E-6 Auto idling-stop is not activated.

 

   

   

 (Setup)  

   (Neutral) 



 (Neutral)     (#13)   

     

: Related

T5-6-29

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting Trouble Symptom A-1 Actuator of only front attachment do not work. Parts Main Controller (Sub) Battery Fuse Box B Pilot Shut-Off Relay Front Control Lever Lock Switch Power Mode Switch Accessory pump Unloader (Brake Charge) Valve Brake Priority Valve Reducing Valve (Combination Valve) Manifold Valve (Combination Valve) Torque Control Solenoid Valve (Main Pump) Pilot Shut-Off Solenoid Valve Pilot Valve Pressure Sensor (Primary Pilot Pressure) Flow Regulator Valve Pressure Sensor (Lift Arm Raise) Pressure Sensor (Bucket Dump) Pressure Sensor (Bucket Roll Back) Spool (Multiple Control Valve) Spool (Steering Valve) Main Relief Valve (Multiple Control Valve) Pump Control Valve Cylinder Main Pump Pump Delivery Pressure Sensor Bleed-Off Compensation Spool (Multiple Control Valve) Pump Regulator Pilot Filter

: Check required

A-2 Actuator speed of front attachment and steering are slow. 

 (#16)       

 

  

  

   



    

: Related

T5-6-30

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting

Parts

Trouble Symptom A-3 Actuator of front attachment does not stop even if a control lever is set to neutral.

Main Controller (Main) Engine Control Module (ECM) Monitor Controller Monitor Key Switch Accelerator Pedal Sensor Forward/Reverse Lever Forward/Reverse Selector Switch Forward/Reverse Switch Pilot Shut-Off Relay Front Control Lever Lock Switch Exhaust Filter Switch Battery Exhaust Filter Differential Pressure Sensor Engine Unit Engine Speed Sensor (Main) Engine Speed Sensor (Sub) Coolant Temperature Sensor Exhaust Temperature Sensor Main Pump Accessory Pump Pump Regulator Pump Delivery Pressure Sensor Manifold Valve Torque Control Solenoid Valve Pilot Shut-Off Solenoid Valve Pressure Sensor (Primary Pilot Pressure)  Pilot Valve  Control Valve Bleed-Off Compensation Spool (Multiple Control Valve) Exhaust Filter Regeneration Control Solenoid Valve Pilot Filter Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor Pressure Sensor (Parking Brake)

: Check required

: Related

T5-6-31

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting Trouble Symptom A-5 Fan speed does not change. Parts Main Controller (Sub) Engine Control Module (ECM) Monitor Controller Monitor MPDr. Key Switch Accelerator Pedal Sensor Power Mode Switch Fan Reverse Rotation Switch Battery Fuse Box A Fuse Box B Fan Valve Fan Speed Control Solenoid Valve Fan Reverse Rotation Control Solenoid Valve Fan Control Valve Fan Motor Accessory Pump (Fan Pump) Engine Unit Engine Speed Sensor (Main)



A-6 Fan does not rotate in reverse when pushing fan reverse rotation switch.  





 



   

  

  



Engine Speed Sensor (Sub) Coolant Temperature Sensor Boost Temperature Sensor Hydraulic Fan Circuit Pressure Sensor Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor Pressure Sensor (Refrigerant Pressure) Pressure Sensor (Parking Brake)

: Check required

   

: Related

T5-6-32

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting Trouble Symptom F-1 All front attachment actuator power are weak.

F-2 Some cylinders are not operated or speed are slow.

Parts 

Main Controller (Sub) Battery Fuse Box B Pilot Shut-Off Relay Front Control Lever Lock Switch Power Mode Switch Accessory Pump Priority Valve (Unloader Valve) Reducing Valve (Combination Valve) Torque Control Solenoid Valve (Main Pump) Front Control Lever Lock Solenoid Valve (Combination Valve) Pilot Valve Pressure Sensor (Primary Pilot Pressure) Shockless Valve (Flow Regulator Valve) Parallel/Tandem Switching Solenoid Valve Lift Arm Flow Rate Control Valve (Multiple Control Valve) Pressure Sensor (Lift Arm Raise) Pressure Sensor (Bucket Dump) Pressure Sensor (Bucket Roll Back) Spool (Multiple Control Valve) Main Relief Valve (Multiple Control Valve) Pump Control Valve (Multiple Control Valve) Cylinder Main Pump Pump Delivery Pressure Sensor Bleed-Off Compensation Spool (Multiple Control Valve) Pump Regulator Pilot Filter

: Check required

 



 

 

 

 

  (Overload)

   



: Related

T5-6-33

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting Trouble Symptom F-3 Front attachment drifts remarkably (when the engine is stopped). Parts Main Controller Monitor Controller Monitor Lift Arm Angle Sensor Accessory pump Unloader (Brake Charge) Valve Combination Valve Pilot Valve Shockless Valve (Flow Regulator Valve) Shockless Valve (Flow Regulator Valve) Restriction Valve (Flow Regulator Valve) Pressure Sensor (Lift Arm Raise) Pressure Sensor (Bucket Dump) Pressure Sensor (Bucket Roll Back) Spool (Multiple Control Valve) Load Check Valve (Multiple Control Valve) Cylinder Main Pump

: Check required



F-4 Shock during bucket dumping is large when stopping lift arm raise / lower operation.

  (Lift Arm Raise)  (Lift Arm Lower)  (Bucket Dump)  

 



: Related

T5-6-34

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting

Parts

Trouble Symptom F-5 F-6 Bucket auto leveler control is Lift arm float control is not not activated. (Detent is not activated. (Detent is not held.) held.)

Main Controller (Sub) Monitor Controller Monitor Battery Battery Relay Fuse Box B Lift Arm Angle Sensor Bucket Proximity Switch Accessory pump Unloader (Brake Charge) Valve Combination Valve Pilot Valve Flow Regulator Valve Spool (Multiple Control Valve) Cylinder Main Pump

: Check required

 

 (#16)

 (#16) 



 (Bucket)

 (Lift Arm)

 (Bucket)

 (Lift Arm)

: Related

T5-6-35

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting

Parts

Trouble Symptom F-7 Lift arm auto leveler height kickout control is not activated.

Main Controller (Sub) Monitor Controller Monitor MPDr. Fuse Box B Lift Arm Angle Sensor Machine Speed Sensor Ride Control Switch Accessory pump Unloader (Brake Charge) Valve Pilot Shut-Off Solenoid Valve (Combination Valve) Pilot Valve Lift Arm Raise Side Coil (Pilot Valve) Lift Arm Lower Side Coil (Pilot Valve) Pressure Sensor (Primary Pilot Pressure) Flow Regulator Valve Pressure Sensor (Lift Arm Raise) Pressure Sensor (Bucket Dump) Pressure Sensor (Bucket Roll Back) Ride Control Solenoid Valve (Option) Ride Control Selector Solenoid Valve (Multiple Control Valve) Spool (Ride Control Valve) Cylinder Accumulator (Ride Control) Main Pump Pump Delivery Pressure Sensor

: Check required

F-8 Lift arm auto leveler lower kickout control is not activated.

F-9 Ride control is not activated.



 (Setting: ON)

 (Setting: ON) 

 (#16) 

 (Lift Arm) 

 (Lift Arm)

  



   (Lift Arm)

 (Lift Arm)

  (Lift Arm)  

: Related

T5-6-36

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting Trouble Symptom S-1 Steering operation is weak.

S-2 Steering operation is slow.

S-3 Shock of steering operation is large.

Parts Main Controller (Sub) Accessory pump Reducing Valve (for Orbitrol) Shuttle Valve Torque Control Solenoid Valve (Main Pump) Orbitrol (Steering Wheel) Stop Valve (Left, Right) Steering Valve (Spool) Overload Relief Valve (Steering Valve) Steering Pressure Switch Steering Cylinder (Left, Right) Main Pump Steering Relief Valve (Steering Valve) Pump Delivery Pressure Sensor Bleed-Off Compensation Spool (Multiple Control Valve) Pilot Filter (Bleed-Off Compensation Valve) Pump Regulator Pilot Filter

: Check required

 

   



  

   (Orifice)



 

  

 





 (Orifice)  



: Related

T5-6-37

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting

Parts

Trouble Symptom S-4 Secondary steering (option) does not operate. (Automatic operation check when the engine starts)

Main Controller (Sub) Monitor Controller Monitor MPDr. Battery Fuse Box B Secondary Steering Relay Machine Speed Sensor Accessory pump Unloader (Brake Charge) Valve Combination Valve Orbitrol (Steering Wheel) Stop Valve (Left, Right) Spool (Steering Valve) Steering Pressure Switch Secondary Steering Pump Delivery Pressure Sensor Steering Cylinder (Left, Right) Main Pump Secondary Steering Motor Secondary Steering Pump

: Check required

  (Setup)   (#20)  

 

 

: Related

T5-6-38

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting

Parts

Trouble Symptom T-1 Although forward/reverse lever is operated, machine does not travel forward/ reverse.

 Main Controller (Main) Monitor Controller  Monitor Battery Fuse Box A  (#10) Fuse Box B  (#8, #15) Accelerator Pedal Sensor Brake Pedal (Right) Switch Brake Valve Forward/Reverse Lever  (Forward / Reverse)  Forward/Reverse Switch  Forward/Reverse Selector Switch Declutch Position Switch  Parking Brake Solenoid  Parking Brake Relay  Parking Brake Switch  Drive Unit (Transmission Assy)  Transmission Control Valve Torque Converter Input Speed Sensor Torque Converter Output Speed Sensor Transmission Intermediate Shaft Speed Sensor Machine Speed Sensor Forward Clutch Solenoid Valve   Reverse Clutch Solenoid Valve  Propeller Shaft  Axle Pressure Sensor (Brake Secondary Pressure) Pressure Sensor (Parking Brake) 

: Check required

T-2 Although forward/reverse lever is set to neutral position, machine travels. (Neutral Control)

T-3 Clutch cut is not operated. (Declutch Control)



 (#8, #15)

 (Neutral)  

  (Forward)



 

   

 

 



: Related

T5-6-39

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting Trouble Symptom T-4 Travel mode can not be changed. Parts  Main Controller (Main) Monitor Controller Monitor Battery Fuse Box B Brake Pedal (Right) Switch  Travel Mode Selector Switch Shift Switch Power Mode Switch Drive Unit (Transmission Assy) Transmission Control Valve Torque Converter Output Speed Sensor Transmission Intermediate Shaft Speed Sensor Machine Speed Sensor Speed Shift Solenoid Valve Pressure Sensor (Brake Secondary Pressure)

: Check required

T-5 Although shift switch is operated, speed shift does not change. (Manual Speed Shift Control)

T-6 Although vehicle speed changes, speed shift does not change automatically. (Automatic Speed Shift Control)



 (#8, #15)  (Manual Mode) 

 (AUTO 1/AUTO 2 Mode)

  

   

 

 

: Related

T5-6-40

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting

Parts

Trouble Symptom T-7 Speed shift is not shifted down when pushing downshift switch (DSS).

 Main Controller (Main) Monitor Controller Monitor Key Switch Battery Fuse Box A Fuse Box B  (#8, #15) Accelerator Pedal Sensor Brake Pedal (Right) Switch Travel Mode Selector Switch Power Mode Switch Forward/Reverse Lever Forward/Reverse Switch Forward/Reverse Selector Switch Shift Switch  Downshift Switch (DSS) Hold Switch  Drive Unit (Transmission Assy)  Transmission Control Valve Torque Converter Output Speed  Sensor Transmission Intermediate Shaft Speed Sensor  Machine Speed Sensor  Speed Shift Solenoid Valve Transmission Oil Filter Transmission Oil Filter Restriction Switch Pressure Sensor (Parking Brake) Lift Arm Angle Sensor Pressure Sensor (Lift Arm Raise) Pressure Sensor (Bucket Dump)

: Check required

T-8 Speed shift is not held when pushing hold switch. (Effective in automatic speed

T-9 Speed shift retard control is not activated. (Effective in automatic speed

shift control mode) 

shift control mode)    (ON) 

 (#8, #15)

    

  

 

  

  

 

: Related

T5-6-41

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting

Parts

Trouble Symptom B-1 Parking brake is not released. (When the engine runs. )

Main Controller (Main) Monitor Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Parking Brake Switch Parking Brake Relay 1 Parking Brake Relay 2 Parking Brake Solenoid Valve Parking Brake Parking Brake Accumulator Brake Charge Valve Pressure Sensor (Parking Brake) Reducing Valve (Combination Valve) Pressure Sensor (Brake Primary Pressure) Service Brake Accumulator Brake Valve Axle (Service Brake) Pressure Sensor (Brake Secondary Pressure) Accessory pump Pilot Filter Engine Remark

: Check required



B-2 B-3 Parking brake is not applied. Service brake function lowers. 

  (ON)  (#10)  (#14)  (Released)  (OFF)  (ON)  

 (#10)  (#14)  (Operated)  (ON)   

  





      

 

The parking brake can be released with the residual pressure in the service brake accumulator even when the engine is stopped.

: Related

T5-6-42

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting

Parts

Trouble Symptom O-1 Clearance light, tail light, and license plate light are not ON.

Main Controller (Main) Monitor Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Light Switch Dimmer Switch Head Light Relay (Left) Head Light Relay (Right) High Beam Relay Head Light Clearance Light Tail Light License Plate Light (Optional)

: Check required

 (Indicator)

O-2 Head light is not ON.

O-3 Head light is not shifted to high beam.

 (Indicator)  (ON)

  (#2, #11, #12) 

 (#2, #6)  (#2)     

  

: Related

T5-6-43

 (#2, #19)  

  (High Beam)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting Trouble Symptom O-4 O-5 Hazard light is not operated. Turn signal light is not operated.

O-6 Horn does not sound.

Parts Main Controller (Main) Monitor Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Hazard Light Switch Turn Signal Lever Horn Switch Flasher Relay Turn Signal Light Relay (Left) Turn Signal Light Relay (Right) Horn Relay Turn Signal Light (Hazard Light) Horn

: Check required

 (Indicator)

 (Indicator)  (ON)

  (#7) 

  (#8)  (#7)

 (#6)

    

  



 

: Related

T5-6-44

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting

Parts

Trouble Symptom O-7 Reverse light is not ON. Reverse buzzer does not sound.

Main Controller (Main) Monitor Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Forward/Reverse Lever Forward/Reverse Selector Switch Forward/Reverse Switch Brake Light Switch (Brake Pedal) Light Switch Work Light Switch Reverse Buzzer Relay Brake Light Relay Work Light (Front) Relay Work Light (Rear) Relay Reverse Light Reverse Buzzer Brake Light Work Light

: Check required

O-8 Brake light is not ON.

O-9 Work light does not light.

 (ON)

 (Indicator)  (ON)

 (#7)  (#13)  (R)

 (#8)



 (#5)  (#2, #17)

 (R)           

: Related

T5-6-45

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting Trouble Symptom O-10 Wiper is not operated.

O-11 Washer is not operated.

O-12 Cab light is not ON.

Parts Main Controller (Main) Monitor Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Front Wiper/ Washer Switch Rear Wiper/ Washer Switch Cab Light Switch Rear Cab Light Switch Door Open/Close Switch (Cab) Front Wiper Relay 1 Front Wiper Relay 2 Rear Wiper Relay Front Washer Relay Rear Washer Relay Front Wiper Motor Rear Wiper Motor Front Washer Motor Rear Washer Motor

: Check required

  (ON)

 (ON)

 (#4)  (#18)  

  (#3)

     (Fast Speed)       

: Related

T5-6-46

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting E-1

Starter does not rotate.

Preparation  In case the radio with the key switch set in the ACC position and the horn with the key switch set in the OFF position are operated normally, the harness between battery and key switch terminal B is considered normal.

 Check that the forward/reverse lever is in the neutral position.  Check the wiring connections first.  Check that #14 fuse in fuse box A is not abnormal.  Check that #8, #10, #13 fuses in fuse box B are not abnormal. Procedure Inspection Method 1 Measure battery voltage and electrolyte density

4 5

8 9 10

Condition -

Replace the neutral relay with Set the key switch other general relay to START after replacing relays Key switch: START Measure voltage between neutral relay harness end #3 and chassis Measure voltage at starter Key switch: START relay harness end terminal S Replace the starter cut relay Set the key switch with other general relay to START after replacing relays Measure voltage between Key switch: START starter cut relay harness end #3 and chassis Measure voltage between Key switch: ON starter cut relay harness end #1 and chassis

Measure voltage at battery relay terminal A Measure voltage at starter terminal C (S) Check continuity between key switch #1 and #6

Evaluation Cause The measured values Faulty battery are out of normal range (Normal range: Voltage: 24 V or more, Electrolyte density: 1.26 or more) Starter: Rotating Faulty neutral relay

Open circuit in harness between key switch and neutral relay

Open circuit in harness between neutral relay and starter relay Faulty starter cut relay

Starter: Rotating

Open circuit in harness between starter relay and starter cut relay

24 V

Key switch: ON

Shortcircuit in harness between starter cut relay and power supply Faulty ECM main relay Faulty ECM Faulty battery relay

Key switch: START

Faulty starter relay

Key switch: START

∞Ω

Faulty key switch

T5-6-47

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-1

Starter does not rotate.

Procedure Inspection Method Condition 11 Monitor Forward/Reverse Forward/reverse lever: N Lever (N) 12 Replace the ECM timer Key switch: START relay with other general relay 13 Measure voltage between Key switch: START ECM main relay harness end #1 and chassis 14 -

Evaluation OFF is displayed Starter: Rotating

Cause Faulty forward/reverse lever Faulty ECM main relay

24 V

Faulty ECM

The above checks resulted all normal.

Faulty starter

 Battery Relay (Terminal A)

 Relay Connector (Harness Side)

90Z7B-05-05-CN03

 Key Switch Connector (Switch Side)

95Z7BTT05-06-07

 Stater Relay Connector (Harness Side)

90Z7B-05-05-CN04

T5-6-48

95Z7BTT05-06-08

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-2

Even if starter rotates, engine does not start.

Preparation  Check the fuel level.  Check that the fuel filter is not clogged.  Perform the air bleeding in the fuel supply line.

Procedure Inspection Method 1 Check for the cranking (the engine crank shaft is driven by the starter motor) by sound. 4 -

Condition Key switch: START

Evaluation No cranking sound

Cause Faulty starter motor, or other power transmission mechanism to the engine

The check (1) above resulted normal.

Faulty ECM or engine unit

T5-6-49

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-3

Engine starts with forward/reverse lever set in the positions except N.

Preparation  Even if the key switch is set to the START position with the forward/reverse lever set in the positions except N (neutral), the starter does not rotate.  Check #8, #13 fuses in fuse box B.  Refer to SYSTEM / Electrical System / Neutral Engine Start Circuit (p. T2-5-12).  Refer to SYSTEM / Hydraulic System.  Check the wiring connections first. Procedure Inspection Method Condition 1 Check continuity between Forward/reverse neutral relay harness end #2 lever position: F and rear chassis or R 2 Replace the neutral relay with Set the key switch other general relay to START after replacing relays 3 -

Evaluation Other than 0 Ω

Cause Open circuit in harness between F/R lever and neutral relay

Starter does not rotate

Faulty neutral relay

The above checks resulted all normal.

Find out cause of trouble by tracing other trouble symptoms

 Relay Connector (Harness Side)

90Z7B-05-05-CN03

T5-6-50

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-4

Power mode is not activated when pushing power mode switch.

Preparation  Check the wiring connections first. Procedure Inspection Method 1 Monitor Power Mode Switch

Condition Power mode switch: ON

Evaluation OFF is displayed

The check (1) above resulted normal

T5-6-51

Cause Faulty power mode switch or open circuit in harness between power mode switch and Main Controller (MC) Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-5

Even if key switch is turned OFF, engine does not stop. 1

Preparation  Remove 2 each of 140 A fusible link (1) and stop the engine as emergency procedures first.  In case other trouble symptoms occur, perform troubleshooting of these troubles first.  If the fault code is not displayed, the key switch may be faulty.

Above Battery Box

 Refer to SYSTEM / Electrical System.

95Z7BTT05-01-02

 Check the wiring connections first.

T5-6-52

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-6

Auto idling-stop is not activated.

Preparation  Check the auto idling-stop setting with the monitor or MPDr. first.  Refer to SYSTEM / Control System and SYSTEM / Electrical System / Auto Idling-Stop Control.  Check the wiring connections first. Procedure Inspection Method Condition 1 Replace auto idling-stop relay with other general relay 2 Replace key switch ON cut relay with other general relay 3 Replace ACC cut relay with other general relay 4 Monitor Forward/Reverse Forward/reverse Lever (N) lever: N 5 Monitor Parking Brake Parking brake Pressure switch: ON Engine: Running

Monitor Pilot Primary Pressure

Front control lever lock switch: UNLOCK position Monitor Exhaust Filter Switch Exhaust filter manual regeneration switch: OFF -

Evaluation The symptom disappears The symptom disappears The symptom disappears F or R is displayed

Cause Faulty auto idling-stop relay Faulty key switch ON cut relay Faulty ACC cut relay Faulty forward/reverse lever

The measured values Stuck spool in parking brake solenoid valve are out of normal range (Normal range: 3.0 ~ 3.7 MPa)(435 ~ 537 psi) Pressure is not Faulty pilot shut-off circuit (A-1) detected ON is displayed

Faulty exhaust filter manual regeneration switch

The above checks resulted all normal

Faulty Main Controller (MC)

T5-6-53

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting A-1

Actuator of only front attachment do not work.

Preparation  If other function (steering) is operated normally, the main pump is considered to be normal. Check that the main circuit pressure increases in the neutral status. If the pressure increases to the specified level, the cause of trouble may exist in the bleed-off compensation spool or exhaust filter regeneration control solenoid valve.

 Pilot valve and multiple control valve spools are unlikely to be faulty at the same time.  Refer to SYSTEM / Electrical System.  Check the wiring connections first.

 Check that #16 fuse in fuse box B is not abnormal. Procedure Inspection Method 1 Monitor Pump Delivery Pressure 2 3

Replace pilot shut-off relay with other general relay Monitor Pilot Primary Pressure Measure resistance between pilot shut-off solenoid valves #1 and #2 Check voltage between pilot shut-off solenoid valve harness end #1 and chassis -

Condition No steering or loading operation

Evaluation Pressure increases up to the main relief set pressure. Pilot shut-off lever: The symptom UNLOCK position disappears Front control Pressure is not lever lock switch: detected UNLOCK position 0/∞ Ω

Key switch: ON

The above checks resulted all normal.

Cause Stuck spool in bleed-off compensator. Faulty pilot shut-off relay Faulty front control lever lock switch Faulty pilot shut-off solenoid valve Open circuit in harness between pilot shut-off solenoid valve and pilot shut-off relay Faulty pilot valve

 Pilot Shut-Off Solenoid Valve Connector (Harness Side)

90Z7-05-CN10

12-

T5-6-54

Pilot Shut-Off (Control Lever Lock) Solenoid Valve Parking Brake Solenoid Valve

95Z7BTT05-06-09

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-2

Actuator speed of front attachment and steering are slow.

Preparation  The pump flow rate is minimized due to some reasons.

 If actuator speed of only steering is slow, the circuit after the steering pilot valve may be faulty (S-3).

 Even if speed is satisfactory, in case power is weak, refer to the troubleshooting for faulty main relief valve (F-1/S-1).

 Refer to SYSTEM / Hydraulic System.

 If actuator speed of only front attachment is slow, the pilot system may be faulty (A-1) or the circuit after the pilot valve may be faulty (F-2). Procedure Inspection Method 1 Monitor Main Pump Delivery Pressure 2

Condition Evaluation Cause No steering or The measured value Faulty bleed-off compensation loading operation exceeds 3.5 ~ 5.0 MPa spool (stuck) Engine: High idling (508 ~ 725 psi) Measure steering time (full Disconnect the Both of the measured Faulty torque control solenoid turn) and lift arm raising time connector of times are out of valve Faulty main pump (fully up) torque control normal range solenoid valve (Full turn: 3.0±0.4 sec Faulty main pump regulator Lift arm fully up: 6.8±0.3 sec) Faulty steering valve Only the steering time is out of normal Problem in the circuit after the Orbitrol (steering pilot valve) range: 3.0 ± 0.4 sec (full turn) Faulty multiple control valve Only the lift arm raising time is out of Problem in the pilot circuit after the pilot valve normal range: 6.8 ± 0.3 sec (fully up) Both of the measured Faulty torque control solenoid times are within the valve normal range. Faulty Main Controller (SC)

fNOTE: The normal range differs depending on the machine condition. Refer to Section 4 for details.

95Z7BTT05-06-02 a-

Torque Control Solenoid Valve Connector

T5-6-55

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-3

Actuator of front attachment does not stop even if a control lever is set to neutral.

Preparation  Stuck spool in the pilot valve or stuck main spool in the multiple control valve is suspected. Procedure Inspection Method 1 Set the front control lever lock switch to LOCK position 2 -

Condition -

Evaluation Actuator stops

Cause Faulty pilot valve (stuck spool)

The check (1) above resulted normal.

Faulty multiple control valve (stuck spool)

T5-6-56

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-5

Fan speed does not change.

Preparation  Refer to SYSTEM / Control System / Fan Speed Control (p. T2-2-54).

 The sensors detect the conditions necessary to operate fan speed control. Therefore, if these sensors fail, fan speed control becomes ineffective.  Accelerator pedal sensor, coolant temperature sensor, boost temperature sensor, hydraulic oil temperature sensor, torque converter oil temperature sensor, and pressure sensor (refrigerant pressure) are also involved in the fan speed control. If these sensors fail, other operating functions will be also affected. Procedure Inspection Method 1 Monitor Target Hydraulic Fan Speed

3 4

Condition Engine: Running

Disassemble and inspect the fan speed control solenoid valve Disassemble and inspect the fan control valve Monitor Hydraulic Fan Circuit Engine: Running Pressure

Evaluation Fan speed does not change according to accelerator pedal depressing amount There is abnormality

Faulty fan speed control solenoid valve

There is abnormality

Faulty fan control valve

Fan pump delivery pressure does not change according to accelerator pedal depressing amount The above checks resulted all normal.

Faulty fan pump

3 2

95Z7B-03-03-02

123-

Cause Faulty engine control module (ECM) or main controller (MC)

Fan Reverse rotation control solenoid valve Fan Speed Control Solenoid Valve Fan Control Valve

T5-6-57

Faulty fan motor

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-6

Fan does not rotate in reverse when pushing fan reverse rotation switch.

Preparation  Refer to SYSTEM / Control System / Fan Reverse Rotation Control (p. T2-2-56).  Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Fan Reversing Switch Parking brake is applied Fan reverse rotation switch: ON 2 Measure resistance between fan reverse rotation control solenoid valves #1 and #2 3 Measure voltage between Key switch: ON fan reverse rotation control solenoid valve harness end #1 and chassis 4 -

Evaluation OFF is displayed

Cause Faulty fan reverse rotation switch

0/∞ Ω (Normal value: Faulty fan reverse rotation 30 Ω) control solenoid valve 0V

Open circuit in harness between fan reverse rotation control solenoid valve and Main Controller (Sub) Faulty Main Controller (Sub)

The above checks resulted all normal.

 Fan Reverse Rotation Control Solenoid Valve (Harness Side) 3 2

90Z7-05-CN10

95Z7B-03-03-02

123-

T5-6-58

Fan Reverse rotation control solenoid valve Fan Speed Control Solenoid Valve Fan Control Valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting F-1

All front attachment actuator power are weak.

Main Relief Valve Set Pressure Lift arm and bucket relief operation

Specification

Remark

31.4 ± 0.5 MPa (4554 ± 73 psi)

Preparation  If operating speeds are extremely slow, pump control may be faulty. Faulty pilot system may also cause this trouble. Procedure Inspection Method 1 Monitor Pump Delivery Pressure

Condition Lift arm relief operation

Evaluation The measured values are out of the specified range. The check (1) above resulted normal.

2 1 95Z7BTT05-06-10 1234-

Main Relief Valve Overload Relief Valve (Bucket Bottom Side, Roll Back) Overload Relief Valve (Lift Arm Rod Side, Lower) Overload Relief Valve (Bucket Rod Side, Dump)

T5-6-59

Cause Faulty main relief valve (readjust) Find out cause of trouble by tracing other trouble symptoms

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-2

Some cylinders are not operated or speeds are slow.

Overload Relief Specification Valve Set Pressure Lift Arm Lower 37.3 ± 0.5 MPa (5410 ± 73 psi) Bucket 37.3 ± 0.5 MPa (5410 ± 73 psi)

Remark

Preparation  When parking brake is released normally, the primary pilot pressure is considered to be normal. Procedure Inspection Method Condition Evaluation Cause 1 Monitor Bucket Roll Back Pilot Full operation of The measured Faulty pilot valve Pressure, Bucket Dump Pilot bucket roll back/ values are out of the Pressure, Lift Arm Raise Pilot dump and lift arm specified range. Pressure raise (Normal range: 3.0 ~ 3.7 MPa (435 ~ 537 psi)) 2 Replace overload relief valves, Symptom is observed Faulty overload relief valve of which the set pressure are with the replaced the same relief valve. 3 The above checks Faulty control valve spool (stuck) resulted all normal. Faulty cylinder (faulty seal kit)

2 1 95Z7BTT05-06-10 1234-

Main Relief Valve Overload Relief Valve (Bucket Bottom Side, Roll Back) Overload Relief Valve (Lift Arm Rod Side, Lower) Overload Relief Valve (Bucket Rod Side, Dump)

T5-6-60

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-3

Front attachment drifts remarkably.

Leakage Check Within the Lift Arm Cylinder 1. Lower the bucket edge onto the ground with the bucket cylinder rod slightly extended from the fully retracted position. 2. Remove the hose from the lift arm cylinder rod side, and drain the oil from the cylinder and the hose. (Cover the removed hose ends to prevent dust or dirt.) 3. Extend the bucket cylinder rod, and lift the bucket. If any oil comes out from the hose connection port and the lift arm cylinder rod retracts, oil leakage occurs within the cylinder. If no oil comes out from the hose connection port but the lift arm cylinder rod retracts, oil leakage occurs in the multiple control valve. Procedure Inspection Method 1 Set the front control lever lock switch to LOCK position 2 Replace the overload relief valve 3 Disassemble and inspect the cylinder 4 -

Condition -

Evaluation The symptom disappears The symptom disappears Abnormality found The above checks resulted all normal.

T5-6-61

Cause Faulty pilot valve Faulty overload relief valve Faulty cylinder (seal kit) Damaged control valve spool Broken spring Loosened spool end

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-4

Shock during bucket dump operation is large when stopping lift arm raise / lower operation.

Preparation  Check that control levers are not abnormal first.  The flow regulator valve may be faulty. Refer to COMPONENT OPERATION / Others / Flow Regulator Valve (p. T3-12-4).  Refer to SYSTEM / Hydraulic System. Procedure Inspection Method 1 Disassemble and inspect the shockless valve 2 Disassemble and inspect the restriction valve 3 -

Condition -

Evaluation Abnormality found

Abnormality found

The above checks resulted all normal.

T5-6-62

Cause Faulty shockless valve in flow regulator valve Faulty restriction valve in flow regulator valve Bound control valve spool, or faulty cylinder (faulty seal kit)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-5

Bucket auto leveler control is not activated. (Detent is not held.)

Preparation  Refer to SYSTEM / Control System / Bucket Auto Leveler Control (p.T2-2-84).  Check #16 fuse in fuse box B.  Check the wiring connections first.

Procedure Inspection Method 1 Measure voltage between pilot valve bucket roll back side coil harness end #1 and chassis 2 Replace the bucket autoleveler relay with other general relay 3 Measure resistance between pilot valve bucket roll back side coil harness ends #1 and #2 4 Measure voltage between bucket leveler relay harness end #1 and chassis 5 -

Condition Key switch: ON

Evaluation 0V

Cause Open circuit in harness between #16 fuse in fuse box B and pilot valve bucket roll back side coil

Bucket roll back detent control lever operation -

The symptom disappears

Faulty bucket auto-leveler

0/∞ Ω

Faulty pilot valve bucket roll back side coil

Open circuit in harness between bucket proximity switch and bucket leveler relay Faulty bucket proximity switch

Bucket roll back detent control lever operation -

The above checks resulted all normal.

 Relay Connector (Harness Side)

 Bucket Roll Back Coil Connector (Harness Side)

90Z7B-05-05-CN03

T5-6-63

90Z7B-05-05-CN05

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-6

Lift arm float control is not activated. (Detent is not held.)

Preparation  Refer to SYSTEM / Control System / Lift Arm Float Control (p.T2-2-86).  Check #16 fuse in fuse box B.  Check the wiring connections first. Procedure Inspection Method 1 Measure voltage between pilot valve lift arm lower side coil harness end #1 and chassis 2 Check resistance between pilot valve lift arm lower side coil harness ends #1 and #2 3 Check continuity between pilot valve lift arm lower side coil harness end #2 and chassis 4 -

Condition Key switch: ON

Evaluation 0V

Cause Open circuit in harness between #16 fuse in fuse box B and pilot valve lift arm lower side coil

0/∞Ω

Faulty pilot valve lift arm lower side coil

Lift arm lower control lever operation

∞Ω

Open circuit in harness between pilot valve lift arm lower side coil and Main Controller (Sub)

The above checks resulted all normal.

Faulty Main Controller (Sub)

 Lift Arm Lower Side Coil Connector (Harness Side)

90Z7B-05-05-CN05

T5-6-64

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-7

Lift arm auto leveler height kickout control is not activated.

Preparation  Check the lift arm auto leveler height kickout setting with the monitor first. The activating conditions for lift arm auto leveler height kickout control are different according to the settings.

 Check #16 fuse in fuse box B.  Check the wiring connections first.

 Refer to SYSTEM / Control System / Lift Arm Auto Leveler Height Kickout Control (p.T2-2-72). Procedure Inspection Method 1 Measure voltage between pilot valve lift arm raise side coil harness end #1 and chassis 2 Check resistance between pilot valve lift arm raise side coil harness ends #1 and #2 3 Check continuity between pilot valve lift arm raise side coil harness end #2 and chassis 4 -

Condition Key switch: ON

Evaluation 0V

Cause Open circuit in harness between #16 fuse in fuse box B and pilot valve lift arm raise side coil

0/∞Ω

Faulty pilot valve lift arm raise side coil

Lift arm raise, detent control lever operation

∞Ω

Open circuit in harness between pilot valve lift arm lower side coil and Main Controller (Sub)

The above checks resulted all normal.

Faulty Main Controller (Sub)

 Lift Arm Raise Side Coil Connector (Harness Side)

90Z7B-05-05-CN05

T5-6-65

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-8

Lift arm auto leveler lower kickout control is not activated.

Preparation  Check the lift arm auto leveler lower kickout setting with the monitor first. The activating conditions for lift arm auto leveler lower kickout control are different according to the settings.  Refer to SYSTEM / Control System / Lift Arm Auto Leveler Lower Kickout Control (p.T2-2-74). Procedure Inspection Method 1 Measure voltage between pilot valve lift arm lower side coil harness end #1 and chassis 2 Check resistance between pilot valve lift arm lower side coil harness ends #1 and #2 3 Check continuity between pilot valve lift arm lower side coil harness end #2 and chassis 4 -

 Check the wiring connections first.  Check #16 fuse in fuse box B.

Condition Key switch: ON

Evaluation 0V

Cause Open circuit in harness between #16 fuse in fuse box B and pilot valve lift arm lower side coil

0/∞Ω

Faulty pilot valve lift arm lower side coil

Lift arm lower, detent control lever operation

∞Ω

Open circuit in harness between pilot valve lift arm lower side coil and Main Controller (Sub)

The above checks resulted all normal.

Faulty Main Controller (Sub)

 Lift Arm Lower Side Coil Connector (Harness Side)

90Z7B-05-05-CN05

T5-6-66

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-9

Ride control is not activated.

Preparation  Check the ride control setting with the monitor or MPDr. first. The activating conditions for ride control are different according to the settings.

 When the parking brake is released normally, the primary pilot pressure is considered to be normal.  Check the wiring connections first.

 Refer to SYSTEM / Control System / Ride Control. Procedure Inspection Method 1 Monitor Ride Control Switch

Condition Ride control switch: ON

Measure resistance at ride control solenoid valves rod side (multiple control valve) and bottom side (ride control valve) -

Evaluation OFF is displayed

Cause Faulty ride control switch or open circuit in harness between ride control switch and Main Controller (Sub) 0/∞ Ω (Normal value: Faulty ride control solenoid Rod side: 26.2 Ω valve (rod side or bottom side) Bottom side: 17.5 Ω)

The above checks resulted all normal.

4 3

1 2 95Z7B-03-12-11 1234-

Ride Control Valve (Option) Ride Control Solenoid Valve (Bottom Side) (Option) Multiple Control Valve Ride Control Solenoid Valve (Rod Side) (Option)

T5-6-67

Stuck control valve spool or faulty accumulator

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-68

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting S-1

Steering operation is weak.

Main Relief Valve Set Pressure Steering relief operation

Specification

Remark

27.4 ± 0.5 MPa (3974 ± 73 psi)

Preparation  If operating speeds are extremely slow, pump control may be faulty. Faulty pilot system may also cause this trouble. Procedure Inspection Method 1 Measure Steering Cylinder Pressure

Condition Steering relief operation

Evaluation The measured values are out of the specified range.

Cause Faulty steering relief valve (readjust)

The check (1) above resulted normal.

Find out cause of trouble by tracing other trouble symptoms

fNOTE: Refer to p. T4-5-10 for the steering relief pressure measurement and adjustment.

T5-6-69

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-2

Steering operation is slow.

Specification Steering cylinder 3.0 ± 0.4 operation time (sec)

Remark Accelerator pedal: Fully depressed Power mode switch: ON Bucket: Empty

Preparation  If speed of front attachment is also slow, the pilot system or main system may be faulty (A-2).  If the pilot system is faulty, the circuit after the steering pilot valve may be faulty.

 Check that the steering wheel is not abnormal first.  Refer to SYSTEM / Hydraulic System.

Procedure Inspection Method Condition 1 Measure Main Pump Pressure Engine: Running Steering relief operation

Measure pressure at port B in Engine: Running reducing valve (for Orbitrol) Accelerator pedal: Fully depressed

Measure pressure at port A in Engine: Running stop valve (left/right) Steering (left or right) operation

Measure pressure at port B in Engine: Running stop valve (left/right) Steering (left or right) operation

Evaluation The measured values are out of normal range (Normal range: 28.0 MPa (4061 psi) or more The measured values are out of normal range (Normal range: 3.5 ± 0.5 MPa (508 ± 73 psi) The measured values are out of normal range (Normal range: 3.5 ± 0.5 MPa (508 ± 73 psi) The measured values are out of normal range (Normal range: 3.5 ± 0.5 MPa (508 ± 73 psi) The above checks resulted all normal.

1 123-

95Z7-05-06-01

T5-6-70

Reducing Valve Port B Stop Valve Port A Stop Valve Port B

Cause Stuck or clogged bleed-off compensator (in multiple control valve)

Faulty reducing valve or shuttle valve Clogged filter

Faulty Orbitrol (steering pilot valve)

Faulty stop valve

Stuck steering valve spool or faulty steering cylinder (faulty seal kit)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-3

Shock of steering operation is large.

Preparation  Check that the steering wheel is not abnormal first.

 Release any remaining pressure before checking gas pressure in the accumulator.

 The steering valve and stop valve may be faulty.  Refer to SYSTEM / Hydraulic System. Procedure Inspection Method 1 Disassemble and inspect the stop valve 2 Disassemble and inspect the steering valve 3 -

Condition -

Evaluation There is abnormality

Cause Faulty stop valve

There is abnormality

The above checks resulted all normal.

Faulty steering valve (stuck spool, clogged orifice) Faulty steering cylinder (faulty seal kit)

95Z7B-7-50-2

fNOTE: Steering Accumulator Gas Pressure: 5.0 MPa (725 PSI)

T5-6-71

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-4 Secondary steering (optional) is not operated. (Automatic operation check when the engine starts) Preparation  Check the secondary steering control setting with the monitor first.

 Check the wiring connections first.  The secondary steering check switch may be faulty when secondary steering operation cannot be checked manually.

 Refer to SYSTEM / Control System / Emergency Steering Control (Option) (p. T2-2-80).  Check that #20 fuse in fuse box B is not abnormal. Procedure Inspection Method 1 Monitor Secondary Steering Pump Delivery Pressure

Replace the secondary steering relay (relay box C3) with other general relay

Measure resistance between secondary steering motor relays #1 and #2 -

Condition Engine starts

Evaluation The measured values are not at the normal level (4.8 MPa) (696 psi) Activate Secondary steering secondary steering system works (Secondary steering operation check switch 0/∞ Ω

The above checks resulted all normal.

#2 95Z7BTT05-06-04

T5-6-72

Cause Faulty secondary steering pump unit

Faulty secondary steering relay

Faulty secondary steering motor relay Faulty Main Controller (Sub)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting T-1

Although forward/reverse lever is operated, machine does not travel forward/reverse.

Preparation  The transmission may be faulty when the transmission warning indicator lights.  Refer to SYSTEM / Control System / Forward/Reverse Lever Priority Control (p. T2-2-34).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (F)

Condition Forward/reverse lever: F, R

Measure transmission clutch pressure

Measure torque converter pressure (at inlet port)

Evaluation OFF is displayed

Cause Faulty forward/reverse lever, or open circuit in harness between forward/reverse lever and Main Controller (Main) The measured values Faulty transmission control valve are out of normal range (Normal range: 2.5 ~ 3.0 MPa (363 ~ 435 psi)) The measured values Faulty transmission control valve are out of normal range (Normal range: 0.7 ~ 0.9 MPa (102 ~ 131 psi)) The above checks Faulty Main Controller (Main) resulted all normal.

T5-6-73

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-2

Although forward/reverse lever is set to neutral position, machine travels.

Preparation  Refer to SYSTEM / Control System / Neutral Control (p. T2-2-32).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (N) 2 Measure transmission clutch pressure 3 -

Condition Forward/reverse lever: N Forward/reverse lever: N -

Evaluation OFF is displayed

Cause Faulty forward/reverse lever

Pressure is Faulty transmission control measurable (not "0"). valve The above check (1) Faulty Main Controller (Main) resulted normal.

T5-6-74

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-3

Declutch is not operated.

 Declutch specified operation pressure Declutch Position Switch Brake pedal angle: Lightly applied (N) Speed Shift: 1st 1.25 MPa (181 psi) or more Speed Shift: 2nd 0.6 MPa (87 psi) or more

Brake pedal angle: Fully applied (D) 2.5 MPa (363 psi) or more 1.5 MPa (218 psi) or more

Preparation  Refer to SYSTEM / Control System / Declutch Control (p. T2-2-44).  When other actuator (steering) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Declutch Position Switch

Cause Faulty declutch position switch Open circuit in harness between declutch position switch and Main Controller (Main) Monitor Service Brake Brake pedal (right) The measured values are out of Faulty brake system (brake Secondary Pressure operation the specified range valve) (For Declutch) Measure transmission The measured values are out of Faulty transmission control clutch pressure normal range (Normal range: valve 1st, LU, H: 2.3 ~ 2.7 MPa (334 ~ 392 psi), 2nd, 3rd, R, L: 2.5 ~ 3.0 MPa (363 ~ 435 psi)) The above checks resulted all Faulty Main Controller (Main) normal.

Condition Declutch position switch: N, D

12-

Evaluation OFF is displayed (0 is displayed on the monitor)

Service Brake Secondary Pressure (for Declutch) Brake Valve

95Z7B-03-10-02

T5-6-75

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-4

Travel mode can not be changed.

Preparation  Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Travel Mode Selector Driving mode Switch switch: AUTO 1/ AUTO 2 mode 2

Evaluation Manual mode is always displayed (0 is displayed on the monitor) The check (1) above resulted normal.

T5-6-76

Cause Faulty driving mode switch Open circuit in harness between driving mode switch and Main Controller (Main) Faulty Main Controller (Main)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-5

Although shift switch is operated, speed shift does not change.

Preparation  Check that the travel mode is Manual mode.  Refer to SYSTEM / Control System / Manual Speed Shift Control (p. T2-2-36).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Shift Switch

Condition Shift switch: 1/2/3/4 position

Measure transmission clutch pressure

Evaluation The position of shift switch is not identical to the displayed range on monitor

Cause Faulty shift switch Open circuit in harness between shift switch and Main Controller (Main) The measured values are out of Faulty transmission control normal range (Normal range: valve 1st, LU, H: 2.3 ~ 2.7 MPa (334 ~ 392 psi), 2nd, 3rd, R, L: 2.5 ~ 3.0 MPa (363 ~ 435 psi)) The above checks resulted all Faulty Main Controller (Main) normal.

T5-6-77

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-6

Although vehicle speed changes, speed shift does not change automatically.

Preparation  Check that the travel mode is AUTO 1/AUTO 2 mode.  Refer to SYSTEM / Control System / Automatic Speed Shift Control (p. T2-2-38).  Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Travel Mode Selector Driving mode Switch switch: AUTO 1/ AUTO 2 mode 2

Monitor Power Mode Switch

Power mode switch: ON

Evaluation Manual mode is always displayed (0 is displayed on the monitor). OFF is displayed.

The check (1) above resulted normal.

T5-6-78

Cause Faulty driving mode switch Open circuit in harness between driving mode switch and Main Controller (Main) Faulty power mode switch Open circuit in harness between power mode switch and Main Controller (Main) Faulty Main Controller (Main)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-7

Speed shift is not shifted down when pushing downshift switch (DSS).

Preparation  Check that the travel mode is AUTO 1/AUTO 2 mode.  Refer to SYSTEM / Control System / Downshift Control (p. T2-2-40).  Check the wiring connections first. Procedure Inspection Method 1 Monitor DSS Switch

Condition Downshift switch (DSS): ON While machine is travelling -

Evaluation OFF is displayed

The check (1) above resulted normal.

T5-6-79

Cause Faulty downshift switch (DSS) Open circuit in harness between downshift switch (DSS) and Main Controller (Main) Faulty Main Controller (Main)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-8

Speed shift is not held when pushing hold switch.

Preparation  Check that the travel mode is AUTO 1/AUTO 2 mode.  Refer to SYSTEM / Control System / Shift Holding Control (p. T2-2-46).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Shift Hold Switch

Condition Hold switch: ON

Evaluation OFF is displayed

The check (1) above resulted normal.

T5-6-80

Cause Faulty shift hold switch Open circuit in harness between shift hold switch and Main Controller (Main) Faulty Main Controller (Main)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-9

Speed shift retard control is not activated.

Preparation  Check the speed shift delay control setting with the monitor first.  Check the parking brake is OFF (not applied).  Refer to SYSTEM / Control System / Speed Shift Delay Control (p. T2-2-42).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (F), (R)

Condition Forward/reverse lever: F and R

Monitor Travel Mode Selector Travel mode: Switch AUTO 1/AUTO 2 mode

Monitor Machine Speed (For Speedometer)

Travel operation

Evaluation N is displayed

Cause Faulty forward/reverse lever Open circuit in harness between forward/reverse lever and Main Controller (Main) Manual mode is Faulty driving mode switch displayed (0 is Open circuit in harness between displayed on the driving mode switch and Main monitor) Controller (Main) Speedometer: 0 km/h Faulty machine speed sensor (mph) Open circuit in harness between machine speed sensor and Main Controller (Main) The above checks Find out cause of trouble by resulted all normal. tracing other trouble symptoms

T5-6-81

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-82

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting B-1

Parking brake is not released. (When the engine runs)

Preparation  When other actuator (loading) is operated normally, the primary pilot pressure is considered to be normal.

 Check the wiring connections first.  Check that #10 fuse in fuse box A is not abnormal.

 Refer to SYSTEM / Electrical System. Procedure Inspection Method 1 Monitor Parking Brake Signal

Measure voltage between parking brake solenoid harness end and chassis Monitor Parking Brake Pressure

Condition Parking brake switch: ON (applied) Engine: Running Key switch: START

Parking brake switch: OFF (released) Engine: Running

Monitor Primary Pilot Pressure (Loading)

Front control lever lock switch: UNLOCK position Engine: Running

Monitor Service Brake Primary Pressure

Parking brake switch: OFF Engine: Running

Replace parking brake relay 1 Parking brake with other general relay switch: OFF Engine: Running Replace parking brake relay 2 Parking brake with other general relay switch: OFF Engine: Running -

Evaluation OFF is displayed

Cause Faulty parking brake switch

Open circuit in harness between #10 fuse in fuse box A and parking brake solenoid The measured values Stuck spool in parking brake solenoid valve are out of normal range (Normal range: 3.0 ~ 3.7 MPa (435 ~ 537 psi)) The measured values Faulty reducing valve are out of normal range (Normal range: 3.5 ± 0.5 MPa (508 ± 73 psi)) The measured values Faulty unloader valve (brake charge valve) are out of normal range (Normal range: 6.9 ~ 11.8 MPa (1000 ~ 1711 psi)) The symptom Faulty parking brake relay 1 disappears The symptom disappears

Faulty parking brake relay 2

The above checks resulted all normal.

Faulty Main Controller (Main)

 Parking Brake Solenoid Valve (Harness Side)

90Z7-05-CN10

T5-6-83

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-2

Parking brake is not applied.

Wear amount of parking brake Brake Disc Brake Plate

Specification mm (in) 7.4 (0.291) 5.0 (0.197)

Allowable Limit mm (in) 7.2 (0.283) 4.8 (0.189)

Preparation  Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Parking Brake Switch Parking brake switch: ON Key switch: ON 2 Monitor Parking Brake Key switch: ON Pressure 3 Disconnect parking brake Key switch: ON solenoid connector

4 5

Check the wear amount of parking brake -

Evaluation OFF is displayed

Pressure is detected

Cause Faulty parking brake switch

Stuck spool in parking brake solenoid valve Parking brake works. Shortcircuit in harness between parking brake solenoid and parking brake relay. Faulty parking brake relay 2 Allowable limit or less Faulty brake disc and faulty brake friction pad The above checks Faulty main controller (MC) resulted all normal.

T5-6-84

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-3

Service brake function lowers.

Wear amount of service brake Brake Disc Brake Ring

Specification mm (in) 7.2 (0.28) 7.0 (0.27)

Allowable Limit mm (in) 6.1 (0.24) 6.4 (0.25)

Preparation  Check the wiring connections first. Procedure Inspection Method 1 Monitor Service Brake Primary Pressure

Condition -

Monitor Service Brake Secondary Pressure

Brake pedal: Fully depressed

Measure Service Brake Accumulator Pressure

Refer to page T45-20.

Check the wear amount of service brake

Refer to page T44-6.

Evaluation The measured values are out of normal range (Normal range: 6.9 ~ 11.8 MPa (1000 ~ 1711 psi)) The measured values are not within the normal values (Normal value: 3.7 ~ 4.3 MPa (537 ~ 624 psi)) The measured values are not within the normal values (Normal value: 11.8 ± 0.5 MPa (1711 ± 73 psi)) -

T5-6-85

Cause Faulty unloader valve (brake charge valve)

Faulty brake valve

Faulty brake accumulator

The wear amount of brake disc is beyond the allowable limit

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-86

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting O-1 Clearance light, tail light, and license plate light are not ON. Preparation  Check that the clearance light, tail light, and license plate light are not broken first.

 Failure of the clearance light indicator lighting will be also affected.

 Check #2 fuse in fuse box B when the clearance lights, tail light, and license plate light on both sides are not ON at the same time.

 Refer to SYSTEM / Electrical System.  Check the wiring connections first.

 Check #11 or #12 fuse in fuse box B when only the lights on left or right side is ON. Procedure Inspection Method 1 Monitor Lighting Switch

Condition Light switch: Clearance light position (or Head light position) -

Evaluation OFF is displayed.

The check (1) above resulted normal.

T5-6-87

Cause Faulty lighting switch Open circuit in harness between light switch and fuses #11 or #12 in fuse box B Faulty fuse #2, #11, #12 in fuse box B

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-2 Head light is not ON. Preparation  Check that the head lights are not broken first.

 Check that the light switch is the head light position.

 The light switch may be faulty (O-1), the dimmer switch or fuse #2 in fuse box B may be faulty when the head lights on both sides are not ON at the same time.

 Refer to SYSTEM / Electrical System.  Check the wiring connections first.

 Check fuses #2, #6 in fuse box A when only the light on right or left side is ON. Procedure Inspection Method 1 Set the dimmer switch to the low beam position 2

Condition Evaluation Key switch: ON The head lights (left/ Light switch: Head right) are not ON light position Replace head light relay (left/ Key switch: ON The head lights (left/ right) with other general relay Dimmer switch: right) are ON Low beam position Measure voltage between Key switch: ON 0V head light relay (left/right) Dimmer switch: harness end #1 and chassis Low beam position

Measure voltage between head light relay (left) harness end #3 and chassis

Key switch: ON 0V Dimmer switch: Low beam position

Measure voltage between head light (left) harness end #512 and chassis Measure voltage between head light relay (right) harness end #3 and chassis

Key switch: ON 0V Dimmer switch: Low beam position Key switch: ON 0V Dimmer switch: Low beam position

Measure voltage between Key switch: ON 0V head light (right) harness end Dimmer switch: #513 and chassis Low beam position

Connector (Harness end)  Head Light Relay (Left/Right)

Cause Faulty dimmer switch Open circuit in harness between dimmer switch and light switch Faulty head light relay (left/ right) Open circuit in harness between head light relay (left/right) and light switch Faulty dimmer switch Open circuit in harness between head light relay (left) and #6 fuse in fuse box A Faulty #6 fuse in fuse box A Open circuit in harness between head light (left) and head light relay (left) Open circuit in harness between head light relay (left) and #2 fuse in fuse box A Faulty #2 fuse in fuse box A Open circuit in harness between head light (right) and head light relay (right)

 Head Light (Left/Right)

#512 #513

95Z7B-05-CN01

T5-6-88

90Z7-05-06CN01

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-3 Head light is not shifted to high beam. Preparation  Check #9 fuse in fuse box A when the high beams at both sides are not ON.

 Failure of the high beam indicator lighting will be also affected.

 Check that the light switch is the head light position.

 Refer to SYSTEM / Electrical System.  Check the wiring connections first.

Procedure Inspection Method 1 Set the dimmer switch to the high beam position 2

Condition Key switch: ON Light switch: Head light position Replace high beam relay with Key switch: ON other general relay Dimmer switch: High beam position Measure voltage between Key switch: ON high beam relay harness end Dimmer switch: High beam #1 and chassis position Key switch: ON Measure voltage between high beam relay harness end Dimmer switch: #3 and chassis High beam position Measure voltage between Key switch: ON head light (left) harness end Dimmer switch: #514 and chassis High beam position Measure voltage between Key switch: ON head light (right) harness end Dimmer switch: #514 and chassis High beam position -

Evaluation Cause High beam is not ON Faulty dimmer switch Open circuit in harness between dimmer switch and light switch High beam is ON Faulty high beam relay

Open circuit in harness between high beam relay and dimmer switch

Open circuit in harness between high beam relay and #9 fuse in fuse box A Faulty #9 fuse in fuse box A Open circuit in harness between head light (left) and high beam relay

The above checks resulted all normal.

Connector (Harness end)  High Beam Relay

Faulty head light (right) Open circuit in harness between head light (right) and high beam relay Faulty head light (right/left) Faulty grounding

 Head Light (Left/Right)

#514

95Z7B-05-CN01

T5-6-89

90Z7-05-06CN01

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-4 Hazard light is not operated. Preparation  Check that the turn signal lights (hazard lights) are not broken first.

 Failure of blinking of the turn signal light indicators at both sides will be also affected.

 Check #7 fuse in fuse box B when all turn signal lights do not blink at the same time. Faulty flasher relay may also cause this trouble.

 Refer to SYSTEM / Electrical System.  Check the wiring connections first.

Procedure Inspection Method 1 Turn the hazard light switch ON

Condition Key switch: OFF

Hazard light switch: ON Hazard light switch: ON

Measure voltage at terminal L in flasher relay Replace turn signal light relay (left) with turn signal light relay (right) Measure voltage between turn signal light relay (left/ right) harness end #1 and chassis Measure voltage between turn signal light relay (left/ right) harness end #3 and chassis Measure voltage between hazard lights (right front/ right rear) harness end #530 and chassis Measure voltage between hazard lights (left front/ left rear) harness end #531 and chassis -

Connector (Harness end)  Turn Signal Light Relay (Left/Right)

Evaluation Hazard light is not operated.

Cause Faulty hazard light switch Open circuit in harness between hazard light switch and #7 fuse in fuse box B 0V Faulty flasher relay Faulty grounding Symptom is observed Faulty turn signal light relays on the opposite side. (left/right)

Hazard light switch: ON

Open circuit in harness between turn signal light relay (left/right) and hazard light switch Faulty diode E (F) Open circuit in harness between turn signal light relay (left/right) and flasher relay

Hazard light switch: ON

The above checks resulted all normal.

Faulty #7 fuse in fuse box B

 Hazard Light (Front)

 Hazard Light (Rear)

 Flasher Relay

Open circuit in harness between hazard lights (right front/ right rear) and turn signal light relay (right) Open circuit in harness between hazard lights (left front/ left rear) and turn signal light relay (left)

#530 #531 L

90Z7-05-06CN02 95Z7B-05-CN01

90Z7-05-06CN03

95Z7BTT05-06-05

fNOTE: Measure voltage from the rear (cable) side of flasher connector.

T5-6-90

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-5 Turn signal light is not operated. Preparation  Check #8 fuse in fuse box A when all turn signal lights do not blink.  Refer to SYSTEM / Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Operate the turn signal lever to the right and left

Condition Key switch: ON

Evaluation All turn signal lights do not blink.

Measure voltage between turn signal light relay (left) harness end #1 and chassis

Key switch: ON Turn signal lever: Left position

Measure voltage between turn signal light relay (right) harness end #1 and chassis

Key switch: ON Turn signal lever: Right position

The above checks resulted all normal.

Connector (Harness end)  Turn Signal Light Relay (Left/Right)

95Z7B-05-CN01

T5-6-91

Cause Faulty turn signal lever Open circuit in harness between turn signal lever and #8 fuse in fuse box A Open circuit in harness between turn signal light relay (left) and turn signal lever Faulty diode E Open circuit in harness between turn signal light relay (right) and turn signal lever Faulty diode F Faulty #8 fuse in fuse box A

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-6 Horn does not sound. Preparation  Check that the horn is not broken first.  Check #6 fuse in fuse box B when the horn does not sound by pushing two horn switches.  Refer to SYSTEM / Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Switch horn relay with other general relay 2 Measure voltage between horn relay harness end #1 and body

Condition Horn switch: ON

Evaluation Horn sounds

Cause Faulty horn relay

Horn switch: ON

The above checks resulted all normal.

Open circuit in harness between horn relay and #6 fuse in fuse box B Faulty #6 fuse in fuse box B Faulty horn switch Open circuit in harness between horn switch and horn relay

Connector (Harness end)  Turn Signal Light Relay (Left/Right)

95Z7B-05-CN01

T5-6-92

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-7 Reverse light is not ON. Reverse buzzer does not sound. Preparation  Check that the reverse light (backup lamp) and reverse buzzer (backup alarm) are not broken first.

 Check that the forward/reverse lever is in the R position.

 Check #7 fuse in fuse box A when the reverse lights at both sides and reverse buzzer are not operated at the same time. Faulty forward/reverse lever (T-1) may also cause this trouble.

 Refer to SYSTEM / Electrical System.  Check the wiring connections first.

Procedure Inspection Method Condition 1 Switch backup lamp/buzzer Key switch: ON relay with other general relay Forward/reverse lever position: R 2 Measure voltage between Key switch: ON reverse lights (left/right) Forward/reverse harness end #537 and chassis lever position: R 3 Measure voltage between Key switch: ON reverse buzzer harness end Forward/reverse #1 and chassis lever position: R 4 Measure voltage between Key switch: ON backup lamp/buzzer relay harness end #1 and chassis

Evaluation Reverse light is ON and reverse buzzer sounds. 0V

Measure voltage between backup lamp/buzzer relay harness end #3 and chassis

Key switch: ON

The above checks resulted all normal.

Connector (Harness end)  Backup Lamp/Buzzer Relay

 Reverse Buzzer

Cause Faulty backup lamp/buzzer relay

Open circuit in harness between reverse lights (left/right) and backup lamp/buzzer relay Open circuit in harness between reverse buzzer and backup lamp/buzzer relay Open circuit in harness between backup lamp/buzzer relay and #13 fuse in fuse boxB, or faulty #13 fuse Open circuit in harness between backup lamp/buzzer relay and #7 fuse in fuse box A Faulty #7 fuse in fuse box A Faulty reverse lights (left/right) Faulty reverse buzzer Faulty grounding

 Reverse Light (Left/Right)

#537

90Z7-05-CN10 95Z7B-05-CN01

T5-6-93

90Z7-05-06CN03

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-8 Brake light is not ON. Preparation  Check that the brake lights are not broken first.  Check #8 fuse in fuse box A when the brake lights at both sides are not ON.  Refer to SYSTEM / Electrical System.  Check the wiring connections first. Procedure Inspection Method Condition Evaluation 1 Replace brake light relay with Brake light switch: The symptom other general relay ON (Brake pedal is disappears applied) 2 Measure voltage between Key switch: ON 0V brake light relay harness end #1 and body 3

The above checks resulted all normal.

Connector (Harness end)  Backup Lamp/Buzzer Relay

95Z7B-05-CN01

T5-6-94

Cause Faulty brake light relay

Open circuit in harness between brake light relay and #8 fuse in fuse box A Faulty #8 fuse in fuse box A Faulty brake light switch Open circuit in harness between brake light switch and brake light relay

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-9 Work light does not light. Preparation  Check that the work lights are not broken first.  Check the wiring connections first.  The light switch may be faulty (O-1), or #2 fuse in fuse box B may be faulty when the work lights at both front and rear sides are not ON at the same time.  Check #5 fuse in fuse box A and #17 fuse in fuse box B when only the light at one side is ON.

 Failure of blinking of the work light indicator will be also affected.  Refer to SYSTEM / Electrical System.

fNOTE:

Work light switch (ON2: front)

Procedure Inspection Method Condition Evaluation 1 Set work light switch to ON 1/ Key switch: ON Work light is not ON. ON 2 Light switch: Clearance light/ Head light position 2 Replace work light relays Key switch: ON Work light on the opposite side is ON. (front/rear) each other Light switch: ON 3 Measure voltage between 0V work light relay (front/rear) harness end #1 and chassis Work light switch: 0 V 4 Measure voltage between ON 1 position work light relay (front) harness end #3 and chassis 5

Measure voltage between work light relay (front) harness end #515 and chassis Measure voltage between work light relay (rear) harness end #3 and chassis

Measure voltage between work light (rear) harness end #517 and chassis -

Connector (Harness end)  Work Light Relay

The above checks resulted all normal.

 Work Light (Front)

90Z7-05-06CN02

T5-6-95

Cause Faulty work light switch Open circuit in harness between work light switch and light switch Faulty work light relay (front/ rear) Open circuit in harness between work light relay (front/rear) and work light switch Open circuit in harness between work light relay (front) and #5 fuse in fuse box A Faulty #5 fuse in fuse box A Open circuit in harness between work light (front) and work light relay (front) Open circuit in harness between work light relay (right) and #17 fuse in fuse box B Faulty #17 fuse in fuse box B Open circuit in harness between work light (rear) and work light relay (rear) Faulty work light relay (front/ rear) Faulty grounding

 Work Light (Rear)

#515

95Z7B-05-CN01

(ON1: front/rear)

#517

90Z7-05-06CN04

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-10 Wiper is not operated.  Front Wiper Preparation  The wiper is driven by electric power routed via the relay circuit. The relay circuit of front wiper is controlled by the column display controller.

 In case the front washer is also not operated, check #4 fuse in fuse box A.  Refer to SYSTEM / Electrical System.

 In case the wiper is not operated, first check if the wiper relay is activated. Next, check if electric power is routed to the wiper motor. Procedure Inspection Method 1 Monitor Front Wiper Relay 1 Output

Monitor Front Wiper Relay 2 Output

Monitor Front Wiper Switch

Replace front wiper relay 1, 2 with each other

Condition Key switch: ON Front wiper/ washer switch: LOW Key switch: ON Front wiper/ washer switch: HI Key switch: ON Front wiper/ washer switch: LOW/HI

Key switch: ON Front wiper/ washer switch: LOW -

 Check the wiring connections first.

Evaluation OFF is displayed.

Cause Open circuit in harness between front wiper relay 1 and column display controller

OFF is displayed.

Open circuit in harness between front wiper relay 2 and column display controller The position of front Faulty front wiper/ washer wiper/ washer switch switch is not identical to the Open circuit in harness between display on monitor. front wiper/ washer switch and column display controller Open circuit in harness between front wiper relay 1, 2 and column display controller The opposite wiper is Faulty front wiper relay 1, 2 operated.

The above checks resulted all normal.

T5-6-96

Faulty column display controller

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B  Rear Wiper Preparation  The rear wiper/ washer switch may be faulty when the rear wiper is not operated.  In case the rear washer is also not operated, check #18 fuse in fuse box B.

Procedure Inspection Method Condition 1 Set rear wiper/ washer switch Key switch: ON to LOW

Evaluation Rear wiper is not operated.

Replace rear wiper relay with other general relay

Rear wiper is operated.

Measure voltage between rear wiper relay harness end #2 and chassis

Measure voltage between rear wiper relay harness end #1 and chassis

Key switch: ON Rear wiper/ washer switch: LOW Key switch: ON Rear wiper/ washer switch: LOW Key switch: ON

Cause Faulty rear wiper/ washer switch Open circuit in harness between rear wiper/ washer switch and rear wiper relay Faulty rear wiper relay

Open circuit in harness between rear wiper relay and rear wiper/ washer switch

Open circuit in harness between rear wiper relay and #18 fuse in fuse box B Faulty #18 fuse in fuse box B Faulty rear wiper motor

The above checks resulted all normal.

Connector (Harness end)  Rear Wiper Relay

95Z7B-05-CN01

T5-6-97

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-11 Washer is not operated.  Front Washer Preparation  Refer to SYSTEM / Electrical System.  Check the wiring connections first.  In case the front wiper is not operated, check #4 fuse in fuse box A. Procedure Inspection Method 1 Replace the front washer relay with other general relay 2 Check continuity between front washer relay harness end #2 and chassis 3

Measure voltage between front washer relay harness end #1 and chassis

Measure voltage between front washer motor harness end #1 and chassis

Monitor Front Washer Switch

Condition Key switch: ON

Evaluation Front washer is operated. ∞Ω

Key switch: ON Front wiper/ washer switch: ON position Front wiper/ 0V washer switch: ON position

Open circuit in harness between front washer relay and front wiper/ washer switch Open circuit in harness between front washer relay and #4 fuse in fuse box A Faulty #4 fuse in fuse box A Open circuit in harness between front washer relay and front washer motor

Key switch: ON Front wiper/ washer switch: ON position Key switch: ON Front wiper/ washer switch: Washer ON

The above checks resulted all normal.

Connector (Harness end)  Front Washer Relay

Cause Faulty front washer relay

The position of front wiper/ washer switch is not identical to the display on monitor.

Faulty front wiper/ washer switch Open circuit in harness between front wiper/ washer switch and column display controller Faulty front washer motor

 Front Washer Motor

95Z7B-05-CN01

95Z7BTT05-06-06

T5-6-98

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B  Rear Washer Preparation  The rear wiper/ washer switch may be faulty when the rear washer is not operated.  In case the rear wiper is not operated, check #18 fuse in fuse box B. Procedure Inspection Method Condition 1 Replace the rear washer relay Key switch: ON with other general relay Rear wiper/ washer switch: Washer ON 2 Measure voltage between Key switch: ON rear washer relay harness end Rear wiper/ #2 and chassis washer switch: Washer ON 3 Measure voltage between Key switch: ON rear washer relay harness end #1 and chassis

Evaluation Rear washer is operated

Cause Faulty rear washer relay

∞Ω

Open circuit in harness between rear washer relay and rear wiper/ washer switch

Measure voltage between rear washer motor harness end #1 and chassis

24 V

Open circuit in harness between rear washer relay and #18 fuse in fuse box B Faulty #18 fuse in fuse box B Open circuit in harness between rear washer relay and rear washer motor

Connector (Harness end)  Rear Washer Relay

Key switch: ON Rear wiper/ washer switch: Washer ON -

The above checks resulted all normal.

 Rear Washer Motor

95Z7B-05-CN01

95Z7BTT05-06-06

T5-6-99

Faulty rear washer motor or faulty #18 fuse in fuse box B

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-12 Cab dome light is not ON. Preparation  Check #3 fuse in fuse box B when the cab dome light and rear cab dome light are not ON at the same time.  Refer to SYSTEM / Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Set cab dome light switch to Door Interlocking Position 2 Set cab dome light switch to ON position

Condition Door open/close switch: ON -

Evaluation Cab dome light is not ON. Cab dome light is not ON.

Set cab rear dome light switch to ON position

Cab rear dome light is not ON.

The above checks resulted all normal.

T5-6-100

Cause Faulty door open/close switch Faulty cab dome bulb Open circuit in harness between cab light and #3 fuse in fuse box B Faulty cab rear dome bulb Open circuit in harness between cab rear dome light and #3 fuse in fuse box B Faulty #3 fuse in fuse box B

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Exchange Inspection 3

Exchange inspection method is a troubleshooting method to find the trouble location by exchanging the suspected part / component with another part / component having identical characteristics.

Many sensors and solenoid valves used on this machine are identical. Therefore, by using this switch-check method, faulty part /component, and/or harness can be easily found. Example: Lift Arm Raise Pilot Pressure Sensor High Input (MC Fault Code 111200-3) Check Method: 1. Switch connectors of pressure sensor (lift arm raise) and pressure sensor (bucket dump). 90TNED-01-02-22a

2. Retry troubleshooting. Result: In case Bucket Dump Pilot Pressure Sensor High Input (MC fault code 111203-3) is displayed, the pressure sensor (lift arm raise) is considered to be faulty.

12-

In case Lift Arm Raise Pilot Pressure Sensor High Input (MC fault code 111200-3) is displayed, the pressure sensor (lift arm raise) harness is considered to be faulty.

fNOTE: To find the identical part to try exchange

inspection, refer to the index pages in the parts catalog. Using the search program incorporated in the electrical parts catalog system, when available, is more effective.

T5-6-101

Flow Regulator Valve Pressure Sensor (Bucket Tilt (Roll Back))

34-

Pressure Sensor (Lift Arm Raise) Pressure Sensor (Bucket Dump)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Air Bleeding Procedures for Brake (Axle) 1

IMPORTANT: If air is mixed in the brake system, the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. In addition, bleed air from the brake system until hydraulic oil (about 0.5 L (0.13 gal)) is drawn from each wheel (4 places) after bubbles stops.

fNOTE: Perform this work on all wheels (4 places) by two or more persons. Air bleed plugs (1) are located on both front and rear axles.

1. Set the parking brake switch of front console to the ON position, start the engine, and increases service brake oil pressure.

95Z7BTT04-05-11

2. Connect clear vinyl tube (2) to either one of two air bleed plugs (1). Insert the other end of clear vinyl tube (2) into clear container (3) filled with hydraulic oil.

2 1

T4GB-05-04-005

T5-6-102

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B 3. Depress brake pedal (4) several times. Then, depress and hold brake pedal (4) to the stroke end. 4. Loosen air bleed plug (1) under condition in step 3 and drain hydraulic oil and air for several seconds. 5. Tighten air bleed plug (1). 6. Drain hydraulic oil after bubbles stops in steps 3 to 5 repeatedly.

fNOTE: When bubbles do not disappear after hydraulic

oil (about 0.5 L (0.13 gal)) is discharged, repeat step 3 to step 5.

4 T4GB-05-04-006

7. Bleed air at other 3 places in the same way as step 3 to step 5. IMPORTANT: After air bleeding is completed at 4 places, bleed air at 4 places again. Bleed air in the same way as step 3 to step 5 twice and check that no air remains inside.

T5-6-103

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-104

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Outline Operation layout of the air conditioning system is illustrated below.

The vents (operator’s front/rear vent, foot vent, and the front window) can be simultaneously or independently selected by air vent damper servo motor (1) in accordance with the set-ventilation mode.

Either fresh or re-circulated air is induced into the air conditioner unit by operating fresh / re-circulated air damper servo motor (6).

The front widow and operator’s front vents are manually selectable. The air conditioning controller controls the air conditioning system.

The induced air flows out of the vents through evaporator (5) or heater (15) by blower motor (11). Evaporator (5) is a device used to cool the air. Heater (15) is a device used to warm the air. In the air conditioning system, after the refrigerant is compressed by the compressor, it is sent to evaporator (5) in which the refrigerant expands to cool the air. Heater (15) warms air by first absorbing heat from warmed engine coolant. Evaporator (5) and heater (15) allow the introduced air to circulate in the system to maintain the temperature at the set temperature.

The air conditioning controller controls the damper operation by corresponding to the job site conditions such as atmospheric and cab inside air temperatures, coolant temperature, operator’s set-temperature, and the selected ventilation mode. In addition, the air conditioning controller displays the air conditioning system operation status on the monitor.

6 1

5 2

TDAA-05-07-001

15 12345-

Air Vent Damper Servo Motor Defroster Vent Rear Vent Front Vent Evaporator

6789-

Fresh / Re-circulated Air Damper Servo Motor Re-circulated Air Sensor Fresh Air Induction Port Re-circulated Air Filter

10- Re-circulated Air Induction Port 11- Blower Motor 12- Power Transistor 13- Frost Sensor

T5-7-1

11 14- Air Mix Damper Servo Motor 15- Heater Core 16- Foot Vent

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Component Layout 1

6 4 3

5 9

8 A 10 TNED-05-07-001

11 95TNED-05-07-02

12 13

View A

90Z7-05-07-01 95TNED-05-07-03

123-

Solar Radiation Sensor Column Display Controller Temperature Control Switch/ Mode Switch

4567-

AUTO/OFF Switch / Blower Switch Accelerator Pedal Key Switch Monitor Controller

891011-

T5-7-2

Air Conditioner Unit Fresh Air Filter Air Conditioner Controller Outdoor Ambient Temperature Sensor

1213141527-

High/Low Pressure Switch Refrigerant Pressure Sensor Air Conditioner Condenser Receiver Tank Compressor

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner

18 17 16 15

20 21

22 23 24 25

TDAA-05-07-028

15- Re-circulated Air Filter 16- Compressor Relay 17- Re-circulated Air Sensor

18- Fresh / Re-circulated Air Damper Servo Motor 19- Frost Sensor 20- Evaporator

21222324-

T5-7-3

Heater Core Air Mix Damper Servo Motor Air Vent Damper Servo Motor Blower Motor Relay

25- Power Transistor 26- Blower Motor

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Functions of Main Parts The functions of the main parts for the air conditioner are described below. The connector No. is shown in the parentheses after the part name.  Controller Controls the air conditioning system. According to the operator’s requests sent via the switches, and the information regarding the air and refrigerant temperature sent from the sensors, the controller judges the air conditioner operating status and controls the blower motor and/or compressor operation as needed by operating the relays. In addition, the controller informs the operator of the air conditioner operating status by displaying the information on the monitor panel.

TDAA-05-07-002

 Power Transistor (CN7) An electric switch to control blower motor voltage.

TDAA-05-07-003

 Blower Motor Relay (CN3) Supplies 24 volts of electricity to the blower motor when the air conditioner is operated. The blower motor relay is turned ON when excited by the current from terminal #30 in controller. TDAA-05-07-004

 Compressor Relay (CN4) Supplies 24 volts of electricity to the compressor clutch when the air conditioner is operated. The compressor relay is turned ON when excited by the current from terminal #29 in controller. TDAA-05-07-005

T5-7-4

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Frost Sensor (CN12) Monitors the fin temperature which is cooled by the evaporator. When the temperature is higher than 3°C (37°F) (approx. 4.2 kΩ), the controller turns the compressor relay ON. When the temperature is lower than 2°C (36°F) (approx. 4.5 kΩ), the controller turns the compressor relay OFF. Therefore, the evaporator in the air conditioner unit is prevented from freezing. The electrical resistance in the frost sensor is 100 Ω to 115 kΩ.

 High/Low Pressure Switch (CN14) Controls the compressor clutch solenoid while monitoring the compressor circuit pressure. The high/low pressure switch consists of a pressure gauge and a switch. The pressure gauge detects the lower pressure range (0.196 ~ 0.225 MPa) (28.4 ~ 32.6 PSI) and the surge pressure range (2.55 ~ 3.14 MPa) (370 ~ 455 PSI). When the circuit pressure is reduced to the lower pressure range or increases to the surge pressure range, the pressure gauge turns the switch OFF so that the compressor operation stops. If the pressure is reduced to the lower range, a lack of refrigerant is suspected. Therefore, damage to the compressor due to a lack of refrigerant is prevented. In case the pressure increases to the surge range, damage to the air conditioner circuit parts due to excessively high circuit pressure is prevented.

 Re-circulated Air Sensor (CN11) Monitors the temperature 0 ~ 25°C (32 ~ 77°F) around the re-circulated air inlet as the interior air temperatures and converts them to the electrical resistance values. The temperature 0 ~ 25°C (32 ~ 77°F) corresponds to a resistance of 1.645 kΩ (0°C) (32°F) to 5 kΩ (25°C) (77°F) respectively. The electrical resistance in the air circulation sensor is 300 Ω to 430 kΩ.

 Outdoor Ambient Temperature (CN15) Monitors the temperature around the front side of the machine as the fresh air temperature, and converts the temperature to the electrical resistance value. The electrical resistance in the fresh air sensor is 100 Ω to 210 kΩ.

TDAA-05-07-006

TDAA-05-07-007

90TDAA-05-07-14

TDAA-05-07-008

TDAA-05-07-009

T5-7-5

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Solar Radiation Sensor (CN16) Converts the amount of solar radiation (illumination intensity) at the cab front to the current values. TDAA-05-07-010

 Fresh / Re-circulated Air Damper Servo Motor (CN10) Opens or closes the fresh/re-circulated air selection louvers. The damper consists of a motor, link mechanism, and position sensing switch. The motor opens or closes the fresh/re-circulated air selection louvers via the link mechanism.

TDAA-05-07-011

T5-7-6

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Air Mix Damper Servo Motor (CN9) Controls opening/closing of the air mixing door in response to the set temperature. The damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes the air mix door via the link mechanism. The potentiometer converts the link movements (the mix door strokes) to the voltage. Both ends of the potentiometer are energized by 5 V from terminals #7 (+) and #25 (-) in controller so that the potentiometer outputs voltage of 0.5 to 4.5 V from the center terminal to terminal #19 in controller corresponding to the link movement. When the set temperature is determined by temperature UP/DOWN signal from the controller, the controller calculates voltage (Vr) corresponding the link position. Further more, the controller checks the air mix door position by voltage (Vf ) from the potentiometer. Then, after the controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf, the controller sends out the current from terminals #15 and #16. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr).

TDAA-05-07-012

T5-7-7

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Air Vent Damper Servo Motor (CN8) Opens or closes the front and rear air vent, foot vent, and defroster vent louvers. The damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes vent louvers via the link mechanism. The potentiometer converts the link movements (vent louvers strokes) to the voltage. Both ends of the potentiometer are energized by 5 V from terminals #7 (+) and #25 (-) in controller so that the potentiometer outputs voltage of 0.5 to 4.5 V from the center terminal to terminal #20 in controller corresponding to the link movement.

TDAA-05-07-013

Depending on the MODE switch set position, vent louvers are operated as shown below. When the front and rear air vent louvers positions are selected, the controller calculates potentiometer voltage (Vr). Furthermore, the controller checks the vent louvers positions by receiving voltage (Vf ) from the potentiometer. Then, after the controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf, the controller sends out the current from terminals #31 and #32. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr). MODE switch position

Front air vent

Rear air vent

Foot air vent

Defroster vent























TNED-05-07-005

TNED-05-07-006

TNED-05-07-007

TNED-05-07-008

TNED-05-07-009

TNED-05-07-010

: Open : Closes

T5-7-8

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Troubleshooting IMPORTANT:  When replacing the compressor due to the breakage of compressor from internal lock, sufficiently clean the air conditioner circuit or replace all the parts.  When cleaning is insufficient or all the parts are not replaced, the air conditioner may be broken due to contaminants remaining in the circuit.  Using deteriorated LLC (coolant) or lowconcentration LLC, the heater core will receive a bad influence and it may lead water leaks and shorten the service life of machine. Replace coolant and manage LLC concentration according to the Operator's Manual.

T5-7-9

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Code List Fault Code

Trouble

Cause

Open circuit in recirculated air sensor

Voltage: more than 4.95 V

Symptoms in Machine Operation When Trouble Occurs. Operation is controlled under such circumstance as no recirculated air sensor is provided.

Remedy

Check the harness. Replace the recirculated air sensor. Shorted circuit in reVoltage: less than 0.3 V Operation is controlled under Check the harness. circulated air sensor such circumstance as no reReplace the recirculated air sensor is provided. circulated air sensor. Check the harness. Open circuit in Voltage: more than Operation is controlled under 4.88 V such circumstance as no outdoor Replace the outdoor ambient ambient temperature sensor is outdoor ambient temperature sensor provided. temperature sensor. Check the harness. Shorted circuit in Voltage: less than Operation is controlled under outdoor ambient 0.096 V such circumstance as no outdoor Replace the outdoor ambient temperature sensor ambient temperature sensor is temperature provided. sensor. Shorted circuit in solar Voltage: more than Operation is controlled under Check the harness. radiation sensor 5.04 V such circumstance as no solar Replace the solar radiation sensor is provided. radiation sensor. Open circuit in frost Voltage: more than The compressor clutch is Check the harness. sensor 4.79 V disengaged. (The compressor Replace the frost stops.) sensor. Shorted circuit in frost Voltage: less than The compressor clutch is Check the harness. sensor 0.096 V disengaged. (The compressor Replace the frost stops.) sensor. Abnormal air vent Shorted circuit: Air vent damper servo motor Check the harness. damper servo motor Voltage: 0 V becomes inoperable. Replace the air Open circuit: Voltage: vent damper servo more than 5 V motor. Abnormal air mix Shorted circuit: Air mix damper servo motor Check the harness. damper servo motor Voltage: less than 0.2 V servo motor becomes inoperable. Replace the air Open circuit: Voltage: vent damper servo more than 4.8 V motor. Abnormal high/low Voltage: 0 V The compressor clutch is Check the harness. refrigerant pressure disengaged. (The compressor Replace the high/ stops.) low pressure switch. CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1 error between monitor harness. controller and air Replace air conditioner controller conditioner controller. CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1 controller harness. Faulty CAN1 harness Replace air conditioner controller.

T5-7-10

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Codes 11 to 22 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 11

Trouble Open circuit in recirculated air sensor

Shorted circuit in recirculated air sensor

Open circuit in outdoor ambient temperature sensor

Inspection Method Measurement of resistance between sensor #1 and #2. Measurement of voltage between sensor harness end #1 and chassis. Measurement of resistance between sensor #1 and #2. Measurement of resistance between sensor #1 and #2. Measurement of voltage between sensor harness end #1 and chassis. -

Shorted circuit in outdoor ambient temperature sensor

Measurement of resistance between sensor #1 and #2. -

Shorted circuit in solar radiation sensor

Continuity check between sensor harness end #1 and #2. -

Open circuit in frost sensor

Shorted circuit in frost sensor

Measurement of resistance between sensor #1 and #2. Measurement of voltage between sensor harness end #1 and chassis. Measurement of resistance between sensor #1 and #2. -

T5-7-11

Evaluation Cause ∞ Ω (Normal value: Faulty sensor. 300 to 430 kΩ) 0V Open circuit in harness #1.

Normal in above check. 0 Ω (Normal value: 300 to 430 kΩ) Normal in above check. ∞ Ω (Normal value: 100 to 210 kΩ) 0V

Normal in above check. 0 Ω (Normal value: 100 to 210 kΩ) Normal in above check. 0Ω

Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1.

Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2. Shorted circuit in harness #1 and #2.

Normal in above Faulty sensor. check. ∞ Ω (Normal value: Faulty sensor. 100 to 115 kΩ) 0V Open circuit in harness #1.

Normal in above check. 0 Ω (Normal value: 100 to 115 kΩ) Normal in above check.

Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Codes 43 to 92 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 43

Trouble Abnormal air vent damper servo motor

Abnormal air mix damper servo motor

Abnormal high/ low refrigerant pressure

CAN communication error CAN bus off error

Inspection Method Measurement of voltage between air vent damper servo motor harness end 7C and chassis. (AUTO/OFF switch / blower switch: ON) Measurement of voltage between air vent damper servo motor harness end 7C and 25D. (AUTO/OFF switch / blower switch: ON) Measurement of voltage between air mix damper servo motor harness end 7D and chassis. (AUTO/OFF switch / blower switch: ON) Measurement of voltage between air mix damper servo motor harness end 7D and 25E. (AUTO/OFF switch / blower switch: ON) -

Evaluation 0V

Cause Faulty controller or open circuit in harness between controller and air vent damper servo motor.

Faulty controller or open circuit in harness between controller and air vent damper servo motor.

Normal in above check. 0V

Faulty air vent damper servo motor. Faulty controller or open circuit in harness between controller and air mix damper servo motor.

Faulty controller or open circuit in harness between controller and air mix damper servo motor.

Normal in above check. 0V

Faulty air mix damper servo motor. Faulty controller or open circuit in harness between controller and high/low pressure switch.

Measurement of voltage between high/low pressure switch harness end A21 and A05. (AUTO/OFF switch / blower switch: ON) Normal in above check. Continuity check in CAN1 Normal harness. Abnormal

Faulty controller. Faulty CAN1 harness.

Continuity check in CAN1 harness.

Faulty controller. Faulty CAN1 harness.

T5-7-12

Normal Abnormal

Faulty high/low pressure switch.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-13

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (1) Condition:  Fault code: Un-displayed  Airflow volume: faulty Blower motor rotates

Normal speed

Slow speed

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Frosted evaporator Adhered dirt on evaporator surface Power source decreases

Poor battery terminal contact Faulty blower motor Faulty power transistor Blower motor Faulty blower motor relay does not rotate Faulty blower motor Faulty power transistor Blower interferes with case Faulty controller Faulty ground in chassis Faulty wiring, disconnection of connector Blowout of power transistor thermal fuse due to locked motor Blowout of fuse Replace with the Blower motor is locked same capacity fuse Faulty wiring Shorted circuit

T5-7-14

Filter cleaning Filter cleaning Remove obstacles Replacement of blower To A Evaporator surface cleaning Check battery charging system Repair Replace Replace Replace Replace Replace Repair Replace the controller Make sure to ground Wirings inspection Replace motor Replace blower motor Refer to wiring diagram and check Wirings inspection

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of frost sensor Faulty frost sensor characteristics Frost sensor is out of evaporator range (faulty sensitivity) No voltage applied to magnet clutch

T5-7-15

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace evaporator sensor. Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace magnet clutch

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (2) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Normal Fresh air enters

Disconnection of A/M link

Close window and door Readjust fresh / re-circulated air selection damper Setting link again

T5-7-16

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-17

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (3) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Abnormal Pressure on lowpressure side is too high (approx. 0.29 MPa or more)

Pressure on highpressure side is too low (pressure is not approx. 0.98 MPa or more)

Pressure on lowpressure side is too low (pressure is approx. 0.05 MPa or less) Pressure is high on both sides of highpressure and lowpressure Cooling in the condenser is insufficient Pressure is low on both sides of highpressure and lowpressure

Overcharge air conditioner with refrigerant Faulty compressor

Remove refrigerant thoroughly and recharge refrigerant to proper level after purging Breakage of head gasket Replace compressor Breakage of inlet valve Replace compressor Clogged foreign matter into inlet Replace compressor valve Faulty valve Replace valve

Excessive open of expansion valve Abnormally low ambient temperature Low refrigerant Faulty compressor Swash plate shoe is locked Piston is locked Faulty suction discharge valve Faulty expansion valve Clogged valve (foreign matter) Temporary clogged due to freezing valve (water intrusion)

To B Replace compressor Replace compressor Replace compressor Replace valve Thoroughly perform purging after replacing valve and receiver

Abnormally low ambient temperature Low refrigerant To B Clogged during refrigeration cycle To C Faulty expansion valve To D Frosted evaporator To A Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing) Overcharge air conditioner Remove refrigerant thoroughly and recharge refrigerant to proper with refrigerant level after purging Faulty hydraulic fan control

Check hydraulic fan control function

Lack of refrigerant

T5-7-18

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor

Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace magnet clutch

B: Low refrigerant Low refrigerant

Low refrigerant quantity Gas leak

Charge refrigerant to proper level Check leak and charge with refrigerant after repairing faulty

C: Clogged during refrigeration cycle Clogged during refrigeration cycle

Clogged receiver dryer Clogged foreign matter in piping

Replace Replace

D: Faulty expansion valve Faulty expansion valve

Clogged valve (foreign matter) Replace valve Temporary clogged due to freezing valve Thoroughly perform purging after (water intrusion) replacing valve and receiver

T5-7-19

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (4) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor does not rotate normally Broken V belt or slipping Faulty compressor (locked) Faulty magnet Repair or clutch replace.

Clutch does not operate due to faulty electrical system

Check wiring

Cooling in the condenser is insufficient

Replace V belt Replace Open circuit in stator coil Replace Air gap between rotor and stator is too large Repair or Replacement Clutch slipping Slip caused by key breakage or inserting no key Replace key Greasy clutch surface Remove oil Layer shorted coil Replace Battery voltage drop Charge Clogged foreign matter between rotor and stator Overhaul Faulty controller Replace the controller Faulty compressor clutch relay Replace Faulty frost sensor Replace Faulty high/low refrigerant pressure switch Replace Abnormally high ambient temperature Abnormal high Too high pressure (2.54 MPa Lack of Clogged fin with Cleaning of fin (368 PSI) or condenser dirt or mud (washing) more) cooling Overcharge air Remove refrigerant thoroughly and conditioner with recharge refrigerant to proper level refrigerant after purging Air incorporation Remove refrigerant thoroughly and in refrigeration recharge refrigerant to proper level cycle after purging Too low Abnormally low ambient temperature (0.98 MPa Low refrigerant To B (142 PSI) or Clogged during refrigeration cycle To C less) Faulty expansion valve To D Frosted evaporator To A Faulty hydraulic fan control Check hydraulic fan control function

T5-7-20

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace evaporator sensor Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace magnet clutch

B: Low refrigerant Low refrigerant

Low refrigerant quantity Gas leak

Charge refrigerant to proper level Check leak and charge with refrigerant after repairing faulty

C: Clogged during refrigeration cycle Clogged during refrigeration cycle

Clogged receiver dryer Clogged foreign matter in piping

Replace Replace

D: Faulty expansion valve Faulty expansion valve

Clogged valve (foreign matter) Replace valve Temporary clogged due to freezing valve Thoroughly perform purging after (water intrusion) replacing valve and receiver

T5-7-21

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (5) Condition:  Fault Code: 44 (Abnormal air mix damper servo motor) Faulty wiring, open circuit, disconnection of connector Faulty servo motor Clogged foreign matter

Wirings inspection

Replace Remove foreign matter

Condition:  Fault Code: 51 (Abnormal high/low refrigerant pressure) High pressure cut is operated

Abnormally high ambient temperature Lack of condenser Clogged fin with dirt or mud Cleaning of fin (washing) cooling Overcharge air Remove refrigerant thoroughly and recharge refrigerant to proper conditioner with level after purging refrigerant Air incorporation in Remove refrigerant thoroughly and recharge refrigerant to proper refrigeration cycle level after purging Low pressure cut is Abnormally low ambient temperature operated Low refrigerant Low refrigerant quantity Charge refrigerant to proper level Gas leak Check leak and charge with refrigerant after repairing faulty Faulty compressor Swash plate shoe is locked Replace compressor Piston is locked Replace compressor Faulty suction discharge valve Replace compressor Faulty expansion valve Clogged valve (foreign matter) Replace valve Temporary clogged due to Thoroughly perform purging freezing valve (water intrusion) after replacing valve and receiver Cooling in the condenser Faulty hydraulic fan control Check hydraulic fan control is insufficient function

T5-7-22

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-23

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty heating (1) Condition:  Fault code: Un-displayed Faulty air flow volume

Blower motor rotates

Normal speed

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Frosted evaporator Adhered dirt on evaporator surface

Slow speed

Power source decreases

Poor battery terminal contact Faulty blower motor Faulty power transistor Blower motor Blowout of fuse Replace with the Blower motor is does not rotate same capacity fuse locked Faulty wiring Shorted circuit Faulty blower motor relay Faulty blower motor Faulty power transistor Blower interferes with case Faulty controller Faulty ground in chassis Faulty wiring, disconnection of connector Blowout of power transistor thermal fuse due to locked motor Air flow volume Coolant temperature is low is normal Coolant Disconnection of air mix damper link temperature is Air incorporation in hot-water circuit normal Clogging, breakage and bending of piping Extremely low ambient temperature Low engine coolant level Broken heater core

T5-7-24

Filter cleaning Filter cleaning Remove obstacles Replacement of blower To A Evaporator surface cleaning Check battery charging system Repair Replace Replace Replace blower motor Refer to wiring diagram and check Wirings inspection Replace Replace Replace Repair Replace the controller Make sure to ground Wirings inspection Replace motor

Setting link again Air Bleeding Circuit Repair or replace. Charge engine coolant to proper level Replace heater core

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice With voltage applied to Faulty magnet clutch Check of clutch circuit Replace clutch relay magnet clutch circuit Faulty wiring of Shorted circuit check Repair evaporator sensor Faulty the evaporator Characteristic check Replace frost sensor sensor characteristics Evaporator sensor is Reinsert (floating distance from evaporator is 3 out of evaporator range mm or less) (faulty sensitivity) No voltage applied to magnet clutch Faulty magnet clutch Replace magnet clutch

T5-7-25

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty heating (2) Condition:  Fault Code: 44 (Abnormal air mix damper servo motor) Clogged foreign matter Faulty wiring, open circuit, disconnection of connector Faulty damper

Remove foreign matter Wirings inspection Replace

T5-7-26

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Others  Faulty air vent switch Fault code is un-displayed Disconnection of link Fault code 43 (Abnormal air vent damper Faulty wiring, open circuit, servo motor) disconnection of connector Faulty servo motor Clogged foreign matter

Setting link again Wirings inspection Replace Remove foreign matter

 Faulty fresh / re-circulated air selection Fault code is un-displayed

Disconnection of link Faulty wiring, open circuit, disconnection of connector Faulty servo motor Clogged foreign matter

Setting link again Wirings inspection Replace Remove foreign matter

 Ambient temperature is higher or lower than set-temperature Fault code 11 (Open circuit in recirculated air sensor) Fault code 12 (Shorted circuit in recirculated air sensor) Fault code is un-displayed (Normal recirculated air sensor)

Open circuit in harness, disconnection Wirings inspection of connector Open circuit in air circulation sensor Replace Shorted circuit in harness Wirings inspection Shorted circuit in air circulation sensor Replace Faulty cooling, faulty heating Check by referring to the items of faulty cooling and faulty heating

T5-7-27

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Noise Case connection. Blower fan motor connection.

Gas blowing sound (roaring). Expansion valve connection. Whistle sound. Gas blowing sound. Clutch disengaging sound.

Compressor rotating sound.

Louver resonance. Fan contacts case. Foreign matter enters case. Brush friction noise, metal and/or thrust washer contact. Gas vibration noise (compressor discharge and/or suction gas noise). Abnormal noise from expansion valve. Expansion valve is normally functioning. Faulty clutch bearing, and/or idle pulley bearing. Contact of clutch armature due to resonance. Loose belt. Loose screws. Noisy compressor. Vibration due to V belt looseness. Loose screws.

Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud. No functional problem exists. Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard. Replace. Repair or replace clutch. Re-tighten screws. Repair or replace. Re-adjust belt. Re-tighten screws.

 Others Water leak. Water splash.

Abnormal smell.

Broken heater core. Broken hose. Clogged case drain port and/or drain hose. Absorbed cigarette and dust smell on evaporator fins.

T5-7-28

Replace. Clean. Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L mode for more than 10 minutes, flush smell out by condensed water.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-29

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Blower motor does not operate. Preparation  Check the wiring connections first. Procedure Inspection Method Condition 1 Switch compressor relay with Key Switch: ON blower motor relay. Blower Switch: ON 2 Measurement of voltage Key Switch: ON between terminal #41B of blower motor relay harness end and chassis. 3 Measurement of voltage Key Switch: ON between terminal #43B of blower Blower Switch: ON motor harness end and chassis. 4 Continuity check between terminals #1 and #2 of blower motor harness end. Key Switch: ON 5 Measurement of voltage between terminal #44B of power Blower Switch: ON transistor harness end and chassis. 6 Measurement of voltage Key Switch: ON between terminal #9B of power Blower Switch: ON transistor harness end and chassis. 7 -

Connector (Harness end)  Blower Motor Relay

Evaluation Cause (check point) Blower motor Faulty blower motor relay. does not operate. 0V Open circuit in harness between fuse #3 and blower motor relay. 0V

0Ω

Open circuit in harness between blower motor relay and blower motor. Faulty blower motor.

Open circuit in harness between blower motor and power transistor.

Faulty air conditioner controller.

Procedures as Faulty power transistor. steps 1 to 6 above are normal.

 Blower motor

TDAB-05-07-027 TDAB-05-07-020

 Power Transistor

TDAB-05-07-028

T5-7-30

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Compressor clutch does not operate. Preparation  Check that fresh air temperature is 0˚C (32˚F) or more first. When fresh air temperature is less than 0˚C (32˚F), the air conditioner controller turns the compressor clutch OFF in order to protect the compressor.  Check that fault code 21 or 22 (abnormal frost sensor) is not displayed. When the frost sensor is abnormal, the compressor clutch does not operate.  Check the wiring connections first. Procedure Inspection Method 1 Switch compressor relay with blower motor relay. 2 Measurement of voltage between terminal #48A of compressor relay harness end and chassis. 3 Measurement of voltage between terminal #42A of compressor clutch relay harness end and chassis. 4 -

Condition Key Switch: ON Blower Switch: ON Key Switch: ON

Evaluation Cause (check point) Compressor is not Faulty compressor relay. operable. 0V Open circuit in harness between fuse #3 and compressor relay.

Key Switch: ON Blower Switch: ON

Procedures as Faulty compressor clutch. steps 1 to 3 above are normal.

Connector (Harness end)  Compressor Relay

Open circuit in harness between compressor relay and compressor clutch.

 Compressor Clutch

TDAB-05-07-019

T5-7-31

TDAB-05-07-024

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Cooling circuit check by using manifold gauge Condition:  Engine Speed: 1500 min-1  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh / re-circulated air selection: Re-circulated Air  Air conditioner inlet temperature: 30 ~ 35°C (86 ~ 95°F) 1. In normal  Low-pressure side pressure: 0.15 ~ 0.25 MPa (21.8 ~ 36.3 PSI)  High-pressure side pressure: 1.37 ~ 1.57 MPa (198.7 ~ 227.7 PSI) NOTE: The reading of manifold gauge may depend on conditions.

TDAA-05-07-018

2. Lack of refrigerant quantity Trouble

Pressure is low on both sides of high-pressure and low-pressure. Cooling performance is low. Cause Refrigerant quantity is low. Gas leak. Remedy Check and repair of gas leak. Charge air conditioner with refrigerant. TDAA-05-07-019

3. Excessive refrigerant, lack of condenser cooling Trouble

Pressure is high on both sides of highpressure and low-pressure. Cooling performance is low. Cause Overcharge air conditioner with refrigerant. Faulty condenser cooling. Remedy Adjust refrigerant quantity. Clean condenser. Check for machine cooling system.

TDAA-05-07-020

4. Water incorporation in circuit. Trouble

After using a certain period of time, lowpressure side gradually indicates negative pressure. Cause Water is mixed in circuit. Remedy Replace receiver tank. Thoroughly perform purging before charging refrigerant to remove water. TDAA-05-07-021

T5-7-32

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 5. Faulty compression of compressor Trouble

Low-pressure side is high and high-pressure side is low. High-pressure becomes equal to low-pressure immediately after stopping the air conditioner. Cause Faulty compressor. Remedy Check and repair of compressor. TDAA-05-07-022

6. Refrigerant does not circulate (clogged circuit) Trouble

When absolutely clogging, low-pressure side indicates negative pressure quickly. When slightly clogging, low-pressure side gradually indicates negative pressure. Cause Dirt or water adheres or freezes to expansion valves, refrigerant does not flow. Remedy Replace receiver tank. Perform purging.

TDAA-05-07-023

7. Air incorporation in circuit Trouble

Pressure is high on both sides of highpressure and low-pressure. When touching low-pressure piping, it is not cold. Cause Air is mixed in system. Remedy Replace refrigerant. Perform purging. TDAA-05-07-024

8. Excessive open of expansion valve Trouble

Pressure is high on both sides of highpressure and low-pressure. Frost (dew) adheres to low-pressure piping. Cause Faulty expansion valve. Remedy Check for installation of thermal cylinder. TDAA-05-07-025

T5-7-33

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Work after Replacing Components The following work is required after replacing compressor, high pressure hose, low pressure hose, condenser, receiver tank, liquid hose, and air conditioner unit. The same work is required when gas leakage is found. 1. Refill Compressor Oil 2. Charge Air Conditioner with Refrigerant  Purging  Charge air conditioner with refrigerant  Warm-up operation  Inspection

T5-7-34

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Refill Compressor Oil When replacing the cooling circuit parts, refill compressor oil to the specified level. Replacement Compressor parts

Condenser

Evaporator

Oilreplenishing quantity

40 cm3 (2.4 in3)

Refer to the following.

 In case of replacing compressor New compressor (1) is charged with oil required for cooling circuit. When replacing new compressor (1), drain excess oil from new compressor (1). Adjust oil level so that it is the same level as oil (B) in compressor (2) to be replaced.

fNOTE: Compressor oil quantity: 160 cm (9.8 in ) 3

TDAA-05-07-015

New Compressor

Replacing Compressor

T5-7-35

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Charge Air Conditioner with Refrigerant Necessity of Purging Be sure to purge the air conditioner circuit with a vacuum before charging with refrigerant (R134a) because the following problems can arise if air or other gases remain in the A/C circuit. 1. Pressure rise in the high pressure side If air remains in the air conditioner circuit, this disturbs the heat exchange between refrigerant and air in the condenser, causing pressure to rise in the high pressure side (compressor side). Usually, refrigerant gas is easily liquefied; however, air cannot be liquefied and remains as a gas in the condenser because the temperature at which air liquefies is extremely low. That is, liquidation of the refrigerant gas in the condenser decreases by the amount of air in the circuit, and the gas pressure in the high pressure side increases accordingly.

W115-02-10-001

2. Metal corrosion If air remains in the air conditioner circuit, a chemical reaction between refrigerant and moisture in the air takes place, and as a result, hydrochloric acid, that corrodes metals such as aluminum, copper and iron, is produced.

W115-02-10-002

3. Plugging of the expansion valve by moisture When high pressure refrigerant gas passes through the expansion valve, gas pressure decreases and temperature drops. Moisture included in high pressure refrigerant gas in the air conditioner circuit freezes at the expansion valve orifice, plugging refrigerant flow. Operation of the air conditioner becomes unstable and cooling efficiency lowers.

W115-02-10-003

T5-7-36

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Procedures for charging air conditioner with refrigerant 1

IMPORTANT: Do not mistake the charge hose connections. 1. Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Connect high-pressure side charge hose (3) and low-pressure side charge hose (6) on manifold gauge (1) to the high-pressure side charge valve (“D” marked) and to the low-pressure side charge valve (“S” marked) located on the compressor, respectively. Connect charge hose (5) located on the center of manifold gauge (1) to vacuum pump (4).

7 6 2 3 5 4

W115-02-10-005

2. Open high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Perform purging for 10 minutes or more by operating vacuum pump (4).

1 7

W115-02-10-005

T5-7-37

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT: If the pointer returns to 0, retighten the line connections and perform purging again.

3. When the low pressure gauge reading falls below -0.1 MPa (-750 mmHg) (-14.5 PSI), close high pressure valve (2) and low pressure valve (7) and stop vacuum pump (4). Wait for approximately five minutes and confirm that the pointer does not return to 0.

W115-02-10-005

4. With high pressure valve (2) and low pressure valve (7) on manifold gauge (1) closed, connect charge hose (5) to refrigerant container (8).

W115-02-10-007

5. Open valve (9) of refrigerant container (8). Push air bleed valve (10) on manifold gauge (1) to purge air in charge hose (5) with the refrigerant pressure. When draining refrigerant, immediately release air bleed valve (10).

5 9

W115-02-10-007

T5-7-38

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT:  Always stop the engine when charging the air conditioner with refrigerant.  Do not position the refrigerant container upside down during charging operation.  When changing the refrigerant container during charging operation, be sure to purge air from the charge hose, as shown in step 10.  Charge the low-pressure side hose first. 6. Fully tighten charge hose (5) connection to gauge manifold (1). Open high pressure valve (2) and valve (9) of refrigerant container (8). Charge with refrigerant (R134a). Close high pressure valve (2) and valve (9) of refrigerant container (8) when high pressure gauge (11) reading reaches 98 kPa (1 kgf/cm2) (14.2 PSI).

W115-02-10-008

fNOTE: Use warm water of 40˚C (104˚F) or less to warm

refrigerant container (8) to aid in charging operation.

5 9 8

IMPORTANT: Use the leak tester for R134a. 7. After charging, check the line connections for gas leaks using leak tester.

W115-02-10-007

T5-7-39

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 8. Confirm that high pressure valve (2) and low pressure valve (7) on gauge manifold (1) and valve (9) of refrigerant container (8) are closed. Start the engine and operate the air conditioner.

1 7

Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool

9 8

W115-02-10-007

IMPORTANT: Do not open high pressure valve (2) on manifold gauge (1). 9. Open low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8) to charge with refrigerant.

1 7

fNOTE: Required refrigerant quantity: 900 ± 50 g (1.98 ± 0.1 lb)

10. If refrigerant container (8) becomes empty during the charging work, replace refrigerant container (8) with a new refrigerant container as follows:  Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1).  Replace the empty container with new refrigerant container (8).  Tighten, then slightly loosen refrigerant container (8) joint.  Slightly open low pressure valve (7) on manifold gauge (1).  When refrigerant container (8) joint starts to leak, immediately tighten refrigerant container (8) joint and close low-pressure valve (7) on manifold gauge (1). 11. After charging, close low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8), and stop the engine.

T5-7-40

9 8

W115-02-10-007

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT: If the air conditioner is operated with very low refrigerant, a bad load will be exerted on the compressor. If the air conditioner is overcharged with refrigerant, cooling efficiency will lower and abnormal high pressure will arise in the air conditioner circuit, causing danger. 12. Start the engine and operate the air conditioner again. Check that cold air blow out from the vents. Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool When attempting to disconnect the dCAUTION: high-pressure-side charge hose, refrigerant and compressor oil may spout. Disconnect the highpressure side charge hose after the high-pressure side pressure drops to less than 980 kPa (10 kgf/ cm2, 142 psi). 13. After checking refrigerant quantity, disconnect the low-pressure-side charge hose first. Disconnect the low-pressure-side charge hose. Wait for the high-pressure-side pressure to drop to less than 980 kPa (10 kgf/cm2, 142 psi). Disconnect the high-pressure-side charge hose.

T5-7-41

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Warm-up Operation After charting the air conditioner, carry out warmup operation five minute to lubricate system with compressor oil. Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool Inspection After warm-up operation, carry out gas leak check and performance check. Refrigerant will produce poisonous dCAUTION: material if exposed to heat of 1000°C (1832°F) or more. Never bring refrigerant close to a fire. 1. Check the air conditioner for gas leaks using a leak tester.  Perform checking under well-ventilated conditions.  Thoroughly wipe off dust from the charge hose connections of the compressor.  Pay special attention to check the line connections.  If any gas leaks are found, retighten the line connections. 2. Performance Check. Carry out performance check of the air conditioner after checking each air conditioner component.

W115-02-10-013

 Check each component for abnormalities.  Carry out ON-OFF check of the compressor clutch.  Check compressor fan belt tension.  Check the coolant level in the radiator.  Operate the air conditioner and check the performance.

W115-02-10-014

T5-7-42

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 3. The checklist before the summer season is as follows:  Check each air conditioner component for abnormalities.  Check the line connections for oil leaks.  Check refrigerant quantity.  Check the engine cooling circuit.  Check V belt for wear. Replace if necessary.  Check for clogged condenser. 4. Off-Season Maintenance  During off-season, operate the idler pulley and compressor at least once a month for a short time to check for any abnormal sounds.  Do not remove the compressor belts during offseason. Operate the compressor occasionally at slow speed for 5 to 10 minutes with the belt slightly loosened in order to lubricate the machine parts.

fNOTE: When the machine is in normal and the air

conditioner is operated with the following conditions, air vent temperature decrease approx. 20°C (68°F) or less. (It may be different under special environment.)

Operating Conditions of the Air Conditioner  Engine Speed: High Idle  Cab Window: Fully closed  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh / re-circulated air selection: Re-circulated Air  Season: Summer

T5-7-43

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Hose and Pipe Tightening Torque

Use the following tightening torque values when connecting the pipes. Joint Location Nut type (Fig. A)

Block joint (Fig. B)

Tube or Bolt Size Tightening Torque N·m (kgf·m) (lbf·ft) Pipe with dia. 8 11.8 to 14.7 (1.2 to 1.5) (8.7 to 10.8) Pipe with D1/2 19.6 to 24.5 (2.0 to 2.5) (14.5 to 18.1) Pipe with D5/8 29.4 to 34.3 (3.0 to 3.5) (21.7 to 25.3) Receiver M6 Bolt 4.0 to 6.8 (4T) (0.4 to 0.7) (3.0 to 5.0) M6 Bolt (6T) 7.9 to 11.8 for other than (0.8 to 1.2) Receiver (5.8 to 8.7)

TDAA-05-07-016 B

TDAA-05-07-017

T5-7-44

INDEX 111000 to 111002...................................................................T5-5-80 111003........................................................................................T5-5-80 111006, 111007, ......................................................................T5-5-83 111008........................................................................................T5-5-88 111009........................................................................................T5-5-83 111010........................................................................................T5-5-88 111012........................................................................................T5-5-83 111013, 111014 .......................................................................T5-5-88 111015........................................................................................T5-5-83 111016........................................................................................T5-5-88 111017........................................................................................T5-5-83 111018........................................................................................T5-5-88 111019........................................................................................T5-5-83 111020, 111021 .......................................................................T5-5-88 111024........................................................................................T5-5-83 111025........................................................................................T5-5-88 111026........................................................................................T5-5-88 111103........................................................................................T5-5-93 111105, 111106 .......................................................................T5-5-93 111200..................................................................................... T5-5-101 111202, 111203 .................................................................... T5-5-101 111204..................................................................................... T5-5-102 111205..................................................................................... T5-5-100 111206..................................................................................... T5-5-103 111207..................................................................................... T5-5-100 111208..................................................................................... T5-5-104 111210 to 111212................................................................ T5-5-107 111214, 111215 .................................................................... T5-5-108 111217..................................................................................... T5-5-103 111309, 111310 .................................................................... T5-5-109 111312..................................................................................... T5-5-102 111313..................................................................................... T5-5-105 111407..................................................................................... T5-5-110 111408..................................................................................... T5-5-117 111410..................................................................................... T5-5-111 111411..................................................................................... T5-5-112 111412..................................................................................... T5-5-113 111413..................................................................................... T5-5-114 111414 to 111421................................................................ T5-5-115 111422..................................................................................... T5-5-118 111423..................................................................................... T5-5-119 111502 to 111504................................................................ T5-5-120 111506, 111507 .................................................................... T5-5-120 111600 to 111602................................................................ T5-5-106 111700 to 111704................................................................ T5-5-121 111900..................................................................................... T5-5-123 111901..................................................................................... T5-5-124 111903..................................................................................... T5-5-125 111906, 111907 .................................................................... T5-5-126 113002, 113003 .......................................................................T5-5-84 113004........................................................................................T5-5-89 113005........................................................................................T5-5-84 113006, 113007 .......................................................................T5-5-89 113010........................................................................................T5-5-84 113011........................................................................................T5-5-89 113311..................................................................................... T5-5-130

115001..................................................................................... T5-5-129 120000 to 120005................................................................ T5-5-128 120014..................................................................................... T5-5-127 120101 to 120104................................................................ T5-5-127 120106..................................................................................... T5-5-127 120300..................................................................................... T5-5-130 120500 to 120507................................................................ T5-5-132 24-Volt Circuit ..........................................................................T5-1-16 5-Volt Circuit.............................................................................T5-1-22 A Accessory Pump......................................................................T5-4-17 Accumulator Charge Time, Service Brake ......................T4-5-21 Accumulator Pressure, Service Brake ..............................T4-5-21 Aftertreatment Device Auto Regeneration...................T5-2-36 Aftertreatment Device Auto Regeneration Stop ........T5-2-36 Aftertreatment Device Manual Regeneration (Forcible) ..............................................................................T5-2-36 Aftertreatment Device No. ..................................................T5-2-37 Aftertreatment Device Serial No., Rewrite ...................... T4-6-1 Aftertreatment Device/Air Cleaner ..................................T5-4-15 Air Bleeding Procedures for Brake (Axle) .................... T5-6-102 Air Bleeding from the Defrosting Piping .......................T5-2-36 Air Conditioner, Component Layout ................................. T5-7-2 Air Conditioner, Outline ........................................................ T5-7-1 Air Conditioner Controller Fault Code List ...T5-5-46, T5-7-10 Air Conditioner Controller Fault Codes 11 to 22 ............................................................. T5-5-133, T5-7-11 43 to 92 ............................................................. T5-5-134, T5-7-12 Air Conditioner Switch Panel ............................................... T5-4-8 Alarm, List..................................................................................T5-2-18 All Actuator System Troubleshooting ............T5-6-30, T5-6-54 Alternator Check .....................................................................T5-1-14 Auto Brake Solenoid Valve .................................................... T4-5-5 Axle Oil Temperature Sensor, Specification ............... T5-5-126 B Battery Voltage Check ..........................................................T5-1-13 Bell Crank Stopper Clearance............................................... T4-4-8 Blower motor does not operate. .......................................T5-7-30 Brake (Axle), Air Bleeding ................................................. T5-6-102 Brake Accumulator Pressure ..............................................T4-5-20 Brake Charge Valve ................................................................T5-4-20 Brake Function Check, Parking ............................................ T4-4-7 Brake Function Check, Service............................................. T4-4-4 Brake Manifold Valve .............................................................T5-4-20 Brake System Troubleshooting.........................T5-6-42, T5-6-83 Brake Warning Pressure (Pressure-Decreasing) ...........T4-5-22 Brake Warning Pressure (Pressure-Increasing).............T4-5-24 Brake Wear Amount, Service ................................................ T4-4-6 Bucket Levelness ....................................................................T4-4-13 Bucket Stopper Clearance ..................................................... T4-4-8 C CAN1 Harness Check .............................................................T5-5-85 CAN2 Harness Check ............................................................T5-5-90 CAN3 Harness Check ............................................................T5-5-94 95Z7B

INDEX CAN4 Harness Check ............................................................T5-5-97 Charge Air Conditioner with Refrigerant .......................T5-7-36 Check by False Signal ............................................................T5-1-23 Column Display Controller Fault Code 115001 ........ T5-5-129 Column Display Controller Fault Code List ...................T5-5-38 Column Display Controller Fault Codes 120500 to 120507 .......................................................... T5-5-131 Combination Valve.................................................................T5-4-20 Communication System......................................................... T5-3-7 Communication Terminal Status ......................................T5-2-22 Communication Terminal Status, List .............................T5-2-23 Compressor clutch does not operate..............................T5-7-31 Compressor Oil, Refill ............................................................T5-7-35 Continuity Check ....................................................................T5-1-15 Control Lever Operating Force ..........................................T4-4-14 Control Lever Stroke ..............................................................T4-4-16 Control Valve, Multiple .........................................................T5-4-19 Controller .................................................................................... T5-4-6 Controller Version...................................................................T5-2-16 Coolant Temperature Gauge ..............................................T5-2-42 Cooling circuit check by using manifold gauge ..........T5-7-32 Correlation between Trouble Symptom and Part Failures .........................................................................T5-6-27 Current Measurement ..........................................................T5-1-16 Cylinder Drift Check ..............................................................T4-4-12 D Daily Report Data, List ............................................................ T5-3-2 DCU Fault Code List ...............................................................T5-5-76 DEF/AdBlue Level Gauge.....................................................T5-2-41 Diagnosing Procedure, Introduction................................. T5-1-1 Diagnosis, Contents ................................................................. T5-6-2 Diagnosis Procedure ............................................................... T5-1-2 Digging Position Adjustment ............................................T5-2-32 Disconnecting Connectors ................................................... T5-1-8 E e-Service, Outline ..................................................................... T5-3-1 ECM Fault Code List ...............................................................T5-5-48 Electric Component Layout (Overview) ........................... T5-4-4 Electric System Inspection .................................................... T5-1-5 Electrical System (Around Fuel Tank) ..............................T5-4-13 Electrical System (Around Hydraulic Oil Tank) .............T5-4-12 Electrical System (Cab) ........................................................... T5-4-5 Electrical System (Relays) ....................................................T5-4-11 Engine.........................................................................................T5-4-14 Engine Fault Code Clear .......................................................T5-2-36 Engine Output Restriction Suspend ................................T5-2-38 Engine Setting .........................................................................T5-2-34 Engine Setting Item, List ......................................................T5-2-35 Engine Speed ............................................................................. T4-3-1 Engine System Troubleshooting ......................T5-6-28, T5-6-47 Engine Tachometer ................................................................T5-2-40 Engine Test .................................................................................. T4-3-1 Exchange Inspection .......................................................... T5-6-101

F Fault Code, Troubleshooting ................................................ T5-5-1 Fault Code Clear, Engine ......................................................T5-2-36 Fault Code List, A/C Controller...........................................T5-5-46 Fault Code List, Column Display Controller ..................T5-5-38 Fault Code List, DCU (SCR) ..................................................T5-5-76 Fault Code List, ECM ..............................................................T5-5-48 Fault Code List, JCU (Stick Steering) ................................T5-5-40 Fault Code List, MC ................................................................T5-5-12 Fault Code List, MPDr. ............................................................. T5-5-3 Fault Code List, Monitor Controller (Monitor) ..............T5-5-37 Fault Code List, SC ..................................................................T5-5-26 Faulty cooling ..........................................................................T5-7-14 Faulty heating ..........................................................................T5-7-24 Flow Regulator Valve .............................................................T5-4-21 Frequency Distribution Data, List ....................................... T5-3-4 Front Attachment System Troubleshooting ................................................................................T5-6-33, T5-6-59 Fuel Level Sensor Specifications .................................... T5-5-131 Functions of Main Parts, Air Conditioner, ........................ T5-7-4 Fuse Box A .................................................................................T5-1-11 Fuse Box B .................................................................................T5-1-11 Fuse Inspection .......................................................................T5-1-10 Fusible Link Inspection.........................................................T5-1-12 H Hose Tightening Torque.......................................................T5-7-44 Hydraulic Cylinder Cycle Time ...........................................T4-4-10 Hydraulic Oil Temperature Sensor, Specification ..... T5-5-124 Hydraulic Pump ......................................................................T5-4-16 I Inspection .................................................................................T5-7-42 Issued Warning Record .........................................................T5-2-17 J JCU Fault Code List ................................................................T5-5-40 Joystick Steering Controls (Option) ................................... T5-4-8 L Lever Stopper Clearance........................................................ T4-4-8 Lift Arm Angle Sensor Learning ........................................T5-2-30 Loading Circuit Main Relief Set Pressure ......................... T4-5-8 Loading Overload Relief Valve Set Pressure .................T4-5-13 M Machine Performance Test.................................................... T4-4-1 Machine Setting......................................................................T5-2-24 Machine Setting Item, List ..................................................T5-2-25 Main Component (Overview) .............................................. T5-4-1 Main Pump................................................................................T5-4-16 Main Pump Delivery Pressure .............................................. T4-5-7 Main Relief Set Pressure, Loading Circuit......................... T4-5-8 Main Relief Set Pressure, Steering Circuit ......................T4-5-10 Main Relief Valve Pressure Adjustment Procedure....... T4-5-9

95Z7B

INDEX MC Fault Code 111003 ..................................................................................T5-5-80 111313 ............................................................................... T5-5-105 111408 ............................................................................... T5-5-117 111413 ............................................................................... T5-5-114 111414 to 111421 .......................................................... T5-5-115 111903 ............................................................................... T5-5-125 111000 to 111002 .............................................................T5-5-80 111006, 111007, 111009, 111012................................T5-5-83 111008, 111010, 111013, 111014, 111025...............T5-5-88 111103, 111105, 111106 ................................................T5-5-93 111204, 111312 .............................................................. T5-5-102 111210 to 111212 .......................................................... T5-5-107 111214, 111215 .............................................................. T5-5-108 111502 to 111504, 111506, 111507 ........................ T5-5-120 111600 to 111602 .......................................................... T5-5-106 111700 to 111704 .......................................................... T5-5-121 120014, 120101 to 120104, 120106 ........................ T5-5-127 MC Fault Code List .................................................................T5-5-12 Monitor ........................................................................................ T5-4-9 Monitor, Outline........................................................................ T5-2-1 Monitor Controller (Information) Fault Code 113311 ............................................................................... T5-5-130 Monitor Controller (Monitor) Fault Code 113002, 113003, 113005, 113010................................T5-5-84 113004, 113006, 113007, 113011................................T5-5-89 120300 ............................................................................... T5-5-130 Monitor Controller (Monitor) Fault Code List ...............T5-5-37 Monitor Panel ..........................................................................T5-4-10 Monitoring .................................................................................. T5-2-6 Monitoring Item, List............................................................... T5-2-8 MPDr. Fault Code List .............................................................. T5-5-3 Multi-Function Monitor.......................................................... T5-4-8 Multiple Control Valve ..........................................................T5-4-19 N Necessity of Purging..............................................................T5-7-36 Number of Brake Pedal Applications ..............................T4-5-21 O Operation Data, List ................................................................. T5-3-2 Operational Performance Standard Table ....................... T4-2-1 Operational Performance Tests ........................................... T4-1-1 Other System Troubleshooting ........................T5-6-43, T5-6-87 Overload Relief Valve Set Pressure ...................................T4-5-13 P Parallel/Tandem Switching Solenoid Valve ..................... T4-5-4 Parking Brake Function Check ............................................. T4-4-7 Parking Brake Pressure .........................................................T4-5-18 Pilot Pressure, Steering Circuit ...........................................T4-5-12 Pipe Tightening Torque ........................................................T5-7-44 Precautions for Inspection and Maintenance ................ T5-1-6 Preparation for Performance Tests ..................................... T4-1-2 Primary Pilot Pressure ............................................................. T4-5-1 Pump Delivery Pressure ......................................................... T4-5-7

R Refill Compressor Oil .............................................................T5-7-35 Refrigerant, Charge Air Conditioner ................................T5-7-36 Relationship between Machine Trouble Symptom and Related Parts ......................................................................... T5-6-3 Relays ............................................................................................ T5-4-6 Rewrite of Aftertreatment Device Serial No. .................. T4-6-1 Ride Control Valve (Option) ................................................T5-4-21 Right Console............................................................................. T5-4-7 S SC Fault Code 111000 to 111002 .............................................................T5-5-80 111003 ..................................................................................T5-5-80 111015, 111017, 111019, 111024................................T5-5-83 SC Fault Code 111016, 111018, 111020, 111021, 111026...............T5-5-88 111200, 111202, 111203 ............................................. T5-5-101 111205, 111207 .............................................................. T5-5-100 111206, 111217 .............................................................. T5-5-103 111208 ............................................................................... T5-5-104 111309, 111310 .............................................................. T5-5-109 111407 ............................................................................... T5-5-110 111410 ............................................................................... T5-5-111 111411 ............................................................................... T5-5-112 111412 ............................................................................... T5-5-113 111422 ............................................................................... T5-5-118 111423 ............................................................................... T5-5-119 111900 ............................................................................... T5-5-123 111901 ............................................................................... T5-5-124 111906, 111907 .............................................................. T5-5-126 120000 to 120005 .......................................................... T5-5-128 SC Fault Code List ...................................................................T5-5-26 Secondary Pilot Pressure ....................................................... T4-5-3 Secondary Steering Group (Option) ................................T5-4-22 Secondary Steering Pump (Option) ................................T5-4-22 Sensor Activating Range .....................................................T4-2-10 Service Brake Function Check.............................................. T4-4-4 Service Brake Pressure (Front and Rear) .........................T4-5-16 Service Brake Wear Amount ................................................. T4-4-6 Service Menu, How to Display ............................................. T5-2-3 Service Menu, Operating Procedures ............................... T5-2-2 Snapshot Data ........................................................................... T5-3-6 Solenoid Valve Adjustment Procedure ............................. T4-5-6 Solenoid Valve Set Pressure .................................................. T4-5-4 Specification Axle Oil Temperature Sensor ..................................... T5-5-126 Fuel Level Sensor ........................................................... T5-5-131 Hydraulic Oil Temperature Sensor ........................... T5-5-124 Transmission Oil Temperature Sensor .................... T5-5-123 Transmission Oil Temperature Sensor .................... T5-5-125 Standard Table, Operational Performance ...................... T4-2-1 Steering Circuit Main Relief Set Pressure .......................T4-5-10 Steering Circuit Pilot Pressure............................................T4-5-12 Steering Overload Relief Valve Set Pressure .................T4-5-13

95Z7B

INDEX Steering Relief Valve Pressure Adjustment Procedure ............................................................................T4-5-11 Steering System Troubleshooting ...................T5-6-37, T5-6-69 Steering Valve ..........................................................................T5-4-21 Surge Suppression Diodes ..................................................T5-1-26 Surge Voltage Diodes............................................................T5-1-26 Switches ....................................................................................... T5-4-9 T Test Harness..............................................................................T5-1-24 Torque Converter Assembly ...............................................T5-4-18 Torque Converter Pressure..................................................T4-5-28 Total Operating Hours, List ................................................... T5-3-5 Transmission Assembly ........................................................T5-4-18 Transmission Clutch Pack Combination .........................T4-5-27 Transmission Clutch Pressure ............................................T4-5-26 Transmission Learning..........................................................T5-2-26 Transmission Oil Temperature Gauge .............................T5-2-41 Transmission Oil Temperature Sensor Specification .................................................T5-5-123, T5-5-125 Travel Speed ............................................................................... T4-4-1 Travel System Troubleshooting ........................T5-6-39, T5-6-73 Troubleshooting ....................................................................... T5-2-4 Troubleshooting, Air Conditioner....................................... T5-7-9 Troubleshooting By Using Fault Codes ............................ T5-5-1 Troubleshooting by Machine Symptom .......................... T5-6-1 U Unloader Valve ........................................................................T5-4-20 Unloader Valve Setting Pressure ......................................... T4-5-1 V Voltage Measurement ..........................................................T5-1-16 W Warm-up Operation ..............................................................T5-7-42 Work after Replacing Components..................................T5-7-34

95Z7B