Kawasaki WHEEL LOADER 45ZV-2 SHOP MANUAL 93204-00090 (1) by www.heydownloads.com

45ZV-2

93204-00090 November 2010

SHOP MANUAL

- Troubleshooting

WHEEL LOADER

45ZV-2 Technical Manual - Troubleshooting

Printed in Japan (k) ( アメリカ用 )

93204-00090

TECHNICAL MANUAL (Troubleshooting) INTRODUCTION........................................................................................................................... IN-01~02 SAFETY ............................................................................................................................................S-1~34 SECTION 4

OPERATIONAL PERFORMANCE TEST...............................................................4FGET-4

Group 1

Introduction ................................................................................................................ T4-1

Group 2

Standard ..................................................................................................................... T4-2

Group 3

Engine Test................................................................................................................. T4-3

Group 4

Wheel Loader Test ..................................................................................................... T4-4

Group 5

Component Test ......................................................................................................... T4-5

Group 6

Adjustment ................................................................................................................. T4-6

SECTION 5 TROUBLESHOOTING............................................................................................4FGET-5 Group 1

Diagnosing Procedure ............................................................................................... T5-1

Group 2

Component Layout..................................................................................................... T5-2

Group 3

Troubleshooting A ...................................................................................................... T5-3

Group 4

Troubleshooting B ...................................................................................................... T5-4

Group 5

Troubleshooting C...................................................................................................... T5-5

Group 6

Electrical System Inspection ...................................................................................... T5-6

TECHNICAL MANUAL (Operational Principle) (P/N 93204-00080) is separately available. It consists of the following sections: SECTION 1 GENERAL Group 1 Specifications Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Priority Valve Group 2 Control Valve Group 3 Steering Valve

Group 4 Group 5 Group 6 Group 7 Group 8 Group 9

HST Pump HST Motor Reduction Axle Brake Master Cylinder Others

ATTACHMENT DIAGRAMS Rear Harness Front Harness Main Harness Electrical Circuit Diagram Hydraulic Circuit Diagram

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.

45ZV-2

INTRODUCTION TO THE READER • This manual is written for an experienced technician 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 (operator’s manual, parts catalog, etc.) in addition to this manual.

MANUAL COMPOSITION • This manual consists the Technical Manual and the Workshop Manual. • Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

• 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 assemble/disassemble 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 : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

IN-01

INTRODUCTION SAFETY ALERT SYMBOL HEADLINE NOTATIONS

AND

In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this 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.

•

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

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

•

NOTE: Indicates supplementary technical information or know-how.

UNITS USED • SI Units (International System of Units) are used in

Example : 24.5 MPa (250 kgf/cm , 3560 psi)

this manual. MKSA system of units and English units are also indicated in parentheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L 3 m kg N N N⋅m N⋅m

Into in ft US gal US qt 3 yd lb kgf lbf kgf⋅m lbf⋅ft

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

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-02

To Convert From MPa MPa kW kW °C km/h -1 min L/min mL/rev

Into

Multiply By 2

kgf/cm psi PS HP °F mph rpm US gpm cc/rev

10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in operator’s manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices.

001-E01A-0001 SA-688

UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. • DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. • WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. • CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. • DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. • Some safety signs don’t use any of the designated signal words above after the safety alert symbol has been used on this machine.

• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

•

SA-1223

NOTE indicates an additional explanation for an element of information. 002-E01A-1223

S-1

SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in operator’s manual. • Safety signs should be installed, maintained and replaced when necessary. • If a safety sign or operator’s manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). • Learn how to operate the machine and its controls correctly and safely. • Allow only trained, qualified, authorized personnel to operate the machine. • Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life. • Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Kawasaki Warranty Policy. • Do not use attachments and/or optional parts or equipment not authorized by Kawasaki. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Kawasaki Warranty Policy. • The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

SA-003

003-E01B-0003

S-2

SAFETY PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire-extinguisher manual. • Establish emergency procedure guidelines to cope with fires and accidents. • Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

004-E01A-0437

WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask.

SA-438

Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438

S-3

SAFETY PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

006-E01A-0434

INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. • In the walk-around inspection be sure to cover all points described in the “INSPECT MACHINE DAILY BEFORE STARTING” section in the operator’s manual.

SA-435 007-E01A-0435

S-4

SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any control such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. • Do not leave parts and/or tools lying around the operator’s seat. Store them in their specified locations. • Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. • Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine. • Keep all flammable objects and/or explosives away from the machine. • After using the ashtray, always cover it to extinguish the match and/or tobacco. • Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

524-E01A-0000

USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. SA-439 008-E01A-0439

S-5

SAFETY ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to miss-operations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. • If not, move the seat forward or backward, and check again. • Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

SA-462

009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT • Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the loader control lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death. • Before leaving the machine, be sure to first lower the front attachment to the ground and then move the loader control lever to the LOCK position. Turn the key switch OFF to stop the engine. • Before leaving the machine, close all windows, doors, and access covers and lock them up.

S-6

SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. • Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. • We recommend that the seat belt be replaced every three years regardless of its apparent condition.

SA-237

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine. • Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. • Use a signal person when moving, or operating the machine in congested areas. Coordinate hand signals before starting the machine. • Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.

SA-398

011-E01A-0398

S-7

SAFETY HANDLE STARTING AIDS SAFELY Starting fluid:

• Starting fluid is highly flammable. • Keep all sparks and flame away when using it. • Keep starting fluid well away from batteries and cables.

• Remove container from machine if engine does not need starting fluid. • To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location. • Do not incinerate or puncture a starting fluid container.

SA-293

036-E01A-0293-3

OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the tire or on ground. • Do not start engine by shorting across starter terminals. • Before starting the engine, confirm that all control levers are in neutral. • Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-431

012-E01B-0431

S-8

SAFETY JUMP-STARTING • Battery gas can explode, resulting in serious injury. • If the engine must be jump-started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual. • The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump-starting is a two-person operation. • Never use a frozen battery. • Failure to follow correct jump-starting procedures could result in a battery explosion or a runaway machine.

SA-032

S013-E01A-0032

INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. • Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing. • Make a work plan. Use machines appropriate to the work and job site. • Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders. • When working on an incline or on a road shoulder, employ a signal person as required. • Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist. • When the footing is weak, reinforce the ground before starting work. • When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery. • Beware of the possibility of fire when operating the machine near flammable objects such as dry grass.

SA-447

015-E01B0447

S-9

SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

SA-521

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481 SA-481

S-10

SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

SA-427

014-E01B-0427

DRIVE SAFELY • Beware of the possibility of slipping and/or turning over the machine when driving on a slope. • When driving on level ground, hold the bucket at mark (A) 300 to 400 mm (12 to 16 in) above the ground as illustrated. • Avoid driving over any obstacles. • Drive the machine slowly when driving on rough terrain. • Avoid quick direction changes. Failure to do so may cause the machine to turn over. • If the engine stops while driving, the steering function becomes inoperative. Immediately stop the machine by applying the bake to prevent personal accident.

• • Even though the machine is equipped with the emergency steering system, if the steering function becomes inoperable during drive operation, press the emergency steering check switch on the right console to activate the emergency steering system. Then, immediately park and stop the machine in a safe location.

• 019-E07A-0448

S-11

SA-44

SAFETY DRIVE MACHINE SAFELY (WORK SITE) • Before driving the machine, always confirm that the steering wheel/ forward/reverse lever direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions.

• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. • When driving up or down a slope, keep the bucket facing the direction of travel, approximately 300 to 400 mm (approximately 12 to 16 in) (A) above the ground. • If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

SA-449

• Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-450

019-E05B-0515

SA-451

DRIVE SAFELY WITH BUCKET LOADED • If the machine is operated incorrectly while driving with the bucket loaded, the machine may turn over. Be sure to follow all of the instructions indicated below. • When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility. • Do not exceed the rated load capacity. Always operate the machine within the rated load capacity. • Avoid fast starts, stops, and quick turns. Failure to do so may result in personal injury and/or death. • Avoid rapid drive direction changes which could possibly cause personal injury and/or death.

S-12

SA-400

SAFETY DRIVE ON SNOW SAFELY • Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces. • The machine may slip more easily than expected on frozen snow surfaces even if the incline is small. Reduce speed when driving. Avoid fast starts, stops and quick turns. • Road shoulder and/or set-up utilities covered with snow are difficult to locate. Be sure where they are before removing snow. • Be sure to use tire chains when driving on snow. • Avoid applying the brake for quick stops on snow. If a quick stop is required, lower the bucket to the ground.

SA-452

052-E02A-0452

TRAVEL ON PUBLIC ROADS SAFELY • This machine is not allowed to drive on public loads with the bucket loaded. • Be sure to empty the bucket. • Hold the bucket at mark (A) 300 to 400 mm (12 to 16 in) above the road surface as illustrated. • Even though the machine is equipped with the emergency steering system, if the steering function becomes inoperable during operation, press the emergency steering check switch on the right console to activate the emergency steering system. Then, immediately park and stop the machine in a safe location.

053-E02A-0453

S-13

SA-453

SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollways: • Select level ground when possible to park machine. • Do not park the machine on a grade. • Lower the bucket to the ground. • Place the forward/reverse lever (switch) in neutral, and pull up the park brake switch (lever) in the ON (parking brake) position. • Run the engine at low idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the lock lever to LOCK position. • Block both tires and lower the bucket to the ground. • Position the machine to prevent rolling. • Park a reasonable distance from other machines.

020-E02A-0516

S-14

SA-457

SA-458

SAFETY AVOID ACCIDENTS FROM BACKING UP AND TURNING • Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine. • Keep all personnel away from the machine by sounding the horn and/or using hand signals. Use extra care to be sure no one is in from the articulation area before turning the machine. • Keep windows, mirrors, and lights in good condition. • Reduce travel speed when dust, heavy rain, fog, etc., reduce the visibility. • In case good visibility is not obtained, use a signal person to guide you.

SA-383

021-E02A-0517

SA-312

AVOID POSITIONING ANYONE

BUCKET

OVER

• Never allow the bucket to pass over co-workers and/or the dump truck operator’s cab. Falling material from the bucket or contact with bucket may cause serious personal accidents and/or damage to the machine. • Avoid carrying the bucket over the co-workers to ensure safe operation.

023-E02A-0518

S-15

SA-518

SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE MACHINE IS PREDICTED, SECURELY HOLD THE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: • Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine. • Reduce operating speeds to avoid tipping or slipping. • Avoid changing direction when traveling on grades. • NEVER attempt to travel across a grade steeper than 5 degrees if crossing the grade is unavoidable. • Reduce speed as necessary when swinging loads.

SA-463

• Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable.

NEVER UNDERCUT A HIGH BANK • The edges could collapse or a landslide could occur causing serious injury or death.

026-E01A-0519

SA-519

S-16

SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. • Before digging, check the location of cables, gas lines, and water lines. • Keep the minimum distance required by law, from cables, gas lines, and water lines. • If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury. • Contact your local “diggers hot line” if available in your area, and/or the utility companies directly. Have them mark all underground utilities.

SA-396

027-E01A-0396

PERFORM TRUCK LOADING SAFELY • Do not operate the machine involuntarily. Unexpected machine movement may cause personal injury and/or death. • Do not lower the bucket with the loader control lever in the FLOAT position. The bucket may free fall, possibly causing personal injury and/or death. • Always select a level surface for truck loading.

028-E01A-397 SA-397

AVOID POWER LINES Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length. 29-E01A-0455 SA-455

S-17

SAFETY PRECAUTIONS FOR OPERATION • If the front attachment or any part of the machine comes in contact with an overhead obstacle, both the machine and the overhead obstacle may become damaged, and personal injury may result. • Take care to avoid coming in contact with overhead obstacles with the bucket or arm during operation.

PRECAUTIONS FOR LIGHTENING • The machine is vulnerable to lighting strikes. • In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine. • After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them. SA-4EK-020

S-18

SAFETY OBJECT HANDLING • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. • When using the machine for craning operations, be sure to comply with all local regulations. • Do not use damaged chains or frayed cables, sables, slings, or ropes. • Before craning, position the upper structure with the position of the bucket support located on the chassis at the front. • Move the load slowly and carefully. Never it suddenly. • Keep all persons well away from the load. • Never move a load over a person’s head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground. • Never attach a sling or chain to the bucket teeth or to the attachment. They may come off, causing the load to fall.

SA-132

032-E01A-0132

PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object.

031-E01A-0432

SA-432

S-19

SAFETY PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Place the forward/reverse lever (switch) in neutral, and turn the parking brake switch (lever) in the ON (parking brake) position. • Run engine at low idle speed without load for 3 minutes. • Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Lower the lock lever to the LOCK position. • Close windows, roof vent, and cab door. • Lock all access doors and compartments.

SA-456

033-E07B-0456

STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. • Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

504-E01A-0034

SA-034

S-20

SAFETY TRANSPORT SAFELY • Be careful because machine may turn over when loading or unloading the machine on or off of a truck or trailer. • Observe the related regulations and rules for safe transportation. • Select an appropriate truck or trailer for the machine to be transported. • Be sure to use a signal person. • Always follow the following precautions for loading or unloading: 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the machine weight. 3. Use a low speed gear. 4. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again. 5. After loading, install the lock bar to securely hold the articulation mechanism. 6. Chock the front and rear of tires. Securely hold the machine to the truck or trailer deck with heavy chains or wire cables. Be sure to further follow the details described in the TRANSPORTING section.

035-E07A-0454

S-21

Less than 15°

SA-454

SAFETY HANDLE FLUIDS SAFELY-AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks. • Always stop the engine before refueling the machine. • Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are flammable. • Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously. • Securely tighten the fuel and oil filler caps.

SA-018

034-E01A-0496 SA-019

S-22

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. • Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 3 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times. 7. Remove the key from the switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Lower the lock lever to the LOCK position. 10. Lock bar connects the front and rear frames. 11. Allow the engine to cool.

SA-028

SA-312

• If a maintenance procedure must be performed with the engine running, do not leave machine unattended. • Never work under a machine raised by the lift arm. • Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of operator’s manual. • Keep all parts in good condition and properly installed. • Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. • When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces. • Disconnect battery ground cable (-) before making adjustments to electrical systems or before performing welding on the machine.

SA-134

500-E02C-0520 SA-527

S-23

SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine. • Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. • Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.

501-E01A-0287

SS2045102

SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. • Always lower the attachment to the ground before you work on the machine. • If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. 519-E01A-0527 SA-527

STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. 502-E01A-0026

S-24

SA-026

SAFETY SUPPORT MAINTENANCE PROPERLY • Explosive separation of a tire and rim parts can cause serious injury or death. • Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service. • Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure. • When inflating tires, use a chip-on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available. • Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts. • Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion.

SA-249

521-E02A-0249

PREVENT PARTS FROM FLYING • Travel reduction gears are under pressure. • As pieces may fly off, be sure to keep body and face away from the axle AIR RELEASE PLUG to avoid injury. • GEAR OIL is hot. Wait for GEAR OIL to cool, and then gradually loosen AIR RELEASE PLUG to release pressure. 503-E03A-0344

SA-344

S-25

SAFETY PREVENT BURNS Hot spraying fluids:

• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting any maintenance or inspection work. SA-225

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)

• Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. S506-E01A-0019

S-26

SA-019

SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. • Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection. • If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-031

507-E03A-0499

SA-292

SA-044

S-27

SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses. Check for Shorts: • Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before each shift or after eight(8) to ten(10) hours operation for loose, kinked, hardened or frayed electrical cables and wires. • Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps. • DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc. Clean up Flammables: • Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. • Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. Check Key Switch: • If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine. 508-E02B-0019

Check Heat Shields: • Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be repaired or replaced before operating the machine. 508-E02A-0393

S-28

SA-019

SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. • Exit the machine.

518-E01A-0393

SA-393

BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. 509-E01A-0016

SA-016

PRECAUTIONS GRINDING

FOR

WELDING

AND

• Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. • Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering. 523-E01A-0818

S-29

SA-818

SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. • Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING •

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. • Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2.

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

511-E01A-0029

S-30

SA-029

SAFETY BEWARE OF ASBESTOS DUST • Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. • Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air. • When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos. • Keep bystanders out of the work site during operation. • Asbestos might be present in imitation parts. Use only genuine Kawasaki Parts.

SA-029

PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery. • Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. • Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first. • Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result. • Loose terminals may produce sparks. Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. • Be sure to wear eye protection when checking electrolyte specific gravity. 512-E01B-0032

S-31

SA-032

SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the instructions described on the container for proper use when handling the refrigerant. • Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere. • Never touch the refrigerant. 513-E01A-0405

SA-405

HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. • A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. • Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment. • See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine. 515-E01A-0309

S-32

SA-309

SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Kawasaki equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. • Do not pour waste onto the ground, down a drain, or into any water source. • Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. • Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

SA-226

516-E01A-0226

BEFORE RETURNING THE MACHINE TO THE CUSTOMER •

After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced.

S517-E01A-0435 SA-435

S-33

SAFETY (Blank)

S-34

SECTION 4

OPERATIONAL PERFORMANCE TEST ―CONTENTS― Group 1 Introduction

Group 5 Component Test

Operational Performance Tests ................... T4-1-1

Main Pump Delivery Pressure......................T4-5-1

Preparation for Performance Tests .............. T4-1-2

HST Pump Delivery Pressure ......................T4-5-2 HST Charging Pump Delivery Pressure.......T4-5-3

Group 2 Standard

Main Relief Pressure ....................................T4-5-4

Operational Performance

HST Pump Relief Pressure ..........................T4-5-6

Standard Table ........................................... T4-2-1

Steering Relief Pressure...............................T4-5-7 Overload Relief Pressure .............................T4-5-8

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

Group 6 Adjustment Fan Belt Tension Adjustment ........................T4-6-1

Group 4 Wheel Loader Test Travel Speed ................................................ T4-4-1 Service Brake Capacity................................ T4-4-2 Service Brake / Parking Brake Wear ........... T4-4-4 Parking Brake Capacity ............................... T4-4-6 Bucket Stopper and Bell Crank Stopper Clearance ................................................... T4-4-8 Hydraulic Cylinder Cycle Time ................... T4-4-10 Dig Function Drift Check ............................ T4-4-12 Control Lever Operating Force .................. T4-4-13 Control Lever Stroke .................................. T4-4-14

4FGET-4-1

45ZV-2

(Blank)

4FGET-4-2

45ZV-2

OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TESTS Use operational performance test procedure to quantitatively check all system and functions on the machine. Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values. 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. 3. To economically operate the machine under optimal conditions.

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. Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine. 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

45ZV-2

OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION TESTS

FOR

PERFORMANCE

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 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 200 m (approx. 650 ft), and to operate steering. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. 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 patterns. 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 piping.

T105-06-01-003

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 averages of measurements if necessary.

T4-1-2

45ZV-2

OPERATIONAL PERFORMANCE TEST / Standard OPERATIONAL PERFORMANCE STANDARD TABLE The standard performance values are listed in the table below. Refer to the Group T4-3 or later for performance test procedures.

Acceletor Pedal: Full Stroke Throttle Limit Switch: OFF High-Low Selector Switch: High ECO Mode Switch: OFF Hydraulic Oil Temperature: 50±5 °C (122±9 °F)

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:

NOTE: 1 mm=0.03937 in PERFORMANCE TEST DESIGNATION

Performance Standard

-1 ENGINE SPEED min (rpm) Slow Idle Speed (without load) Fast Idle Speed (without load) Fast Idle Speed (with steering relieved) Fast Idle Speed (with front attachment relieved)

1100±50 2350±50 2200 or more 2200 or more

VALVE CLEARANCE (IN, EX)

mm (in)

Remarks

Reference Page T4-3-1

0.13 to 0.17 (0.005 to 0.007)

RADIATOR CAP OPENING PRESSURE 2

kPa (kgf/cm , psi)

T4-2-1

49 (0.5, 7.1)

With the engine cold

45ZV-2

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION TRAVEL SPEED km/h (mph) First Gear (Forward/Reverse) Second Gear (Forward/Reverse) SERVICE BRAKE CAPACITY m (ft) SERVICE BRAKE/PARKING BRAKE mm (in) WEAR Brake Disc PARKING BRAKE CAPACITY mm (in)/5 min BUCKET STOPPER CLEARANCE mm (in) BELL CRANK STOPPER CLEARANCE mm (in) HYDRAULIC CYLINDER CYCLE TIME sec Lift Arm Raise Lift Arm Lower Lift Arm Lower (Float) Bucket Tilt Bucket Dump Steering (engine: full) DIG FUNCTION DRIFT CHECK mm (in)/15 min Lift Arm Cylinder Bucket Cylinder

Performance Standard

Remarks

Reference Page T4-4-1

7.0 (4.3)/7.0±1.0 (4.3±0.6) 13.0 (8.1)/13.0±1.5 (8.1±0.9) 5 (16.4) or less

4.5 to 2.6 (0.18 to 0.10) 0 4 (0.16) or less 0

T4-4-2 T4-4-4 Allowable Limit: 2.6 (0.10) or more T4-4-6 T4-4-8 T4-4-8 T4-4-10

5.0±0.5 (0.20±0.02) 3.5±0.4 (0.14±0.015) 3.0 (0.12) 1.3±0.3 (0.05±0.01) 1.0±0.3 (0.04±0.01) 2.1 (0.08) T4-4-12 8 (0.31) or less 8 (0.31) or less

T4-2-2

45ZV-2

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION

Performance Standard

CONTROL LEVER OPERATING FORCE

Remarks

Reference Page T4-4-14

N (kgf, lbf)

Lift Arm Raise Lift Arm Lower Lift Arm Lower Float Lift Arm Lower Float Release Bucket Lever Tilt Bucket Lever Dump Steering Wheel (Right/Left) FNR Lever (F/R) Accelerator Pedal

24.5 (2.4, 5.5) or less 24.5 (2.4, 5.5) or less 44.1 (4.4, 9.9) or less 17.7 (1.7, 4.0) or less 24.5 (2.4, 5.5) or less 24.5 (2.4, 5.5) or less 13.1±3.3 (1.3±0.3, 2.9±0.7) 9.8 (0.9,2.2)/9.8 (0.9, 2.2) 98 (9.8, 22) or less

T4-2-3

45ZV-2

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION CONTROL LEVER STROKE mm (in) Lift Arm Raise Position Lift Arm Lower Position Lift Arm Lower Float Position Bucket Lever Tilt Position Bucket Lever Dump Position Steering Wheel Rotation (Right Max. to Left Max.) Forward/Reverse Lever (F/R) Accelerator Pedal Depressing Angle (without play) Brake Pedal (Right/Left) Depressing Angle (without play) Steering Wheel Play Brake Pedal Play ELECTROLYTE DENSITY (Specification at 20 °C) TIRE INFLATION kPa (kgf/cm2, psi)

Performance Standard

Remarks

Reference Page T4-4-14

70 (2.76) 70 (2.76) 110 (4.33) 50 (1.97) 50 (1.97) 4.7 rev 40 (1.57)/40 (1.57) 30° 38° 20 to 40 (0.79 to 1.57) 10 (0.39) 1.26 240 (2.4, 35)

T4-2-4

Allowable Limit: 1.16

Tire Size: 17.5-65-20-1PR (L-2)

45ZV-2

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION MAIN PUMP DELIVERY PRESSURE 2

MPa (kgf/cm , psi)

HST PUMP DELIVERY PRESSURE 2

MPa (kgf/cm , psi)

HST CHARGE PUMP DELIVERY PRESSURE 2

MPa (kgf/cm , psi)

Performance Standard

Remarks

Reference Page

1.5±0.1 (15±1, 218±15) 2.5±0.1 (25±1, 363±15) 2.5±0.1 (25±1, 363±15)

In neutral

T4-5-1

MAIN RELIEF VALVE PRESSURE

T4-5-2 T4-5-3 T4-5-4

MPa (kgf/cm , psi)

Lift Arm (Relief operation)

20.6±0.5 (210±5, 2990±73) 20.6±0.5 (210±5, 2990±73) 43.7±0.5 (446±5, 6340±73)

Bucket (Relief operation) HST PUMP RELIEF PRESSURE OVERLOAD RELIEF PRESSURE (Reference values at 30 L/min) Bucket Tilt

T4-5-6 T4-5-8

MPa (kgf/cm , psi)

Bucket Dump STEERING RELIEF PRESSURE 2

MPa (kgf/cm , psi)

T4-2-5

23.6±0.5 (240±5, 3420±73) 23.6±0.5 (240±5, 3420±73) 23.6±0.5 (240±5, 3420±73)

T4-5-7

45ZV-2

OPERATIONAL PERFORMANCE TEST / Standard (Blank)

T4-2-6

45ZV-2

OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Summary: 1. Measure the engine speed by using the monitor unit. NOTE: 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 monitor of the machine, which is started on the service mode. 2. Warm up the machine until coolant temperature reaches 50°C (122°F) or more, hydraulic oil temperature is 50±5°C (122±9°F).

M4FG-01-010

T4-3-1

45ZV-2

OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: 1. Measure the items as followings: slow idle (with no load), fast idle (with no load), fast idle (when the steering is relieved), and fast idle (when the front attachment is relieved). CAUTION: Always make sure that the steering area is clear and that co-workers are out of the steering area before starting the measurement. 2. When measuring, set the switch and test condition as shown in the table below in response to the engine speed to be measured.

Slow Idle (with no load) Fast Idle (with no load) Fast Idle (when steering is relieved) Fast Idle (when front attachment is relieved)

Forward/Reverse Lever N N

Accelerator Pedal Not depressing Fully depressing

Fully depressing

Brake Pedal

Parking Brake Switch

Fully depressing

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 tilted in and relieved.

Evaluation: Refer to Operational Performance Standard in T4-2. Remedy: Refer to Troubleshooting in T5.

T4-3-2

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test TRAVEL SPEED Summary: 1. The overall performance of the travel drive system is judged by measuring the time necessary for traveling 20 m (66 ft).

6. Convert the measurement value into km/h. Measurement value (seconds) = S (sec) Converted value (hourly speed) = A (km/h) A=

Preparation: 1. Adjust air pressure of the tires evenly in advance. 2 240 kPa (2.4 kgf/cm ) at tire size 17.5/65-20-10PR (L-2) 2. On a firm, level and ground, prepare a 20 m (66 ft) straight travel course, and 70 m (230 ft) acceleration/deceleration zones. (For measurement at 2nd gear, an acceleration zone of 200 m (656 ft) is needed.) 3. Empty the bucket, and hold the lift arm at 0.3 to 0.4 m (12 in to 1 ft 4 in) above the ground. 4. Keep the hydraulic oil temperature at 50±5°C (122±9°F). Warm the axle oil by repeating travel and brake application. Warm up the engine so that the needle of the indicators of the engine coolant temperature gauge rises above the horizontal position.

20 × 3600 S × 1000

Evaluation: Refer to Operational Performance Standard in T4-2.

Remedy: Refer to Trouble Shooting in T5.

0.3 to 0.4 m (12” to 1’4”)

End

Travel Course

Acceleration Zone Start T4FG-04-04-001

Measurement: WARNING: Do not measure while in reverse , due to this being a hazard. (Forward/Reverse lever: F) 1. Measure for each mode (Speeds 1 to 2). 2. Select the pedal, switch, and forward/reverse lever as follows. High-Low Selector Parking Brake Switch Switch 1st gear Low OFF 2nd gear High OFF

Accelerator Pedal Full depression Full depression

eco Mode Switch OFF OFF

3. Set the forward/reverse lever at F (Forward) position. Start driving the machine from the acceleration zone with the accelerator pedal at full stroke. 4. Measure the travel speed (sec) of each travel mode. 5. Repeat the measurement three times and calculate the mean values.

T4-4-1

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test SERVICE BRAKE CAPACITY Summary: 1. The overall performance of the service brake is judged. 2. The braking capability of the brake is an item of safety control. Conduct the performance test correctly. Preparation: 1. Adjust air pressure of the tires evenly in advance. 2 240 kPa (2.4 kgf/cm ) at tire size 17.5/65-20-10PR (L-2) 2. On dry pavement, prepare a 350 m (1150 ft) straight travel course (a 300 m (985 ft) of acceleration/deceleration zone and a 50 m (165 ft) of measurement road), and set the brake starting point. 3. Empty the bucket, and hold the lift arm at 0.3 to 0.4 m (12 in to 1 ft 4 in) above the ground. 4. Keep hydraulic oil temperature at 50±5°C (122±9 °F). Warm the axle oil by repeating travel and brake application. Warm up the engine so that the needle of the indicators of the engine coolant temperature gauge rises above the horizontal position.

6. Repeat the measurement three times and calculate the average value. Evaluation: Refer to Operational Performance Standard in T4-2.

Remedy: Refer to Trouble Shooting in T5.

0.3 to 0.4 m (12” to 1’4”) Stopping Distance Stopping Point Brake Starting T4FG-04-04-002 Point

Measurement: WARNING: Do not measure while in reverse, due to this being a hazard. (FNR switch: F) 1. Measurement for high-speed mode. 2. Select the pedal, switch, and forward/reverse lever as follows. High-Low Selector Accelerator Parking Brake Switch Switch Pedal High (2nd gear) OFF Full depression

ECO Mode Switch OFF

3. Set the forward/reverse lever at the F (Forward) position. From the acceleration zone, travel at the maximum speed 34 km/h (21 mph) by fully depressing the accelerator pedal. 4. Depress the brake pedal at the brake starting point, and completely stop the vehicle. (Right Service Brake Pedal) Release the accelerator pedal at the same time. 5. Measure the distance from the brake starting point to the center of the front tire.

T4-4-2

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test (Blank)

T4-4-3

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test SERVICE BRAKE / PARKING BRAKE WEAR 1

Summary: Service brake disc wear at the service brake of the axle is measured by the wear gauge.

Preparation: 1. Clean inspection plug (1) on the axle. 2. Remove inspection plug (1) and washer (2). 3. Install special tool (4) for measurement. 4. Insert dial gauge (5) into special tool (4) until its end comes in contact with brake piston (3). Then, secure dial gauge (5) with set screw (6).

7 4

Measurement: 1. Start the engine. Release the parking brake. 2. Set the zero point of dial gauge (5). 3. Operate the service brake by depressing the brake pedal. Or operate the parking brake by turning the parking brake switch ON. 4. Measure the movement of brake piston (3) by using dial gauge (5) at this time.

Evaluation: 1. In case the value measured by using dial gauge (5) is beyond 2.6 mm (0.1 in), brake discs (7) have been worn in excess of allowable limit. 2. In the method above, in case the brake disc has been worn in excess of allowable limit, or in case the service brake part has been disassembled, refer to Operational Performance Standard in T4-2.

T4FG-04-04-012

5 T4FG-04-04-014

24 +0.1 (0.95+0.004)

Wrench Size 24 (0.95)

0.4

(0.35)

(0.016)

M16×2.0

30°

(0.63x0.08)

24 (0.95)

NOTE: The service brake part is located in the front axle. It is not located in the rear axle. Axle oil may drip off while loosening inspection plug (1).

8 (0.3)

6 M6×1.0 (0.24×0.04)

Unit: mm (in) T4FG-04-04-013

NOTE: 1 mm=0.03937 in

T4-4-4

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test (Blank)

T4-4-5

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test PARKING BRAKE CAPACITY Summary: 1. The function of the parking brake on a determined slope is measured. 2. The braking capability of the brake is an item of safety control. Conduct the performance test correctly.

Preparation: 1. Measure the test on a plane slope of 11.31° (20%). 2. Empty the bucket, and hold the bucket at 0.3 to 0.4 m (12 in to 1 ft 4 in) above the ground. 3. Keep hydraulic oil temperature at 50±5°C (122±9 °F). 4. Warm the axle oil by repeating travel and brake application. Warm up the engine so that the needle of the indicators of the engine coolant temperature gauge rises above the horizontal position.

Measurement: 1. Stop the machine on the slope, set the parking brake switch to the P position. 2. Stop the engine. 3. After the vehicle has stopped, put a mark (white line) on the tire and the ground surface respectively. 4. After five minutes, measure the distance between the white lines on the tire and the ground surface. 5. Repeat the measurement three times and calculate the average value.

0.3 to 0.4m

(12” to 1’4”)

11.31°(20%)

T4FG-04-04-006

Evaluation: Refer to Operational Performance Standard in T4-2.

T4-4-6

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test (Blank)

T4-4-7

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test BUCKET STOPPER AND BELL CRANK STOPPER CLEARANCES Summary: Wear and deformation conditions of the bucket stopper (dump end and tilt end) and the clearance between the bell crank stopper and the cross tube are measured.

Preparation: Stop the vehicle on flat level ground and operate the parking brake.

Measurement: 1. Bucket dump stopper 1-1. Raise the lift arm at the highest raising position. Stop the engine. 1-2. While stopping the engine, dump the bucket slowly until the bucket contacts the dump stopper. At this time, measure strokes (A, B) of the bucket cylinder and the lift arm cylinder and dump angle (C) of the bucket. In addition, measure the clearance between the bell crank stopper and the cross tube. 1-3. At the same time, measure the contact conditions of the bucket dump stoppers (left and right). 2. Bucket tilt stopper 2-1. Raise the lift arm until stroke (E) of the lift arm cylinder becomes the length of the standard dimension. 2-2. Set the engine at slow idle speed, and roll bucket back until the bucket slowly contacts the bucket stopper. 2-3. At this time, measure strokes (D, E) of the bucket cylinder and the lift arm cylinder and tilt angle (F) of the bucket. In addition, measure height (G) from the ground to the bucket’s lowest position. 2-4. Measure the contact conditions of the bucket tilt stoppers (left and right) at the same time.

Bucket Dump Stopper

Bell Crank Stopper

T4FG-04-04-007

Bucket Tilt Stopper

T4FG-04-04-008

T4-4-8

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test Evaluation: 1. Bucket Dump Stopper 1-1. Cylinder Strokes (A, B) Bucket Cylinder Lift Arm Cylinder A B 220±1.5 mm 685±1.5 mm (8.7±0.06”) (27.0±0.06”)

2. Bucket Tilt Stopper 2-1. Cylinder Strokes (D, E) Bucket Cylinder Lift Arm Cylinder D E 590±1.5 mm 255±1.5 mm (23.2±0.06”) (10.0±0.06”)

1-2. Bucket Dump Angle (C) C 49±2°

2-2. Bucket Tilt Angle (F) F 53°±2

1-3. Clearance between Bell Crank Stopper and Cross Tube

2-3. Height from Ground to Bucket Lowest Position (G) G 340 mm (13.4”)

Clearance between Bell Crank Stopper and Cross Tube Standard Limit

0 mm -

2-4. Clearance between Bucket Dump Stopper and Lift Arm

1-4. Clearance between Bucket Dump Stopper and Lift Arm Clearance at Unsymmet- Longitudinal and Lateral rical Contact Clearance of a Stopper 0 4 mm (0.16”)

0 4 mm (0.16”)

Clearance at Unsymmet- Longitudinal and Lateral rical Contact Clearance of a Stopper 0 4 mm (0.16”)

0 4 mm (0.16”)

Clearance at Unsymmetrical Contact Clearance Limit Left

Clearance at Unsymmetrical Contact

Right

Longitudinal and Lateral Clearance of a Stopper Clearance Limit Clearance Limit Left

Right Left

Longitudinal and Lateral Clearance of a Stopper

Right

T4GB-04-04-009

Clearance Limit Left

Right T4GB-04-04-009

T4-4-9

NOTE: Standard dimensions indicate those of a new tire at the designated air pressure.

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test HYDRAULIC CYLINDER CYCLE TIME

Lift Arm Cylinder:

Summary: 1. The overall performance of the cylinders drive system (between main pump and each cylinder) is judged by measuring the operating time of the cylinders for the lift arm, bucket and steeering. 2. Empty the bucket in advance.

Preparation: 1. Measure by using the following positions. 1-1. Measurement of Lift Arm Cylinder (for Raising) Fully tilt the bucket and lower the lift arm. 1-2. Measurement of Lift Arm Cylinder (for Lowering) Lower the lift arm until the bucket bottom surface touches the ground horizontally. 1-3. Measurement of Bucket Cylinder Raise the lift arm to the highest position. 1-4. Measurement of Steering Cylinder Empty the bucket and set the front attachment at the travel forward position.

(for Raising)

T4GB-04-04-016

(for Lowering)

2. Keep hydraulic oil temperature at 50±5°C (122±9 °F).

T487-04-03-005

Bucket Cylinder: CAUTION: Perform this test on soft ground in order to reduce damage to the bucket.

T487-04-03-006

Travel Position

0.3 to 0.4 m (12” to 1’4”) M4FG-04-001

T4-4-10

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test Measurement: 1. Select the pedal, switch, and forward/reverse lever as follows. Parking Brake Accelerator Pedal Switch Lift Arm Full Stroke ON (for Raising) (Engine: Fast Idle) Lift Arm Full Stroke ON (for Lowering) (Engine: Fast Idle) Full Stroke Bucket ON (Engine: Fast Idle) Full Stroke Steering OFF (Engine: Fast Idle)

Forward/Reverse Lever

eco Mode Switch

OFF

2. Perform measurement operation as follows. (including the buffer range) 2-1. Measurement of Lift Arm Cylinder (for Raising) Operate the loader control lever to full stroke and measure the movement time of the lift arm from the lowest position to the highest position. 2-2. Measurement of Lift Arm Cylinder (for Lowering) Lower the bucket onto the ground. Set the bucket in the horizontal position. Raise the lift arm to the highest position. Set the loader control lever at the float position and measure the movement time of the bucket from the highest position to ground contact position. 2-3. Measurement of Bucket Cylinder Operate the loader control lever to full stroke and measure the movement time of the bucket from the full tilt position to the full dump position. 2-4. Measurement of Steering Cylinder Operate the steering wheel full stroke and measure the movement time of the steering wheel from the right stop to the left stop, and from the left to the right end. WARNING: Before measurement, confirm that there are no persons or obstacles in the steering range. 3. Repeat the measurement three times and calculate the average value. Evaluation: Refer to Operational Performance Standard in T4-2.

Remedy: Refer to Trouble Shooting in T5.

T4-4-11

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test DIG FUNCTION DRIFT CHECK Summary: 1. Internal leakage of the lift arm, bucket cylinders and control valves with a normal loaded bucket is measured by the settlement (shrinkage) of the cylinder rod. 2. Measurement is made in the standard front attachment configuration (standard bucket). 3. When measurement is made immediately after cylinder replacement, purging air from the cylinder before measurement by slowly operating the cylinders to both stroke ends several times is required.

Preparation: 1. Load the bucket with weight or sand equivalent to the standard load. 1440 kg (3170 lb) 2. Extend the lift arm to the maximum reach, and hold the bucket at an angle of about 5° declined forward from full tilting.

Bucket Cylinder

WARNING: Do not allow any persons to be under the bucket. 1. Keep hydraulic oil temperature at 50±5°C (122±9 °F).

Lift Arm Cylinder

Measurement: 1. Stop the engine. 2. After 15 minutes, measure the shrinkage of the lift arm cylinder and the shrinkage of the bucket cylinder respectively. (Shrinkage dimension=A-B) 3. Repeat the measurement three times and calculate the average value.

Evaluation: Refer to Operational Performance Standard in T4-2.

T4FG-04-04-009

B A T4FG-04-04-010

Remedy: Refer to Trouble Shooting in T5.

T4-4-12

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test CONTROL LEVER OPERATING FORCE Summary: 1. Performance of the control levers, pedals and steering wheel must be checked, and their operating forces measured. 2. Maximum operating force of the control levers, pedals, and steering wheel must be checked. 3. Measurement of each control lever is to be checked at the center of the grip. Measurement of accelerator pedal is to be checked at 150 mm (6 in) from the pedal support. Measurement of brake pedal is to be checked at center of pedal pad.

Preparation: 1. Empty the bucket in advance. 2. Keep hydraulic oil temperature at 50±5°C (122±9 °F).

Travel Position

M4FG-04-001

0.3 to 0.4 m (12” to 1’4”)

Measurement: 1. Measurement for each control lever, pedal, and steering wheel. 2. Select the pedal, switch, and forward/reverse lever as follows. Accelerator Pedal Neutral (Engine Slow Idle)

Parking Forward/Reverse Brake Switch Lever ON

T4FG-04-04-011

WARNING: Before measurement, confirm that there are no persons or obstacles in the steering range or close to loader boom or bucket. 3. Attach a spring balance scale (tension type) to the loader control lever and the forward/reverse lever. Measure the maximum operating force while operating them to the end of their strokes. 4. For the pedals, attach a spring balance scale (compression type) or a load cell at the measurement position and measure the operating force while slightly depressing the pedal. 5. For the steering wheel, attach a spring balance scale (tension type) to the knob, and measure the maximum operating force while operating. 6. Repeat the measurement three times and calculate the average value.

Accelerator Pedal Knob

M4FG-01-006

Brake Pedal (Pedal Pad)

Evaluation: Refer to Operational Performance Standard in T4-2.

T4-4-13

45ZV-2

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test CONTROL LEVER STROKE Summary: 1. Operating condition and free motion of control levers, pedals, and steering wheel must be checked, and their strokes measured. 2. Measurement of each control lever is to be checked at the tip of the grip. Measurement of each pedal is to be checked at the top of the pedal. 3. In case lever stroke free movement is present in the neutral position, divide the free movement between both side lever strokes.

Preparation: 1. Keep hydraulic oil temperature at 50±5°C (122±9 °F).

Measurement: 1. Measurement of Control Levers 1-1. Place the bucket bottom on the ground. 1-2. Stop the engine. 1-3. Measure the stroke from the neutral position to the end of the loader control lever movement and the forward/reverse lever at the top center of the grip. 2. Measurement of Pedals 2-1. Place the bucket on the ground. 2-2. Stop the engine. 2-3. Measure the stroke from the neutral position to the end of the pedal movement at the top of the pedal. 3. Measurement of Steering Wheel 3-1. Start the engine (low idle). 3-2. Raise the bucket slightly above the ground. 3-3. Measure the number of rotations while rotating the steering wheel from the left stroke limit to the right limit. 4. Repeat the measurement three times and calculate the average value.

Evaluation: Refer to Operational Performance Standard in T4-2.

T4-4-14

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP DELIVERY PRESSURE Summary: Measure the main pump delivery pressure to check performance.

Preparation: 1. Stop the engine. 2. Disconnect hose (1) and remove elbow (2) from the delivery port of the main pump. Install elbow (3)(1-1/16-12 UNF), a nipple, a pressure gauge, and a coupling between the main pump and the hose. : 32 mm (1.26 in) T4FG-04-05-007

NOTE: Elbow (3) (1-1/16-12 UNF) and the parts equivalent to elbow (2), which has been ported for a pressure gauge, can be used. 3. Start the engine. Check for oil leakage at the pressure gauge connection. 4. Maintain hydraulic oil temperature at 50±5°C (122±9°F). Measurement: 1. Set engine speed at high idle. Depress the accelerator pedal fully. 2. Measure pressure with the control levers in neutral without load. 3. Repeat the measurement three times and calculate the average value. Evaluation: Refer to Operational Performance Standard in T4-2. Remedy: Refer to Troubleshooting in T5.

T4-5-1

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test HST PUMP DELIVERY PRESSURE Summary: Measure the HST pump delivery pressure to check performance. WARNING: Injection hazard. High-pressure oil in circuit. Be careful with hoses, gauges and all connections to not have leaks. Preparation: 1. Stop the engine. 2. Remove the plug from HST pump delivery port (MA) (1). Install an adapter (G1/4), a hose, and a pressure gauge. : 6 mm (0.24 in)

Pressure Gauge Adapter

3. Start the engine. Check for oil leakage at the pressure gauge connection. 4. Maintain hydraulic oil temperature at 50±5°C (122±9°F). Measurement: 1. Set engine speed at high idle. Depress the accelerator pedal fully. 2. Measure pressure with the control levers in neutral without load. 3. Repeat the measurement three times and calculate the average value.

T4FG-04-05-008

Evaluation: Refer to Operational Performance Standard in T4-2. Remedy: Refer to Troubleshooting in T5.

T4-5-2

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test HST CHARGING PRESSURE

PUMP

DELIVERY

Summary: Measure the HST charging pump delivery pressure to check performance. WARNING: Injection hazard. High-pressure oil in circuit. Be careful with hoses, gauges and all connections to not have leaks. Preparation: 1. Stop the engine. 2. Disconnect hose (1) and elbow (2) from the HST charge pump filter delivery port. Install elbow (3) (3/4 – 16UNF), a nipple, a pressure gauge, and a coupling between the filter and the hose. : 22 mm (0.87 in), 24 mm (0.94 in), 27 mm (1.06 in)

3 2

NOTE: Elbow (3) (3/4-16 UNF) and the parts equivalent to elbow (2) which has been ported for use with a pressure gauge can be used.

T4FG-04-05-009

1. Start the engine. Check for oil leakage at the pressure gauge connection. 2. Maintain hydraulic oil temperature at 50±5°C (122±9°F). Measurement: 1. Set engine speed at high idle. Depress the accelerator pedal fully. 2. Measure pressure with the control levers in neutral without load. 3. Repeat the measurement three times and calculate the average value. Evaluation: Refer to Operational Performance Standard in T4-2. Remedy: Refer to Troubleshooting in T5.

T4-5-3

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF PRESSURE Summary: Measure the main relief valve set pressure to check performance. WARNING: Injection hazard. High-pressure oil in circuit. Be careful with hoses, gauges and all connections to not have leaks. Preparation: 1. Stop the engine. 2. Remove the plug from pressure check port (1) at the bucket cylinder bottom side. Install an adapter (G1/8), a hose, and a pressure gauge. : 5 mm (0.20 in)

Pressure Gauge

3. Start the engine. Check for oil leakage at the pressure gauge connection. 4. Maintain hydraulic oil temperature at 50±5°C (122±9°F). Measurement: 1. Set engine speed at high idle. Depress the accelerator pedal fully. 2. Slowly operate the loader control lever. Operate the cylinder to the stroke end (retract/extend) and pressurize the circuit over main relief pressure. 3. Repeat the measurement three times and calculate the average value.

Adapter

T4FG-04-05-010

Control Valve

Evaluation: Refer to Orerational Performance Standard in T4-2.

T4FGE⊶03-02-003

Main Relief Valve

T4-5-4

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Procedure

Valve

Pressure

Adjustment 1

1. Loosen lock nut (1). : 19 mm (0.75 in) 2. Turn adjusting screw (2) and adjust the relief pressure to the specification. 3. Tighten lock nut (1). : 29±2 N⋅m (21 lbf⋅ft) 4. Check the relief set pressure. NOTE: Standard Change in Pressure Adjusting Screw 1/4 1/2 3/4 Turns Change MPa 4.44 8.87 13.7 in 2 (kgf/cm , (45.3, (90.5, (135.8, Pressure psi) 644) 1290) 1990)

2 T4FG-04-05-005

1 1

17.7 (181, 2570) Pressure Increase

Pressure Decrease

W107-02-05-129

T4-5-5

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test HST PUMP RELIEF PRESSURE Summary: Measure the HST pump relief valve set pressure at the HST pump delivery port to check performance of the HST pump relief valve. WARNING: Injection hazard. High-pressure oil in circuit. Be careful with hoses, gauges and all connections to not have leaks.

Pressure Gauge

Adapter

Preparation: 1. Stop the engine. 2. Remove the plug from HST pump delivery port (MA) (1). Install an adapter, a hose, and a pressure gauge. : 6 mm (0.24 in) 3. Start the engine. Check for oil leakage at the pressure gauge connection. 4. Maintain hydraulic oil temperature at 50±5°C (122±9°F).

T4FG-04-05-008

Measurement: 1. Slightly raise the lift arm with the bucket placed against a pile. 2. Select the forward 1st gear, depress the accelerator pedal before a wheel spins, and relieve the HST relief valve. 3. Repeat the measurement three times and calculate the average value. Evaluation: Refer to Orerational Performance Standard in T4-2.

T4-5-6

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test STEERING RELIEF PRESSURE Summary: Measure the steering relief valve set pressure at the steering cylinder inlet port to check performance. WARNING: Injection hazard. High-pressure oil in circuit. Be careful with hoses, gauges and all connections to not have leaks. Preparation: 1. Stop the engine. 2. Remove the plug from pressure test port (1) at the steering cylinder bottom side. Install an adapter (G1/8), a hose, and a pressure gauge. : 5 mm (0.20 in) 3. Start the engine. Check for oil leakage at the pressure gauge connection. 4. Maintain hydraulic oil temperature at 50±5°C (122±9°F). Measurement: 1. Install an articulation lock bar. 2. Set engine speed at high idle. Depress the accelerator pedal fully. 3. Slowly operate the steering wheel and pressurize the steering circuit over relief valve pressure setting. 4. Repeat the measurement three times and calculate the average value.

Pressure Gauge

Adapter

T4FG-04-05-011

Evaluation: Refer to Orerational Performance Standard in T4-2.

T4-5-7

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD RELIEF PRESSURE Summary: 1. The circuit pressure should 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 set-pressure is not a proper method. In addition, in case a main relief valve designed to leak a small quantity of oil before reliving is used, its pre-leaking start pressure should 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 should be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit. 3. If the overload relief valve performance should be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range. Measure the main pressure of the front functions.

3. Start the engine. Check for oil leakage at the pressure gauge connection. 4. Maintain hydraulic oil temperature at 50±5°C (122±9°F). Measurement: 1. Set engine speed at high idle. Depress the accelerator pedal fully. 2. Operate the lift arm or bucket control lever for the overload relief valve to be measured. Operate the cylinder to the stroke end (extend/retract). 3. Read the pressures on the pressure gauge at this time. 4. Repeat the measurement three times and calculate the average value. Evaluation: In case the pressure of the bucket or lift arm circuit which has been measured is specification of the main relief valve set pressure, this is normal. Refer to Operational Performance Standard in T4-2.

Pressure Gauge

Adapter

T4FG-04-05-010

WARNING: Injection hazard. High-pressure oil in circuit. Be careful with hoses, gauges and all connections to not have leaks. Preparation: 1. Stop the engine. 2. Remove the plug from the pressure check port (1) at the tilt cylinder bottom side. Install an adapter (G1/8), a hose, and a pressure gauge. : 5 mm (0.20 in)

T4-5-8

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test Overload Relief Procedure

Valve

Pressure

Adjustment

NOTE: In principle, adjust the overload relief valve pressure by using a test equipment. 1

Loosen lock nut (1) and turn adjusting screw (2). 1. Loosen lock nut (1). : 19 mm (0.75 in) 2. Turn adjusting screw (2) and adjust the relief pressure to the specification. : 6 mm (0.24 in) 3. Tighten lock nut (1). : 19 mm (0.75 in) : 29±2 N⋅m (21 lbf⋅ft ) 4. After adjustment, check the set pressure. NOTE: Standard Change in Pressure Adjusting Screw 1/4 1/2 3/4 Turns Change MPa 3.92 7.84 11.8 in 2 (40, (80, (120, (kgf/cm , Pressure psi) 569) 1140) 1710)

2 T4FG-04-05-005

1 15.7 (160, 2280)

Pressure Increase

Pressure Decrease

W107-02-05-129

T4-5-9

45ZV-2

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-10

45ZV-2

OPERATIONAL PERFORMANCE TEST / Adjustment FAN BELT TENSION ADJUSTMENT Summary: If the fan belt is loosened, battery charge is insufficient or the fan belt will wear out prematurely. If the fan belt is too tight, the water pump bearings and the bearings of the alternator will be damaged. Adjust the fan belt within specification. Measurement: With the engine off, push the fan belt between alternator (1) and crank pulley (2) by finger. Measure slack of the fan belt. Pushing force: Approx. 98 N (10 kgf, 72 lbf)

CAUTION: The engine becomes hot during operation. Wait for the engine to cool before starting the measurement. Entanglement hazard. Remove key from starter switch and tag the machine out of service. Evaluation:

M4FG-07-038

Slack of fan belt: 7 to 9 mm (0.28 to 0.35 in) Adjustment: 1. Loosen mounting bolts (3, 4) of alternator (5). 2. Move alternator (5) forward or back-ward to correctly adjust the belt tension. 3. Securely tighten mounting bolts (3, 4).

3 5

NOTE: When the fan belt is replaced with a new one, the fan belt may not have the correct tension. After the engine has run at slow idle for 3 to 5 minutes, check slack of the fan belt.

T4-6-1

M4FG-07-037

45ZV-2

OPERATIONAL PERFORMANCE TEST / Adjustment (Blank)

T4-6-2

45ZV-2

SECTION 5

TROUBLESHOOTING ―CONTENTS― Group 1 Diagnosing Procedure

Group 4 Troubleshooting B

Introduction ................................................ T5-1-1

Troubleshooting B Procedure

Diagnosing Procedure ................................ T5-1-2

(Machine Diagnosis

How to Operate Service Mode of Monitor ... T5-1-5

by Using Trouble Symptom) ................. T5-4-1

How to Use Error Code Readout Switch ..... T5-1-6

Engine System Failure List ...................... T5-4-2 Engine System Troubleshooting............... T5-4-3

Group 2 Component Layout

Vehicle System Failure List .................... T5-4-12

Main Component Layout (Overview) ........... T5-2-1

Travel System Troubleshooting .............. T5-4-14

Main Component Layout (Body) ................. T5-2-2

Brake System Troubleshooting .............. T5-4-34

Main Component Layout (Travel System) ... T5-2-3

Steering System Troubleshooting........... T5-4-42

Electrical System (Overview) ...................... T5-2-4

Front Attachment System

Electrical System (Inside of Cab) ................ T5-2-5

Troubleshooting.................................. T5-4-47

Engine...................................................... T5-2-10 HST Pump / Main Pump ........................... T5-2-10

Group 5 Troubleshooting C

Reduction Gear / HST Motor..................... T5-2-11

Troubleshooting C Procedure

Control Valve............................................ T5-2-11

(Trouble Shooting for Monitor) ................ T5-5-1 Malfunction of Indicator Light Check

Group 3 Troubleshooting A Troubleshooting A Procedure...................... T5-3-1 HST Control Unit Error Code List................ T5-3-2 HST Control Unit Error Code 1-1 ................ T5-3-3 HST Control Unit Error Codes 2-1, 2-2 ....... T5-3-4 HST Control Unit Error Code 2-3 ................ T5-3-6 HST Control Unit Error Code 2-4 ................ T5-3-8 HST Control Unit Error Code 3-1 .............. T5-3-10 HST Control Unit Error Code 3-2 .............. T5-3-12 HST Control Unit Error Codes 3-3, 3-4 ..... T5-3-14 HST Control Unit Error Code 3-5 .............. T5-3-16 HST Control Unit Error Codes 4-1, 4-2 ..... T5-3-17

4FGET-5-1

System ................................................... T5-5-2 Malfunction of Coolant Temperature Gauge .................................................... T5-5-4 Malfunction of Fuel Gauge ....................... T5-5-6 Malfunction of Turn Signal Indicators (Left and Right)....................................... T5-5-8 Malfunction of Hazard Light Indicator ....... T5-5-9 Malfunction of High Beam Indicator........ T5-5-10 Malfunction of Working Light Indicator ... T5-5-12 Malfunction of Preheat Indicator............. T5-5-14 Malfunction of HST Warning Indicator .... T5-5-15

45ZV-2

Malfunction of Air Filter Restriction Indicator ............................................... T5-5-16 Malfunction of Engine Oil Low Pressure Indicator ............................................... T5-5-19 Malfunction of Overheat Indicator ........... T5-5-20 Malfunction of Stop Indicator .................. T5-5-21 Malfunction of Service Indicator.............. T5-5-22 Malfunction of Parking Brake Indicator.... T5-5-24 Malfunction of Clearance Light Indicator ............................................... T5-5-26 Malfunction of Brake Oil Low Level Indicator ............................................... T5-5-28 Malfunction of Discharge Warning Indicator ............................................... T5-5-30 Malfunction of Monitor Display................ T5-5-32 Malfunction of Ride Control Indicator ...... T5-5-33

Group 6 Electrical System Inspection Precautions for Inspection and Maintenance...........................................T5-6-1 Instructions for Disconnecting Connectors .............................................T5-6-3 Fuse Inspection ........................................T5-6-6 Fusible Link Inspection .............................T5-6-8 Battery Voltage Check ..............................T5-6-9 Alternator Check..................................... T5-6-10 Continuity Check .................................... T5-6-11 Voltage and Current Measurement ......... T5-6-12

4FGET-5-2

45ZV-2

TROUBLESHOOTING / 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 5 groups; Diagnosing Procedure, Troubleshooting A (base machine diagnosis by using monitor error codes), Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status), Troubleshooting C (monitor diagnosis), and Electrical System Inspection.

• Troubleshooting A (base machine diagnosis by using monitor error codes) Refer to these procedures if any error codes are displayed when trouble is diagnosed by using the HST error code readout switch of the monitor.

• Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status) Refer to these procedures for diagnosis by using trouble symptom.

• Troubleshooting C (monitor diagnosis) Refer to these procedures when gauges and/or indicators are malfunctioning.

• Electrical System Inspection Refer to this group when required to obtain precautions and/or information for the electrical system inspection.

T5-1-1

45ZV-2

TROUBLESHOOTING / Diagnosing Procedure DIAGNOSING 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. 2. Ask the operator Before inspecting, get the full malfunctions from the operator below.

story

T4GB-05-01-001

(a) How is the machine being used? (Find out if the machine is being operated correctly) (b) When was the trouble noticed, and what types of work was the machine doing at that time? (c) What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time? (d) Did the machine have any other troubles previously? If so, which system was affected and 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.

T4GB-05-01-002

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 tester when checking the fuses.

T4GB-05-01-003

T5-1-2

45ZV-2

TROUBLESHOOTING / Diagnosing Procedure 4. Operate the machine yourself Try to identify the trouble by operating the machine yourself. If the trouble cannot be confirmed (the problem intermittently appears and disappears), stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses correponding to the trouble. NOTE: It should take time to find the malfunction when troubleshooting. The malfunction may occur due to up and down changes of hydraulic temperature, weather and special conditions including heat expansion and shorted harness from moisture. The information of weather, when the mulfunction occurs, time from engine start to when the trouble occurs are also important.

T5-1-3

45ZV-2

TROUBLESHOOTING / Diagnosing Procedure 5. Perform troubleshooting CAUTION: Do not disconnect harnesses or 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 using the service mode of monitor. Check operating condition of each component by referring to Troubleshooting in this section and by using the monitoring function of the service mode of the monitor. 6. Trace possible causes Before reaching a conclusion, check the most likely 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.

T5-1-4

45ZV-2

TROUBLESHOOTING / Diagnosing Procedure HOW TO OPERATE SERVICE MODE OF MONITOR When the engine starts normally, the monitor is started in normal mode and only items, which can be displayed in normal mode, are displayed on the liquid crystal display (LCD).

Liquid Crystal Display (LCD)

Information Display

When the monitor is started in service mode according to the following procedures, the items which can be displayed in normal mode are shown in the table below.)

How to Start Monitor in Service Mode 1. While pushing the monitor display selector (up) and (down) in the monitor at the same time, turn the key switch ON.

Monitor Display Selector (Down)

Monitor Display Selector (Up)

M4FG-01-010

NOTE: When the key switch is set from off to on and the engine starts, the monitor is started in normal mode.

How to Use Monitor in Service Mode 1. Whenever pushing the monitor display selector (up) in the monitor, the data in the information display is changed.

DISPLAY LIST OF MONITOR SERVICE MODE Display Order 1. 2.

Description

Monitor Display

Unit

Remark

Model Hour Meter

○○○○○○ ○○○○○.○ h

− hour

Odometer

○○○○○○

Km or mile

4. 5.

Engine Speed Coolant Temperature

○○○○○○ ○○○○○○

min-1 °C

Service Mode Normal Mode Normal Mode (“Mile” is displayed when pushing the mode selection switch.) Service Mode Service Mode

T5-1-5

45ZV-2

TROUBLESHOOTING / Diagnosing Procedure HOW TO USE ERROR CODE READOUT SWITCH Service Indicator

When the HST warning indicator and the service indicator light functions, the HST warning indicator flashes and fault codes on the HST related parts (electrical system) can be read by pushing the error code readout switch. (Refer to the table below.) When multiple abnormalities are found, the flashing state of the HST warning indicator is changed according to the detected abnormal contents each time the error code readout switch is pushed. NOTE: The error code readout switch detects only electrical system related faults. Several possible reasons other than the electrical system may occur. Refer to Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status).

Service Indicator Error Code Readout Switch

M4FG-01-010

Error Code List of Error Code Readout Switch

1-1

Flashing State of HST Warning Indicator Flashing OFF Flashing (1 sec.) (2 sec.) (1 sec.) Once → Once

Start-up condition

2-1

Twice

→

Once

HST motor output

2-2

Twice

→

Twice

HST Pump output

2-3

Twice

→

2-4

Twice

→

Three times Four times

Three times Three times Three times Three times Three times Four times Four times

→

Once

Speed Sensor

Faulty speed sensor

→

Twice

Engine speed sensor

Faulty engine speed sensor

→

Three times Four times Five times

Brake Pedal Angle sensor low voltage Brake Pedal Angle sensor high voltage

→

Once

Low voltage

→

Twice

High voltage

Error Code

3-1 3-2 3-3 3-4 3-5 4-1 4-2

→ →

Content

Parking brake Overrunning buzzer

High-Low selector switch

T5-1-6

Cause Low or high controller supply voltage Open circuit of HST motor solenoid output cable Open circuit of HST pump solenoid output cable Open circuit of parking brake relay output cable Open circuit of overrunning buzzer output cable

Low voltage of Brake Pedal Angle sensor High voltage of Brake Pedal Angle sensor Faulty High-Low selector switch Low controller supply voltage (10 V or less) High controller supply voltage (17 V or more)

TROUBLESHOOTING / Component Layout MAIN COMPONENT LAYOUT (OVERVIEW) 4

3 2

T4FGE-01-02-001

12 9 11 1 - Bucket

2 - Bell Crank 3 - Bucket Cylinder

T4FGE-01-02-002

4 - Head Light / Turn Signal / Hazard Light / Clearance Light 5 - Fuel Tank 6 - Lift Arm Cylinder

T5-2-1

7 - Lift Arm

8 - Bucket Link 9 - Hydraulic Oil Tank

10 - Rear Combination Light (Turn Signal Light / Hazard Light / Clearance Light / Brake Light) 11 - Reverse Light 12 - Backup Alarm

45ZV-2

TROUBLESHOOTING / Component Layout MAIN COMPONENT LAYOUT (BODY)

9 10 11

13 22 21 14

20 19 18

T4FG-01-02-005

123456-

Bucket Cylinder Lift Arm Cylinder Steering Valve Priority Valve Brake Master Cylinder Parking Brake Solenoid Valve

7 - Hydraulic Oil Tank 8 - Hydraulic Oil Return Filter 9 - Hydraulic Oil Suction Filter 10 - Brake Oil Tank 11 - Air Cleaner 12 - Coolant Reservoir

T5-2-2

13 - Oil Cooler 14 - Radiator 15 - Fuel Pre-Filter 16 - Fuel Filter 17 - Fuel Pump 18 - Engine

19 - HST Pump 20 - Gear Pump 21 - HST Filter 22 - Fuel Tank 23 - Control Valve

45ZV-2

TROUBLESHOOTING / Component Layout MAIN COMPONENT LAYOUT (TRAVEL SYSTEM)

3 4 5

T4FG-01-02-006

1 - Front Axle 2 - Steering Cylinder

34-

HST Motor Reduction Gear

T5-2-3

Rear Axle

Propeller Shaft

45ZV-2

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (OVERVIEW) 2

Inside of Cab Refer to T1-2-5.

4 5

16 7 15 14

8 9

13 12

10 T4FGE-01-02-007

1 - Horn 2 - Brake Light Switch 3 - Brake Pedal Angle Sensor 4 - HST Controller 5 - Air Cleaner Restriction Switch

6 - Coolant Temperature Sensor 7 - Reverse Alarm 8 - Battery 9 - Engine Speed Sensor 10 - Starter Relay 1

T5-2-4

11 - Glow Relay

16 - Speed Sensor

12 - Fusible Link (100 A ) (2 Used) 13 - Brake Oil Level Sensor 14 - Starter Relay 2 15 - Fuel Level Sensor

17 - Bucket Proximity Switch

45ZV-2

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (INSIDE OF CAB) 1

Front Console Refer to T5-2-7.

Right Console Refer to T5-2-6.

Rear Console Refer to T5-2-8.

T4FG-01-02-008

Radio (Optional)

Rotary Beacon Switch (Optional)

T5-2-5

Auxiliary

45ZV-2

TROUBLESHOOTING / Component Layout Right Console 1

2 3 4 5 6

9 8 M4FG-01-009

1 - Loader Control Lever 2 - Auxiliary Control Lever (Optional) 3 - Auxiliary Control Lever Lock (Optional)

4 - Auxiliary 5 - Ride Control Switch (Optional)

T5-2-6

6 - eco Mode Switch 7 - Heater Switch (Optional)

8 - Key Switch 9 - Loader Control Lever Lock

45ZV-2

TROUBLESHOOTING / Component Layout Front Console 1

13 5 12 6

7 10 8 9

T4FG-01-02-009

1 - Monitor Panel (Refer to T1-2-9.) 2 - Horn Switch 3 - Steering Wheel

5 - Front Wiper Switch (Cab)

8 - Light Switch

6 - Rear Wiper Switch (Cab)

9 - Neutral Lever Lock (Forward/Reverse Lever) 10 - Forward/Reverse Lever

7 - Turn Signal Lever / Dimmer Switch

11 - High-Low Selector Switch 12 - Work Light Switch (Cab) 13 - Hazard Light Switch

4 - Parking Brake Switch

T5-2-7

45ZV-2

TROUBLESHOOTING / Component Layout Rear Console 3

4 5 6 7 8 9 10

T4FG-01-02-010

Fuse Box

Parking Brake Relay [1]

Buzzer (Overrun Alarm) 3 - Fuse Box (Cab)

Parking Brake Relay [2]

Alternator Indicator Relay [3]

T5-2-8

HST Control Relay [4]

Emergency Parking Brake Relay [5] 9 - Flasher Unit (Turn Signal/ Hazard Light)

10 - Front Work Light Relay (Cab) 11 - Rear Work Light Relay (Cab) 12 - Front Wiper Relay (Cab)

45ZV-2

TROUBLESHOOTING / Component Layout Monitor Panel

22 12

13 M4FG-01-010

1 - Coolant Temperature Gauge 2 - Left Turn Signal Indicator

7 - Stop Indicator

13 - Not Used

19 - Overheat Indicator

8 - Service Indicator

3 - High Beam Indicator

9 - Parking Brake Indicator

14 - Discharge Warning Indicator 15 - Error Code Readout Switch

4 - Monitor Display 5 - Work Light Indicator (Optional) 6 - Right Turn Signal Indicator

10 - Clearance Light Indicator 11 - Fuel Gauge

16 - Preheat Indicator 17 - Monitor Display Selector

20 - Engine Oil Low Pressure Indicator 21 - Air Filter Restriction Indicator 22 - HST Warning Indicator

12 - Brake Oil Low Level Indicator

18 - Not Used

T5-2-9

45ZV-2

TROUBLESHOOTING / Component Layout ENGINE 3

T4FG-01-02-011

1 - Starter 2 - Engine Speed Sensor

45-

Engine Oil Filter Alternator

67-

Fuel Pre-Filter Fuel Filter

89-

Fuel Pump Coolant Temperature Sensor

3 - Engine Oil Pressure Switch

HST PUMP, MAIN PUMP 1

7 T4FG-01-02-012

1 - Main Pump 2 - High-Pressure Relief Valve

Forward Selection Solenoid Valve 4 - Pump Solenoid Valve

T5-2-10

Low-Pressure Relief Valve

Displacement Angle Control Cylinder

Reverse Selection Solenoid Valve

45ZV-2

TROUBLESHOOTING / Component Layout REDUCTION GEAR, HST MOTOR

T4FG-01-02-013

CONTROL VALVE

8 9

4 T4FGE-01-02-014

HST Motor

4 - Electromagnetic Detent (Bucket)

Motor Solenoid Valve

5 - Overload Relief Valve (Bucket: Rod Side)

3 - Reduction Gear

7 - Overload Relief Valve (Auxiliary (Coupler): Rod Side) 8 - Overload Relief Valve (Auxiliary (Coupler): Bottom Side)

Overload Relief Valve (Bucket: Bottom Side)

10 - Main Relief Valve

6 - Make-Up Valve (Lift Arm: Rod Side)

T5-2-11

45ZV-2

TROUBLESHOOTING / Component Layout Component Layout 1

5 8

6 T4FGE-03-02-002

1 - Overload Relief Valve (Coupler: Rod Side) 2 - Overload Relief Valve (Coupler: Bottom side) 3 - Make-Up Valve (Lift Arm: Rod Side)

4 - Overload Relief Valve (Bucket: Rod Side) 5 - Overload Relief Valve (Bucket: Bottom Side)

T5-2-12

6 - Main Relief Valve 7 - Load Check Valve (Bucket Circuit)

8 - Load Check Valve (Lift Arm Circuit) 9 - Load Check Valve (Coupler Circuit)

45ZV-2

TROUBLESHOOTING / Component Layout

T4FGE-03-02-003

Section B-B

Section A-A

5 2

T4FG-03-02-004 T4L1-03-02-004

T4FG-03-02-005

12-

Main Relief Valve

Overload Relief Valve (Coupler: Rod Side) 3 - Load Check Valve (Coupler Circuit)

Overload Relief Valve (Coupler: Bottom side) 5 - Make-Up Valve (Lift Arm: Rod Side)

T5-2-13

Load Check Valve (Lift Arm Tandem Circuit) 7 - Overload Relief Valve (Bucket: Rod Side)

Load Check Valve (Bucket Tandem Circuit) 9 - Overload Relief Valve (Bucket: Bottom Side)

45ZV-2

TROUBLESHOOTING / Component Layout (Blank)

T5-2-14

45ZV-2

TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE Refer to Troubleshooting A in case any error codes are displayed after diagnosing by using the error code readout switch on the monitor. • How to Read the Troubleshooting Flow Charts

YES (OK)

・

(2)

After completing the checking and/or measuring procedures in box (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1)

NO (NOT OK)

・ · Key switch: ON

・

(3)

Instructions, reference, and/or inspection methods and/or measurements are occasionally YES Faulty proportional solenoid described under the box. If incorrectly checked or measured, not only will troubleshooting valve. be unsuccessful but also damage to the components may result.

Causes of machine problems are stated in the thick-line box. Scanning quickly through the NO thick-line boxes allows you to estimate the possible causes before actually following the flow chart.

NOTE: Harness end connector viewed from the open-end side of all connector images are shown in this section.

Harness End Connector

Harness

Open End Side

T6L4-05-03-001

T5-3-1

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTROL UNIT ERROR CODE LIST Error Code 1-1

2-1

2-2

2-3 2-4 3-1

Trouble Faulty start-up condition

Faulty HST motor displacement angle control output Faulty HST pump displacement angle control output Faulty parking brake control output Faulty overrunning buzzer Faulty speed sensor

3-2

Faulty engine speed sensor

3-3

Faulty brake pedal angle sensor low voltage Faulty brake pedal angle sensor high voltage Faulty forward/reverse lever

3-4

3-5

4-1

Faulty low voltage

4-2

Faulty high voltage

Cause

Influenced Control The supplied voltage to the HST control unit is reduced. HST pump (10 V or less) control The supplied voltage to the HST control unit is raised. HST motor (17 V or more) control Failure is diagnosed only when the HST control unit starts. Faulty harness. HST motor Faulty proportional solenoid valve. control Faulty harness. Faulty proportional solenoid valve.

HST pump control

Faulty harness. Faulty relay. Open circuit in harness of overrunning buzzer output. Faulty overrunning buzzer. The detected value is 60 km/h (37 mph) or more. Emergency stop of the detected value (The signal is stopped over 15 km/h (9 mph) or more when the HST brake is depressed at 50 % or less in the operable range.) The following abnormal values are detected. • Less than 300 min-1 when machine speed is 5 km/h (3 mph) or more. • 0 min-1 when terminal L of the alternator is 12 V. • Engine speed is beyond 5000 min-1. The sensor input voltage to the HST control unit is 0.25 or less.

Emergency parking brake Buzzer control when overrunning HST motor control (100 % output)

HST pump control (40 % output)

HST pump control (50 % output) The sensor input voltage to the HST control unit is 4.75 HST pump or more. control (50 % output) Control selecting The following conditions are detected. • The forward and the reverse signals are detected forward and reverse travel at the same time. • Detected machine speed is below in sequence. operation -1 3 km/h (2 mph) with engine speed at 1500 min or more without inputting the forward and the reverse signal. → 0 km/h (0 mph)→ 3 km/h (2 -1 mph) with engine speed at 1500 min or more. The supplied voltage to the HST control unit is 10 V or Normal operation less. The supplied voltage to the HST control unit is 17 V or Normal operation more.

T5-3-2

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTORL UNIT ERROR CODE 1-1 Error Code 1-1

Trouble

Cause

Faulty start-up condition

Symptoms in Machine Operation Remedy When Trouble Occurs The machine cannot travel. Check the battery. Check the alternator. Replace the HST control unit.

YES

Faulty HST control unit

Start engine.Check if battery terminal voltage is within normal range, between 12 V and 15 V. Faulty alternator NO

Check if battery terminal voltage is within normal range, between 11 V and 15 V. · Key switch: OFF

Faulty battery NO

T5-3-3

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTROL UNIT ERROR CODES 2-1, 2-2 Error Code 2-1

2-2

Trouble

Cause

Faulty HST motor displacement angle control output Faulty HST pump displacement angle control output

Faulty harness. Faulty proportional solenoid valve.

Influenced Control HST motor control

Faulty harness. Faulty proportional solenoid valve.

HST pump control

YES

Disconnect connectors of HST control unit and proportional solenoid valve. Check for continuity between terminals #1 and #2, or #a and #b of proportional solenoid valve connector. YES

Check for continuity between terminal #1 or #a of proportional solenoid valve and body.

Check for continuity between HST control unit and terminal #2 or #b of proportional solenoid valve. · Refer to the table.

List of connection relationship between each proportional solenoid valve connector terminal and HST Control Unit connector terminal.

HST Control Unit Connector

Pump solenoid valve connector #2

Motor solenoid valve connector #b

#30

#31

T5-3-4

45ZV-2

TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation Remedy When Trouble Occurs. The machine speed cannot Check the harness. increase. Replace the proportional solenoid valve. The traction force is reduced. The machine cannot travel. Check the harness. Replace the proportional solenoid valve.

Shorted circuit in harness between HST control unit and proportional solenoid valve

YES YES

Faulty proportional solenoid valve

Connect all connectors. Replace proportional solenoid valve and retry. Check if error code disappears.

Faulty HST control unit NO

Open circuit in harness between terminal #1 or #a of proportional solenoid valve and body

Open circuit in harness between HST control unit and terminal #2 or #b of proportional solenoid valve.

Connector (Harness end of connector viewed from the open end side) HST Control Unit Connector

T4FG-05-04-001

T5-3-5

Pump Solenoid Valve Connector

Motor Solenoid Valve Connector

T4FG-05-04-009

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTROL UNIT ERROR CODE 2-3 Error Code 2-3

Trouble Faulty parking brake control output

Cause

Influenced Control Emergency parking brake

Faulty harness. Faulty relay.

YES

Disconnect connectors of HST control unit and emergency parking brake relay. Check for continuity between terminals #c and #g of emergency parking brake relay

YES

Check for continuity between terminal #g of emergency parking brake relay and body.

Check for continuity between terminal #29 of HST control unit and terminal #c of emergency parking brake relay.

Connector (Harness end of connector viewed from the open end side) HST Control Unit Connector

Emergency Parking Brake Relay

T4FG-05-04-003 T4FG-05-04-001

T5-3-6

45ZV-2

TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs. The emergency parking brake Check the harness. inoperable Replace the relay.

Remedy

Shorted circuit in harness between HST control unit and emergency parking brake relay

YES

Faulty emergency parking brake relay

Connect all connectors. Replace relay and retry. Check if error code disappears. Faulty HST control unit NO

Open circuit in harness between terminal #g of emergency parking brake relay and body

Open circuit in harness between terminal #29 of HST control unit and terminal #c of emergency parking brake relay

T5-3-7

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTROL UNIT ERROR CODE 2-4 Error Code 2-4

Trouble

Cause

Faulty overrunning buzzer

Open circuit in harness of overrunning buzzer output. Faulty overrunning buzzer.

Influenced Control Buzzer control when overrunning

YES

Disconnect connectors of HST control unit and buzzer. Check for continuity between terminals #1 and #2 of buzzer. YES

Check for continuity between terminal #2 of buzzer and body.

Check for continuity between terminal #15 of HST control unit and terminal #1 of buzzer.

Connector (Harness end of connector viewed from the open end side) HST Control Unit Connector

Overrunning Buzzer Terminal (Plug) ＃1

＃2

T4FG-05-04-001

T4FG-05-04-004

T5-3-8

45ZV-2

TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs. The buzzer cannot operate when Check the harness. the machine overruns. Replace the buzzer.

Remedy

Shorted circuit in harness between HST control unit and buzzer

YES

Faulty buzzer

Connect all connectors. Replace buzzer and retry. Check if error code disappears. Faulty HST control unit NO

Open circuit in harness between terminal #2 of buzzer and body

Open circuit in harness between terminal #15 of HST control unit and terminal #1 of buzzer

T5-3-9

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTROL UNIT ERROR CODE 3-1 Error Code 3-1

Trouble

Cause

Influenced Control The detected value is 60 km/h (37 mph) or more. HST motor Emergency stop caused by the detected value (The control (100% signal is stopped over 15 km/h (9 mph) or more when output) the HST brake is depressed at 50% or less in the operable range.)

Faulty speed sensor

YES

Replace vehicle speed sensor and retry. Check if error code disappears. YES

Disconnect HST control unit connector and connector 1-B of monitor unit. Check for continuity between terminal #37 of harness end connector of HST control unit and terminal #b of harness end connector in vehicle speed sensor.

Disconnect connector of speed sensor. Check if voltage between terminal #a and #c of harness end connector is 5±0.5 V. · Key switch: ON

Check if voltage between terminal #a of harness end connector in speed sensor and body is 5V.

Connector (Harness end of connector viewed from the open end side)

Speed Sensor Connector

b c T4FG-05-04-005

T5-3-10

45ZV-2

TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs. The machine speed cannot increase.

Remedy Check the harness. Replace the sensor.

Faulty speed sensor

YES

Faulty HST control unit

Open circuit in harness between terminal #37 of HST control unit and terminal #b of speed sensor

Open circuit in harness between terminal #7 of HST control unit and terminal #c of speed sensor

Open circuit in harness between terminal #36 of HST control unit and terminal #a of speed sensor

Connector (Harness end of connector viewed from the open end side) Monitor Connector 1-B

HST Control Unit Connector

PRESSURE CHECK PORT

T4FG-05-04-001

T5-3-11

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTROL UNIT ERROR CODE 3-2 Error Code 3-2

Trouble

Cause

Influenced Control The following abnormal values are detected. HST pump • Less than 300 min-1 when machine speed is 5 control (40% km/h (3 mph) or more. output) • 0 min-1 when terminal L of the alternator is 12 V. • Engine speed is beyond 5000 min-1.

Faulty engine speed sensor

YES

Replace engine speed sensor and retry. Check if error code disappears.

YES

Disconnect connector of HST control unit. Check for continuity between terminal #37 of harness end connector of HST control unit and terminal #b of harness end connector in engine speed sensor.

Disconnect connector of engine speed sensor. Check if voltage between terminals #a and #c of harness end connector is 5 V. · Key switch: ON

Check if voltage between terminal #a of harness end connector in engine speed sensor and body is 5±0.5 V. · Key switch: ON

Connector (Harness end of connector viewed from the open end side) Engine Speed Sensor Connector

HST Control Unit Connector

b c T4FG-05-04-007

T4FG-05-04-001

T5-3-12

45ZV-2

TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs. The machine speed cannot increase. Tractive force is reduced.

Remedy Check the harness. Replace the sensor.

Faulty engine speed sensor

YES

Faulty HST control unit

Open circuit in harness between terminal #37 of HST control unit and terminal #b of engine speed sensor

Open circuit in harness between terminal #7 of HST control unit and terminal #c of engine speed sensor

Open circuit in harness between terminal #36 of HST control unit and terminal #a of engine speed sensor

T5-3-13

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTROL UNIT ERROR CODES 3-3, 3-4 Error Code 3-3

3-4

Trouble Faulty brake pedal angle sensor low voltage Faulty brake pedal angle sensor high voltage

Cause

Influenced Control The sensor input voltage to the HST control unit is 0.25 HST pump or less. control (50% output) The sensor input voltage to the HST control unit is 4.75 HST pump or more. control (50% output)

YES

Replace brake pedal angle sensor and retry. Check if error code disappears. YES

Disconnect connector of HST control unit. Check for continuity between terminal #48 of harness end connector of HST control unit and terminal #b of harness end connector of brake pedal angle sensor.

Disconnect connector of brake pedal angle sensor. Check if voltage between terminals #a and #c of harness end connector is 5±0.5 V. · Key Switch: ON

Check if voltage between terminal #a of harness end connector of brake pedal angle sensor and body is 5±0.5 V. · Key switch: ON

Connector (Harness end of connector viewed from the open end side) Brake Pedal Angle Sensor Connector c

HST Control Unit Connector

b a T4FG-05-04-007

T4FG-05-04-001

T5-3-14

45ZV-2

TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs. The machine speed cannot increase. Tractive force is reduced. The machine speed cannot increase. Tractive force is reduced.

Remedy Check the sensor angle when not depressing the pedal. Check the harness. Replace the sensor. Check the sensor angle when not depressing the pedal. Check the harness. Replace the sensor.

Faulty brake pedal angle sensor

YES

Faulty HST control unit

Open circuit in harness between terminal #48 of HST control unit and terminal #b of brake pedal angle sensor

Open circuit in harness between terminal #49 of HST control unit and terminal #c of brake pedal angle sensor

Open circuit in harness between terminal #47 of HST control unit and terminal #a of brake pedal angle sensor

T5-3-15

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTROL UNIT ERROR CODE 3-5 Error Code 3-5

Trouble

Cause

Faulty forward/reverse lever

Symptoms in Machine Operation When Trouble Occurs. Machine speed cannot increase.

Influenced Control Control when The following conditions are detected. • The forward and the reverse signals are detected selecting forward and reverse travel at the same time. • Detected machine speed is below in sequence. operation -1 3 km/h (2 mph) with engine speed at 1500 min or more without inputting the forward and the reverse signal. → 0 km/h (0 mph) → 3 km/h (2 -1 mph) with engine speed at 1500 min or more. Remedy Check the harness. Replace the FNR lever.

YES

Disconnect connector of forward/reverse lever. Check for continuity between terminals #e and #f of connector.

Shorted circuit in harness between FNR lever connector and HST control unit connector

Faulty FNR lever NO

Disconnect connector of HST control unit. Check for continuity between terminals #10 and #11 of connector.

YES

Disconnect connector of forward/reverse lever. Check for continuity between terminal #10 of harness end connector of HST control unit and terminal #e of harness end connector of forward/reverse lever. NO

Open circuit in harness between terminal #11 of HST control unit and terminal #f of forward/reverse lever

Open circuit in harness between terminal #10 of HST control unit and terminal #e of forward/reverse lever

Connector (Harness end of connector viewed from the open end side) Forward/Reverse Lever Connector c g

b f

HST Control Unit Connector

a e T4FG-05-04-008

T4FG-05-04-001

T5-3-16

45ZV-2

TROUBLESHOOTING / Troubleshooting A HST CONTROL UNIT ERROR CODES 4-1, 4-2 Error Code 4-1

Trouble

Cause

Faulty low voltage

4-2

Faulty high voltage

Influenced Control The supplied voltage to the HST control unit is 10 V or Normal operation less. The supplied voltage to the HST control unit is 17 V or Normal operation more.

Symptoms in Machine Operation When Trouble Occurs. -

Remedy

Check the battery. Check the alternator. Check the alternator.

YES

Faulty HST control unit

Start engine. Check if battery terminal voltage is within normal range, between 12 V and 15 V. Faulty alternator NO

Check if battery terminal voltage is within normal range, between 11 V and 15 V. · Key switch: OFF Faulty battery NO

T5-3-17

45ZV-2

TROUBLESHOOTING / Troubleshooting A (Blank)

T5-3-18

45ZV-2

TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE (Machine Diagnosis by Using Trouble Symptom) Refer to troubleshooting B for diagnosis by using trouble symptom.

• Engine System Troubleshooting • Travel System Troubleshooting • Brake System Troubleshooting • Steering System Troubleshooting • Front Attachment System Troubleshooting

T5-4-1

45ZV-2

TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM FAILURE LIST Trouble symptoms regarding the engine

1. Starter motor does not operate

2. Hard to start engine

3. Idle speed is unstable.

4. Engine power decreases at high loaded.

5. Excessive dark smoke in the exhaust gas.

6. Engine overheats.

7. Unusual noise is generated from engine.

8. Excessive engine oil consumption.

9. Excessive fuel consumption.

T5-4-2

45ZV-2

TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING Trouble symptoms

1. Starter motor does not operate. Faulty battery

Battery Faulty battery charge

Open circuit or poor contact Looseness or corrosion of terminal Faulty starter switch

Wiring

Faulty starter relay 2 Faulty battery ground cable

Trouble symptoms

2. Hard to start engine

Stuck plunger

Fuel system

Delivery valve malfunction Injection pump

Faulty control rack operation Control pinion looseness Faulty feed pump operation

Insufficient fuel injection

No fuel in the fuel tank Air in the fuel system Water in fuel Clogged fuel filter Others Fuel pipe connection loose Clogged fuel hose Crack or looseness of injection pipe Clogged breather hose in fuel tank

T5-4-3

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

2. Hard to start engine

Fuel system Incorrect injection timing

Wear of tappet, roller and cam

Injection starting pressure is too low.

Faulty nozzle and nozzle holder Seizure of needle valve

Faulty spray pattern

Wear. fatigue or breakage of nozzle spring

Valve burnout

Engine unit

Seizure or wear in valve stem Valve spring breakage Compression pressure decrease

Faulty valve clearance Wear of cylinder, piston and piston ring Sticking or breakage of piston ring Blow-by of head gasket

Faulty engine control mechanism Others Faulty preheat system

T5-4-4

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

3. Idle speed is unstable

Fuel system Plunger spring breakage Delivery valve malfunction Faulty control rack operation Injection pump Faulty governor operation Faulty adjustment of idling spring Faulty fuel pump operation

Injection amount uneven

Air suction in the fuel system Water intrusion in fuel Others Fuel pipe connection looseness Clogged breather hose in fuel tank

Injection timing incorrect

Seizure of needle valve Wear, fatigue of nozzle spring

Faulty spray pattern

Carbon build-up at injection tip

Faulty nozzle and nozzle holder

Injection starting pressure uneven

Engine Unit

Compression loss (Refer to the Hard to start engine)

Others

Faulty engine control mechanism

T5-4-5

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

4. Engine power decreases at high loaded

Fuel system Wear or seizure in plunger Delivery valve malfunction Faulty control rack operation Injection pump Faulty governor operation Faulty fuel pump operation Injection amount uneven Air suction in the fuel system Water intrusion in fuel Others Fuel pipe connection looseness Clogged breather hose in fuel tank

Wear of tappet, roller and cam

Injection timing incorrect

Seizure of needle valve Wear, fatigue of nozzle spring

Faulty spray pattern

Carbon build-up at injection tip

Compression loss (Refer to the Hard to start engine)

Engine Unit

Others

Insufficient intake-air

Clogged air cleaner

Faulty exhaust

Clogged muffler

T5-4-6

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

5. Excessive dark smoke in the exhaust gas

Fuel system Wear or seizure in plunger Plunger spring breakage

Uneven or excess injection

Delivery valve malfunction Faulty control rack operation

Wear of tappet, roller and cam Incorrect injection timing Looseness of tappet adjust bolt

Seizure of needle valve Wear, fatigue of nozzle spring

Faulty spray pattern

Carbon build-up at injection tip

Injection starting pressure is too low.

Looseness of nozzle adjust screw

Compression loss (Refer to the Hard to start engine)

Engine Unit

Others

Clogged air cleaner

Insufficient intake-air

T5-4-7

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

6. Engine overheats

Cooling system Wear of water pump seal Wear or seizure in plunger Water leak

Crack of hose, piping or looseness of clamp Head gasket damage

Faulty water pump operation Clogged radiator Faulty radiator cap Part malfunction Faulty Thermostat Looseness or damage of fan belt Adhered deposit on coolant path

Excessive fuel injection Incorrect injection timing Combustion system Faulty spray pattern Injection starting pressure drop

Faulty engine oil circulation Lubrication system Oil cooler malfunction

Carbon build-up in combustion chamber Clogged muffler

Others

Overload

T5-4-8

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

7. Unusual noise is generated from engine

Injection timing incorrect Injection amount uneven Injection starting pressure too high Knocking noise Faulty spray pattern Faulty fuel ignition Compression pressure decrease (Refer to the Hard to start engine)

Wear of cylinder and piston Seizure or breakage of piston and piston ring Wear of connecting rod small end bushing and piston pin Wear or breakage of crank pin and connecting rod bearing Hammering sound

Wear or breakage of crankshaft journal and journal bearing Excessive axial play of crankshaft and camshaft Looseness of flywheel or crank pulley Wear of tappet and cam Excessive valve clearance

Wear or breakage of bearings of alternator or water pump Continuously sounds

Wear of timing gear or faulty contact Looseness or damage of fan belt

T5-4-9

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

8. Excessive engine oil consumption

Lubrication System Looseness of oil filter installation or faulty O-ring Lubrication System

Looseness of oil pan installation or faulty gasket Looseness of oil pipe connection or pipe cracked

Engine Unit Wear of cylinder liners and pistons Breakage or sticking of piston rings Oil level up Clogged oil holes of piston and oil ring Clogged breather pipe

Wear of valve stem or valve guides Oil level down Faulty valve stem oil seals

Faulty gasket and oil seal

Oil leaks

T5-4-10

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

9. Excessive fuel consumption

Fuel system Wear or seizure in plunger Plunger spring breakage

Uneven or excess injection

Delivery valve malfunction Faulty control rack operation

Wear of tappet, roller and cam Incorrect injection timing Looseness of tappet adjust bolt

Seizure of needle valve Wear, fatigue of nozzle spring

Faulty spray pattern

Carbon build-up at injection tip

Injection starting pressure too low

Looseness of nozzle adjust screw

Compression loss (Refer to the Hard to start engine)

Engine Unit

Others

Overheat (Refer to the Engine overheats.)

Clogged air cleaner

Insufficient intake-air

T5-4-11

45ZV-2

TROUBLESHOOTING / Troubleshooting B VEHICLE SYSTEM FAILURE LIST Trouble symptoms regarding the vehicle performance A: Travel performance 1. The vehicle does not travel at all (traveling is impossible forward and reverse). 2. Traveling is impossible either forward or reverse. 3. Travel speed decreased. 4. Travel at engine low idle operation. 5. HST oil (hydraulic oil) decreases. 6. Leakage from the axle and the reduction gear. 7. Abnormal noise is generated or traveling is impossible.

B: Brake performance 1. Brake valve application force decreases 2. Parking brake does not apply 3. Dragging of parking brake

C: Steering performance 1. Steering operation is impossible or heavy 2. Machine mistracks.

T5-4-12

45ZV-2

TROUBLESHOOTING / Troubleshooting B

Trouble symptoms regarding the vehicle performance D: Work performance 1. Lift arm does not raise or the raising time is long. 2. Excessive lift arm cylinder drift at the neutral position of control lever. 3. It is impossible to raise the front wheel with the lift arm cylinder. 4. The lift arm cylinder drift is too fast at a specific position. 5. When trying to raise the lift arm, it lowers before it rises. 6. Bucket roll back time is too long or operation force is weak. 7. Bucket dump drift is excessive when the loader control lever is in neutral position. 8. Bucket dump speed increases too quickly at a specified position. 9. Bucket wobbles while traveling. 10. The operation of loader control lever is too stiff.

T5-4-13

45ZV-2

TROUBLESHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING Trouble symptoms

A-1. The vehicle does not travel at all (traveling is impossible forward and reverse)

(1) Oil shortage in the hydraulic oil tank

Check the hydraulic oil level. 1. Park the machine on level ground. 2. Lower the bucket or the attachment to the ground horizontally. 3. Stop the engine. Check that the oil level of the sight glass is between the upper limit mark and the lower limit mark. T4FG-05-02-001

Hydraulic oil level is low.

Hydraulic oil level is normal.

Repair oil leak and add oil.

M4EJ-07D-002

(2) Clogged suction strainer

Remove suction strainer (1) in the hydraulic oil tank. Check for restrictions.

Restricted

Not restricted

Check HST filter element (2) and hydraulic oil filter element (3). Check for the foreign particles, which cause suction strainer (1) restriction.

Clean suction strainer

3 T4FG-05-02-002

Repair of hydraulic cylinders and hose

Repair of hydraulic pump

(Metal fragments including copper powder)

(Nylon and rubber pieces)

T5-4-14

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-1. The vehicle does not travel at all (traveling is impossible forward and reverse)

(3) Degradation and milky white hydraulic oil, or use of improper hydraulic oil.

Perform the check of hydraulic oil. 1. Check if oil is degraded and discolored to brown. 2. Check if water entered oil and oil is discolored to white. 3. Check if bubbles (air) are mixed in oil and oil is discolored to white. (Air is sucked from oil pump inlet system) 4. Check if the specified hydraulic oil (especially pay attention to viscosity) is used. (Refer to the Operator's Manual.)

Oil: Faulty

T4EJ-05-04-003

Oil: Normal

Oil: Change

(4) Wear of the spline of HST pump, damage of coupling.

Check if bucket operation and steering operation operate properly.

Not operable

Operable 2

Wear of the spline of HST pump drive shaft (1), damage of coupling (2)

T4FG-05-02-004

Replacement of drive shaft and coupling

T5-4-15

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-1. The vehicle does not travel at all (traveling is impossible forward and reverse)

(5) Faulty operation or faulty adjustment of brake (inching) pedal linkage

Confirm that the brake (inching) lever is in the closed position. 1. Stop the engine, adjust stopper (2) so that dimension A is 180±5 mm (7.1±0.2 in) when brake (inching) pedal (1) is not operated (when not depressing the pedal). 2. Adjust nut (3) so that dimension B is 160 mm (6.3 in). NOTE: When the pedal is not depressed, confirm that the inching lever of the brake pedal angle sensor (3) always returns to the closed position.

Lever is not at the closed position.

Lever is at the closed position.

Repair or adjustment of linkage

Open 42° Brake Pedal Angle Sensor Close

1 2 A

T4FG-05-02-005

T5-4-16

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-1. The vehicle does not travel at all (traveling is impossible forward and reverse)

(6) Faulty parking brake solenoid valve or parking brake switch (dragging brake).

Measure the terminal voltage of parking brake solenoid valve. 1. After starting the engine, operate the parking switch to OFF. 2. Check that the forward/reverse lever is locked in neutral. 3. Disconnect the connector of parking brake solenoid valve. 4. Operate the parking brake switch from OFF to ON and measure voltage. (Measure with machine side connector.) Specification: Voltage 10.95 to 14.4 V

Out of Specification

Within Specification

Faulty parking brake solenoid Valve.

1. Faulty parking brake switch 2. Faulty parking brake relay [1] 3. Poor contact of connector and ground line

Replacement of faulty parts

T5-4-17

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-1. The vehicle does not travel at all (traveling is impossible forward and reverse)

(7) Faulty pump solenoid valve

Measure the terminal voltage of pump solenoid valve. 1. After starting the engine, operate the parking switch to OFF. 2. Check that the forward/reverse lever is locked in neutral. 3. Disconnect the connector of pump solenoid valve in the HST pump. (Measure with machine side connector.) Specification: Voltage 10.95 to 14.4 V

Out of specification

Within Specification

Normal

1. Faulty pump solenoid valve 2. Poor contact of connector and ground line

Replacement of faulty parts

Pump Solenoid Valve

(Machine Side)

T4FG-05-02-006

T5-4-18

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-1. The vehicle does not travel at all (traveling is impossible forward and reverse)

(8) Hydraulic pressure drop of low-pressure relief valve

Measure hydraulic pressure in the low-pressure (charging) circuit. 1. Measure HST charging pump delivery pressure according to Operational Performance Test. 2. As for specification, refer to Operational Performance Standard. NOTE: Measure hydraulic oil temperature at operating temperature (40 to 60°C (104 to 140°F)).

Out of specification

Within Specification

Remove low-pressure relief valve. Check for a foreign object, damage or stuck material at the seat surface.

T5-4-19

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-2. Traveling is impossible either forward or reverse

(1) Faulty forward/reverse lever or electrical wiring.

Measure the terminal voltage of forward/reverse selection solenoid valve. 1. After starting the engine, turn the parking switch ON. 2. Disconnect the connector of forward/reverse selection solenoid valve. 3. Set the forward/reverse lever in the Neutral position and turn the parking brake switch OFF. (Perform the measurement below on the machine side connector.) 4. Engage the forward/reverse lever in the Forward position and measure voltage. Specification: Voltage 10.95 to 14.4 V 5. Engage the forward/reverse lever in the Reverse position and measure voltage. Specification: Voltage 10.95 to 14.4 V

Out of specification

Within Specification

Faulty solenoid on measured side Possible faulty wiring harness

1. Faulty forward/reverse lever 2. Faulty parking brake relay [1] 3. Faulty parking brake switch

Replace faulty parts Solenoid (for Reverse)

Machine Side

Machine Side Solenoid (for Forward)

T5-4-20

T4FG-05-02-008

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-2. Traveling is impossible either forward or reverse

(2) Measurement of hydraulic pressure in high-pressure circuit (HST Pump)

Measure high-pressure circuit in HST pump. 1. Install the oil pressure gauge to the gauge port MA (Forward). (G 1/4) 2. Measure HST pump relief pressure according to Operational Performance Test. 3. As for specification, refer to Operational Performance Standard.

Hydraulic pressure drop

Within Specification

Faulty high-pressure relief valve

HST motor check

Port MA

T4FG-05-02-007

T5-4-21

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-2. Traveling is impossible either forward or reverse

(3) Faulty high-pressure relief valve

Remove and check the high-pressure relief valve. 1. Check for faulty (looseness and so on) high-pressure relief valve installation. (If the relief valve is loose, the circuit between high-pressure and low-pressure is connected and pressure decreases.) 2. If there is no installation fault, remove the high-pressure relief valve. Check for foreign objects on valve seat surface. 3. Switch the forward high-pressure relief valve and the reverse high-pressure relief valve. Check for the change of trouble symptoms. 4. Replace the high-pressure relief valve with a new one and check if trouble symptoms disappear.

Abnormal

Normal

Repair or replacement of high-pressure relief valve

HST motor assembly check

High-Pressure Relief Valve

T4FG-05-02-007

T5-4-22

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-3. Travel speed decreases.

Confirm travel speed Measure the travel speed according to Operational Performance Test.

Travel speeds decrease in each mode.

Low mode: Specification High mode: The speed cannot reach maximum.

Engine power is low

Dragging of brake (service, parking)

Specification

Normal

(1) Engine power shortage (poor speed)

Measure the engine fast idle speed under no load. Measure the engine fast idle speed under no load according to Engine Performance Test / Engine speed.

Out of Specification

Within Specification

Investigate the reason why the engine speed decreases under no load. 1. The adjustment of control is faulty. Even if the accelerator pedal is fully depressed, the pedal does not get in contact with the fast idle stopper. 2. Clogged fuel filter or air filter 3. Faulty fuel pump or injection nozzle 4. Other engine trouble

Measure of boom stroke speed 1. Place the lift arm to the highest position. 2. In addition, set the lever to the “Raise” position. Operate the main relief valve and measure the engine speed. 3. As for specification, refer to Operational Performance Standard.

T4FG-05-02-009

Out of Specification

Within Specification Dragging of brake (service, parking)

Engine repair

T5-4-23

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-4. Travel at engine low idle speed.

(1) Engine low idle speed is too high.

Measure the engine low idle speed. 1. Measure the engine low idle speed according to Engine Performance Test / Engine speed. 2. As for specification, refer to Operational Performance Standard.

Out of Specification

Within Specification

1. The adjustment of accelerator linkage is faulty. Even if the accelerator pedal is returned, the pedal does not get in contact with the low idle stopper in the governor. 2. Foreign objects get caught in the accelerator pedal and the accelerator pedal is not returned completely. 3. Rust and sticking of accelerator linkage.

Faulty bleeding air from HST circuit. 1. Fill HST pump and motor with hydraulic oil. 2. Place directional selector lever in neutral. 3. Idle at low idle for 3 minutes. System should be free from air at this point.

(2) Faulty bleeding air from HST circuit

1. When the machine travels with the forward/reverse lever set in the Neutral position, check the hydraulic oil. (Especially pay attention to viscosity.) 2. After the engine starts, when the machine travels with the forward/reverse lever set in the Neutral position for a moment, bleed air from HST circuit. Cause of trapping air is replacement of hydraulic oil filter or element, repair of motor or residual air when replacing HST piping or hose. If any cause cannot be found, as air may be sucked from the loosened part of HST piping and hose, check and retighten the hose and piping.

T5-4-24

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-5. HST oil (hydraulic oil) decreases.

(1) Faulty rear oil seal (1) of HST motor

When there is a leak at the seal of the HST motor (1), oil in the hydraulic oil tank lowers, and the oil level in the reduction gear box rises. Oil blowoff leakage from the breather is present. CAUTION: If operating with a low level of hydraulic oil, repair it immediately as a serious failure may occur to HST pump or motor, such as seizure of moving parts.

HST Motor

Breather

Reduction Gear Box

1 T4FG-05-02-018

T5-4-25

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-6. Leakage from the axle and the pinion gear shaft

(1) Oil leaks from tightening nut (2) on drive pinion (1) of the front axle

Looseness between drive pinion (1) and the spline of input flange (3)

Faulty O-ring (4) on the spline

Remove tightening nut (2) and turn input flange (3) by hand. Check for looseness at the spline

Loose

Not loose

Replace O-ring (4)

Replace drive pinion (1) or input flange (3) or both

3 T4FG-05-02-010

4 2

T5-4-26

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-6. Leakage from the axle and the reduction gear

(2) Oil leaks from oil seal (5) of front axle input flange (3)

Faulty oil seal (5) or wear of the seal running surface of input flange (3)

Wear or damage of bearings (6), (7)

Turn input flange (3) by hand. Check for looseness of the flange

Loose

Not loose

Replace bearings (6), (7)

Replace oil seal (5) or input flange (3) or both

6 5 3 T4FG-05-02-010

T5-4-27

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-6. Leakage from the axle and the planetary gear

(3) Oil leaks from oil seal (1) of wheel hub

Faulty oil seal (1)

Wear and damage of bearings (2), (3)

Remove the wheel and move the wheel hub (4) by hand. Check for looseness of axial direction and periphery direction

Loose

Not loose

Replace bearings (2), (3)

Replace oil seal (1)

T4FG-05-02-011

T5-4-28

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-6. Leakage from the axle and the reduction gear

(4) Oil leaks from output flange (1) tightening nut (2) of the reduction gear box

Looseness between shaft (3) and the spline of output flange (1)

Faulty O-ring (4) in the spline

Remove tightening nut (2) and turn output flange (1) by hand. Check for looseness at the spline

Loose

Replace shaft (3) or output flange (1) or both

Not loose

Replace O-ring (4)

1 2 3

T4FG-03-06-002

T5-4-29

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-6. Leakage from the axle and the reduction gear box

(5) Oil leaks from oil seals (5), (6) of output flanges (1)

Wear and damage of bearings (7), (8)

Faulty oil seal (5), (6) or wear of the seal running surface of input flange (1)

Turn output flange (1) by hand. Check for looseness at the spline

Loose

Not loose

Replace bearings (7), (8)

Replace oil seals (5), (6) or output flanges (1)

6 T4FG-03-06-002

T5-4-30

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-7. Abnormal noise is generated or traveling is impossible

(1) Shortage, degradation, or deterioration of oil in the axle housing

Remove level plug in the axle housing. Check oil level. In addition, remove drain plug. Check for any abnormality such as dirt, milky white material (water emulsification of oil) or incorrect viscosity of oil.

Abnormal

Normal

Add oil to the specified level or change oil (As for the specified oil, refer to Operator's Manual)

(2) Shortage, degradation, or deterioration of oil in the reduction gear box

Check oil amount in the reduction gear box. In addition, check for any abnormality such as dirt, milky white material (water emulsification of oil) or incorrect viscosity of oil.

Low oil level Degradation and deterioration

Excess oil level

Add oil to the specified level or change oil (As for the specified oil, refer to Operator's Manual)

Check oil level. When level is too high, remove drain plug and drain oil to the specified level. Then, operate the machine and check oil level.

T5-4-31

Normal

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-7. Abnormal noise is generated or traveling is impossible

Looseness of spline (2) of the propeller shaft due to wear or damage of universal joint (1).

Remove the propeller shaft assembly. Check for looseness of spline part (2) or wear and damage of universal joint (1).

Replacement of faulty parts

Front Axle to Reduction

1 2 T4FG-05-02-012

T5-4-32

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

A-7. Abnormal noise is generated or traveling is impossible

Wear and damage of axle inner parts

Wear and damage of reduction gear box inner parts

Drain and recover oil. Check for foreign objects (fragments and metal powder from gear and bearings).

Foreign matter present

Replacement of defect parts

When the area (front, rear axle or reduction gear box) of unusual noise is not easily found, identify the faulty area by using the following methods. 1. Raise the machine and hold the machine up by using stands. 2. Remove propeller shaft (1) and operate only the rear wheels. If unusual noise stops, it can be determined that trouble is in the front axle. If unusual noise continues, the trouble is in the rear axle.

Front Axle

Reduction Box Rear Axle

1 T4FG-05-02-013

T5-4-33

45ZV-2

TROUBLESHOOTING / Troubleshooting B BRAKE SYSTEM TROUBLESHOOTING Trouble symptoms

B-1. Brake valve application force decreases

(1) Leakage from the brake piping

Check oil amount in the brake oil tank in the master cylinder. If oil level is low, check for oil leaks from the master cylinder and brake piping.

Brake oil low level

Normal

Oil leaks to the exterior are found.

Oil leaks to the exterior are not found.

Repair oil leaks Add brake oil

Add brake oil to specification.

Mixing air in brake system

Operate the service brake. Check oil level in the brake oil tank.

Oil level lowers

Oil level is normal.

Oil leaks at the reduction gear.

When there are no external brake oil leaks and brake oil level lowers quickly, oil leaks may occur in the front axle. 1. Wear and damage of O-ring of the brake piston or O-ring of the parking brake piston. 2. Wear and damage of piston sliding surface.

Replace O-ring or faulty parts

T5-4-34

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

B-1. Brake valve application force decreases

(2) Air in brake system

Depress brake pedal and check for a soft sponge-like application.

Has sponge-like feeling

Not sponge-like

Bleed air from system

(3) Faulty brake master cylinder

Check if the pedal can be stopped with the brake pedal depressed. When oil leaks occur in the brake master cylinder, the brake pedal does not stroke normally, even when the brake pedal is firmly depressed. Causes of oil leaks in the master cylinder are: 1. Wear and damaged cup (1) 2. Wear and damage of cylinder inner surface CAUTION: In case of faulty cup (2), oil leaks to atmosphere may occur. 2

T4FG-05-02-014

Without internal oil leaks

With internal oil leaks

Repair or replace master cylinder

T5-4-35

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

B-1. Brake valve application force decreases

(4) Brake chatter is heard when service brake is applied.

Degradation of brake oil or axle oil. Use of incorrect brake oil Check brake oil and axle oil. The wet disc brakes are built into the front axle. When using degraded oil or other than the specified (different viscosity) oil for the brake circuit, may cause a decrease of brake valve application force, brake chatter and abnormal wear.

Degradation of oil, water intrusion or use of other than specified oil

There is a burned smell from axle oil.

Change brake oil

Change axle oil

Normal

(5) Wear or damage of brake disc or brake plate

Wear of brake disc (1), brake plate (2) or damage of brake piston sliding face As for the allowable limit of brake disc (1) and brake piston (2), refer to Operational Performance Standard. 1

T4FG-05-02-015

NOTE: Abnormal or premature wear of brake disc (1) or plates (2) way be caused by dragging brakes.

Replace faulty parts.

T5-4-36

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

B-2. Parking brake does not apply

(1) Parking brake does not apply whether the engine stops or the engine runs.

Wear or damage of brake disc (1) or brake plate (2)

Refer to B-1 step (5).

(2) Parking brake applies when the engine stops, but it is not applied when the engine runs and the parking switch is set to the ON position.

Faulty parking brake solenoid valve, parking switch or parking brake relay When the parking brake does not apply when the parking switch is set to the ON position, the following trouble may occur. 1. The parking solenoid is energized → Faulty switch, relay or harness 2. The parking brake solenoid valve is stuck in the released position. NOTE: When the parking brake is normal after performing step (1) and step (2), measure the parking brake oil pressure at the illustrated measuring points. Specification: 0 kgf/cm²

Parking Brake Solenoid Valve

T4FG-05-02-016

Repair or replace faulty parts

T5-4-37

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

B-3. Dragging of parking brake

(1) Faulty parking brake electrical system

Measure the terminal voltage of parking brake solenoid. 1. After starting the engine, operate the parking switch to RESET. 2. Check that the forward/reverse lever is locked in neutral. 3. Disconnect the connector of parking brake solenoid valve. 4. Operate the parking brake switch from ON to OFF and measure the voltage. (Measure with machine side connector.) Specification: Voltage 10.95 to 14.4 V

Parking Brake Solenoid Valve

T4FG-05-02-017

Machine Side

0 V or operating voltage or less

Normal.

1. Faulty parking brake switch 2. Faulty parking brake relay 3. Poor contact of connector and ground line 4. Faulty wiring harness

Faulty parking brake solenoid valve

Replace faulty parts

T5-4-38

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

B-3. Dragging of parking brake

(2) Faulty parking brake hydraulic system

Measure parking brake oil release pressure (charging pressure). 1. Disconnect the hose from Port G (G 1/4) on HST pump and install the oil pressure gauge. 2. Start the engine and measure the pressure. Specification is equal to standard value of HST charging pump delivery pressure. 3. As for specification, refer to Operational Performance Standard. 4. Measure hydraulic oil temperature at operating temperature (40 to 60°C (104 to 140°F)).

Out of Specification

Within Specification

Faulty parking brake solenoid valve

Normal.

T4FG-05-02-007

Port G (G 1/4)

T5-4-39

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

B-3. Dragging of parking brake

(3) Faulty parking brake hydraulic system

Measure parking brake oil pressure on the parking brake solenoid side. 1. Remove hose of the parking solenoid valve side. Install the oil pressure gauge. 2. Start the engine and operate the parking switch to RESET. Measure the pressure. Specification is equal to standard value of HST charging pump delivery pressure. 3. As for specification, refer to Operational Performance Standard. 4. Measure hydraulic oil temperature at operating temperature (40 to 60°C (104 to 140°F)).

Release oil pressure or less

Stuck parking brake solenoid valve

Replace parking brake solenoid

Parking Brake Solenoid Valve T4FG-05-02-016

T5-4-40

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

B-3. Dragging of parking brake

(4) Seizure in brake disc and brake plate

Disassemble the parking brake. Check for seizure and damage (warpage) of brake discs (1) and brake plates (2). As for allowable limit for wear of brake disc (1) and brake piston (2), refer to Operational Performance Standard.

T4FG-05-02-015

Replace faulty parts

T5-4-41

45ZV-2

TROUBLESHOOTING / Troubleshooting B STEERING SYSTEM TROUBLESHOOTING Trouble symptoms

C-1. Steering operation is impossible or heavy

Measurement of steering time When some complaints about “Steering operation is heavy” are received, first measure the steering time. Check whether the steering feels heavy (slow) regardless of normal function or if the steering is heavy (slow) due to a malfunction. Measure the hydraulic cylinder cycle time according to Operational Performance Test. 1. Park the machine on a level paved road with traveling position. Release the parking brake. 2. Keep hydraulic oil temperature at operating temperature (about 40 to 60°C (104 to 140°F)). 3. The bucket must be empty. 2 4. Check the tire air pressure. Standard air pressure: 240 kPa (2.4 kgf/cm , 34.8 psi) 5. Measure the steering time from the left stop to the right stop and from the right stop to the left stop at high idle speed. As for specification, refer to Operational Performance Standard.

Out of Specification

Within Specification

Normal

D-1 (1) Oil level low in the hydraulic oil tank D-2 (2) Clogged suction strainer

T5-4-42

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

C-1. Steering operation is impossible or heavy

(1) Hydraulic pressure drop at steering main relief valve

Measure steering oil pressure. Measure the steering relief pressure according to Operational Performance Test. As for specification, refer to Operational Performance Standard.

Out of Specification

Within Specification

Repair or replace main pump

Normal

(2) Damage of piston seals in steering cylinder

Perform the internal oil leak check of steering cylinder. 1. Turn the steering wheel to the right and get in contact with the frame stopper. Stop the engine. 2. Remove cylinder rod side hose (1) of steering cylinder. Install plug (2) to hose (1). 3. Start the engine and set engine speed at fast idle. Supply pressure oil to the cylinder bottom side while turning the steering wheel to the right. 4. If pressure oil flows out from cylinder port (3), the piston seals in cylinder may be damaged.

1 2 3

T4EJ-05-04-027

With oil leaks

No oil leaks

Repair of steering cylinder

Normal.

T5-4-43

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

C-1. Steering operation is impossible or heavy

(3) Faulty steering valve (sticking or wear of spool and sleeve)

Measure the operating force of steering wheel. 1. Park the machine on a level paved road in traveling position. Release the parking brake. 2. Keep hydraulic oil temperature at operating temperature (40 to 60°C (104 to 140°F)). 3. The bucket must be empty. 4. Measure the operating (rotational) force of steering wheel at engine low idle speed and high idle speed in this condition. At the same time, check for unevenness (sticking) of operating (rotational) force. As for specification, refer to Operational Performance Standard.

Measure the slip amount of steering wheel. 1. Turn the steering wheel completely to the right or left and cause the chassis to contact the frame stopper (end of stroke). 2. While turning the steering wheel from this point, the steering wheel rotates while slipping due to the internal leaks of steering valve. Measure the revolutions of steering wheel per 1 minute. Specification Specification on a new machine: 3.5 rev/min When the amount of steering wheel slippage reaches 5.25 rev/min or more, steering valve repair or replacement is required as the internal leaks become excessive.

Out of Specification

Repair or replace steering valve

T5-4-44

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

C-1. Steering operation is impossible or heavy

(4) Faulty priority valve operation

Disassemble and check priority valve. The causes of faulty priority valve operation are shown below. 1. Stuck spool (1) 2. Clogged orifice (2) 3. Permanent deformation of spring (3) 2

W4FC-03-11-003

Repair or replace priority valve

T5-4-45

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

C-2. Machine mistracks

(1) Faulty steering valve (sticking or wear of spool and sleeve) (2) Damage of piston seals in steering cylinder

Refer to C-1 (3), (4).

(3) Looseness of the steering cylinder mounting pin part and center pin

Check of looseness Replacement of pin and bushing

(4) Tire wear or not uniform air pressure in tire

Check for abnormal wear, pressure drop (blowout) of the specified tire, use of other than the specified size tires and so on. Repair, replacement or air charge of tire

T5-4-46

45ZV-2

TROUBLESHOOTING / Troubleshooting B FRONT ATTACHMENT SYSTEM TROUBLESHOOTING Trouble symptoms

D-1. Lift arm does not raise or the raising time is long.

Measure the raising time of lift arm. When complaints about “Lift arm rising time is slow” are received, measure the lift arm raising time first. Check whether the lift arm raising speed is slow regardless of normal function, or if the lift arm raising speed is slow due to a malfunction. 1. Measure the time with a stopwatch required for raising the lift arm from the ground to the maximum height according to Operational Performance Test. NOTE: The value is the specification for a new machine. The machine becomes slightly slower after high hours of operation.

T4FG-05-02-020

The lift arm raising speed is considerably slower than specification.

Within Specification

(1) Low oil level in the hydraulic oil tank

Normal

T5-4-47

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-1. Lift arm does not raise or the raising time is long.

(1) Low oil level in the hydraulic oil tank

Check the oil level in the hydraulic oil tank. 1. Park the machine on level ground. 2. Lower the bucket or the attachment level to the ground. 3. Stop the engine. Check that the oil level is within the lower sight glass.

M4EJ-07D-002

Hydraulic oil level is normal.

Hydraulic oil level is low.

Cavitation noise from the pump

Repair oil leak and add hydraulic oil.

(2) Clogged suction strainer (1)

Remove suction strainer (1) in the hydraulic oil tank. Check for restriction.

With restriction

T4FG-05-02-002

No restriction

Check HST filter element (2) and hydraulic oil filter element (3). Check for foreign particles, which cause suction strainer (1) restriction.

Clean suction strainer

Aluminum or metal fragments

Nylon and rubber pieces

Repair hydraulic pump

Repair hydraulic cylinders or hose

T5-4-48

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-1. Lift arm does not raise or the raising time is long.

(3) Faulty adjustment of control link

(mm (in)) Dump

Measure the stroke of control lever.

In Neutral

7.2 (0.3)

7.2 (0.3) Tilt

Remove nut (1). Operate the lever to each position and check if rod ends (2) and (3) are moved more than the specification of spool.

Float 5.6 (0.2) Lower 7.2 (0.3) In Neutral 7.2 (0.3) Raise

Bucket Spool

Specification or less

Specification or more

Adjustment or repair of control link

Repair of control valve

6 (0.2)

Lift Arm Spool T4FG-05-02-022

(mm (in)) 203 (8.0) 190 (7.5) 11 (0.4) 13 (0.5)

Loader Control Lever Control Lever (Auxiliary spool)

Control Valve T4FGE-05-02-021

Control Cable

T5-4-49

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-1. Lift arm does not raise or the raising time is long.

(4) Hydraulic pressure drop of main relief valve or faulty main pump

Measure the main hydraulic pressure of control valve. Measure the main relief pressure according to Operational Performance Test. Specification: Refer to Operational Performance Standard

Hydraulic pressure drop

Adjustment or replacement of relief valve (Perform the adjustment according to Operational Performance Test.)

Pressure does not increase even after adjustment.

Adjustment of overload relief valve, repair, or replacement of main pump Main Relief Valve Control Valve

Hydraulic Pressure Down (Counterclockwise)

Lock Nut

Hydraulic Pressure Raise (Clockwise) Adjusting Screw

T5-4-50

T4FGE-05-04-001

45ZV-2

TROUBLESHOOTING / Troubleshooting B

Trouble symptoms

D-1. Lift arm does not raise or the raising time is long.

(5) Faulty priority valve operation

Disassemble and check the priority valve 1. Check for stuck spool (1) or clogged orifice (2).

If sticking or restricted

Normal

Clean or replace defective parts

W4FC-03-11-003

T5-4-51

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-1. Lift arm does not raise or the raising time is long.

(6) Damage of piston seals in lift arm cylinder

Perform internal oil leak check of lift arm cylinder. 2. Tilt (roll backward) the bucket and lower the lift arm to the lowest position. 3. Remove hose (1) of lift arm cylinder bottom side. Install plug (2) in order to prevent the oil from spouting from hose (1). 4. Start the engine. Set the loader control lever to the Lower position and apply hydraulic pressure on lift arm cylinder rod side. NOTE: Do not shift the loader control lever from the Lower position to the Float position at this time. 4. If pressurized oil flows out from lift arm cylinder bottom side port (3), the piston seals in cylinder may be damaged.

Repair of lift arm cylinder

T4FG-05-02-024

T5-4-52

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-1. Lift arm does not raise or the raising time is long.

(7) Breakage of the coupling of HST pump or main pump, or spline wear.

When the lift arm does not move at all when the front attachment and the steering are operated, start the engine and check if the machine moves.

Machine does not move

Machine moves

Wear of spline of coupling (1) in main pump, wear or breakage of coupling (2) in HST pump, or wear of the spline

Repair or replace defective parts

2 1

T4FG-05-02-025

T5-4-53

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-2. Excessive lift arm cylinder drift at the neutral position of control lever Measure the lift arm cylinder drift.

For complaints that the “Lift arm drifts at the Hold (Neutral) position of control valve”, first check the lift arm drift specification. 1. Measure the hydraulic cylinder drift amount according to Operational Performance Test. 2. As for specification, refer to Operational Performance Standard.

Within specification

The hydraulic cylinder drift amount is considerably larger than specification.

Normal

T5-4-54

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-2. Excessive lift arm cylinder drift at the neutral position of control lever

(1) Damage of piston seals in lift arm cylinder

Perform internal oil leak check of lift arm cylinder. 1. Tilt (roll backward) the bucket and lower the lift arm to the lowest position. 2. Remove hose (1) of lift arm cylinder bottom side. Install plug (2) in order to prevent the oil from spouting from hose (1). 3. Start the engine. Set the loader control lever to the Lower position and apply hydraulic pressure on lift arm cylinder rod side. NOTE: Do not shift the loader control lever from the Lower position to the Float position at this time. 4. If pressurized oil flows out from lift arm cylinder bottom side port (3), the piston seals in cylinder may be damaged.

Repair of lift arm cylinder

T4FG-05-02-024

T5-4-55

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-2. Excessive lift arm cylinder drift at the neutral position of control lever

(2) Faulty oil tight in control valve lift spool

Disassemble and check the control valve. 1. When there is a dent, scratch, rust or corrosion on spool (1) or housing (2), repair by using sandpaper #2000 or oil stones. 2. If the repair is impossible, replace the plunger section as an assembly.

Repair control valve or replace plunger section assembly

T4FG-05-02-026

T5-4-56

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-3. It is impossible to raise the front wheel with the lift arm cylinder.

(1) Faulty make-up valve operation

Cylinder drift of lift arm is normal. Raise the front wheel by fully dumping the bucket and using the lift arm cylinder. If it is impossible to raise and hold up the front wheel, remove and check the make-up valve. 1. When the poppet seal surface (2) of make-up valve (1) is in poor condition, pressurized oil on piston rod side will directly relieve to the drain circuit through make-up valve; it is impossible to hold the front wheel raised by the lift arm cylinder.

Clean or replace make-up valve

T4FG-03-02-015

T5-4-57

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-4. The lift arm cylinder drift is too fast at a specific position.

(1) Expansion or scratch of the lift arm cylinder tube

Measure the lift arm cylinder tube inner diameter. Check for expansion in a given area. In addition, check for a dent or scratch on the piston sliding surface. Standard diameter: inner diameter:

85 mm (3.3 in)

Repair or replace lift arm cylinder tube

T4FG-05-02-027

Cylinder Gauge (Inner Diameter Measurement)

T5-4-58

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-5. When trying to raise the lift arm, it lowers before it rises.

(1) Faulty load check valve

When the cylinder drift of the lift arm is normal and the lift lever is placed in the raise position while loading the bucket, when the lift arm drops slightly prior to rising, remove and check the load check valve (1). 1. When the load check valve (1) is normal, oil flows from the control valve to the bottom side of lift cylinder. However pressurized oil cannot flow from the cylinder to the control valve. 2. Therefore, even if a load is applied on the bucket and lift cylinder piston side pressure P1 is larger than pressure P2 (at low speed and low pressure), the lift arm does not lower. 3. Damage of poppet seat surface (2), foreign objects trapped in valve, or stuck poppet or damage of spring (3) permits pressurized oil to flow from P1 to P2 and the lift arm is lowered for momentarily prior to reengaging the circuit and raising the boom arms.

Main Relief Valve

3 T4FG-05-02-028

Clean or replace load check valve

T5-4-59

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-6. Bucket roll back time is too long or operation force is weak. Measure the operating (tilt back) time of the bucket.

For complaints that the “Bucket operation is slow”, first measure the bucket operating time. Check whether the bucket operation is actually slow or the bucket operation is slow due to a malfunction. 1. Measure the time for operating the bucket from maximum dump to maximum roll back at the highest position of lift arm according to Operational Performance Test. NOTE: The value is the specification for a new machine. The machine becomes slightly slower after high hours of operation.

T4FG-05-02-029

Within Specification

The operating speed is considerably slower than specification.

Normal

(1) Low oil level in the hydraulic oil tank (2) Clogged suction strainer (3) Looseness or faulty adjustment of control link (4) Hydraulic pressure drop of main relief valve or faulty main pump (5) Faulty priority valve operation

T5-4-60

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-6. Bucket roll back time is too long or operation force is weak.

(1) Damage of piston seals in bucket cylinder

Perform a bucket cylinder internal oil leak check. 1. Lower the lift arm to the lowest position and roll the bucket back. 2. Remove hose (1) from bucket cylinder rod side. Install plug (2) in order to prevent the oil from spouting from hose (1). 3. Start the engine. Set the loader control lever to the roll back position and apply hydraulic pressure on the bucket cylinder bottom side. 4. If pressurized oil flows out from bucket cylinder port (3), the piston seals in cylinder may be damaged.

Repair of bucket cylinder

T4FG-05-02-030

T5-4-61

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-6. Bucket roll back time is too long or operation force is weak.

(2) Hydraulic pressure loss of overload relief valve Measurement of overload relief valve hydraulic pressure 1. Measure the overload relief pressure according to Operational Performance Test. As for specification, refer to Operational Performance Standard. 4

2. Increase the set pressure of main relief valve (1). When tightening the adjusting screw, when hydraulic pressure does not increase, the gauge reading is the set pressure of piston rod side overload relief (2). After measuring and adjusting the overload relief valve set pressure, return the main relief valve (1) set pressure to its normal setting. 3. Lower the bucket onto the ground horizontally. Remove and replace tilt cylinder hoses (4) and (5) on the cylinder side. (Connect hose (4) to the cylinder bottom side and insert hose (5) to the rod side.)

NOTE: With hoses reversed, the bucket tilts back when operating the loader control lever to the dump side. With opposite lever action, the bucket is dumped when operating the loader control lever to the roll back side. Increase the set pressure of main relief valve (1). Operate the loader control lever to roll back continuously. (The bucket is being placed in the dump position.) When tightening the adjusting screw, if the hydraulic pressure does not increase, the pressure shown on the pressure gauge is the set pressure of cylinder bottom side overload relief valve (3). After measuring and adjusting the overload relief valve set pressure, return the main relief valve (1) set pressure to specification. Return tilt cylinder hoses (4) and (5) to the original position. 4. Set pressure specifications of overload relief valves. Specification: Refer to Operational Performance Standard

T5-4-62

T4FG-05-02-031

A B

Control Valve

1 T4FGE-05-04-002

A: Tightening (clockwise) → Oil pressure increase B: Loosening (counterclockwise) → Oil pressure decrease

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-6. Bucket roll back time is too long or operation force is weak.

(3) All of measurement values in paragraph 1 to paragraph 3 of Measurement of Overload Relief Valve Hydraulic Pressure are the same or lower than the main relief valve specification

Faulty main relief valve.

Faulty main pump.

Faulty overload relief valves or faulty adjustment of both overload relief valves (2) and (3)

(4) Measurement values in paragraph 1 to paragraph 2 of Measurement of Overload Relief Valve Hydraulic Pressure are the same or lower than the main relief valve specification. In addition, measurement value in paragraph 3 is at specification.

Faulty overload relief valves or faulty adjustment of overload relief valve (2) <Adjustment Methods> (1) According to paragraph 2 of Measurement of Overload Relief Valve Hydraulic Pressure, hydraulic pressure of overload relief valve (2) can be measured by using an oil pressure gauge. (2) Loosen lock nut (6) of overload relief valve (2) (3) While reading the needle of oil pressure gauge, turn adjusting screw (7) by using a hexagonal Allen wrench so that the needle indicates specified pressure. A: Tightening (clockwise) → Oil pressure increases B: Loosening (counterclockwise) → Oil pressure decreases Specification: Refer to Operational Performance Standard NOTE: As the relief valve adjustment is very sensitive, do not loosen quickly. ٠ Hold adjusting screw (7) by using a hexagonal Allen wrench and secure by using lock nut (6). ٠ Measure the overload relief pressure again and confirm that set pressure is to specification. ٠ Adjust the main relief valve set pressure to specification.

Control Valve

T4FG-03-02-013

T4FGE-05-04-002

T5-4-63

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-6. Bucket roll back time is too long or operation force is weak.

(5) All of measurement values in paragraph 1 to paragraph 3 of Measurement of Overload Relief Valve Hydraulic Pressure are the same or lower than the main relief valve specification. In addition, measurement value in paragraph 2 is to specification.

Faulty overload relief valve or faulty adjustment of overload valve (3)

<Adjustment Methods> (1) According to paragraph 3 of Measurement of Overload Relief Valve Hydraulic Pressure, hydraulic pressure of overload relief valve (3) can be measured by using an oil pressure gauge. (2) Loosen lock nut (6) of overload relief valve (3) (3) While reading the needle of oil pressure gauge, turn adjusting screw (7) by using a hexagonal Allen wrench so that the needle indicates specified pressure. A: Tightening (clockwise) → Oil pressure increases B: Loosening (counterclockwise) → Oil pressure decreases Specification: Refer to Operational Performance Standard NOTE: As the relief sensitivity is exceedingly sensitive, do not loosen quickly. ٠ Hold adjusting screw (7) by using a hexagonal Allen wrench and secure by using lock nut (6) ٠ Measure the overload relief pressure again and confirm that set pressure is to specification. ٠ Adjust the main relief valve set pressure to specification.

Control Valve

2 B A T4FG-03-02-013

T4FGE-05-04-002

(6) When measurement values in paragraph 2 of Measurement of Overload Relief Valve Hydraulic Pressure is higher than specification, refer to paragraph 4 and adjust overload relief valve (2) (7) When measurement values in paragraph 3 of Measurement of Overload Relief Valve Hydraulic Pressure is higher than specification, refer to paragraph 5 and adjust overload relief valve (3)

T5-4-64

45ZV-2

TROUBLESHOOTING / Troubleshooting B

Trouble symptoms

D-7. Bucket dump drift is excessive when the loader control lever is in neutral position. Measure the natural bucket dump drift

For complaints that the “Bucket is dump at the Neutral (Hold) position of control valve”, first check if the dump drift is within specification. Measure the hydraulic cylinder drift amount according to Operational Performance Test. As for specification, refer to Operational Performance Standard.

The hydraulic cylinder drift is considerably slower than specification.

Within Specification

Internal oil leak check of tilt cylinder

Normal

(1) Internal oil leak check of bucket cylinder

Perform a bucket cylinder internal oil leak check. 1. Refer to D-6 (1).

Repair bucket cylinder

T5-4-65

45ZV-2

TROUBLESHOOTING / Troubleshooting B

Trouble symptoms

D-7. Bucket dump drift is excessive when the loader control lever is in neutral position.

(2) Faulty overload relief valve oil tight

Check oil tight in the overload relief valve. 1. Check if the front axle (tires) are raised and held by using bucket cylinder. 2. When foreign objects are inside the overload relief valve and the seat surface contact is poor, pressurized oil of bucket cylinder rod side directly relieves to the hydraulic oil tank circuit through overload relief valve, and it is impossible to hold the front axle up when the bucket cylinder rod is extended. (The front axle is lowered gradually.) 3. As the bucket cylinder rod side valve (2) and the cylinder bottom side valve (1) consist of the same parts, it is possible to check for the function of both valves by changing places. 4. In case of faulty oil tight in overload relief valve (bucket cylinder bottom side (1)), bucket dump occurs. In case of faulty oil tight in overload relief valve (bucket cylinder rod side (2)), it is impossible to raise and hold the front axle up. 2 1

T4FGE-05-04-003

Faulty oil tight in overload relief valve

Oil tight in overload relief valve is normal.

Clean or replace overload relief valve

T5-4-66

45ZV-2

TROUBLESHOOTING / Troubleshooting B

Trouble symptoms

D-7. Bucket dump drift is excessive when the loader control lever is in neutral position.

(3) Faulty oil tight in control valve bucket spool

Disassemble and check control valve. 1. When there is a dent, scratch, rust or corrosion on spool (1) or housing (2), repair by using sandpaper #2000 or oil stones. 2. If the repair is impossible, replace the bucket plunger section as an assembly.

Repair of control valve or replacement of section assembly

2 T4FG-03-02-006

T5-4-67

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-8. Bucket dump speed increases too quickly at a specified position.

(1) Expansion or scratch of bucket cylinder tube

Measure the bucket cylinder tube inner diameter. Check for expansion in a given area. In addition, check for a dent or scratch on the piston sliding surface. Standard diameter: inner diameter: 85 mm (3.3 in)

Cylinder Gauge (Inner Diameter Measurement) T4FG-05-02-027

Repair or replacement of bucket cylinder tube

T5-4-68

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-9. Bucket wobbles while traveling.

(1) Damage of piston seals in bucket cylinder

Refer to D-4 (1).

(2) Hydraulic pressure loss of overload relief valve

Refer to D-4 (2).

(3) Faulty oil tight in overload relief valve

Refer to D-5 (2).

(4) Faulty oil tight in control valve tilt spool

Refer to D-5 (3).

(5) Wear of pins and bushings in linkage

Replace of pins and bushings

T5-4-69

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-10. The operation of loader control lever is too stiff. Measure the operating force of control lever.

For complaints that “Control lever operation is heavy”, first check the operating force of control lever. Measure the Lever Operating Force according to Operational Performance Test. As for specification, refer to Operational Performance Standard.

The operating force of control lever is considerably greater than specification.

Within specification

Normal

Repair or replace control cable

T5-4-70

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-10. The operation of loader control lever is too stiff.

(1) High operating resistance of control lever

Loosen nut (1). Remove control cable (2) from the control valve and operate the control lever.

Cable operation is normal.

The operating force is very heavy.

Repair or replace control cable

Loader Control Lever Control Lever (Auxiliary spool)

Control Valve T4FG-05-02-036

T5-4-71

45ZV-2

TROUBLESHOOTING / Troubleshooting B Trouble symptoms

D-10. The operation of loader control lever is too stiff.

(2) Stuck control valve spool

Measure the operating force of spool by using a push-pull gauge. 1. The operating force when the bucket spool is in the Hold or Neutral position. 2. The operating force when the bucket spool is at full stroke in the Tilt or Dump position. 3. The operating force when the lift arm spool is in the Hold or Neutral position. 4. The operating force when the lift arm spool is at full stroke in the Raise or Lower position. 5. Float release (detent release) operating force As for specification, refer to Operational Performance Standard.

The operating force of control lever is considerably greater than specification.

Within specification

Disassemble and check control valve

Normal

T5-4-72

45ZV-2

TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE Use troubleshooting C when any monitors, such as gauges or indicators malfunction.

• How to Read Troubleshooting Flow Charts

YES (OK) (2)

・

After completing the checking and/or measuring procedures in box (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1) NO (NOT OK)

・ · Key switch: ON

(3)

Instructions, reference, and/or instruction methods on inspection and/or measurements are occasionally described under the box. If incorrectly checked or measured, not only will troubleshooting be unsuccessful but also damage to components may result.

Causes of machine problems are stated in the thick-line box. Scanning quickly through the thick-line boxes, allows you to estimate the possible causes before actually following the flow chart.

・

NOTE: Harness end connector viewed from the open-end side of connectors image shown in this section.

Harness End Connector

Open End Side

Harness

T6L4-05-03-001

T5-5-1

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM • Check the wiring connections first.

YES

Indicator does not illuminate when indicator light check operation is performed.

Check if all indicators do not illuminate.

YES

Check power line · Fuse · Disconnect connector 1-A. Check for continuity between terminal #2 of harness end and fuse terminal #11 in fuse box A. Check if trouble occurs.

To A

Conduct troubleshooting of each indicator which does not illuminate.

Faulty fuse #11 in fuse box A, or open circuit in harness between fuse #11 and monitor.

A Faulty monitor unit NO

Connector (Harness end of connector viewed from the open end side) Monitor Unit Connector 1-A #2

T183-05-04-013

T5-5-2

45ZV-2

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-5-3

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PERATURE GAUGE

COOLANT

TEM-

• Check the wiring connections first.

YES

Coolant temperature gauge pointer does not move at all.

Disconnect coolant temperature sensor. Connect harness end terminal to body. Check if temperature gauge pointer swings to (H) side. · Key switch: ON

Disconnect connector 2-A in monitor unit. Check if voltage at terminal #9 of monitor unit end connector is 5V.

YES

Coolant temperature gauge pointer swings over scale.

Disconnect coolant temperature sensor. Check if pointer returns to zero. · Key switch: ON NO

Disconnect connector 2-A in monitor unit. Check if voltage at terminal #9 of monitor unit end connector is 5V.

YES

Coolant temperature gauge pointer keeps moving unstably.

Disconnect coolant temperature sensor. Connect harness end terminal to body. Check if pointer swings and is stabilized to (H) side. · Key switch: ON NO

T5-5-4

45ZV-2

TROUBLESHOOTING / Troubleshooting C

Coolant Temperature Gauge Faulty coolant temperature sensor.

YES

Open circuit in harness between monitor unit and sensor. Faulty monitor unit. T4GB-05-07-005

Faulty coolant temperature sensor.

YES

Shorted circuit in harness between monitor unit and sensor.

Coolant Temperature Sensor Coolant Temperature °C (°F) 25 (77) 40 (104) 50 (122) 80 (176) 95 (203) 105 (221) 120 (248)

Resistance (kΩ) 7.6±0.76 4.0±0.35 2.7±0.22 0.92±0.07 0.56±0.04 0.42±0.03 0.28±0.01

Faulty monitor unit.

Connector (Harness end of connector viewed from the open end side)

Monitor Unit Connector 2-A #9

Faulty coolant temperature sensor.

T183-05-04-013

Faulty monitor unit.

T5-5-5

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL GAUGE • Check the wiring connections first.

YES

Fuel gauge pointer does not move at all.

Disconnect fuel sensor plugs (yellow-red line, black line). Connect body harness ends. Check if pointer swings to upper limit (FULL) side. · Key switch: ON

Disconnect connector 2-A in monitor unit. Check if voltage at terminal #8 of monitor end connector is 5 V.

YES

Fuel gauge pointer swings over scale.

Disconnect fuel sensor plug (yellow-red line, black line). Check if pointer returns to zero. · Key switch: ON NO

Disconnect connector 2-A in monitor unit. Check if voltage at terminal #8 of monitor end connector is 5 V.

YES

Fuel gauge pointer keeps moving unstably.

Disconnect fuel sensor plugs (yellow-red line, black line). Connect body harness ends. Check if pointer swings and is stabilized to (FULL) side. · Key switch: ON

T5-5-6

45ZV-2

TROUBLESHOOTING / Troubleshooting C

Fuel Gauge

Upper Limit

Faulty fuel sensor.

YES

1/2

Open circuit in harness between monitor unit and sensor.

Lower Limit

Faulty monitor unit. T4GB-05-07-007

Fuel Sensor

YES

441±8 mm

Faulty fuel sensor.

Shorted circuit in harness between monitor unit and sensor.

Upper Limit (FULL) R236.7

70±8 mm

269.3 mm

Float

1/2

Faulty monitor unit. NO Lower Limit (EMPTY) T4FG-05-03-003

NOTE: 1 mm = 0.03937 in

Faulty fuel sensor.

Float Position Upper Limit (FULL) 1/2 Lower Limit (EMPTY)

Resistance (Ω) 10+0-4 38 90+10-0

Faulty monitor unit.

Connector (Harness end of connector viewed from the open end side) Monitor Unit Connector 2-A #8 Fuel Sensor

T183-05-04-013

T5-5-7

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF TURN SIGNAL INDICATORS (LEFT AND RIGHT) • Check the wiring connections first. • If the turn signal indicators (left and right) do not flash, the flasher unit may be faulty.

Although turn signal lever is applied, turn signal light and turn signal indicator at one side does not blink.

YES

Faulty turn signal lever

Burnt indicator light or open circuit in harness between turn signal lever and light.

When hazard light switch is applied, check if all turn signal lights or turn signal indicators light or flash.

T5-5-8

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HAZARD LIGHT INDICATOR • The hazard light indicator lights when the hazard switch is turned ON. If the hazard light does not light while turn signal lights or flashes, the harness between hazard switch and monitor unit way be faulty or monitor unit way be faulty. • Check the wiring connections first.

T5-5-9

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HIGH BEAM INDICATOR • Check the wiring connections first.

YES

Although dimmer switch is turned to HIGH beam position, high beam indicator does not illuminate.

Check if voltage at terminal #3 in fuse box is 12 V.

YES

Although dimmer switch is not in HIGH beam position, high beam indicator lights.

Check for continuity between terminals #c and #g of headlight switch end connector.

Disconnect connector 2-B of monitor unit. Check if high beam indicator goes out.

Faulty fuse or open circuit in harness between fuse and headlight.

Connect the disconnected connector. Disconnect connector of head light switch. Check if high beam indicator goes out.

Faulty monitor unit. NO

T5-5-10

45ZV-2

TROUBLESHOOTING / Troubleshooting C

YES

Connect the disconnected connector. Disconnect connector 2-B in monitor unit. Check if voltage at terminal #22 of harness end connector is 0 V.

Open circuit in harness between head light switch and monitor unit.

YES

Faulty logic circuit in monitor unit or burnt indicator light.

Faulty headlight switch. NO

YES

Faulty headlight switch.

Shorted circuit in harness between monitor and headlight switch.

Connector (Harness end of connector viewed from the open end side) Monitor Unit Connector 2-B

Headlight Switch Connector #22

f T4FG-05-03-004

T4GB-05-05-002

T5-5-11

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF WORK LIGHT INDICATOR • Check if the working light switch and headlight switch are in the ON position.

• If the clearance light indicator also does not light, the common circuit for clearance light indicator and working light indicator may be faulty. Refer to MALFUNCTION OF CLEARANCE LIGHT INDICATOR. • Check the wiring connections first. NOTE: Front work light is optional. Disconnect connector 1-B in monitor unit. YES Check if voltage at terminal #23 of harness end connector is 12 V. Although work light switch is turned to ON position, work light indicator does not illuminate.

Check if work light illuminates.

YES

Faulty work light indicator

Open circuit in harness between work light switch and monitor unit.

YES Disconnect connector of work light switch.Check if voltage at terminal #1 of NO harness end connector is 12 V.

· Work light switch: ON

Although work light switch is turned to OFF position, work light indicator illuminates.

Check for continuity between terminal #1 of work light switch end connector and body.

Open circuit in harness between fuse and work light switch, or faulty fuse.

YES

Faulty work light switch

Shorted circuit in harness between work light switch and monitor unit

Check if work light illuminates.

T5-5-12

45ZV-2

TROUBLESHOOTING / Troubleshooting C

Open circuit in harness between work light switch and monitor unit.

YES

Faulty work light switch.

Connector (Harness end of connector viewed from the open end side) Monitor Unit Connector 1-B

Work Light Switch Connector

Work Light Relay

#23 c g T4GB-05-05-002

T5-5-13

a e T4FG-05-03-005

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PREHEAT INDICATOR • In case the preheat system malfunctions, refer to Troubleshooting A.

• Check the wiring connections first.

Preheat indicator lights although preheat system does not operate.

Disconnect connector of glow relay. Check if preheat indicator goes out.

Connect connector of glow relay. YES Disconnect R1 of starter switch. Check if preheat indicator goes out.

· Key switch: ON NO

Check for continuity between terminal #50 of harness end connector ECM-B in ECM and body.

YES

Preheat indicator does not light although preheat system operates.

YES Faulty starter switch.

Faulty glow plug relay.

Faulty monitor unit.

Disconnect connector 2-A of monitor unit. Check if voltage at terminal #1 is 12 V.

Open circuit in harness between glow relay and monitor unit.

· Key switch: Preheat NO

Connector (Harness end of connector viewed from the open end side) Monitor Unit Connector 2-A

Glow Relay Connector #a

11 T4FG-05-03-007

T4FG-05-03-006

T5-5-14

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HST WARNING INDICATOR • Check the wiring connections first.

Faulty HST control unit

YES

Although HST is abnormal, indicator does not illuminate.

Disconnect connector of HST control unit. Connect terminal #34 to body. Check if indicator illuminates.

YES

Open circuit in harness between monitor unit and HST control unit

Connect terminal #15 of connector 1-A in monitor unit to body. Check if indicator illuminates.

Faulty monitor unit

Connector (Harness end of connector viewed from the open end side) Monitor Unit Connector 1-A

#15

T183-05-04-013

T5-5-15

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR • Check the wiring connections first.

YES

Although air filter is clogged, indicator does not illuminate.

Check if indicator illuminates when key switch is turned to ON position.

Disconnect plug (red) of air filter restriction switch. Connect plug of harness end to body. Check if indicator illuminates. · Key switch: ON

· Key switch: ON

Disconnect connector 1-A in monitor unit. Check for continuity between terminal #9 of harness end connector and air filter restriction switch.

YES

Although air filter is not clogged, indicator illuminates.

Disconnect plug of air filter restriction switch. Check if indicator goes out.

· Disassemble and visually inspect. · Verify that air filter is not moist.

· Key switch: ON

YES

Disconnect terminal #9 of connector 1-A in monitor unit. Check if indicator goes out. · Key switch: ON

T5-5-16

45ZV-2

TROUBLESHOOTING / Troubleshooting C

Faulty air filter restriction switch.

YES

Faulty monitor unit.

Open circuit in harness between monitor unit and air filter restriction switch.

Connector (Harness end of connector viewed from the open end side)

Faulty monitor unit, or burnt indicator light.

Monitor Unit Connector 1-A

T183-05-04-013

Faulty air filter restriction switch.

Shorted circuit in harness between monitor unit and air filter restriction switch.

Faulty monitor unit.

T5-5-17

45ZV-2

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-5-18

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL LOW PRESSURE INDICATOR

NOTE: Pressure may remain in the circuit for a few moments after the engine stops. If the engine starts in this condition, the indicators may not light.

• Check the wiring connections first.

YES

Indicator does not illuminate when engine oil pressure is low.

Indicator does not go out although engine is running. · Check oil filter for clogging.

Check if indicator illuminates when key switch is turned to ON position.

Disconnect engine oil pressure switch terminal. Connect terminal to body. Check if indicator illuminates. NO

· Key switch: ON · Engine: Stopped

Open circuit in harness between engine oil pressure switch and monitor unit

Faulty monitor unit, or burnt indicator light

YES

Faulty engine oil pressure switch

Disconnect engine oil pressure switch terminal. Check if indicator goes out. · Key switch: ON · Engine: Stopped

Faulty engine oil pressure switch

T5-5-19

Shorted circuit in harness between engine oil pressure switch and monitor unit

45ZV-2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF OVERHEAT INDICATOR • Check the wiring connections first.

Indicator does not illuminate when overheat occurs.

YES

Faulty monitor unit

Faulty coolant temperature gauge, or open circuit in harness

Check if coolant temperature pointer swings beyond (H). · Key switch: ON

Indicator does not go out although coolant temperature is low. · Check oil filter for clogging.

Faulty monitor unit

T5-5-20

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF STOP INDICATOR • When the following troubles occur, the stop indicator illuminates in order to show the trouble to the operator. Stop and repair the machine. • Although the machine is repaired and if the stop indicator does not go out, another indicator on monitor must illuminate. Refer to the pages corresponding to the indicator in this group or diagnose according to Troubleshooting A. • Although there is no trouble and if the stop indicator does not go out, the logic circuit in monitor unit may be faulty. (When an abnormal value is detected, the stop indicator illuminates;) • Low engine oil pressure • Overheat of the engine (high temperature of engine coolant) • Low level of service brake oil (low level of brake oil tank)

T5-5-21

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF SERVICE INDICATOR • When the following troubles occur, the service indicator illuminates in order to show the trouble to the operator. Stop and maintain the machine. • Although the machine is maintained and if the service indicator does not go out, another indicator on monitor must illuminate. Refer to the pages corresponding to the indicator in this group or diagnose according to Troubleshooting A. • Although there is no trouble and if the service indicator does not go out, the logic circuit in monitor unit may be faulty. (When an abnormal value is detected, the service indicator illuminates;) • Faulty charging by the alternator • Illuminating the engine warning indicator • Illuminating the HST warning indicator NOTE: When the parking brake is applied with the engine running and the forward/reverse lever is set in neutral position, the parking brake indicator and the service indicator illuminate. This is normal.

T5-5-22

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-5-23

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PARKING BRAKE INDICATOR • Check the wiring connections first.

YES

Although brake switch is not turned to Parking position, indicator illuminates.

Disconnect connector 1-A in monitor unit. Check if indicator goes out.

YES Exchange parking YES brake relay [1] with parking brake relay [2]. Check if indicator illuminates.

Although brake switch is in Parking position, indicator does not illuminate.

When key switch is turned to ON position, check if indicator illuminates.

Connector (Harness end of connector viewed from the open end side) NO

Monitor Unit Connector 1-A

T183-05-04-013

#17

T5-5-24

TROUBLESHOOTING / Troubleshooting C

Shorted circuit in harness between monitor unit and parking brake switch

Faulty monitor unit

Faulty parking brake relay [2]

YES

Faulty monitor unit

Open circuit in harness between monitor unit and parking brake relay [2]

Disconnect connector 1-A of monitor unit. Check if voltage at terminal #17 is 12 V.

Faulty monitor unit, or burnt indicator light

T5-5-25

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF CLEARANCE LIGHT INDICATOR • If the light switch is OFF and the clearance light and indicator light, the light switch may be faulty or the harness between light switch and clearance light or monitor unit may be shorted. • Check the wiring connections first.

YES Indicator does not illuminate.

Check if clearance light illuminates.

· Light switch：ON

Disconnect connector 1-B in monitor unit. Check if voltage at terminal #21 of harness end connector is 12 V.

Faulty light switch NO

YES

Burnt indicator light

Open circuit in harness between light switch and monitor unit

Connector (Harness end of connector viewed from the open end side) Monitor Unit Connector 1-B

#21

T4GB-05-05-002

T5-5-26

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-5-27

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BRAKE OIL LOW LEVEL INDICATOR • Check the wiring connections first.

YES

Although brake oil is low, indicator does not illuminate.

Disconnect connector of brake oil level switch and short the harness ends. Check if indicator illuminates. · Key switch: ON

When key switch is turned to ON position, check if indicator illuminates.

· Key switch: ON NO

YES

Although brake oil level is full, indicator illuminates.

Disconnect connector of brake oil level switch. Check if indicator goes out. · Key switch: ON

YES

Disconnect connector 1-A in monitor unit. Check if indicator goes out. · Key switch: ON

T5-5-28

Insert a clip into rear of terminal #13 of connector 1-A in monitor unit and connect to body. Check if indicator illuminates.

TROUBLESHOOTING / Troubleshooting C

Faulty brake oil level switch

YES

Open circuit in harness between monitor unit and brake oil level switch

Faulty monitor unit NO

Faulty monitor unit, or burnt indicator light

Faulty brake oil level switch

Connector (Harness end of connector viewed from the open end side)

Shorted circuit in harness between monitor unit and brake oil level switch

Monitor Unit Connector 1-A

Faulty monitor unit T183-05-04-013

#13

T5-5-29

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF DISCHARGE WARNING INDICATOR • Check the wiring connections first.

Connector (Harness end of connector viewed from the open end side) Starter Relay 2 Connector #b c g

a e T4FG-05-03-005

YES YES

Although engine is running, discharge warning indicator does not go out.

Check if voltage at terminal #14 of connector 1-A in monitor unit is 12 V. · Engine: Running

Check if voltage at *terminal L in alternator is 12 V.

Disconnect connector of charge lamp relay [3]. Check if indicator goes out.

YES

NO · Engine: Running

NOTE: *Terminals L in the alternator are water-resistant type connectors so that it is not practical to measure voltage. Measure voltage at terminal #b in the starter relay 2. Check for continuity between terminal #b in the starter unit and terminal L in the alternator first.

YES

Check if voltage at terminal #14 of connector 1-A in monitor unit is 12 V. · Engine: Running

YES

Although charging is low, discharge warning indicator does not illuminate.

Check if voltage at *terminal L in alternator is 12 V.

When key switch is turn to ON position, check if indicator illuminates. NO

· Key switch: ON

T5-5-30

TROUBLESHOOTING / Troubleshooting C Connector (Harness end of connector viewed from the open end side)

Monitor Unit Connector 1-A

Charge Lamp Relay [3] Connector

a T183-05-04-013

e #14 T4FG-05-03-005

Faulty monitor unit

Faulty charge lamp relay [3]

Shorted circuit in harness between charge lamp relay [3] and monitor unit

Faulty regulator or alternator

Faulty monitor unit

YES Disconnect charge lamp relay [3]. Check if voltage at terminal #c is 12 V.

YES

Faulty charge lamp relay [3]

Open circuit in harness between charge lamp relay [3] and monitor unit

Connect terminals #b to #e of connector in charge lamp relay [3]. Check if indicator illuminates.

Faulty fuse #9, or open circuit in harness between fuse #9 and charge lamp relay [3]

Faulty alternator

Faulty monitor unit, or faulty discharge warning indicator

T5-5-31

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF MONITOR DISPLAY • The data on the monitor display is shown after the signal has been directly entered from the sensors. This activates the logic circuit of the monitor unit. Therefore, check if the sensors corresponding to the trouble are normal. Description Data on liquid crystal display

Data on data display

Cause of Trouble

Neutral indicator Forward/reverse indicator Driving mode indicator Speedometer Ride control indicator Odometer Displayed in normal mode

Hour meter

Displayed in normal mode

T5-5-32

The sensor system detecting the related signal is faulty. (As for the machine, some trouble must occur. Refer to Troubleshooting A and conduct the remedy.). Refer to T5-3-33. The sensor system detecting the related signal is faulty. (As for the machine, some trouble must occur. Refer to Troubleshooting A and conduct the remedy.) As for these troubles, the liquid crystal display in monitor unit may be faulty or the logic circuit may be faulty. The alternator is faulty, the harness between terminal L in the alternator and terminal #14 of connector 1-A in monitor unit is faulty, or the clock circuit in monitor unit is faulty.

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF RIDE CONTROL INDICATOR • Check the wiring connections first.

YES

When ride control switch is turned ON, indicator does not illuminate.

Disconnect connector 1-A in monitor unit. Connect terminal #10 of harness end to body. Check for continuity. · Ride control switch: ON

Check if ride control is operated correctly.

NO YES

Disconnect connector of ride control switch. Connect terminal #2 of harness end to body. Check if indicator illuminates. NO

Check if ride control is activated.

YES

Faulty harness between ride control switch and monitor unit Faulty ride control switch

Faulty harness between terminal #2 of ride control switch and monitor unit

Faulty ride control switch

YES

When ride control switch is turned OFF, indicator does not go out.

Faulty monitor unit

Disconnect connector 1-A in monitor unit. Check if indicator goes out.

Shorted circuit in harness between ride control switch and monitor unit

Faulty monitor unit NO

Connector (Harness end of connector viewed from the open end side) Monitor Unit Connector 1-A Ride Control Switch Connector

燃

#10

T183-05-04-013

T5-5-33

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-5-34

TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect the battery 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 circuiting. 2. Color coding of wire harnesses As for the color codes of wire harnesses in the electrical system, refer to the table below. 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 R L O Y Br Gy Sb

Color Red Blue Orange Yellow Brown Gray Light blue

Code W G Lg B P Pu

Color White Green Light green Black Pink Purple

NOTE: Code BW indicates a black base wire with white fine-line marking.

T5-6-1

45ZV-2

TROUBLESHOOTING / Electrical System Inspection 3. Precautions for connecting and disconnecting terminal connectors 1) When disconnecting the harnesses, grasp them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate the connectors, if a lock is provided. (Refer to Instructions for Disconnecting Connector on T5-5-3.) 2) 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 cleaned out and dried. 3) Before connecting the terminal connectors, check that no terminals are bent or coming loose. In addition, as most connectors are made of brass, check that no terminals are corroding. 4) When connecting terminal connectors provided with a lock, insert them together until the lock “clicks.” 5) Pull the wires of the harness near the connector in order to check if it is correctly connected. 4. Precaution for using a circuit tester 1) Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to check the object to be measured, voltage range and current polarity. 2) 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.

T5-6-2

Correct

Incorrect

T107-07-06-001

Correct Rust Incorrect (Deformation) Incorrect (Separation) T107-07-06-002

Wind a Piece of Wire

Tester Probe

T4FC-05-08-101

45ZV-2

TROUBLESHOOTING / Electrical System Inspection INSTRUCTIONS CONNECTORS

FOR

DISCONNECTING • Pull and Separate Type

• Push, Unlock, and Separate Type NOTE: The connectors will not be easily separated although the lock is pushed while being pulled. Push the lock first before pulling the connectors. The lock is located on the female side connector (harness end side).

T107-04-05-004

IMPORTANT: Before pulling and separating, release the lock of the connector in the solenoid valve by using a pair of pincers.

T107-04-05-002

• Raise Lock, Pull, and Separate Type

T107-04-05-003

T4GB-05-06-003

T5-6-3

45ZV-2

TROUBLESHOOTING / Electrical System Inspection • Unlock, Move the Lever, and Pull Type NOTE: When unlocking, release the lock by one hand, slowly pull the lever by another hand, and separate the connector.

T4GB-05-06-001

T4GB-05-06-002

• Rotate the Lock and Pull Type NOTE: Pinch the harness end connector, rotate the projection part counterclockwise while pushing, and separate the connector.

T4GB-05-06-007

T5-6-4

45ZV-2

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-6-5

45ZV-2

TROUBLESHOOTING / Electrical System Inspection 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. Inspect the fuse by following the instructions described below. 1. Turn the key switch ON. When the key switch is turned ON, electric power is supplied to all circuits except for #1, #2, #3, #4, and #5 fuse. (Refer to the next page). 2. Remove the fuse box cover. Set a circuit tester voltage in order to meet the circuit specification to be measured. (Measurement Range: 0 to 30 V) 3. Ground the negative probe of a circuit tester to the body. Touch the terminals located away from the fuse of the fuse box with the positive probe of a circuit tester one at a time. When normal continuity of a fuse is intact, a circuit tester will indicate 10 to 15 V (battery voltage).

Fuse Box

NOTE: The inside terminals of the fuses of the fuse box are connected to the power source, while the outside terminals of the fuses of the fuse box are connected to loads (accessories). Therefore, test all fuses in the same manner except for #1, #2, #3, #4, and #5 fuse. Check #1 and #2 fuses with the key switch in the ON position, headlight switch in the ON position, dimmer switch in the Low-beam position and follow the procedure in step3. Check #3 fuse with the key switch in the ON position, headlight switch in the ON position, dimmer switch in the High position, and follow the procedure in step 3. Check #4 and #5 fuses with the key switch in the ON position, headlight switch in the Clearance Light position, and follow the procedure in step 3.

Accessory (outside) －

＋

Fuse

Accessory (Outside)

T5-6-6

Power Source (Inside)

T142-06-06-004

45ZV-2

TROUBLESHOOTING / Electrical System Inspection Fuse Box Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Capacity 10 A 10 A 15 A 5A 5A 15 A 15 A 10 A 10 A 10 A 10 A 30 A 15 A 10 A 15 A

Connected to Headlight (Left) Headlight (Right) Headlight (High Beam) Clearance Light (Left), Tail Light (Right) Clearance Light (Right), Tail Light (Left) HST (Forward), HST (Reverse), Solenoid, Parking Brake Solenoid, Reverse Light, Reverse Buzzer, Relay (1), Relay (2) Horn, Brake Light Engine Stop Solenoid, Fuel Pump Starter Relay 2, Alternator, Engine Speed Sensor, Relay (3) Bucket Auto Leveler Proximity Switch, Control Valve Detent (Tilt) Monitor Headlight, Clearance Light, Tail Light HST Controller Monitor Backup Power Option Power Option Power Option Power Unused Option Power Hazard Light, Flasher Unit

M4FG-07-047

5-6-7

TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION Inspection 1. Open the engine hood. Remove the cover from the battery box at the center of the counterweight. Disconnect the negative cable from the battery. 2. Two fusible links (100 A) are located in the left front of the engine room when the front attachment is set forward. 3. Visually inspect the fusible link. 4. Connect the negative cable to the battery.

○ +

Replacement 1. Check that the negative cable of the battery in the battery box at the center of the counterweight has been disconnected. 2. Two fusible links (100 A) are located in the left front of the body when the front attachment is set forward. 3. Remove and replace the fusible link. 4. Connect the negative cable to the battery.

M4FG-07-042

Fusible Link (100A)

T5-6-8

M4FG-01-048

TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. 2. Open the hood. Remove the cover from the battery box at the center of the counterweight. 3. Check voltage between the battery positive terminal and the body (ground). Normal Voltage: 12 V NOTE: If voltage is abnormal, recharge or replace the battery.

○ +

4. Start the engine. Check voltage between the battery positive terminal and the body (ground). M4FG-07-042

Normal Voltage: 13 to 15 V NOTE: If voltage is abnormal, check the charging system.

T5-6-9

TROUBLESHOOTING / Electrical System Inspection ALTERNATOR CHECK In general, the alternator indicator remains off when the alternator is generating power. If the alternator indicator comes on while the engine is running, the alternator may be faulty. How to Check Alternator 1. Turn the key switch to the ON position. Confirm that the alternator indicator lamp illuminates. 2. Measure voltage between terminal B of the alternator and the body (ground). If the measured voltage is around 12 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 cause of the malfunction. When voltage is 0 V, the wiring between fuse box and alternator or the ground line to the engine might be open circuits. 3. Next, start the engine and measure voltage generated while as the alternator rotates. As described above, measure voltage between terminals B and P on the end of the alternator. If voltage is around 14 V, the alternator is operating normally. If the measured voltage is equal to battery voltage (around 12 V), there is some trouble with the alternator or the regulator.

T5-6-10

B P

＋－

T4FG-05-04-001

TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Harness

Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the machine chassis by using a clip. Then, check continuity of the harness through the body as illustrated. If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity

Connect to the body.

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

A ×

Short-circuit between the harness and the body.

T107-07-05-003

T5-6-11

TROUBLESHOOTING / Electrical System Inspection VOLTAGE MENT

AND

CURRENT

MEASURE-

Turn each 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. 12-Volt Circuit Start checking the circuit from the power source or actuator side. Check circuit sections in order until the entire circuit has been tested. Thereby, the faulty location in the circuit will be found. Black Probe (Negative) of Circuit Tester: To ground to the body Red Probe (Positive) of Circuit Tester: To touch the location to be measured Engine Power Source Circuit Stopped Stopped Stopped Stopped Preheat Circuit Started Started Starting Circuit Started Started Started Started Charging Circuit Fast Speed Fast Speed Fast Speed

Key Switch

Location to be Measured

Specification

OFF OFF OFF OFF

Between (2) and (1): Battery Between (3) and Ground: Battery / Power Source Between (4) and Ground: Fusible Link Between (5) and Ground: Backup Current*

10 to 12.5 V 10 to 12.5 V 10 to 12.5 V 6 mA

START START

Between (6) and Ground: Key Switch Between (7) and Ground: Glow Plug

10 to 12.5 V 10 to 12.5 V

START START START START

Between (8) and Ground: Key Switch Between (9) and Ground: Starter (B) Between (10) and Ground: Starter (S) Between (11) and Ground: Starter Relay 2 (S)

10 to 12.5 V 10 to 12.5 V 10 to 12.5 V 10 to 12.5 V

10 to 12.5 V

ON ON

Between (12) and Ground: Alternator (B) / Generating Voltage Between (13) and Ground: Generating Voltage Between (14) and Ground: Monitor

ACC

Between (15) and Ground: Radio

10 to 12.5 V

10 to 12.5 V 10 to 12.5 V

Accessory Circuit Stopped

NOTE: *Measure after disconnecting the negative cable from the battery.

T5-6-12

TROUBLESHOOTING / Electrical System Inspection

Fuse Box (Body) Key Switch B R1 R2 BR ACC C HEAT OFF ON

To Cab Harness

START 8

ECM monitor 14

1A-1

2A-1 1A-14

Forward/ Reverse F N Lever

Starter Relay 1 Starter Motor

Glow Plug

Starter Relay 2 R

11 9 R L S P

Alternator

R L

Glow Relay

Charge Lamp Relay (3)

Fuel Pump

2 +

Battery Fusible Link (100 A) (2 Used)

T5-6-13

T4FG-05-04-002

TROUBLESHOOTING / Electrical System Inspection 5V Circuit

• Voltage between terminal #1 and the body

Power Source 1

Two Polarities

With the key switch turned OFF, disconnect the connector. Measure voltage between the terminal of 5V power source on the body harness end connector and the vehicle frame (ground).

• Key switch: ON • Circuit Tester black probe (negative):

Signal or Ground 2

Vehicle frame (ground)

• Circuit Tester red probe (positive): Terminal of 5V power source T107-07-05-006

Evaluation: If the measured voltage is within 5±0.5 V, the circuit up to the terminal of 5V power source is normal.

Power Source Signal Ground 1 2 3

Three Polarities

IMPORTANT: Altough terminal #1 is the teminal of 5V power source on the illustration, all the terminals are not terminals of 5V power source. Before measurement, check the electrical circuit diagram for the correct connector and terminal to be measured.

• Voltage between terminal #1 and the ground terminal With the key switch turned OFF, disconnect the sensor connector. Measure voltage between the terminal of 5V power source on the body harness end connector and the ground terminal.

T107-07-05-007

Power Source 1

Two Polarities

Signal or Ground 2

• Key switch: ON • Circuit Tester black probe: Ground terminal (terminal #2 or #3) • Circuit Tester red probe: Terminal of 5V power source

T107-07-05-008

Evaluation: If the measured voltage is within 5±0.5 V, the circuits up to the terminal of 5V power source and the ground terminal are normal.

Three Polarities

IMPORTANT: Altough terminal #1 is the teminal of 5V power source, terminal #2 is the signal and #3 is the ground terminal respectively on the illustration, all the connectors are not arranged similarly. Before measurement, check the electrical circuit diagram for the correct connector and terminal to be measured.

T5-6-14

Power Source Signal Ground 1 2 3

T107-07-05-009