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60Z7

93206-00380

SHOP MANUAL Operational Performance Test Troubleshooting

Printed in Japan (K) ( オセアニア用 )

93206-00380

May 2015

SHOP MANUAL WHEEL LOADER

60Z7 Operational Performance Test Troubleshooting

93206-00380 May 2015

SHOP MANUAL (Operational Performance Test & Troubleshooting) INTRODUCTION ........................................................................................................................... IN-01~02 Symbol and Abbreviation ...............................................................................................................SY-1~2 SECTION 4

OPERATIONAL PERFORMANCE TEST

Group 1

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

Group 2

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

Group 3

Engine Test ............................................................................................................. T4-3-1

Group 4

Machine Performance Test ..................................................................................... T4-4-1

Group 5

Component Test ...................................................................................................... T4-5-1

SECTION 5

TROUBLESHOOTING

Group 1

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

Group 2

Monitor .................................................................................................................... T5-2-1

Group 3

e-Service ................................................................................................................. T5-3-1

Group 4

Component Layout .................................................................................................. T5-4-1

Group 5

Troubleshooting A ................................................................................................... T5-5-1

Group 6

Troubleshooting B ................................................................................................... T5-6-1

Group 7

Troubleshooting C ................................................................................................... T5-7-1

Group 8

Air Conditioner ........................................................................................................ T5-8-1

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.

60Z7(OCE)

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 (operation and maintenance manual, parts catalog, engine technical material, Kawasaki shop materials, etc.) in addition to this manual.

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

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

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

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

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

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

IN-01

Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

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

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

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

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

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

fNOTE: Indicates supplementary technical information or knowhow.

Units Used SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behind SI units.

Example: 24.5 MPa (250 kgf/cm2, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

0.03937

0.003281

US gal

0.2642

US qt

1.057

yd3

1.308

Weight

2.205

Force

kgf

0.10197

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

MPa

psi

145.0

1.360

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Power

Flow rate

-1

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

IN-02

0.10197 2

10.197

SYMBOL AND ABBREVIATION Symbol and Abbreviation Symbol / Abbreviation TO TT T/M W, W/M MC

ECM GSM

GPS CAN

A/C OP, OPT MPDr. WU Li ATT EGR

Name

Explanation

Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual

Technical manual (Operational Principle). Technical manual (Troubleshooting). Technical manual. Workshop manual (Removal and Installation, Disassembly and Assembly). Main Controller Main controller. MC controls the engine, HST pump, HST motor, and transmission according to the machine operating condition. Engine Control Module Engine controller. ECM controls fuel injection amount according to the machine operating condition. Global System for Mobile communications Communication controller. GSM is a type of wireless controller communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone. Global Positioning System Global positioning system. Controller Area Network CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization). Air Conditioner Air conditioner. Option Optional component. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and adjustment. Warming-Up Warming-up. Low (Slow) Idle Slow idle engine speed. Attachment Attachment. Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the intake manifold and combines it with intake-air. Therefore, combustion temperature is lowered and generation of oxide of nitrogen (NOx) is controlled.

SY-1

SYMBOL AND ABBREVIATION (Blank)

SY-2

SECTION 4

OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction

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

Group 2 Standard

Operational Performance Standard Table.................. T4-2-1 Sensor Activating Range................................................... T4-2-8

Group 3 Engine Test

Engine Speed........................................................................ T4-3-1 Lubricant Consumption.................................................... T4-3-3

Group 4 Machine Performance Test

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

Group 5 Component Test

Main Pump Delivery Pressure......................................... T4-5-1 HST Pump Delivery Pressure............................................ T4-5-2 HST Charging Pump Delivery Pressure (HST Charging Pump Relief Pressure)..................... T4-5-3 Brake/Transmission Pump Delivery Pressure............. T4-5-4 Loading Circuit Main Relief Set Pressure..................... T4-5-6 HST Pump Relief Pressure................................................. T4-5-8 Steering Circuit Relief Pressure.....................................T4-5-10 Overload Relief Valve Set Pressure..............................T4-5-12 HST Pump Displacement Angle Control Pressure............................................................................T4-5-14 HST Motor Displacement Angle Control Pressure............................................................................T4-5-16 Transmission Clutch Pressure........................................T4-5-18 Primary Pilot Pressure (Hydraulic Operated Type: Option)........................T4-5-20 Secondary Pilot Pressure (Hydraulic Operated Type: Option)........................T4-5-22 Accumulator Gas Pressure..............................................T4-5-24 Ride Control Accumulator (Option).......................T4-5-25 Ride Control Accumulator Gas Pressure Adjustment (Option)................................................T4-5-26

60Z7 (US) Trbl

(Blank)

60Z7 (US) Trbl

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

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

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

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.

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

T4-1-1

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

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

T4-1-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Operational Performance Standard Table The standard Performance values are listed in the table below. Refer to the Group T4-3 to T4-5 for performance test procedures. Values indicated in parentheses are reference values. Performance Test Designation

Unit

Engine Speed Low Idle Speed (without load) High Idle Speed (without load) High Idle Speed (with HST relieved) High Idle Speed (with front attachment relieved) Engine Speed Low Idle Speed (without load) High Idle Speed (without load) High Idle Speed (with HST relieved) High Idle Speed (with front attachment relieved) Lubricant Consumption (Rated output)

min-1

The following switch positions shall be selected and the hydraulic oil temperature shall be maintained as indicated below as the preconditions of performance tests unless otherwise instructed in each performance test procedure:  Accelerator Pedal: Full Stroke  Hydraulic Oil Temperature : 50±5 °C (122±9 °F)

Performance Standard

Reference Page T4-3-1

860±25 1980±50 1970±50 1900±50

Power mode switch: OFF Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr.

T4-3-1

860±25 2150±50 2190±50 2060±50

Power mode switch: ON Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Hour meter: 2000 hours or less

T4-3-3

min-1

mL/h

Remarks

20 or less

T4-2-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Travel Speed First Speed (Forward/Reverse) Second Speed (Forward/Reverse) Travel Speed First Speed (Forward/Reverse) Second Speed (Forward/Reverse) Service Brake Function Check

km/h (mph)

Service Brake Wear Amount Brake Disc (t=6.2) Brake Ring (t=5.0) Parking Brake Function Check Parking Brake Wear Amount Friction Plate (t=2.5) Steel Plate (t=1.6) Bucket Stopper Clearance Lever (Bell Crank) Stopper Clearance Front Pin Wear Amount Front Bushing Wear Amount Clearance Between Front Pin and Bushing

mm (in)

Performance Standard

11.1±1.1 (6.9±0.7) 34.5+0.4/-3.5 (21.4+0.2/-2.2) km/h (mph)

m (ft)

mm/5 min mm (in)

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

11.1±1.1 (6.9±0.7) 34.5+0.4/-3.5 (21.4+0.2/-2.2) 5 (16) or less

Remarks Power mode switch: OFF Value indicated on MPDr. Value indicated on MPDr. Power mode switch: ON Value indicated on MPDr. Value indicated on MPDr. Vehicle speed: 20 km/h (12.4 mph)

Reference Page T4-4-1

T4-4-1

T4-4-4 T4-4-6

6.2 (0.24) 5.0 (0.20) 0

Allowable limit: 5.2 (0.21) Allowable limit: 4.5 (0.18)

2.5 (0.098) 1.6 (0.063) 0 0 to 3 (0 to 0.12) 0.3 (0.01)

Allowable limit: 2.2 (0.087) Allowable limit: 1.4 (0.055)

T4-2-2

T4-4-7 -

T4-4-8 T4-4-8 Allowable limit: -1.0 (-0.04) Allowable limit: -1.5 (-0.06) -

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Hydraulic Cylinder Cycle Time Lift Arm Raise Lift Arm Lower (Float) Bucket Dump Steering Hydraulic Cylinder Cycle Time Lift Arm Raise Lift Arm Lower (Float) Bucket Dump Steering Cylinder Drift Check Lift Arm Cylinder Bucket Cylinder Bucket Bottom Bucket Levelness

sec

Performance Standard

Remarks Power mode switch: OFF

Reference Page T4-4-10

Power mode switch: ON

T4-4-10

5.9±0.3 2.7±0.5 (2.6±0.3) 1.4±0.3 2.7±0.3 sec 5.9±0.3 2.7±0.5 (2.6±0.3) 1.4±0.3 2.7±0.3 mm (in)/15 min

T4-4-12 15 (0.60) or less 10 (0.39) or less 70 (2.76) or less 13 (0.51) or less

T4-2-3

T4-4-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Control Lever Operating Force Lift Arm Raise Lift Arm Lower Lift Arm Lower (Float) Lift Arm Lower (Float Release)

N (kgf ) (lbf )

Bucket Control Lever Roll Back Bucket Control Lever Roll Back (Detent) Bucket Control Lever Roll Back (Detent Release) Bucket Control Lever Dump Steering Forward/Reverse Lever Accelerator Pedal Brake/Declutch Pedal (Right/ Left)

Performance Standard

Remarks

39 (4.0) (8.8) or less 34 (3.5) (7.6) or less 54 (5.5) (12.1) or less 29±10 (3.0±1) (6.5±2.2) or less 34 (3.5) (7.6) or less 29 (3.0) (6.5) or less

Joystick type lever Joystick type lever Joystick type lever Joystick type lever Joystick type lever Joystick type lever

29±10 (3.0±1) (6.5±2.2) Joystick type lever or less 34 (3.5) (7.6) or less Joystick type lever 9.8 (1.0) (2.2) or less 60 rpm (with steering wheel operated) 11.8+1/-2 (1.2+0.1/-0.2) (2.65+0.22/-0.45) 25±3.5 (2.6±0.4) (5.6±0.8) 255 (26) (57) or less When operating brake pedal (fully)

T4-2-4

Reference Page T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

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

mm (in)

(Rotation)

Performance Standard

Remarks

110±1.5 (4.3±0.06) 85±15 (3.3±0.60) 135±15 (5.3±0.60) 110±15 (4.3±0.60) 100±15 (3.9±0.60) 5 (0.20) or less

Joystick type lever Joystick type lever Joystick type lever Joystick type lever Joystick type lever 60 rpm (with steering wheel operated)

50±5 (2.0±0.20) 5 to 15 (0.2 to 0.6) 0 to 5 (0 to 0.2)

T4-2-5

Reference Page T4-4-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

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

deg.

Bias Tire Radial Tire

Performance Standard 18±1.5 19.3±0.5 1.26

Remarks (without play)

Reference Page T4-4-16

Allowable limit: 1.16

kPa (kgf/cm2) (PSI)

216+20/0 (2.2+0.2/0) (31.3+2.9/0) 425+50/0 (4.4+0.5/0) (61.6+7.3/0)

f NOTE: The tire inflation is different depending on size of tires.

T4-2-6

Size of Tires: 18.4-24-10 PR Size of Tires: 17.5 R25

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Performance Standard

Remarks

Main Pump Delivery Pressure

MPa (kgf/cm2) (PSI) MPa (kgf/cm2) (PSI) MPa (kgf/cm2) (PSI) MPa (kgf/cm2) (PSI) MPa (kgf/cm2) (PSI)

1.5 to 2.5 (15 to 25) (217.6 to 362.6) 2.1±0.3 (21±3) (304.6±43.5) 2.5±0.3 (25±3) (362.6±43.5) 1.6 to 1.8 (16 to 18) (232 to 261)

In neutral, Value indicated on MPDr. In neutral, Value indicated on MPDr. In neutral, Value indicated on MPDr. In neutral, Value indicated on MPDr. Value indicated on MPDr.

HST Pump Delivery Pressure HST Charging Pump Delivery Pressure Brake/Transmission Pump Delivery Pressure Main Relief Set Pressure

20.6+1.5/-0.5 (210+15/-5) (2988+218/-73) Relief Operation of Bucket 20.6+1.5/-0.5 (210+15/-5) (2988+218/-73) HST Pump Relief Pressure MPa (kgf/cm2) 40.2+1.9/-0.5 (410+19/-5) (PSI) (5831+275/-73) 2 HST Charging Pump Relief Pressure MPa (kgf/cm ) 2.5±0.3 (25±3) (PSI) (362.6±43.5) Steering Relief Pressure MPa (kgf/cm2) 17.2+1.5/-0.5 (175+15/-5) (PSI) (2495+218/-73) 2 Overload Relief Pressure MPa (kgf/cm ) (PSI) Bucket Dump 16.2+1.5/-0.5 (165+15/-5) (2350+218/-73) HST Pump Displacement Angle Control MPa (kgf/cm2) 2.05±0.1 (21±1) (PSI) (297±14.5) Pressure HST Motor Displacement Angle Control MPa (kgf/cm2) 40.2+1.9/-0.5 (410+19/-5) Pressure (PSI) (5831+275/-73) 2 Transmission Clutch Pressure MPa (kgf/cm ) (PSI) Fast Speed (engine: low idle speed) 1.8±0.3 (18±3) (261±43.5) Fast Speed (engine: high idle speed) 2.0±0.3 (20±3) (290±43.5) Slow Speed (engine: low idle speed) 1.8±0.3 (18±3) (261±43.5) Slow Speed (engine: high idle speed) 2.0±0.3 (20±3) (290±43.5) Primary Pilot Pressure MPa (kgf/cm2) 3.7(38) (537) or less (PSI) Secondary Pilot Pressure MPa (kgf/cm2) 3.2 (33) (464) or less (PSI) Accumulator Gas Pressure MPa (kgf/cm2) (PSI) Ride Control (Option) 2.1 to 2.3 (21.4 to 23.5) (305 to 334)

Reference Page T4-5-1 T4-5-2 T4-5-3 T4-5-4 T4-5-6

Relief Operation of Lift Arm

T4-2-7

T4-5-8 T4-5-3 T4-5-10 (Reference)

T4-5-12

T4-5-14 T4-5-16 T4-5-18

(Hydraulic Operated Type: Option) (Hydraulic Operated Type: Option)

T4-5-20 T4-5-22 T4-5-24

20 °C (68 °F)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Sensor Activating Range 1. Checking Method  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Unless specified: Engine Speed High Idle Speed

Power Mode Switch ON

• Monitor each sensor by using MPDr. 2. Sensor Activating Range Item

Operation

Unit

HST Pump Delivery Pressure

Neutral

MPa (kgf/cm ) (PSI) 2.1±0.3 (21±3) (304.6±43.5)

HST Relieved

MPa (kgf/cm2) (PSI) 40.2+1.9/-0.5 (410+19/-5) (5831+275/-73) MPa (kgf/cm2) (PSI) 1.0 to 2.5 (10 to 25) (145 to 363)

Main Pump Delivery Pressure Neutral Parking Brake Pressure

Specification 2

Control Lever: Relieved

MPa (kgf/cm2) (PSI) 20.1 to 21.8 (205 to 222) (2915 to 3162)

Parking Brake Switch: ON

MPa (kgf/cm2) (PSI) 0 to 0.3 (0 to 3) (0 to 43.5)

Parking Brake Switch: OFF

MPa (kgf/cm2) (PSI) 1.6 to 1.8 (16 to 18) (232 to 261)

T4-2-8

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

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

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

Preparation: 1. Select the service menu of monitor (of MPDr.). 2. Warm up the machine until coolant temperature reaches 50 °C (122 °F) or more and hydraulic oil temperature is 50±5 °C (122±9 °F).

T4-3-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Measurement: When measuring with the HST dCAUTION: function relieved, put the blocks onto the front

and rear tires in order not to move the vehicle and keep away from it. 1. Measure the items as shown in the table below. 2. When measuring, set the switch and test condition as shown in the table below in response to the engine speed to be measured.

Item Slow Idle Speed (with no load) Fast Idle Speed (with no load) Fast Idle Speed (with HST relieved) Fast Idle Speed (with front attachment relieved)

Forward/Reverse Lever, Shift Switch N

Accelerator Pedal

Parking Brake Switch Power Mode Switch

No depression

ON/OFF

Forward Second

Full stroke

ON/OFF

Forward Second

Full stroke

OFF

ON/OFF

Forward Second

Full stroke

OFF

ON/OFF

Item Slow Idle Speed (with no load) Fast Idle Speed (with no load) Fast Idle Speed (with HST relieved) Fast Idle Speed (with front attachment relieved)

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 and relieved.

Evaluation: Refer to Operational Performance Standard (p.T4-2-1). Remedy: Refer to Troubleshooting B. NOTE: Engine System Troubleshooting (T5-6-16).

T4-3-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Lubricant Consumption Measuring Method 1. Place the machine on level firm ground and leave the machine for at least one hour in order to let the lubricant return to the oil pan when the engine stops. At this time, confirm that the machine is level by using a leveler. 2. Record read-out A (unit: hour) of the hour meter. 3. Replenish the lubricant up to the high-level gauge. 4. Operate the machine for at least 100 hours or until the oil level lowers to the low-level gauge. IMPORTANT: Keep the machine-leaving time in step 1 above. 5. Place the machine on level firm ground and leave the machine for at least one hour in order to let the lubricant return to the oil pan when the engine stops. At this time, confirm that the machine is level by using a leveler. 6. Record read-out B (unit: hour) of the hour meter. 7. Replenish the lubricant up to the high-level gauge while measuring the oil-replenishing volume C.

fNOTE: When measuring, use a high-precision

measuring cylinder or the like. 8. Determine lubricant consumption from the following equation: Oil replenishing volume (C) [mL] / Operating hours (B-A) [hr]

Evaluation: Refer to Operational Performance Standard (p.T4-2-1).

T4-3-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test (Blank)

T4-3-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Speed Summary: Measure the time required for the machine to travel a 50 m (164 ft) test track and check the performance of the travel drive system (HST pump to HST motor). Preparation: 1. Adjust air pressure of the tires evenly in advance.  Bias Tire: 216 kPa (2.2 kgf/cm2, 31 psi)  Radial Tire: 425 kPa (4.3 kgf/cm2, 62 PSI) 2. Provide a flat, solid test track 50 m (164 ft) in length, with extra length of 70 m (229 ft) on both ends for machine acceleration and deceleration. 3. Empty the bucket and hold the lift arm with it raised 0.3 m (12 in) above the ground. 4. Maintain the hydraulic oil temperature at 50±5°C (122±9°F). Warm the axle oil satisfactorily by repeating travel operation and brake operation.

a c

c T4GB-04-04-001

abc-

T4-4-1

0.3 m (12 in) Test Track Acceleration/Deceleration Zone

de-

End Start

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: Do not perform measurement in dCAUTION: reverse to avoid accident. 1. Measure in each mode (first speed and second speed). 2. Set the following conditions. Shift Switch First Speed Second Speed

Slow (L) Fast (H)

Parking Brake Switch OFF OFF

Accelerator Pedal Full Stroke Full Stroke

Power Mode Switch ON/OFF ON/OFF

3. Set the forward/reverse lever to the F (forward) position. Start traveling the machine in the acceleration zone with the accelerator pedal depressed to the stroke end.

Slow (L) Speed Limit Switch OFF OFF

4. Measure the travel speed (sec) of each travel mode. 5. Repeat the measurement three times and calculate the mean values.

6. Convert the measurement value to be expressed in km/h. Measurement value (seconds) = S (sec) Converted value (hourly speed) = A (km/h) A = (50×3600)/(S×1000)

Evaluation: Refer to Operational Performance Standard (p.T4-2-2).

T4FJ-01-02-014 12-

Remedy: Refer to Troubleshooting B. NOTE: Travel System Troubleshooting (p.T5-6-26)

T4-4-2

Transmission Machine Speed Sensor

HST Motor

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

T4-4-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Service Brake Function Check Summary: 1. Check the performance of the service brake. 2. The braking capability of the brake is an item of safety control. Be sure to conduct the performance test. Preparation: 1. Adjust air pressure of the tires evenly in advance.  Bias Tire: 216 kPa (2.2 kgf/cm2, 31 psi)  Radial Tire: 425 kPa (4.3 kgf/cm2, 62 PSI) 2. On a paved dry road, prepare a 150 m (492 ft) straight travel course (a 100 m (328 ft) of acceleration zone and a 50 m (164 ft) of test track) and set the brake starting point.

a c

3. Empty the bucket and hold the lift arm with it raised 0.3 m (12 in) above the ground. 4. Maintain the hydraulic oil temperature at 50±5°C (122±9°F) Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the needle of the coolant temperature gauge should rise above the horizontal position.

ab-

T4-4-4

0.3 m (12 in) Stopping Distance

cd-

T4GB-04-04-002

Stopping Point Brake Starting Point

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: Do not perform measurement in dCAUTION: reverse to avoid accident. (Forward/reverse lever: F) 1. Measure in fast speed mode.

2. Set the following conditions. Shift Switch Fast (H)

Parking Brake Switch OFF

Accelerator Pedal Full Stroke

3. Set the forward/reverse lever to the F (forward) position. Start traveling the machine in the acceleration zone with the accelerator pedal depressed to the stroke end and travel at 20 km/h (12.4 mph). 4. Release the accelerator pedal and step on the right service brake pedal at the brake starting point. Completely stop the machine. 5. Measure the distance from the brake starting point to the point where the front tire is contacting. 6. Repeat the measurement three times and calculate the mean values. Add traveling distance 0.56 m (1 ft 10 in) to the mean value. This is stopping distance.

Evaluation: Stopping distance: 5 m (5.5 yard) or less Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-29)

T4-4-5

Power Mode Switch ON

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Service Brake Wear Amount 1

Summary: Check the brake disc wear amount at the service brake of the axle by using wear gauge (2) or a thickness gauge (5.3 mm, 0.21 in). Preparation: 1. Clean around in plug (1) of the axle and loosen it. 2. In case of the rear axle, in plug (1) is located below the center line of the differential. Loosen inspection plug (1) after draining axle oil. 3. After the measurement is completed, apply LOCTITE #512 onto inspection plug (1). Install it to inspection port (7).

T4GB-04-04-004

l : 14 mm (0.55 in) m : 150 N·m (15 kgf·m) (111 lbf·ft) Measurement: 1. Operate the service brake by stepping on the brake pedal. 2. Insert wear gauge (2) into inspection port (7) until it contacts brake disc (4) between brake ring (3) and end plate (5).

TNCC-04-04-001

Evaluation:

1. When wear gauge (2) has entered between brake ring (3) and end plate (5), and the model point of wear gauge (2) fits housing surface (6) the wear amount of brake disc (4) does not reach the maximum allowable limit of use. When wear gauge (2) has not entered between brake ring (3) and end plate (5), and the model point is above housing surface (6), brake disc (4) is worn in excess of the maximum allowable limit of use.

5 4

2. When the wear amount is beyond the maximum allowable limit of use or the service brake portion has been assembled, refer to Operational Performance Standard in T4-2.  Distance (L) between Housing Surface (6) and Brake Disc (4): 43 mm (1.7 in)  Brake ring (3) thickness (default): 5.0 mm (0.20 in)

T4-4-6

TNCC-04-04-002

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Parking Brake Function Check Summary: 1. Measure the parking brake function on a specified slope. 2. The braking capability of the brake is an item of safety control. Be sure to conduct the performance test.

Preparation: 1. Measure on a pavement surface with a gradient of 20 % (11.31°). 2. Empty the bucket and hold the bucket with it raised 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 in) above the ground. 3. Maintain the hydraulic oil temperature at 50±5°C (122±9 °F). Warm the axle oil satisfactorily by repeating travel operation and brake operation.

a b T4GB-04-04-003

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

2. Stop the engine. 3. After the machine has stopped, put a mark (white line) on the tire and the road surface respectively. 4. After five minutes have passed, measure the amount of movement between white lines of tire and road surface. 5. Repeat the measurement three times and calculate the mean values.

Evaluation: No movement. Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-29)

T4-4-7

0.4 to 0.5 m (1 ft 4 in to 1 ft 8 in)

11.3°

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Bucket Stopper, Lever (Bell Crank) Stopper Clearance Summary: Measure wear and deformation conditions of the bucket stopper (dump side and rollback side) and the clearance between lever (bell crank) stopper (b) and the cross tube. Preparation: 1. Stop the machine on a plane road surface and operate the parking brake.

a b

Measurement:  Bucket Dump Stopper (a) 1. Raise the lift arm to the highest lifting position and stop the engine. 2. With the engine stopped, slowly dump the bucket until the bucket dump stoppers (a) contact the lift arm. 3. At this time, measure strokes (A and B) of the bucket cylinder and the lift arm cylinder and dump angle (C) of the bucket. In addition, measure the clearance between lever stopper (b) and the cross tube. 4. At the same time, measure the contact condition of bucket dump stopper (a) (left and right) to the lift arm.

T4GB-04-04-008 a-

Bucket Dump Stopper

Lever (Bell Crank) Stopper

 Bucket Rollback Stopper (c) 1. Raise the lift arm until lift arm cylinder stroke (E) becomes the length of the standard dimension found on the following page. 2. With engine at idle speed, slowly roll the bucket back until the bucket rollback stoppers (c) just make contact with the lift arm.

3. At this time, measure strokes (D and E) of the bucket cylinder and the lift arm cylinder and rollback angle (F) of the bucket. In addition, measure height (G) from the ground to the bucket lowest point. 4. At the same time, measure the contact condition of bucket rollback stoppers (c) (left and right) to the lift arm.

T4GB-04-04-010 c-

T4-4-8

Bucket Rollback Stopper

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

2. Bucket Rollback (Tilt) Stopper

 Cylinder Strokes (A and B) Bucket Cylinder (A) Lift Arm Cylinder (B) mm (in) mm (in) 390±1.5 (15±0.06) 986±2 (39±0.08)

 Cylinder Strokes (D and E) Bucket Cylinder (D) Lift Arm Cylinder (E) mm (in) mm (in) 683 (26.9) 433 (17.0)

 Bucket Dump Angle (C) C (deg.) 48±2

 Bucket Roll Back (Tilt) Angle (F) F (deg.) 49

 Clearance between Lever Stopper and Cross Tube (b) Clearance between Stopper and Tube mm (in) Standard 3 (0.12) or less Limit -

 Height from Ground to Bucket Lowest Point (G) G (mm) (in) 370 (14.6)  Clearance between Bucket Rollback Stopper and Lift Arm (c) Clearance at Longitudinal and Unsymmetrical Lateral Clearance of Contact Each Stopper mm (in) mm (in) Standard 0 0

 Clearance between Bucket Dump Stopper and Lift Arm (a) Clearance at Longitudinal and Unsymmetrical Lateral Clearance of Contact Each Stopper mm (in) mm (in) Standard 0 0 Limit 2.0 (0.08) 4 (0.16)

fNOTE:  Clearance at Unsymmetrical Contact (left stop compared to right stop)

Limit

tires (standard) at the specified air pressure.

Right stop

 Longitudinal and Lateral Clearance of Each Stopper

Clearance limit Longitudinal contact

4.0 (0.16)

fNOTE: Standard dimensions indicate those with new

Clearance limit Left stop

3.0 (0.12)

Lateral contact

T4-4-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Hydraulic Cylinder Cycle Time

Lift Arm Cylinder: (Raising)

Summary: 1. Measure the operating time of cylinders for the lift arm, bucket, and steering and check the performance of the cylinder operate system (main pump to each cylinder). 2. The bucket should be empty. T4GB-04-04-016

Preparation: (Lowering)

1. Measurement is made for the following positions.  Measurement of Lift Arm Cylinder (Raising) Fully tilt the bucket and lower the lift arm.  Measurement of Lift Arm Cylinder (Lowering) Lower the lift arm until the bucket bottom surface touches the ground horizontally.  Measurement of Bucket Cylinder Lift the lift arm to the highest position.  Measurement of Steering Cylinder Empty the bucket and take the travel forward position.

T487-04-03-005

Bucket Cylinder:

2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Select ground covered with sand or dCAUTION: something so that the bucket contacts the ground with buffer.

T487-04-03-006

Travel Position

a M4GB-04-001 a-

T4-4-10

0.3 m (12 in)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the pedal, switches, and forward/reverse lever as follows. Accelerator Pedal Lift Arm (Raising) Lift Arm (Lowering) Bucket Steering

Full stroke (engine: high idle speed) Neutral (engine: low idle speed) Full stroke (engine: high idle speed) Full stroke (engine: high idle speed)

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the steering area before starting the measurement. 2. Measure the cylinder cycle times as follows: (Cylinder full stroke includes cylinder cushioning zone.)

 Measurement of Lift Arm Cylinder (Raising) Operate the lift arm control lever to the stroke end. Measure the time of movement of the lift arm from the lowest position to the highest position.  Measurement of Lift Arm Cylinder (Lowering) Lower the bucket onto the ground in the horizontal position and lift the lift arm to the highest position. Keep the lift arm control lever at the a float position. Measure the time of movement of the bucket reaching the ground.  Measurement of Bucket Cylinder Operate the bucket control lever to the stroke end. Measure the time of movement of the bucket from the full tilt position to the full dump position.  Measurement of Steering Cylinder Operate the steering wheel to the stroke end. Measure the time of movement of the steering wheel from the right to the left stroke end and from the left to the right stroke end. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard (p.T4-2-3). Remedy: Refer to Troubleshooting B. NOTE: Front Attachment System Troubleshooting (p.T56-18)

T4-4-11

Parking Brake Switch ON ON ON OFF

Forward/ Reverse Lever F N F N

Power Mode Switch ON/OFF ON/OFF ON/OFF ON/OFF

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Cylinder Drift Check Summary: 1. Measure dig function drift, which can be caused by oil leakage in lift arm cylinder, bucket cylinder, and the control valve, with the bucket loaded. 2. Measure in the standard front condition (standard bucket). 3. In case measurement is made immediately after the cylinder replacement, bleed air from the cylinder before measurement by operating the cylinders slowly to the stroke end several times.

Preparation: 1. Load the bucket with either soil or a weight equivalent to the weight standard 2800 kg (6173 lb).

Never allow any personnel to be dCAUTION: under the bucket. 2. In the front position, extend the lift arm to the maximum reach and hold the bucket at an angle of about 5 degrees declined forward from full tilting. 3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). a

Measurement:

1. Stop the engine. 2. In 15 minutes after the engine has been stopped, measure the change in position of lift arm cylinder (2) (b), bucket cylinder (1) (b), and bottom of the bucket (a). 3. Repeat the measurement three times and calculate the mean values.

Bucket Cylinder

Bucket Bottom Drift Amount

T4GB-04-04-014 Lift Arm Cylinder

Evaluation: Drift amount: Lift Arm Cylinder: 15 mm (0.6 in) or less Bucket Cylinder: 10 mm (0.4 in) or less Bucket Bottom (a): 70 mm (2.8 in) or less

b TNEE-04-04-001 b-

Remedy: Refer to Troubleshooting B. NOTE: Front Attachment System Troubleshooting (p.T56-18)

T4-4-12

Cylinder Drift Amount

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Bucket Levelness Summary: Check left and right inclinations of the bucket.

Preparation: 1. Place the unloaded machine on a horizontal bed. (In case a bed is not available, place it on a horizontal flat concrete. Deal with the measurement values as guide lines.) 2. Adjust the tire air pressure to the designated value. 1

3. Lower the bucket onto the bed in the horizontal position.

T4GB-04-04-011

Measurement: Never put hands, feet, and measuring dCAUTION: instruments under the bucket. 1. Raise the bucket bottom slightly above the bed. 2. Measure the vertical distance from the bed and the bottom surface of cutting edge (1) on the left and right ends, and confirm the difference. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Drift amount: 13 mm (0.51 in) or less

T4-4-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Operating Force Summary: 1. Measure a play and operating condition of each control lever, pedal, and steering wheel, and measure operating force of them. 2. Measure maximum operating force of each control lever, pedal, and steering wheel.

Travel Position

3. Measure the lever stroke along the control lever operation from the grip center of each control lever. Measure at 150 mm (6 in) from the pedal support of each pedal.

Preparation:

M4GB-04-001

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

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

T4-4-14

0.3 m (12 in)

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

Accelerator Parking Pedal Brake Switch Each Neutral ON Control (engine: low Lever idle speed) Each Neutral ON Pedal (engine: low idle speed) Steering Neutral OFF Wheel (engine: low idle speed)

Forward/ Reverse Lever N

Control Lever Lock OFF

TNDF-04-04-003

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the steering area before starting the measurement.

3. Attach a spring balance scale (tension type) onto each of the lift arm, bucket, and forward/reverse lever. Measure the maximum operating force by operating them to the stroke end.

4. In case of the pedals, attach a spring balance scale (compression type) or a load cell onto them. Measure the operating force when they are stepped slightly.

12-

5. In case of the steering wheel, attach a spring balance scale (tension type) onto knob (1). Measure the maximum operating force when it is moved. 6. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (p.T4-2-4).

T4-4-15

Knob Accelerator Pedal

2 3-

Brake Pedal

MNDB-01-001

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Stroke Summary: 1. Measure a play and operating condition of each control lever, pedal, and steering wheel, and measure the stroke. 2. Measure at the grip tip of each control lever. Measure at the pedal top of each pedal. 3. In case lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes. Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Measure as follows.  Measurement of Control Lever  Lower the bucket bottom onto the ground.  Stop the engine.  Measure each lever stroke from neutral to the stroke end of each control lever of lift arm, bucket, and forward/reverse at the grip top center.  Measurement of Pedal  Lower the bucket bottom onto the ground.  Stop the engine.  Measure the stroke from neutral to the stroke end of the pedal at the pedal top.  Measurement of Steering Wheel  Start the engine. (Low idle)  Float the bucket slightly above the ground.  Measure the number of times of rotation required for movement of the steering wheel from the right to the left stroke end and from the left to the right stroke end. 2. Measure the chord length from neutral to the stroke end. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (p.T4-2-5).

T4-4-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Pump Delivery Pressure Summary: 1

Measure the main pump output pressure at the delivery port in main pump in neutral condition.

fNOTE: The pressure value can be checked on the MPDr. Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove plug (2) of the main piping inlet in priority valve (1). Install adapter (5) (ST 6453), nipple (3) (ST 6069), and pressure gauge (4) (ST 6932). j : 17, 19, 22 mm (0.67, 0.75, 0.87 in)

3 T4FJ-04-05-001

123-

Priority Valve Plug Nipple

45-

Pressure Gauge Adapter

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

Measurement: 1. Select the following conditions. Accelerator Pedal

Power Mode Switch

Parking Brake Switch

Forward/Reverse Lever Steering

Full stroke

2. Measure pressure with the control levers in neutral without load. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard (neutral): 1.5~2.5 MPa (217.6~362.6 PSI) Remedy: Refer to Troubleshooting A for any accompanied error code. Refer to Troubleshooting B for observed phenomena.

fNOTE:

Front Attachment System Troubleshooting (p.T5-6-18) Steering System Troubleshooting (p.T5-6-24)

T4-5-1

Neutral

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

Summary: Measure the HST pump output pressure at the check port (MA, MB) (1, 4) of the HST pump in neutral condition.

fNOTE: The pressure value can be checked on the MPDr. Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug (G1/4) from pressure check port MB (1) of the HST pump. Install nipple (2) (ST 6069) and pressure gauge (3) (ST 6932). l : 6 mm (0.24 in) j : 19 mm (0.75 in)

2 TNDF-04-05-007

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

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

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

2. Measure pressure with the control levers in neutral without load.

fNOTE: Measure at pressure check port MB (1) when

measuring the pressure driving in forward direction. Measure at pressure check port MA (4) when measuring the pressure driving in reverse direction.

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

Evaluation:

4 T4FJ-04-05-004 a-

Engine Side

Machine Right Side

Pressure Check Port MB (Forward Side) Nipple

34-

Pressure Gauge Pressure Check Port MA (Reverse Side)

Standard (neutral): 2.1±0.3 MPa (304.6±43.5 PSI) Remedy: Refer to Troubleshooting B.

T4-5-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test HST Charging Pump Delivery Pressure (HST Charging Pump Relief Pressure) Summary:

Measure delivery pressure of the HST charging pump at pressure check port G (1) of the HST pump in neutral condition.

fNOTE: The pressure value can be checked on the MPDr.

3 4

Preparation: 1. Stop the engine. 1

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

TNCC-04-05-001

3. Remove the plug (G1/2) from pressure check port G (1) of the HST pump. Install adapter (4) (ST 6596), nipple (3) (ST 6069), and pressure gauge (2) (ST 6932).

l : 10 mm (0.4 in) j : 19, 22 mm (0.75, 0.87 in) 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

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

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

2. Measure pressure with the control levers in neutral without load.

1 T4FJ-04-05-004 a-

Engine Side

Machine Right Side

12-

Pressure Check Port G Pressure Gauge

34-

Nipple Adapter

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

Evaluation: Standard (neutral): 2.5±0.3 MPa (362.6±43.5 PSI) Remedy: Refer to Troubleshooting B.

T4-5-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Brake/Transmission Pump Delivery Pressure

fNOTE: The pressure value can be checked on the MPDr. 4

Preparation: 1. Stop the engine. 2. Disconnect hose (1) from brake/transmission oil filter (2). Install tee (3) (ST 6572) and pressure gauge (4) (ST 6932) between brake/transmission oil filter (2) and hose (1).

j : 19, 22 mm (0.75, 0.87 in)

3. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

Measurement:

T4FJ-04-05-002

1. Select the following conditions. Accelerator Pedal Full stroke

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

123-

2. Measure pressure with the control levers in neutral without load. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard (neutral): 1.6~1.8 MPa (232~261 PSI) Remedy: Refer to Troubleshooting B.

T4-5-4

Hose Brake/Transmission Oil Filter Tee

Pressure Gauge

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test (Blank)

T4-5-5

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Loading Circuit Main Relief Set Pressure Summary: Measure the main relief valve (1) set pressure of the control valve at the main piping inlet in priority valve (2). Check the performance of main relief valve (1) in the control valve.

fNOTE: The pressure value can be checked on the MPDr.

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

3. Remove plug (3) of the main piping inlet in priority valve (2). Install adapter (6) (ST 6453), nipple (5) (ST 6069), and pressure gauge (4) (ST 6932).

TNCC-04-05-004

2 3

j : 17, 19, 22 mm (0.67, 0.75, 0.87 in)

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F) 6

5 T4FJ-04-05-001

Machine Front Side

123-

Main Relief Valve Priority Valve Plug

T4-5-6

456-

Pressure Gauge Nipple Adapter

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

Power Mode Switch

Parking Brake Switch

Forward/Reverse Lever

Full stroke

2. Slowly operate the bucket or lift arm control lever to the stroke end and relieve each function. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard (lift arm/bucket relief operation): 20.6 MPa (2988 PSI)

T4-5-7

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test HST Pump Relief Pressure

Summary: Measure the high-pressure relief valve set pressure of the HST pump at pressure check port MB (1) in the HST pump. Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug (G1/4) from pressure check port MB (1) of the HST pump. Install nipple (2) (ST 6069) and pressure gauge (3) (ST 6932).

l : 6 mm (0.24 in) j : 19 mm (0.75 in)

2 TNDF-04-05-007

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

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

fNOTE: Measure at pressure check port MB (1) when

measuring the pressure driving in forward direction. Measure at pressure check port MA (4) when measuring the pressure driving in reverse direction. a

T4FJ-04-05-004

Engine Side

Machine Right Side

Pressure Check Port MB (Forward Side) Nipple

34-

Pressure Gauge Pressure Check Port MA (Reverse Side)

T4-5-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: Set the blocks onto the front and rear dCAUTION: tires in order not to move the vehicle and keep away from it. 1. Select the following conditions.

Parking Brake Switch

Forward/Reverse Lever

Shift Switch

OFF

F/R

H (Second Speed)

2. Slowly depress the accelerator pedal to the stroke end with the service brake depressed. Measure the pressure with the HST circuit relieved. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard: 40.2 MPa (5831 PSI) Remedy: Refer to Troubleshooting B.

T4-5-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Steering Circuit Relief Pressure Summary: Measure the steering relief valve set pressure at the main piping inlet in priority valve (1). Check the performance of the relief valve in priority valve (1).

1 2

Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 5

3. Remove plug (2) of the main piping inlet in priority valve (1). Install adapter (5) (ST 6453), nipple (3) (ST 6069), and pressure gauge (4) (ST 6932). j : 17, 19, 22 mm (0.67, 0.75, 0.87 in) 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

3 T4FJ-04-05-001

123-

5. Maintain the hydraulic oil temperature at 50±5 °C

T4-5-10

Priority Valve Plug Nipple

45-

Pressure Gauge Adapter

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

Power Mode Switch

Parking Brake Switch

Forward/Reverse Lever

Full stroke

2. Install the articulation lock bar. Slowly operate the steering wheel and relieve the steering. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard: 17.2 MPa (2495 PSI) Remedy: Refer to Troubleshooting B. IMPORTANT: The steering relief set pressure cannot be adjusted by the relief valve in priority valve (1). The relief valve should be replaced as an assembly in case it is faulty.

T4-5-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Overload Relief Valve Set Pressure Summary: 1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable. 2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set pressure more than the overload valve set-pressure is not a proper method. In addition, main relief valve may be designed to leak a small quantity of oil before reliving. In this case, its preleaking start pressure must be increased more than the overload relief valve set pressure. However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate. Some overload relief valves come in contact with the control valve body to block the oil passage. When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit. 3. If the overload relief valve performance must 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.

T4-5-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Preparation: 1. Stop the engine.

1 2

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

3. Remove plug (2) of the main piping in priority valve (1). Install adapter (5) (ST 6453), nipple (3) (ST 6069), and pressure gauge (4) (ST 6932). j : 17, 19, 22 mm (0.67, 0.75, 0.87 in) 5

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

123-

Priority Valve Plug Nipple

45-

Pressure Gauge Adapter

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

Power Mode Switch ON

3 T4FJ-04-05-001

Parking Brake Switch ON

2. Slowly operate the bucket or lift arm control lever to the stroke end and relieve each function. 3. Read pressures on the pressure gauge at this time. 4. Repeat the measurement three times and calculate the mean values.

Evaluation: Performance of the overload relief valves are normal if the measured main relief pressures are within the specified value range. NOTE: The overload relief pressure value is given for reference.

Standard (Bucket Dump): 16.2 MPa (2350 PSI)

T4-5-13

Forward/Reverse Lever N

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test HST Pump Displacement Angle Control Pressure

Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug (G1/4) from pressure check port X1 (1) of the HST pump. Install nipple (2) (ST 6069) and pressure gauge (3) (ST 6932). l : 6 mm (0.24 in) j : 19 mm (0.75 in) To 1

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

2 TNDF-04-05-007

fNOTE: Measure at pressure check port X1 (1) when

measuring the pressure driving in forward direction. Measure at pressure check port X2 (4) when measuring the pressure driving in reverse direction. 1

4 T4FJ-01-02-012

12-

T4-5-14

Pressure Check Port X1 (Forward Side) Nipple

34-

Pressure Gauge Pressure Check Port X2 (Reverse Side)

Parking Brake Switch

Forward/Reverse Lever

Shift Switch

OFF

F/R

H (Second Speed)

Evaluation: Standard: 2.05 ± 0.1 MPa (297 ± 14.5 PSI) Remedy: Refer to Troubleshooting B.

T4-5-15

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test HST Motor Displacement Angle Control Pressure

Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug (G1/4) from pressure check port M1 (1) of the HST motor. Install nipple (2) (ST 6069) and pressure gauge (3) (ST 6932). l : 6 mm (0.24 in) j : 19 mm (0.75 in) 1

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

2 TNDF-04-05-007

T4FJ-03-06-011

View A

T4FJ-04-05-008

12-

T4-5-16

Pressure Check Port M1 Nipple

34-

Pressure Gauge HST Circuit Pressure Sensor

Parking Brake Switch

Forward/Reverse Lever

Shift Switch

OFF

H (Second Speed)

Evaluation: Standard: 40.2 MPa (5831 PSI) Remedy: Refer to Troubleshooting B.

T4-5-17

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Transmission Clutch Pressure

Summary: Measure the operating pressure of the transmission clutch in fast and slow speed at pressure check port Hi (1) and pressure check port Lo (4) of the transmission. Preparation: 1. Stop the engine. 2. Remove the plugs (Rc 1/8) from pressure check port High (1) and pressure check port Low (4) (2 places). Install nipple (2) (ST 6066) and pressure gauge (3) (ST 6932). j : 19 mm (0.75 in) 3. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

2 TNDF-04-05-007

4. Maintain the transmission oil temperature at 60 to 80 °C (140 to 176 °F).

fNOTE: Measure at pressure check port High (1)

when measuring the pressure in fast speed. Measure at pressure check port Low (4) when measuring the pressure in slow speed.

T4FJ-03-06-011

View A

T4FJ-04-05-010 12-

T4-5-18

Pressure Check Port High Nipple

34-

Pressure Gauge Pressure Check Port Low

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: Set blocks (5) onto the front and rear dCAUTION: tires in order not to move the vehicle. Then, keep away from it. 1. Select the following conditions. Shift Switch H (Second Speed) L (First Speed)

Brake Power Mode Parking Brake Pedal Switch Switch Full stroke ON OFF Full stroke ON

T4GB-04-05-017

OFF 5-

2. Operate the forward/reverse lever and the shift switch. Measure the clutch pressure in fast and slow speed. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard (Engine low idle): 1.8±0.3 MPa (261±43.5 PSI) Standard (Engine high idle): 2.0±0.3 MPa (290±43.5 PSI) Remedy: Refer to Troubleshooting B.

T4-5-19

Block

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure (Hydraulic Operated Type: Option) Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. A

3. Disconnect hose (1) from HST charge oil filter (2). Install adapter (3) (ST 6477), nipple (4) (ST 6069), and pressure gauge (5) (ST 6932) between HST charge oil filter (2) and hose (1). j : 19, 22, 27 mm (0.75, 0.87, 1.06 in) 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

2 M4FJ-07-009

View A

4 5

TNCC-04-05-003

123-

T4-5-20

Hose HST Charge Oil Filter Adapter

45-

Nipple Pressure Gauge

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

Power Mode Switch

Full stroke

Parking Brake Switch Forward/Reverse Lever ON N

2. Measure pilot pressure on the pressure gauge without load. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard: 3.7 MPa (537 PSI)

T4-5-21

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure (Hydraulic Operated Type: Option)

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

3. Measure pressure between the pilot valve and control valve (2). Remove pilot hose (1) from the circuit to be measured at the control valve (2) side. Install tee (4) (ST 6573) and pressure gauge (3) (ST 6932).

1 TNCC-04-05-004

j : 17, 19, 22 mm (0.67, 0.75, 0.87 in)

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 1

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F)

TNDF-04-05-004

4 12-

Measurement:

Pilot Hose Control Valve

34-

Pressure Gauge Tee

1. Select the following conditions. Accelerator Pedal

Power Mode Switch

Parking Brake Switch

Full stroke

2. Measure pilot pressure by using pressure gauge (2) with the lift arm and bucket control levers operated to full stroke. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard: 3.2 MPa (464 PSI) Remedy: Refer to Troubleshooting B.

T4-5-22

Forward/Reverse Lever Control Lever Lock Switch N Release

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test (Blank)

T4-5-23

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Accumulator Gas Pressure

dCAUTION:  Allow only qualified personnel to handle the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator. Caution is required to prevent fires from occurring. T4GB-04-05-017

 Do not strike the accumulator. Keep the accumulator away from sparks and/or flames.

 Do not directly heat the accumulator. Do not weld the accumulator housing.

 Release pressure before starting any work on the piping lines. Summary: 1. Measure the gas pressure of accumulator in the ride control circuit (OPT) at the accumulator gas charging port.

Preparation: Set blocks (1) onto the front and rear dCAUTION: tires in order not to move the vehicle. Then, keep away from it.

T4-5-24

Block

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Ride Control Accumulator (Option) 8

1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. IMPORTANT: Do not loosen drain plug (9) more than 2 turns. It may fly out due to remaining pressure. 3. Loosen nut (10) and drain plug (9) of ride control valve (8) by one turn and release remaining pressure of accumulator (1) left in the ride control circuit. j : 13 mm (0.5 in) m : 10~12 N·m (1~1.2 kgf·m) (7.4~8.6 lbf·ft) l : 4 mm (0.16 in) m : 7~9 N·m (0.7~0.9 kgf·m) (5.2~6.6 lbf·ft) 9, 10

4. Remove cap (3) from gas charging port (2) in accumulator (1).

123-

j : 20 mm (0.8 in)

2, 3 1

Accumulator Gas Charging Port Cap

IMPORTANT: Use charging tool (4) (ST 7917). When installing it to gas charging port (2), turn it by hands until joint (b) reaches the end of gas charging port (2). Then, secure it by tightening nut (a). 5. Install charging tool (4) to gas charging port (2).

TNCC-04-05-005 8- Ride Control Valve 9- Drain Plug 10- Nut

6. Turn valve (5) clockwise until it stops.

IMPORTANT: Do not turn valve (7) excessively as charging tool (4) is damaged. 7. Turn valve (7) clockwise. When the pointer of pressure gauge (6) starts moving, stop turning it.

2 1 TNDF-04-05-011

Measurement: Confirm the charging pressure by using pressure gauge (6).

Nut

Joint

45-

Charging Tool Valve

67-

Pressure Gauge Valve

Evaluation: Standard: 2.1~2.3 MPa (305~334 PSI)

T4-5-25

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Ride Control Accumulator Gas Pressure Adjustment (Option) 7

The pressure is reduced or increased according to the results.

 When the pressure is reduced: Slowly turn valve (5) counterclockwise and discharge the charging gas into the atmosphere. 2 1 TNDF-04-05-011

1234-

T4-5-26

Accumulator Gas Charging Port Cap Charging Tool (ST 7917)

567-

Valve Pressure Gauge Valve

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test  When the pressure is increased: 7

Check the specified pressure of dCAUTION: charging gas cylinder as the gas cannot be

4 5

accumulated in the accumulator beyond its specified pressure.

1. Install hose (8) to charging tool (4). 2

2. Turn valves (5, 7) of charging tool (4) counterclockwise until they stops. Set them to the status to discharge the charging gas into the atmosphere. 3. Remove cap (3) from gas charging port (2). 4. Turn joint (b) of charging tool (4) by hands until it reaches the end of gas charging port (2). Then, secure it by tightening nut (a). 5. Install reducing valve (9) to charging gas cylinder (10). Install hose (8) to reducing valve (9).

6. Turn valve (c) of reducing valve (9) counterclockwise and close reducing valve (9).

c 10

7. Open the cock of charging gas cylinder (10).

TNDF-04-05-012

8. Slowly turn valve (c) of reducing valve (9) clockwise and open reducing valve (9). 9. Check that the gas has been discharged from valve (5) of charging tool (4). Then, stop turning valve (c) of reducing valve (9) and stop increasing the pressure. 10. Turn valve (5) of charging tool (4) clockwise until it stops.

ab-

Nut Joint

Valve

12345-

Accumulator Gas Charging Port Cap Charging Tool (ST 7917) Valve

678910-

Pressure Gauge Valve Hose (ST 7917) Reducing Valve (ST 7917) Charging Gas Cylinder

11. Turn valve (7) of charging tool (4) clockwise. Stop turning it when a response is made.

T4-5-27

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 12. The pointer of pressure gauge (6) moves down a little after the charging gas enters accumulator (1).

4 5

13. Further turn valve (c) of reducing valve (9) clockwise charging and accumulate the gas until the pressure is increased to the specified value.

3 a

IMPORTANT: Before checking the enclosed gas pressure, close reducing valve (9) and make the pointer of pressure gauge (6) stable. IMPORTANT: It takes time for a while until closing reducing valve (9) and making the pointer of pressure gauge (6) stable. 14. When the charging gas pressure is high, turn valve (5) counterclockwise and discharge the enclosed gas into the atmosphere.

15. When the charging gas pressure reaches the specified value, turn valve (c) of reducing valve (9) counterclockwise, close reducing valve (9), and close the cock of enclosed gas cylinder (10). 9

16. Turn valve (7) of charging tool (4) counterclockwise until it stops. Slowly turn valve (5) counterclockwise and discharge the charging gas from hose (8).

17. Loosen nut (a) of charging tool (4). Turn joint (b) and remove sealing tool (4) from gas charging port (2).

10 TNDF-04-05-012

18. Install cap (3) to gas charging port (2). ab-

Nut Joint

Valve

123456-

Accumulator Gas Charging Port Cap Charging Tool Valve Pressure Gauge

78910-

Valve Hose Reducing Valve Charging Gas Cylinder

T4-5-28

SECTION 5

TROUBLESHOOTING CONTENTS Group 1 Diagnosing Procedure

Introduction........................................................................... T5-1-1 Diagnosis Procedure........................................................... T5-1-2 Electric System Inspection................................................ T5-1-5 Precautions for Inspection and Maintenance............ T5-1-6 Instructions for Disconnecting Connectors............... T5-1-8 Fuse Inspection...................................................................T5-1-10 Fuse Box A.......................................................................T5-1-11 Fuse Box B.......................................................................T5-1-12 Fusible Link Inspection....................................................T5-1-13 Battery Voltage Check......................................................T5-1-14 Alternator Check................................................................T5-1-15 Continuity Check...............................................................T5-1-16 Voltage and Current Measurement.............................T5-1-18 24-Volt Circuit................................................................T5-1-18 5-Volt Circuit...................................................................T5-1-22 Check by False Signal.......................................................T5-1-23 Test Harness.........................................................................T5-1-24

Group 2 Monitor

Outline..................................................................................... T5-2-1 Monitor Display............................................................... T5-2-2 Vehicle Information Display....................................... T5-2-2 Operating Procedures of Service Menu....................... T5-2-3 How to display service menu..................................... T5-2-4 Engine Speed................................................................... T5-2-4 Coolant Temperature.................................................... T5-2-4 HST Oil Temperature..................................................... T5-2-4 Fault Code......................................................................... T5-2-5 Fuel Consumption.......................................................... T5-2-5 List of Service Menu Display....................................... T5-2-6 Coolant Temperature Gauge and HST Oil Temperature Gauge...................................................... T5-2-7 Fuel Gauge............................................................................. T5-2-8

Group 3 e-Service

Outline..................................................................................... T5-3-1 List of Operation Data........................................................ T5-3-2 List of Daily Report Data.............................................. T5-3-2 List of Frequency Distribution Data......................... T5-3-3 List of Total Operating Hours..................................... T5-3-4 List of Alarm..................................................................... T5-3-5 Communication System.................................................... T5-3-6

Group 4 Component Layout

Main Component (Overview).......................................... T5-4-1 Main Component (Travel System)................................. T5-4-2 Electrical System (Overview)........................................... T5-4-3 Electrical System (Components Related with Relays).......................... T5-4-4 Electrical System (Components Related with Engine)......................... T5-4-4 Electrical System (Cab)....................................................... T5-4-5 Front Console................................................................... T5-4-6 Right Console................................................................... T5-4-7 Rear Console.................................................................... T5-4-8 Monitor Panel.................................................................. T5-4-9 Engine....................................................................................T5-4-10 Pump Device.......................................................................T5-4-11 Transmission/HST Motor.................................................T5-4-12 Control Valve.......................................................................T5-4-13 Priority Valve........................................................................T5-4-14 Ride Control Valve (Option)............................................T5-4-15 Secondary Steering Block (Option).............................T5-4-16 Secondary Steering Pump (Option)............................T5-4-16 Pilot Shut-Off Solenoid Valve (Hydraulic Operated Type)(Option).......................T5-4-17

Group 5 Troubleshooting A

Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure.............................. T5-5-1 MPDr. Fault Code Reference Table................................. T5-5-3 MC Fault Code List............................................................... T5-5-7 ICF Fault Code List.............................................................T5-5-10 Monitor Controller Fault Code List..............................T5-5-11 Air Conditioner Controller Fault Code List................T5-5-13 Communication Terminal Fault Code List.................T5-5-15 ECM Fault Code List...........................................................T5-5-17 MC Fault Codes 111004, 111910, 111914.................T5-5-33 CAN1 Harness Check........................................................T5-5-34 MC Fault Code 111103.....................................................T5-5-37 MC Fault Code 111217.....................................................T5-5-38 MC Fault Code 111330.....................................................T5-5-39 MC Fault Code 111331.....................................................T5-5-40 MC Fault Code 111332.....................................................T5-5-41 MC Fault Code 111422.....................................................T5-5-42 MC Fault Codes 111430, 111434..................................T5-5-43 MC Fault Codes 111450, 111451..................................T5-5-44

60Z7 (US) Trbl

MC Fault Code 111455.....................................................T5-5-45 MC Fault Code 111457.....................................................T5-5-46 MC Fault Code 111622.....................................................T5-5-47 MC Fault Code 111801.....................................................T5-5-48 MC Fault Code 111904.....................................................T5-5-49 MC Fault Code 111908.....................................................T5-5-50 MC Fault Code 111922.....................................................T5-5-51 Monitor Controller Fault Code 115000......................T5-5-52 CAN1 Harness Check........................................................T5-5-54 Monitor Controller Fault Code 115001......................T5-5-57 Monitor Controller Fault Code 115011......................T5-5-58 Monitor Controller Fault Code 115014......................T5-5-59 Specification of Hydraulic Oil Temperature Sensor.................................................T5-5-59 Monitor Controller Fault Code 115015......................T5-5-60 Monitor Controller Fault Codes 120500 to 120502.........................................................T5-5-61 Monitor Controller Fault Codes 120506, 120507, 120510, 120512, 120515, 120518...........................T5-5-62 Air Conditioner Controller Fault Codes E11 to E22........................................................................T5-5-63 Air Conditioner Controller Fault Codes E43 to E92........................................................................T5-5-64

Group 6 Troubleshooting B

Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure.................. T5-6-1 Relationship between Machine Trouble Symptoms and Related Parts..................................... T5-6-3 Correlation between Trouble Symptoms and Part Failures....................................................................T5-6-15 Engine System Troubleshooting.............................T5-6-16 Front Attachment System Troubleshooting.......T5-6-18 Steering System Troubleshooting..........................T5-6-24 Travel System Troubleshooting...............................T5-6-26 Brake System Troubleshooting................................T5-6-29 Other System Troubleshooting...............................T5-6-30 Engine System Troubleshooting..................................T5-6-35 Front Attachment System Troubleshooting.............T5-6-39 Steering System Troubleshooting...............................T5-6-49 Travel System Troubleshooting....................................T5-6-51 Brake System Troubleshooting.....................................T5-6-61 Other System Troubleshooting.....................................T5-6-65 Transporting Wheel Loader (Urgent Situation).......T5-6-87 Precautions for Self-Traveling..................................T5-6-87 Precautions for Towing...............................................T5-6-88 How to Release Parking Brake in Case of Emergency and When Engine Stops.....................T5-6-90 Recovery After Parking Brake Release........................T5-6-91

Group 7 Troubleshooting C

Troubleshooting C (Monitor Diagnosis) Procedure.......................................................................... T5-7-1 Column Monitor (Gauges and Indicators)............. T5-7-1 Malfunction of Monitor Buzzer....................................... T5-7-3 Malfunction of Coolant Temperature Gauge............. T5-7-4 Malfunction of Fuel Gauge............................................... T5-7-5 Malfunction of HST Oil Temperature Gauge.............. T5-7-6 Malfunction of Monitor Display...................................... T5-7-8 Malfunction of Light Bulb Check System..................T5-7-10 Malfunction of Left And Right Turn Signal Light Indicators.........................................................................T5-7-11 Malfunction of Hazard Light Indicator.......................T5-7-12 Malfunction of High Beam Indicator..........................T5-7-13 Malfunction of Work Light Indicator...........................T5-7-14 Malfunction of Maintenance Light..............................T5-7-16 Malfunction of Preheat Indicator.................................T5-7-17 Malfunction of HST Oil Temperature Indicator.......T5-7-18 Malfunction of HST Warning Indicator.......................T5-7-19 Malfunction of Engine Oil Pressure Indicator..........T5-7-20 Malfunction of Overheat Indicator..............................T5-7-21 Malfunction of Engine Warning Indicator.................T5-7-22 Malfunction of Service Indicator..................................T5-7-23 Malfunction of Parking Brake Indicator.....................T5-7-24 Malfunction of Clearance Light Indicator.................T5-7-25 Malfunction of Secondary Steering Indicator (Option)............................................................................T5-7-26 Malfunction of Low Steering Oil Pressure Indicator (Option)............................................................................T5-7-27 Malfunction of Alternator Indicator............................T5-7-28 Malfunction of Control Lever Lock Indicator (Option)............................................................................T5-7-29 Malfunction of Seat Belt Indicator (Option).............T5-7-30

Group 8 Air Conditioner

Outline..................................................................................... T5-8-1 Component Layout........................................................ T5-8-2 Functions of Main Parts..................................................... T5-8-6 Troubleshooting.................................................................T5-8-11 Air Conditioner Controller Fault Code List................T5-8-12 Air Conditioner Controller Fault Codes E11 to E22........................................................................T5-8-13 Air Conditioner Controller Fault Codes E43 to E92.......................................................................T5-8-14 Faulty cooling......................................................................T5-8-16 Faulty heating.....................................................................T5-8-26 Others....................................................................................T5-8-29 Work after Replacing Components.............................T5-8-36 Refill Compressor Oil........................................................T5-8-37 Charge Air Conditioner with Refrigerant..................T5-8-38 Hose and Pipe Tightening Torque................................T5-8-46

60Z7 (US) Trbl

Group 8 Air Conditioner

Outline..................................................................................... T5-8-1 Component Layout........................................................ T5-8-2 Functions of Main Parts..................................................... T5-8-4 Troubleshooting................................................................... T5-8-9 Air Conditioner Controller Fault Code List................T5-8-10 Air Conditioner Controller Fault Codes E11 to E22........................................................................T5-8-11 Air Conditioner Controller Fault Codes E43 to E92.......................................................................T5-8-12 Faulty cooling......................................................................T5-8-14 Faulty heating.....................................................................T5-8-24 Others....................................................................................T5-8-27 Work after Replacing Components.............................T5-8-34 Refill Compressor Oil........................................................T5-8-35 Charge Air Conditioner with Refrigerant..................T5-8-36 Hose and Pipe Tightening Torque................................T5-8-44

60Z7 (US) Trbl

(Blank)

60Z7 (US) Trbl

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Introduction Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to quickly find the cause of the machine trouble and solution. The troubleshooting section in this manual consists of eight groups; Diagnosing Procedure, Monitor, e-Service, Component Layout, Troubleshooting A (Base Machine Diagnosis by Using Fault Codes), Troubleshooting B (Machine Diagnosis by Using Trouble Symptom), Troubleshooting C (Monitor Diagnosis), and air conditioner.  Troubleshooting A (Base Machine Diagnosis by Using Fault Codes) Refer to these procedures if any fault codes are displayed when each controller is diagnosed by using MPDr. (or the the service menu of monitor).

 Diagnosing Procedure This group explains procedures of troubleshooting and precautions and/or information for the electrical system inspection. Example: Fuse Inspection  Monitor This group contains the display screen of monitor and the operating procedures of service menu.  e-Service This group contains as follows. Download data from the monitor controller and Upload. Procedures when starting satellite communication, when installing the satellite communication controller and when replacing the monitor controller. Explanation for the satellite communication system.

IMPORTANT: The monitor controller receives and retains a record of the electrical signal system malfunction of each controller in the form of fault codes by using the CAN communication. In addition, the self-diagnosing function records the electrical signal system malfunction in the form of fault codes

 Component Layout

Example: Fault Code 111000-2: Abnormal EEPROM  Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Refer to troubleshooting B for diagnosis by using trouble symptom. Refer to these procedures when no fault codes are displayed after diagnosing the machine by using MPDr. (or the service menu of monitor). Example: Even if accelerator pedal is operated, engine speed does not change.  Troubleshooting C (Monitor Diagnosis) This procedure is used when there are malfunctions on components regarding monitor, such as gauges or indicators. Example: The fuel gauge is not operated.  Air Conditioner This group contains system of the air conditioner, troubleshooting, and procedures for charging air conditioner with refrigerant.

T5-1-1

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Diagnosis Procedure These six basic steps are essential for efficient troubleshooting: 1. Study the system  Study the machine's technical manuals.  Know the system and how it works, and what the construction, functions and specifications of the system components are. (Construction and functions) 2. Ask the operator Before inspecting, get the full story of malfunctions from the operator below.

T107-07-01-001

 Operating condition: How is the machine being used? (Find out if the machine is being operated correctly.)  Trouble identification: When was the trouble noticed, and what types of work the machine doing at that time?  Trouble symptom: What are the details of the trouble? Did the trouble slowly get worse, or did it appear suddenly for the first time?  Trouble history: Did the machine have any other troubles previously? If so, which parts were repaired before? 3. Inspect the machine Before starting the troubleshooting procedure, check the machine's daily maintenance points, as shown in the operator's manual. Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine.

T4GB-05-01-002

If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result, wasting time. Check for blown fuses before troubleshooting. Even if a fuse looks normal by visual inspection, a fine crack is difficult to find. Always use a circuit tester when checking the fuses. 4. Operate the machine yourself Reproduce the trouble on the machine and make sure the actual phenomenon. If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses corresponding to the trouble.

T5-1-2

T4GB-05-01-003

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5. Perform troubleshooting Do not disconnect wire harnesses or dCAUTION: hydraulic lines while the engine is running. The

machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Stop the engine before disconnecting wire harnesses or hydraulic lines. Perform diagnosis by connecting MPDr. to the machine or by using the service menu of monitor. In case any fault code has been displayed by diagnosis by using MPDr. (the service menu of monitor), check the cause of the trouble by referring to Troubleshooting A in this section. In case any fault code has been displayed by diagnosis by using MPDr. (the service menu of monitor), write the fault code. Delete the fault code once and retry self-diagnosis again. If the fault code is displayed again, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code (displayed by the service menu of monitor) will be deleted. Therefore, in case the problems which are not easily re-predicable are encountered, check the fault code by using MPDr.. In case the fault code is not displayed, check operating condition of each component by referring to Troubleshooting B in this section and by using MPDr. (the service menu of monitor). NOTE: Note that the fault codes displayed do not necessarily indicate machine trouble. The controller stores even temporary electrical malfunctions, such as a drop in battery output voltage or disconnection of the switches, sensors, etc., for inspections. For this reason, the "RETRIAL" is required to erase the accumulated fault codes from the controller memory and to confirm if any fault codes are indicated after the "RETRIAL".

T5-1-3

TNED-05-01-001

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

T4GB-05-01-006

T5-1-4

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

T5-1-5

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

R Red

W White

L Blue

G Green

Y B Yellow Black

Or Lg Orange Light green

fNOTE:  Code BW indicates a black base wire with white fineline marking.  Initials "O" and "Or" both stand for the color orange.  Wires with longitudinal stripes printed on them are not color coded. Do not confuse them with color coded wires.

T5-1-6

Br P Brown Pink

Gr Gray

V Violet

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 3. Precautions for connecting and disconnecting terminal connectors.  When disconnecting the wire harnesses, grasp them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate connectors, if a lock is provided. (Refer to Instructions for Disconnecting Connector on T5-1-8.)  The water-resistant connectors keep water out. If water enters them, water will not easily drain from them. When checking the water-resistant connectors, take extra care not to allow water to enter the connectors. If water gets into the connectors, reconnect only after the connectors are thoroughly dried.  Before connecting the terminal connectors, check that no terminals are bent (3) or coming off (4). In addition, as most connectors are made of brass, check that no terminals are rusting (2).  When connecting terminal connectors provided with a lock, insert them together until the lock "clicks."  Pull the wire harness near the connector in order to check if it is correctly connected.

TDAA-05-08-002

1 2 3

4 TDAA-05-08-003 12-

Correct Rusting

34-

Bent Coming Off

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

TDAA-05-08-004

T5-1-7

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

T107-04-05-002

 Raise Lock, Pull, and Separate Type

T107-04-05-003

T4GB-05-06-003

 Pull and Separate Type IMPORTANT: Before pulling and separating, unlock the connector in the solenoid valve by using a pair of pincers.

T107-04-05-004

T5-1-8

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

TDAA-05-08-005

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

T4GB-05-06-001

T4GB-05-06-002

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

T4GB-05-06-007

T5-1-9

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Inspection Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a circuit tester in order to correctly inspect fuse continuity. Use a circuit tester in order to correctly inspect fuse continuity by following the instructions described below.

fNOTE: All terminals located along the lengthwise

center line of fuse box are connected to the power source, while terminals located away from center of the fuse box are connected to loads (accessories). Therefore, test all fuses in the same method.

1. Set the key switch to the ON position. When the key switch is in the ON position, current from key switch terminal M turns the battery relay ON so that electric power is supplied to all circuits. (Refer to the circuit diagram.)

a, b

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

10 9 8 7 6

20 19 18 17 16

5 4 3 2 1

15 14 13 12 11

M178-07-034 a-

Fuse Box A

Fuse Box B

a b

TNED-01-02-009

T5-1-10

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Box A (a) Fuse No. Capacity Connected to 1 5A Shift Switch, Quick Shift Switch, Traction Control Switch, Power Mode Switch, Ride Control Switch (Option) 2 5A Back Buzzer Relay (Power), Backup Buzzer, Backup Light 3 5A Turn Signal Lever, Brake Light Relay (Power), Turn Signal Light Relay (R), Turn Signal Light Relay (L), Brake Light (RH), Brake Light (LH) 4 10 A Fuel Pump Relay (Power), Fuel Pump 5 10 A Horn Relay (Power), Horn Switch, Horn 6 10 A Flasher, Hazard Light Switch 7 10 A Load Dump Relay, ICF, Monitor Controller, GSM (Option), GPS (Option) 8 30 A ECM 9 10 A Head Light Relay (Power), Head Light (RH), Head Light (LH) 10 15 A MC, Forward/Reverse Lever 11 5A Hazard Light Switch, Parking Brake Switch, Clearance Light (Rear) (RH), Clearance Light (Rear) (LH), Clearance Light (Front) (RH), Clearance Light (Front) (LH), Traction Control Switch, Control Lever Lock Switch, Power Mode Switch, Ride Control Switch (Option), License Light (Option) 12 15 A Option 2 13 10 A Load Dump Relay, Battery Relay, Monitor Controller, Buzzer, ICF, Tachograph, Alternator Indicator Relay 1, Alternator Indicator Relay 2 Fresh/Re-Circulated Air Damper Servo Motor (Air Conditioner), Air Conditioner Controller (Air Conditioner), Compressor Relay (Air Conditioner), Blower Motor Relay (Air Conditioner), GSM (Option), GPS (Option) 14 10 A MC, Parking Brake Relay 1, Preheat Relay 1, ECM 15 10 A Coil (Lift Arm Raise Side) (Manually Operated Type) (Option), Coil (Bucket Roll Back Side) (Manually Operated Type) (Option), Coil (Lift Arm Lower Side) (Hydraulic Operated Type) (Option), Coil (Lift Arm Raise Side) (Hydraulic Operated Type) (Option), Coil (Bucket Roll Back Side) (Hydraulic Operated Type) (Option), Pilot Shut-Off Relay (Hydraulic Operated Type) (Option), Coupler Switch (Option) 16 20 A Work Light (Rear) Relay, Rear Work Light (RH), Rear Work Light (LH) 17 5A Light Switch, Dimmer Switch 18 15 A Option 1 19 10 A High-Beam Relay, Head Light High-Beam (RH), Head Light High-Beam (LH) 20 5A Parking Brake Solenoid Valve, Parking Brake Relay 2

T5-1-11

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Box B (b) Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Capacity Connected to 5A Radio 10 A Cigar Lighter 15 A Wiper Motor (F), Wiper Relay (F)2, Wiper Relay (F)1, Washer Relay (F), Washer Motor (F) 5A Secondary Steering Pump Relay (Option), Secondary Steering Motor 20 A Front Work Light Relay, Front Work Light (RH), Front Work Light (LH) 10 A Wiper Relay (R), Washer Relay (R) 15 A Power Unit 20 A Seat Heater (Option) 10 A Beacon Light Switch (Option) 20 A Blower Motor Relay (Air Conditioner) 5A Radio, Front Cab Light, Tachograph 10 A Compressor Relay (Air Conditioner) 10 A Compressor Relay (Air Conditioner), High/Low Pressure Switch (Air Conditioner) 15 A Glass Heater (Front) (Option) 15 A Glass Heater (Rear) (Option) 20 A Glass Heater (Side) (Option) 10 A Option 3 10 A Option 4 -

T5-1-12

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fusible Link Inspection 1

Inspection 1. Visually inspect fusible links (1, 2, 3).

Replacement 1. Disconnect the negative cable from the battery. 2. Pull out fusible links (1, 2, 3). Replace fusible links (1, 2, 3).

3. Connect the negative cable to the battery.

TNCC-05-01-001

1, 2, 3

T111-04-05-015

12-

Fusible Link B (65A) Fusible Link A (65A)

Fusible Link (100 A)

Preheat Relay 2

Battery Relay

T5-1-13

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

fNOTE: If voltage is abnormal, recharge or replace the battery. 2. Start the engine. Check voltage between the battery positive terminal and the body (ground). Normal Voltage: 26 to 28 V

fNOTE: If voltage is abnormal, check the charging system.

T4FC-05-08-003

T5-1-14

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

MNDB-01-008

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

TNCC-05-01-003

T5-1-15

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

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

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

 Single-line short-circuit check Disconnect both end connectors of the wire harness and check continuity between one end connector of the wire harness and the body:  0 Ω = Short-circuit is present.  ∞ Ω = No short-circuit is present.  Multi-line continuity check Disconnect both end connectors of the wire harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the shortcircuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c). By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c).  0 Ω = Line (B) - (b) has discontinuity.  ∞ Ω = Line (A) - (a) has discontinuity.  Multi-line short-circuit check Disconnect both end connectors of the wire harness, and check continuity between terminals (A) and (B) or (C).  0 Ω = Short-circuit exists between the lines.  ∞ Ω = No short-circuit exists between the lines.

T107-07-05-003

A B C

a b c

T107-07-05-004

A B C

a b c

T107-07-05-005

T5-1-16

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure (Blank)

T5-1-17

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

Key Switch

Location to be Measured

Specification

OFF OFF OFF OFF OFF OFF

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

ON or START ON or START

Between (7) and Ground: Fusible Link A Between (13) and Ground: Heater Plug *2

20 to 25 V 20 to 25 V

ON ON ON

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

Between (12) and Ground: Alternator (B), Generating Voltage Between (9) and Ground: Battery Relay, Generating Voltage Between (7) and Ground: Fusible Link (100 A), Generating Voltage Between (15) and Ground: Monitor Controller (#2-28)

ON ON ON

Between (12) and Ground: Alternator (B) Between (11) and Ground: Load Dump Relay Between (6) and Ground: Battery Relay

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

ON ON ON

Between (10) and Ground: Key Switch Between (14) and Ground: Radio Between (5) and Ground: Fusible Link

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

One Battery One Battery Two Batteries Battery Power Fusible Link A (65A) Backup Current *1

*1 Before measurement, disconnect the negative cable from the battery. *2 The preheating circuit is operated for the preheating time according to the coolant temperature.

T5-1-18

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

13 to 30 V

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

g 10

2 3

d c

5 j #2-28

b 13 14

TNCB-02-05-000

abc-

Battery Alternator Fusible Link A (65A)

def-

Battery Relay Heater Plug Load Dump Relay

ghi-

T5-1-19

Key Switch Fuse Box A Fuse Box B

jMonitor Controller k- Fusible Link (100 A) m- Radio

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

Key Switch

Location to be Measured

Specification

START START START START START START START START START START START

Between (16) and Ground: Between (17) and Ground: Between (18) and Ground: Between (19) and Ground: Between (20) and Ground: Between (21) and Ground: Between (22) and Ground: Between (23) and Ground: Between (24) and Ground: Between (25) and Ground: Between (26) and Ground:

Battery Relay (Coil) Battery Relay (Switch) Starter Relay 1 Starter Relay 1 ECM (K73) Fuse Box A Key Switch ECM (K88) MC (#13) MC (E41) MC (E42)

T5-1-20

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

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

20 22

g K73

23 24 25

K88

#13 #41 #42

18 b 19

TNCB-02-05-000

ab-

Starter Motor Starter Relay 1

cd-

Battery Relay Key Switch

eg-

T5-1-21

Fuse Box A ECM

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

Two Polarities 1

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To ground to the body  Red (Positive) probe terminal of circuit tester: To terminal #1 T107-07-05-006

Evaluation: If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 is normal. Three Polarities 1

T107-07-05-007

 Voltage between terminal #1 and the ground terminal Turn OFF the key switch, and disconnect the sensor connector. Measure the voltage between terminal #1 (5 V power supply) on the body harness end connector and the ground terminal (terminal #2 for two-polarities or terminal #3 for three-polarities connector) under the following conditions.

Two Polarities 1

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To ground terminal (Terminal #2 or #3)  Red (Positive) probe terminal of circuit tester: To terminal #1

T107-07-05-008

Evaluation: If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 or the ground terminal (terminal #2 or #3) is normal.

Three Polarities 1

T107-07-05-009

T5-1-22

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Check by False Signal Turn the key switch OFF. Disconnect the sensor connector. Turn the key switch ON. Connect terminal #1 (power source) of the body harness end connector to terminal #2 (signal). (Power voltage is used as a false signal.) Check this state by using the monitor function of MPDr. When the maximum value is displayed, MC and the circuit up to the body harness end connector are normal. If "ON" is displayed, the pressure switch circuits are normal.

Two Polarities 1

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

fNOTE: Some kinds of sensors can be monitored by the

T107-07-05-010

Three Polarities

service menu of the monitor.

T107-07-05-011

T5-1-23

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Test Harness

Parts Number 4283594 (ST 7126)

Install a test harness between connectors. Check the circuit condition depending on whether the test harness lamp lights or extinguishes during operation.  Parts Number 4283594 (ST 7126) Use in order to check a single-line (discontinuity and/or voltage).  During Operation: Light is ON.

T107-07-05-012

Parts Number (ST 7226)

 Parts Number (ST 7226) Use in order to check the solenoid valve unit circuits.

 When the corresponding control lever or switch is operated: Light is ON.

150

4 50 50

1 T107-07-06-015

Connect a test harness to the wire harness end connector of pressure sensor. Check the state of pressure sensor circuit.  ST 6701 for high-pressure sensor  ST 6703 for low-pressure sensor

TDAA-05-06-003

T5-1-24

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Connecting Procedure of Test Harness

fNOTE: The connecting procedures of test harness of HST circuit pressure sensor (1) are explained. 1. Disconnect a connector of HST circuit pressure sensor (1).

TNCC-05-01-002

2. Connect the male end connector of test harness (3) (ST 6701) to wire harness end connector (4) of pressure sensor (1). 3. Connect dummy sensor (2) equivalent to #4436271 to the female end connector of test harness (3) (ST 6701).

TDAA-05-06-002

4 TDAA-05-06-003

T5-1-25

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure (Blank)

T5-1-26

SECTION 5 TROUBLESHOOTING Group 2 Monitor Outline 1

7 8

36 35

34 33

14 32

15 31

1234-

16 30

Left Turn Signal Light Indicator High Beam Indicator Work Light Indicator Right Turn Signal Light Indicator 5- (Unused) 6- (Unused) 7- Service Indicator 8- Maintenance Indicator 9- Parking Brake Indicator 10- Clearance Light Indicator 11- Control Lever Lock Indicator (Option)

12131415-

(Unused) (Unused) Brake Oil Low Level Indicator Secondary Steering Indicator (Option) Low Steering Oil Pressure Indicator (Option) Seat Belt Indicator (Option) Discharge Warning Indicator Fuel Gauge Power Mode Indicator Monitor Display Selection Switch

161718192021-

27 26

24 23

20 19

22- (Unused) 23- Monitor Display Selection Switch (Up) 24- Preheat Indicator 25- Monitor Display Selection Switch (Down) 26- (Unused) 27- Monitor Display 28- (Unused) 29- Engine Warning Indicator 30- Overheat Indicator 31- Coolant Temperature Gauge

fNOTE: Refer to the separated volume, Operator’s Manual for details of the monitor panel.

T5-2-1

MNDB-01-034

32- Engine Oil Low Pressure Indicator 33- (Unused) 34- (Unused) 35- (Unused) 36- (Unused) 37- (Unused) 38- HST Warning Indicator 39- HST Oil Temperature Indicator 40- HST Oil Temperature Gauge

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitor Display

1- Monitor Display 2- Monitor Display Selection Switch 3- Monitor Display Selection Switch (Up) 4- Monitor Display Selection Switch (Down) 5- Speedometer 6- Vehicle Information Display 7- Traction Control Indicator 8- F-N-R/Shift Position Indicator

9- Ride Control Indicator (Option)

MNDB-01-008

10- ECO Indicator 8

Vehicle Information Display (6)

12- Engine Speed Display 13- Coolant Temperature Display 14- HST Oil Temperature Display 15- (Unused) 16- Fuel Consumption Display 17- (Unused) 18- Hour Meter Display 19- Average Fuel Consumption Display 20- Odometer Display 7

21- Fault Code Display

MNCB-01-007

22- (Unused) 19

18 17 16

T5-2-2

MNCB-01-007

SECTION 5 TROUBLESHOOTING Group 2 Monitor Operating Procedures of Service Menu IMPORTANT: The service menu is provided only for maintenance activity. Do not explain this function to your customers. The following items can be displayed on the monitor without using MPDr.  Clock (time, 24-hour) *  Hour Meter *  Odometer *  INFO (Information) *  Engine Speed  Coolant Temperature  HST Oil Temperature  Fault Code  Fuel Consumption  Average Fuel Consumption

f NOTE: The menu without an asterisk mark (*) are additionally displayed in Service Mode.

f NOTE: Refer to the Operator’s Manual for details of the normal menu with an asterisk mark (*).

T5-2-3

SECTION 5 TROUBLESHOOTING Group 2 Monitor How to display service menu 1. Push monitor display selection switches (2, 3) beyond two seconds at the same time while the clock is displayed on Vehicle Information Display Screen (1) with the key switch set in the ON position or the engine running. By this operation, Service Menu is added to Vehicle Information Display Screen (1). 2. When setting the key switch to the OFF position, the normal menu appears. MNDB-01-008

Engine Speed

Current Engine Speed (5) is displayed. (Figure A) When pushing monitor display selection switch (3) once on this screen, Coolant Temperature is displayed. Coolant Temperature

Current Engine Coolant Temperature (6) is displayed. (Figure B) When pushing monitor display selection switch (3) once on this screen, Transmission Oil Temperature is displayed. 6

HST Oil Temperature

Current HST Oil Temperature (7) is displayed. (Figure C) When pushing monitor display selection switch (3) once on this screen, Fault Code is displayed. 7

T5-2-4

TNDF-05-02-005

SECTION 5 TROUBLESHOOTING Group 2 Monitor Fault Code 1. Current fault code (5) can be displayed. (Figure E)

2. When some Fault Codes (5) exist and whenever pushing monitor display selection switch (2), other fault codes are displayed. TNDB-05-02-006

3. When pushing monitor display selection switch (3) once on this screen, Fuel Consumption is displayed.

f NOTE: When the trouble of Fault Code (5) on the screen is solved, '-----' (bar) is displayed.

f NOTE: When Fault Code (5) does not exist, ERROR (6) is displayed. In this case, '-----' (bar) is displayed.

MNDB-01-008

Fuel Consumption/Average Fuel Consumption 1. Current Fuel Consumption (7) is displayed. (Figure F)

TNDB-05-02-007

2. When pushing monitor display selection switch (2) once on this screen, Average Fuel Consumption (8) up to the present is displayed. (Figure G)

8 G

3. Whenever pushing monitor display selection switch (4) on this screen, Unit is changed (l/hgal/h). TNDB-05-02-008

4. When pushing monitor display selection switch (3) once on this screen, Clock is displayed. (Figure H)

TNDB-05-02-009

T5-2-5

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Service Menu Display Display Order Item 1 Clock (time, 24-hour) * 2 Hour Meter * 3 Odometer * 4 INFO (Information) * 5 Engine Speed 6 Coolant Temperature 7 HST Oil Temperature 8 Fault Code 9 Fuel Consumption 10 Average Fuel Consumption

Unit h, min h km (mile) min-1 ºC ºC ERROR l/h (gal/h) l/h (gal/h)

Data Input signal from ECM Input signal from ECM Input signal from Monitor Controller -

f NOTE: The menu without an asterisk mark (*) are available in Service Mode only.

T5-2-6

SECTION 5 TROUBLESHOOTING Group 2 Monitor Coolant Temperature Gauge and HST Oil Temperature Gauge Coolant Temperature Gauge E D

No. A B C D E

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

No. A B C D E

Coolant Temperature ºC (ºF) 25 (77) 50 (122) 80 (176) 120 (248) (125) (257)

A TNED-05-02-003

f NOTE: When the coolant temperature reaches the (D)

zone or more, the maintenance indictor on the monitor panel is ON and the buzzer sounds.

HST Oil Temperature Gauge E D

TNDB-05-02-010

f NOTE: When the HST oil temperature reaches the (D)

zone for ten seconds or more, the maintenance indictor on the monitor panel is ON.

T5-2-7

SECTION 5 TROUBLESHOOTING Group 2 Monitor Fuel Gauge Fuel Gauge A

a C D TNDB-05-02-011

f NOTE: When the fuel gauge reaches the (C) zone, indictor (a) on the monitor panel is ON.

T5-2-8

No. A

Fuel Level (%) 100 (FULL)

Fuel Sensor (Ω) 10 0/-4

B C D

50 12 0 (EMPTY)

32.9 77±3 90+10/0

SECTION 5 TROUBLESHOOTING Group 3 e-Service Outline ICF (Information Controller) saves the input signals from various sensors and switches of the machine as data. Various input signals are recorded as operation data in ICF. The recorded data is downloaded to the personal computer and is uploaded to the center server via LAN, so that the data can be used as “e-Service”. The machine equipped with the communication terminal (option) sends the data to the center server by using the communication terminal. (As for the communication system, refer to T5-3-6.)

T5-3-1

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Operation Data List of Daily Report Data Item Date Fuel Level Fuel Usage Amount Machine Hour Meter Engine Operating Hours Operating Distance Radiator Coolant Temperature Outside Temperature (Cab spec. machine only) Fuel Temperature HST Oil Temperature Engine Operating Hour Distribution

Idling Hours

Details Date of daily report data. The value of the final remained fuel during a day when the engine stops. The value of fuel used during a day. Hour meter cumulative hours. Total engine operating hours during a day. Driving distance during a day. The highest radiator coolant temperature during a day. The highest outside temperature during a day. The highest fuel temperature during a day. The highest HST oil temperature during a day. Engine operating hour distribution during a day. (Operating hours are recorded only when alternator output signal is continuously delivered for more than 10 minutes.) Total Idling hours during a day.

fNOTE: The daily operation in this table is equivalent to

the hours between 0:00 and 23:59:59 counted by the ICF built-in clock. In case the engine is kept operated beyond 0:00, such data are recorded as those for the following day.

T5-3-2

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Frequency Distribution Data Item Engine Speed Front Attachment Circuit Pressure Output Shaft Torque Radiator Coolant Temperature HST Oil Temperature Vehicle Speed HST Motor 1 Displacement Angle Output Shaft Speed Select Speed Shift Slow Speed (L) Select HST Circuit Pressure/Engine Speed

Details Frequency distribution of engine speed. Frequency distribution of front attachment circuit pressure. Frequency distribution of output shaft torque. Frequency distribution of coolant temperature. Frequency distribution of HST oil temperature. Frequency distribution of vehicle speed. Frequency distribution of HST motor displacement angle. Frequency distribution of output shaft speed. Frequency distribution of select speed shift. Frequency distribution of slow speed (L) select. Frequency distribution of HST circuit pressure and engine speed.

T5-3-3

SECTION 5 TROUBLESHOOTING Group 3 e-Service List Of Total Operating Hours Item Hour Meter Engine Operating Hour Traveling Distance

Details Hour meter’s value accumulated in monitor controller. Total engine operating hours. Total traveling distance.

T5-3-4

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Alarm Item 1 Overheat Alarm 2 Engine Warning Alarm 3 Engine Oil Pressure Alarm 4 Alternator Indicator Alarm 5 Service Brake Oil Level Alarm 6 Emergency Steering Operation Alarm 7 Steering Oil Pressure Alarm 8 HST Oil Temperature Alarm 9 HST Failure Alarm 10 Overrun Alarm

Details Date when the overheat indicator lights Date when the engine warning indicator lights Date when the engine oil low pressure indicator lights Date when the discharge warning indicator lights Date when the brake oil low level indicator lights Date when the secondary steering indicator lights Date when the low steering oil pressure indicator lights Date when the HST oil temperature indicator lights Date when the HST warning indicator lights Date when the overrun alarm buzzer sounds

fNOTE: When the alarm above is recorded, check each item.

If the monitor is faulty, refer to Trouble-shooting C.

T5-3-5

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

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

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

T5-3-6

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

3 2

9 10 11 12

23 22

13 14

21 20

15 TNCC-01-02-001

1234567-

Bucket Bell Crank (Lever) Bucket Cylinder Lift Arm Steering Valve Control Lever Brake Valve

891011121314-

Priority Valve Hydraulic Oil Tank Brake Oil Reserve Tank Muffler Coolant Reservoir Oil Cooler Radiator

15161718192021-

T5-4-1

Intercooler Fuel Tank Engine Fuel Pre-Filter Fuel Main Filter Air Cleaner Pump Device

22232425-

Declutch Valve Control Valve Lift Arm Cylinder Bucket Link

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Main Component (Travel System)

5 6 7

8 TNCC-01-02-002

123-

Front Axle Steering Cylinder HST Filter

456-

Brake/Transmission Oil Filter Transmission Propeller Shaft (Rear)

789-

T5-4-2

Rear Axle HST Motor Propeller Shaft (Front)

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

7 8 9 10 11

12 16 15 14

TNCC-01-02-003

12345-

Bucket Proximity Switch Front Work Light Horn Front Wiper Motor (Cab) Pressure Sensor (Front Attachment Pressure)

67891011-

Rear Wiper Motor (Cab) HST Oil Temperature Sensor Battery Relay Reverse Buzzer Rear Work Light Battery

12- Rear Combination Light (Turn Signal Light, Tail Light, Brake Light, Backup Light) 14- Fuel Level Sensor 15- Brake Oil Level Switch 16- Brake Light Switch

T5-4-3

17- Clearance light/Turn Signal light 18- Head Light

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Electrical System (Components Related with Relays) 2

5 TNCC-01-02-004 a-

Front Side of Machine

12-

Fusible Link B (65A) Fusible Link A (65A)

34-

Fusible Link (100A) (2 Used) Battery Relay

Preheat Relay 2

Electrical System (Components Related with Engine) 7

TNCC-01-02-011

9 a-

Front Side of Machine

ECM

Fuel Pressure Switch (Fuel Main Filter)

T5-4-4

Electric fuel pump

Water Separator Switch (Fuel Pre-Filter)

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

a 4

TNDB-01-02-032 Detail E

E 12 7

TNDB-01-02-029

TNCC-05-02-012

Front Console (Refer to T5-4-6.)

Right Console (Refer to T5-4-7.)

Rear Console (Refer to T5-4-8.)

1234-

Radio Upper Switch Panel (Option) Speaker Rear Wiper Motor

5789-

Accelerator Pedal Sensor Brake Light Switch Front Wiper Motor Air Conditioner Controller

10111213-

Front Wiper (1) Relay (WR1) Front Wiper (2) Relay (WR2) GSM (Option)/GPS (Option) Flasher Relay

T5-4-5

15- MC (Main Controller)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Front Console 1

2 3

MNDB-01-001

15 16 17 12 18

19 20

22 14

123456-

MNDB-01-002

Air Conditioner Vent Hazard Light Switch Work Light Switch Parking Brake Switch Neutral Lever Lock (For Forward/Reverse Lever) Steering Wheel

78910-

Monitor Panel Wheel Horn Switch Accelerator Pedal Brake/Inching Pedal (Both at left and right are interlocked.) 11- Front/Rear Wiper Switch

21 MNDB-01-003

12- Forward/Reverse Lever/Shift Switch 13- Steering Column Tilt Pedal 14- Tilt/Telescopic Lever 15- Turn Signal Lever/Light Switch/Dimmer Switch 16- Key Switch

T5-4-6

171819202122-

Slow Speed (L) Select Switch Auxiliary Auxiliary Auxiliary Ashtray Cigar Lighter

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Right Console  Manual Type (Standard) 1

11 4

12-

Control Lever Auxiliary Control Lever Lock (Option)

345-

Auxiliary Control Lever (Option) Ride Control Switch (Option) Power Mode Switch

678-

MNCB-01-005

Back Buzzer Switch (Option) Secondary Steering Operation Check Switch (Option) Auxiliary

9- Traction Control Switch 10- Control Lever Lock 11- Quick Shift Switch (QSS)

 Hydraulic Pilot Type (Option) 2 1

4 5

9 10

12345-

Joystick Type Lever Auxiliary Control Lever (Option) Control Lever Lock Switch Auxiliary Traction Control Switch

678910-

Power Mode Switch Auxiliary Auxiliary Back Buzzer Switch (Option) Auxiliary

14 13

11- Secondary Steering Operation Check Switch (Option) 12- Auxiliary 13- Auxiliary 14- Auxiliary 15- Ride Control Switch (Option)

T5-4-7

MNCB-01-006

16171819-

Armrest Adjust Handle Armrest Quick Shift Switch (QSS) Horn Switch

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Rear Console

1 4 12 11 10 9

17 16 15 14 13

22 21 20 19 18

27 26 25 24 23

12345678-

Fuse Box B Fuse Box A MPDr. Connector Preheat Relay 1 Back Buzzer Relay A/C Condenser Relay (CR1) A/C Condenser (High Pressure) Relay (CR2) Fuel Pump Relay (A-R1)

9101112-

Head Light Relay (A-R2) High-Beam Relay (A-R3) Bucket Leveler Relay (A-R4) Alternator Indicator Relay 1 (A-R5) 13- Work Light (Front) Relay (A-R6) 14- Work Light (Rear) Relay (A-R7) 15- Right Turn Signal Light Relay (A-R8)

16- Horn Relay (A-R9) 17- Alternator Indicator Relay 2 (A-R10) 18- Parking Brake Relay 1 (B-R1) 19- Parking Brake Relay 2 (B-R2) 20- Control Lever Lock Relay (B-R3) (Option) 21- Brake Light Relay (B-R4) 22- Load Dump Relay (B-R5)

T5-4-8

TNED-01-02-009

23- Neutral Relay (B-R6) 24- Left Turn Signal Light Relay (B-R7) 25- Front Washer Relay (B-R8) 26- Rear Wiper Relay (B-R9) 27- Rear Washer Relay (B-R10) 28- Relay Box A 29- Relay Box B

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Monitor Panel

39 38

37 12 36 35

14 15

33 32

1234-

Left Turn Signal Light Indicator High-Beam Indicator Work Light Indicator Right Turn Signal Light Indicator 5- (Unused) 6- (Unused) 7- Service Indicator 8- Maintenance Indicator 9- Parking Brake Indicator 10- Clearance Light Indicator 11- Control Lever Lock Indicator (Option)

16 31 30

12131415161718192021-

29 28 27 26

25 24 23 22 21 20 19 18 17

(Unused) (Unused) Brake Oil Low Level Indicator Secondary Steering Indicator (Option) Low Steering Oil Pressure Indicator (Option) Seat Belt Indicator (Option) Alternator Indicator Fuel Gauge Power Mode Indicator Monitor Display Selection Switch

T5-4-9

MNDB-01-034

32- Engine Oil Low Pressure Indicator 33- (Unused) 34- (Unused) 35- (Unused) 36- (Unused) 37- (Unused) 38- HST Warning Indicator 39- HST Oil Temperature Indicator 40- HST Oil Temperature Gauge

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Engine

1 2

8 7

6 5 4

13 11

10 TNCC-01-02-010

1234-

Common Rail Pressure Sensor Alternator Fan Belt Auto Tension Pulley

567-

Engine Oil Filter Starter Coolant Temperature Sensor

Boost Pressure/Boost Temperature Sensor 9- Engine Oil Pressure Sensor 10- Cam Angle Sensor

T5-4-10

11- Crank Speed Sensor 12- EGR Valve 13- Supply Pump

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Pump Device

1a 2

Engine Side

1 A

10 1b

7 T4FJ-01-02-012

Arrow View A

T4FJ-01-02-012

Forward/Reverse Control Solenoid Valve 1a- Forward Side Solenoid Valve 1b- Reverse Side Solenoid Valve

2356-

Cutoff Valve HST Pump Main Pump Brake/Transmission Pump

789-

T5-4-11

Low-Pressure Relief Valve DA Valve High-Pressure Relief Valve (Forward Circuit Side)

10- Displacement Angle Control Cylinder 11- High-Pressure Relief Valve (Reverse Circuit Side)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Transmission/HST Motor 1

7 Machine Front Side

T4FJ-01-02-014

123-

Transmission Machine Speed Sensor Driving Mode Selection Valve

456-

Driving Mode Selection Solenoid Valve HST Motor HST Circuit Pressure Sensor

789-

T5-4-12

Displacement Angle Control Solenoid Valve Driving Control Solenoid Valve Parking Brake Solenoid Valve

10- Parking Brake 11- Pressure Sensor (Parking Brake)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Control Valve  Manually Operated Type (Standard)

Machine Front Side

2 T4FJ-01-02-015

Main Relief Valve

Overload Relief Valve (Bucket: Rod Side)

 Hydraulic Operated Type (Option) 4

Machine Front Side

5 1

12-

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

Make-Up Valve (Lift Arm: Rod Side)

T5-4-13

Overload Relief Valve (Lift Arm: Bottom Side)

TNCC-03-02-001

Overload Relief Valve (Bucket: Bottom Side)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Priority Valve

T4FJ-01-02-016 Machine Front Side

Pressure Sensor (Front Attachment Pressure)

T5-4-14

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Ride Control Valve (Option)

12-

Overload Relief Valve Ride Control Solenoid Valve

Ride Control Accumulator

T5-4-15

TNCC-01-02-014

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

2 1

3 1-

Secondary Steering Block

TNCC-01-02-015

Check Valve

Steering Pressure Switch

Secondary Steering Pump

Secondary Steering Pump (Option) 5

TNED-01-02-019

Relief Valve

Gear Pump

T5-4-16

Electric Motor

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Pilot Shut-Off Solenoid Valve (Hydraulic Operated Type)(Option)

2 1 3 4

TNCC-01-02-013

Pilot Shut-Off Solenoid Valve

Pressure Sensor (Primary Pilot Pressure)

34-

T5-4-17

Pilot Accumulator Check Valve

SECTION 5 TROUBLESHOOTING Group 4 Component Layout (Blank)

T5-4-18

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing by using MPDr. or the service menu of the monitor.  Diagnosis Procedure  The diagnosis procedures for the displayed fault codes are explained in this group.  In case more than one fault code are displayed at the same time, MC may be faulty or the power/ground of the sensor system may be faulty.  When the MC fault code is displayed with other fault code, replace MC.  When fault code 111003-3 (Abnormal Sensor Voltage) is displayed with other fault code, diagnose for fault code 111003-3 first.  In case more than one fault code other than those described above are displayed at the same time, diagnose for each fault code.  It may be required that the machine is operated or the test harness is connected at inspection. Check the items of preparation and perform inspection according to the procedures when diagnosing. NOTE: All connector images in this section are viewed from the open end side of wire harness end.

1 2

T6L4-05-03-001

Wire Harness End Connector

Wire Harness

T5-5-1

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Contents of Diagnosis

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

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

A: B: C, D, E,

Evaluation

Cause

(D) (G)

(E) (H)

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

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

T5-5-2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code Reference Table Fault Code

MPDr. Message

Category

Reference 1

Reference 2

111004-2

CAN Communication Error 1

T5-5-7

T5-5-33

111103-3

Accelerator Pedal Sensor Circuit High Input

T5-5-7

T5-5-37

111103-4

Accelerator Pedal Sensor Circuit Low Input

T5-5-7

T5-5-37

111217-3

Primary Pilot Pressure Sensor Circuit High Input

T5-5-7

T5-5-38

111217-4

Primary Pilot Pressure Sensor Circuit Low Input

T5-5-7

T5-5-38

T5-5-7

T5-5-39

T5-5-7

T5-5-39

111330-3 111330-4

Pressure Sensor (Front Attachment Pressure) Circuit High MC Input Pressure Sensor (Front Attachment Pressure) Circuit Low MC Input

111331-3

HST Circuit Pressure Sensor Circuit High Input

T5-5-7

T5-5-40

111331-4

HST Circuit Pressure Sensor Circuit Low Input

T5-5-7

T5-5-40

111332-5

Enable Signal Disconnection Error

T5-5-7

T5-5-41

111422-2

Ride control Solenoid Valve Abnormal FB

T5-5-7

T5-5-42

111430-2

Displacement Angle Control Solenoid Valve Abnormal FB MC

T5-5-7

T5-5-43

111434-2

Driving Control Solenoid Valve Abnormal FB

T5-5-8

T5-5-43

111450-2

Forward Side Solenoid Valve Output Error

T5-5-8

T5-5-44

111451-2

Reverse Side Solenoid Valve Output Error

T5-5-8

T5-5-44

111455-2

Shift Switch Signal Output Error

T5-5-8

T5-5-45

111457-2

Back Buzzer Relay Output Error

T5-5-8

T5-5-46

111622-2

Vehicle Speed Sensor Error

T5-5-8

T5-5-47

111801-4

Abnormal Decline in Controller Voltage

T5-5-8

T5-5-48

111904-2

Abnormal Forward/Reverse Lever

T5-5-8

T5-5-49

111908-3

Slow Speed (L) Select Switch Circuit High Input

T5-5-9

T5-5-50

111908-4

Slow Speed (L) Select Switch Circuit Low Input

T5-5-9

T5-5-50

111910-2

CAN Engine Speed Reception Failure

T5-5-9

T5-5-33

111914-2

CAN Coolant Temperature Data Reception Failure

T5-5-9

T5-5-33

111922-2

HST Oil Temperature Data Reception Failure

T5-5-9

T5-5-51

T5-5-3

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code Reference Table (Continued) Fault Code

MPDr. Message

Category

Reference 1

Reference 2

114000-2

CAN Communication Error

Information (ICF)

T5-5-10

114001-2

Flash Memory Read/Write Error

Information (ICF)

T5-5-10

114002-2

External RAM Read/Write Error

Information (ICF)

T5-5-10

114003-2

Abnormal EEPROM

Information (ICF)

T5-5-10

114006-2

Communication Terminal : Communication Error Information (ICF)

T5-5-10

114008-2

Abnormal Internal RAM

Information (ICF)

T5-5-10

114100-2

Communication Terminal: Abnormal EEPROM

Communication Terminal

T5-5-15

Communication Terminal

T5-5-15

Communication Terminal

T5-5-15

Communication Terminal

T5-5-15

Communication Terminal

T5-5-15

Communication Terminal

T5-5-15

Communication Terminal

T5-5-15

114101-2 114102-2 114103-2 114104-2 114105-2 114106-2

Communication Terminal: Abnormal IB/OB Queue Communication Terminal: Abnormal Local Loop Back Communication Terminal: No Satellite Found Communication Terminal: Remote Loop Back Error 1 Communication Terminal: Remote Loop Back Error 2 Communication Terminal: Transmission/ Receiving Data Unmatched

T5-5-4

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code Reference Table (Continued) Fault Code

MPDr. Message

Category

Reference 1

Reference 2

115000-2

CAN Communication Error 1

Monitor Controller

T5-5-11

T5-5-52

115001-2

Abnormal REG input H level

Monitor Controller

T5-5-11

T5-5-57

115003-2

Abnormal EEPROM

Monitor Controller

T5-5-11

115011-3

Open circuit in fuel level sensor

Monitor Controller

T5-5-11

T5-5-58

115011-4

Shorted circuit in fuel level sensor

Monitor Controller

T5-5-11

T5-5-58

115014-3

HST Oil Temperature Sensor Circuit High Input

Monitor Controller

T5-5-11

T5-5-59

115014-4

HST Oil Temperature Sensor Circuit Low Input

Monitor Controller

T5-5-11

T5-5-59

115015-3

Parking Brake Pressure Sensor High Voltage

Monitor Controller

T5-5-11

T5-5-60

115015-4

Parking Brake Pressure Sensor Low Voltage

Monitor Controller

T5-5-11

T5-5-60

115018-2

24 V Output Error

Monitor Controller

T5-5-11

T5-5-5

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code Reference Table (Continued) Fault Code

MPDr. Message

Category

Reference 1

Reference 2

120500-2

Overheat Alarm

Monitor Controller

T5-5-12

T5-5-61

120501-2

Engine Warning Alarm

Monitor Controller

T5-5-12

T5-5-61

120502-2

Engine Oil Pressure Alarm

Monitor Controller

T5-5-12

T5-5-61

120504-2

Hydraulic Oil Level Alarm

Monitor Controller

T5-5-12

120505-2

Brake Pressure Alarm

Monitor Controller

T5-5-12

120506-2

Steering Oil Pressure Alarm

Monitor Controller

T5-5-12

T5-5-62

120507-2

Transmission Error Alarm

Monitor Controller

T5-5-12

T5-5-62

120510-2

HST Oil Temperature Alarm

Monitor Controller

T5-5-12

T5-5-62

120512-2

Emergency Steering Alarm (Lighting)

Monitor Controller

T5-5-12

T5-5-62

120515-2

Engine Alarm

Monitor Controller

T5-5-12

T5-5-62

120518-2

Emergency Steering Alarm (Blinking)

Monitor Controller

T5-5-12

T5-5-62

fNOTE:  Refer to page T5-5-13 for the air conditioner controller fault code list.  Refer to page T5-5-17 for the ECM fault code list.

T5-5-6

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code List Fault Code

Trouble

Cause

111004-2

CAN Communication Error 1 Accelerator Pedal Sensor Circuit High Input Accelerator Pedal Sensor Circuit Low Input Primary Pilot Pressure Sensor Circuit High Input Primary Pilot Pressure Sensor Circuit Low Input Pressure Sensor (Front Attachment Pressure) Circuit High Input Pressure Sensor (Front Attachment Pressure) Circuit Low Input HST Circuit Pressure Sensor Circuit High Input

Faulty MC. Faulty CAN1 harness. Voltage: more than 4.74 V

111103-3

111103-4

111217-3

111217-4

111330-3

111330-4

111331-3

Voltage: less than 0.25 V Voltage: more than 4.75 V Voltage: less than 0.25 V Voltage: more than 4.75 V

Check the CAN1 harness. Replace MC.

Engine speed is fixed to 1000 Check the wire harness. Replace the accelerator min-1. pedal sensor. Engine speed is fixed to 1000 Check the wire harness. Replace the accelerator min-1. pedal sensor. Control lever lock indicator is Check the wire harness. always OFF. Replace the pressure sensor (primary pilot pressure). Control lever lock indicator is Check the wire harness. always OFF. Replace the pressure sensor (primary pilot pressure). The traction control cannot Check the wire harness. be activated. Replace the pressure sensor (front attachment pressure). The traction control cannot be activated.

Check the wire harness. Replace the pressure sensor (front attachment pressure).

Voltage: more than 4.75 V

The maximum speed and maximum traction force are limited. (While driving in forward direction) The maximum speed and maximum traction force are limited. (While driving in forward direction) The driving is impossible.

Check the wire harness. Replace the HST circuit pressure sensor.

The ride control (ption) becomes ineffective.

Check the wire harness.

The maximum speed and maximum traction force are limited.

Check the wire harness.

HST Circuit Pressure Voltage: less than Sensor Circuit Low 0.25 V Input

111332-5

Enable Signal Disconnection Error Ride Control Solenoid Valve Abnormal FB

111430-2

Remedy

Voltage: less than 0.25 V

111331-4

111422-2

Symptoms in Machine Operation When Trouble Occurs The maximum speed is limited.

Faulty wire harness

Solenoid valve output: 140 mA or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Displacement Angle Solenoid valve Control Solenoid output: 140 mA Valve Abnormal FB or more, feedback current: More than 920 mA or less than 70 mA; both are detected.

T5-5-7

Check the wire harness. Replace the HST circuit pressure sensor. Check the wire harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code List Fault Code

111434-2

111450-2

111451-2

111455-2

111457-2

111622-2

111801-4 111904-2

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs Driving Control Solenoid valve When vehicle speed is Solenoid Valve output: 140 mA reduced while driving in Abnormal FB or more, feedback reverse direction, vehicle current: More than speed is decelerated 920 mA or less than immediately. 70 mA; both are detected. Faulty wire harness. Driving in only reverse Forward Side Faulty forward side direction is possible. Solenoid Valve Output Error solenoid valve. Reverse Side Faulty wire harness. Driving in only forward Solenoid Valve Faulty reverse side direction is possible. Output Error solenoid valve. Shift Switch Signal Faulty shift switch. Transmission gear range is Output Error Faulty wire harness. shifted to fast speed range when driving with slow speed range. Back Buzzer Relay Faulty wire harness. The back buzzer does not Output Error Faulty back buzzer sound while driving in relay. reverse direction. Vehicle Speed Vehicle speed The maximum speed is Sensor Error is (immediately limited. decelerated) shifted Transmission gear range to 0 km/h from 10 cannot be shifted. km/h. Faulty vehicle speed sensor. Abnormal Decline in MC input voltage: The driving operation is Controller Voltage less than 4 V impossible. Abnormal Forward/ The forward and The driving operation is Reverse Lever reverse travel impossible. signals are detected at the same time.

T5-5-8

Remedy

Check the wire harness.

Check the wire harness. Replace the forward side solenoid valve. Check the wire harness. Replace the reverse side solenoid valve. Check the wire harness. Replace the shift lever switch. Check the wire harness. Replace the back buzzer relay. Check the wire harness. Replace the vehicle speed sensor.

Check the wire harness. Replace MC. Check the wire harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code List Fault Code

Trouble

111908-3

Slow Speed (L) Voltage: more than Select Switch Circuit 4.74 V High Input

111908-4

Voltage: less than Slow Speed (L) Select Switch Circuit 0.25 V Low Input

111910-2

CAN Engine Speed Faulty CAN1 Reception Failure harness. CAN Coolant Faulty CAN1 Temperature Data harness. Reception Failure HST Oil Temperature Faulty CAN1 Data Reception harness. Failure

111914-2

111922-2

Cause

Symptoms in Machine Operation When Trouble Occurs The driving slow speed selection control is not activated. Vehicle speed is fixed to minimum speed while driving at slow speed. The driving slow speed selection control is not activated. Vehicle speed is fixed to minimum speed while driving at slow speed. The maximum speed is limited. The operation is normal.

Remedy

The driving operation is impossible.

Check the wire harness.

T5-5-9

Check the wire harness.

Check the wire harness. Check the wire harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ICF Fault Code List Fault Code 114000-2

Trouble CAN Communication Error

114001-2

Flash Memory: Read/Write Error

114002-2

External RAM: Read/Write Error

114003-2

Abnormal EEPROM

114006-2

Communication Terminal: Communication Error

114008-2

Abnormal Internal RAM

Cause The data cannot be received normally due to noise on the CAN line. The internal memory is abnormal with the key switch set ON. The internal memory is abnormal with the key switch set ON. The internal memory is abnormal with the key switch set ON. Communication with the communication terminal cannot be performed for 30 seconds or more. The internal memory is abnormal with the key switch set ON.

Remedy Retry by using MPDr.. If the fault code is displayed after retry, perform the inspection of the CAN communication line. After initializing ICF by using MPDr., retry the troubleshooting. If the fault code is displayed after retry, ICF may be broken. Replace ICF. When initializing ICF, all stored data is deleted. After initializing ICF by using MPDr., retry the troubleshooting. If the fault code is displayed after retry, ICF may be broken. Replace ICF. When initializing ICF, all stored data is deleted. Retry the troubleshooting by using MPDr.. If the fault code is displayed after retry, ICF may be broken. Replace ICF.

Check the communication line, power line, and fuses for communication terminal. Then, retry the troubleshooting by using MPDr.. If the fault code is displayed after retry, the communication equipment may be broken. Replace the communication equipment. Retry the troubleshooting by using MPDr.. If the fault code is displayed after retry, ICF may be broken. Replace ICF.

T5-5-10

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller Fault Code List Fault Code

115000-2

115001-2

115003-2 115011-3

115011-4

115014-3

115014-4

115015-3

115015-4

115018-2

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs CAN Communication Faulty monitor The alarms and meters Check the CAN1 Error 1 controller. on the monitor cannot harness. Faulty CAN1 harness. be displayed correctly. Replace the monitor controller. The alternator Check the wire Abnormal REG input Faulty alternator indicator is turned on. harness. H level indicator relay 1. Check alternator Faulty monitor indicator relay 1. controller. Check the alternator. Faulty alternator. Abnormal EEPROM Faulty monitor Replace the monitor controller. controller. Open circuit in fuel 131±5 Ω or less The fuel gauge Check the wire level sensor continues for 5 (pointer) points to E. harness. seconds. Replace the fuel level sensor. Shorted circuit in fuel 4±2 Ω or less The fuel gauge Check the wire level sensor continues for 5 (pointer) points to E. harness. seconds. Replace the fuel level sensor. HST Oil Temperature Voltage: more than The overheat Check the wire Sensor Circuit High 4.35 V prevention control is harness. Input not activated. Replace the HST oil temperature sensor. HST Oil Temperature Voltage: less than 0.1 V The overheat Check the wire Sensor Circuit Low prevention control is harness. Input not activated. Replace the HST oil temperature sensor. Parking Brake Pressure 4.75 V or more The parking brake Check the wire Sensor Circuit High continues for 200 indicator is tuned off. harness. Input msec. Replace the pressure sensor (parking brake). Parking Brake Pressure 0.25 V or less The parking brake Check the wire Sensor Circuit Low continues for 200 indicator is tuned off. harness. Input msec. Replace the pressure sensor (parking brake). 24 V Output Error Faulty monitor Check the wire controller. harness. Replace the monitor controller.

T5-5-11

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller Fault Code List Fault Code 120500-2

Trouble Overheat Alarm

120501-2

Engine Warning Alarm Engine Oil Pressure Alarm Hydraulic Oil Level Alarm Brake Pressure Alarm

120502-2 120504-2 120505-2

120506-2 120507-2 120510-2 120512-2

120515-2 120518-2

Cause Remedy Coolant temperature is high while Check the wire harness. the engine runs. Replace the overheat switch. Faulty engine system. Refer to Engine Troubleshooting Manual. Engine oil pressure is reduced. Hydraulic oil level is lowered. Open circuit in wire harness. Brake oil pressure decreases.

Steering Oil Faulty steering pressure switch Pressure Alarm (option). Transmission Error Faulty transmission system. Alarm HST Oil Temperature HST oil temperature is high while Alarm the engine runs. Emergency Steering Faulty secondary steering system Alarm (Lighting) (option). Engine Alarm Faulty engine system Emergency Steering Faulty secondary steering pump Alarm (Blinking) (option).

T5-5-12

Check the wire harness. Replace the engine oil pressure switch. Check the wire harness. Replace the hydraulic oil level switch. Check the wire harness. Replace the pressure sensor (brake primary pressure). Check the wire harness. Replace the steering pressure switch (option). Check the wire harness. Check the wire harness. Replace the HST oil temperature sensor. Check the wire harness. Replace the secondary steering pump delivery pressure sensor. Refer to Engine Troubleshooting Manual. Check the wire harness. Replace the secondary steering operation check switch (option).

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Code List Fault Code

Trouble

E11

Open circuit in recirculated air sensor

E12

E13

E14

E17

E18

E21

E22

Cause

Symptoms in Machine Operation When Trouble Occurs Voltage: more than 4.95 V Operation is controlled under such circumstance as no recirculated air sensor is provided.

Remedy

Check the wire harness. Replace the recirculated air sensor. Check the wire Shorted circuit in Voltage: less than 0.3 V Operation is controlled harness. recirculated air sensor under such circumstance as Replace the no recirculated air sensor is recirculated air provided. sensor. Open circuit in Voltage: more than 4.88 V Operation is controlled under Check the wire harness. outdoor ambient such circumstance as no temperature sensor outdoor ambient temperature Replace the outdoor ambient sensor is provided. temperature sensor. Shorted circuit in Voltage: less than 0.096 V Operation is controlled under Check the wire outdoor ambient such circumstance as no harness. temperature sensor outdoor ambient temperature Replace the sensor is provided. outdoor ambient temperature sensor. Open circuit in solar Operation is controlled under Check the wire radiation sensor such circumstance as no solar harness. radiation sensor is provided. Replace the solar radiation sensor. Shorted circuit in solar Voltage: more than 5.04 V Operation is controlled under Check the wire radiation sensor such circumstance as no solar harness. radiation sensor is provided. Replace the solar radiation sensor. Open circuit in frost Voltage: more than 4.79 V The compressor clutch is Check the wire sensor disengaged. (The compressor harness. stops.) Replace the frost sensor. Shorted circuit in frost Voltage: less than 0.096 V The compressor clutch is Check the wire sensor disengaged. (The compressor harness. stops.) Replace the frost sensor.

fNOTE: Refer to p.T5-5-63 for further information.

T5-5-13

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Code List Fault Code

Trouble

E43

Abnormal air vent damper

E44

Abnormal air mix damper

E51

Abnormal high/low refrigerant pressure

E91

CAN communication error

E92

CAN bus off error

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs Shorted circuit: Voltage: Air vent damper servo Check the wire harness. 0V motor becomes inoperable. Replace the air vent Open circuit: Voltage: damper servo motor. more than 5 V Shorted circuit: Voltage: Air mix damper servo Check the wire harness. motor becomes inoperable. Replace the air vent less than 0.2 V damper servo motor. Open circuit: Voltage: more than 4.8 V Voltage: 0 V The compressor clutch Check the wire harness. is disengaged. (The Replace the high/low compressor stops.) pressure switch. Faulty CAN1 harness Air conditioner stops. Check the CAN1 between monitor harness. Replace air conditioner controller. controller and air conditioner controller. Faulty air conditioner Air conditioner stops. Check the CAN1 controller. harness. Replace air Faulty CAN1 harness. conditioner controller.

fNOTE: Refer to p.T5-5-64 for further information.

T5-5-14

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Communication Terminal Fault Code List Fault Code 114100-2

Trouble Communication Terminal: Abnormal EEPROM

114101-2

Communication Terminal: Abnormal IB/OB Queue

114102-2

Communication Terminal: Abnormal Local Loop Back

114103-2

Communication Terminal: No Satellite Found Communication Terminal: Remote Loop Back Error 1

114104-2

114105-2

Communication Terminal: Remote Loop Back Error 2

114106-2

Communication Terminal: Transmission/Receiving Data Unmatched

Cause The internal memory of satellite communication terminal (option) is abnormal. The internal memory of satellite communication terminal (option) is abnormal. Abnormality is detected on communication test with the satellite. Satellite can not be caught. Abnormality is detected on communication test with the satellite and base station. Abnormality is detected on communication test with the satellite and base station. Transmission/receiving data with the satellite is unmatched.

T5-5-15

Remedy Replace the controller (satellite communication terminal). Replace the controller (satellite communication terminal). Check the communication antenna for satellite. Check the communication antenna for satellite. Replace the controller (satellite communication terminal). Replace the controller (satellite communication terminal). Replace the controller (satellite communication terminal).

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-16

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code DEUTZ HCM

1024

51-3

1226

1227

1025

1228

1229

1232

51-4

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs Abnormal EGR Faulty EGR valve. The output Valve Shorted circuit in wire harness power to the power source. decreases. Faulty wire harness. The output Abnormal EGR Faulty EGR valve. Valve Shorted circuit in wire harness power decreases. at terminal A19 of ECM. Faulty wire harness. Abnormal EGR Faulty EGR valve. The output Valve Shorted circuit in wire harness power at terminal A20 of ECM. decreases. Faulty wire harness. Abnormal EGR Faulty EGR valve. The output Valve Shorted circuit in wire harness power to the ground. decreases. Faulty wire harness. The output Abnormal EGR Faulty EGR valve. Valve Shorted circuit in wire harness power decreases. at terminal A19 of ECM. Faulty wire harness. Abnormal EGR Faulty EGR valve. The output Valve Shorted circuit in wire harness power at terminal A20 of ECM. decreases. Faulty wire harness. EGR Valve High Faulty EGR valve. The output Current Voltage measured by ECM is power low. decreases.

T5-5-17

Remedy

Check the wire harness. Replace the EGR valve.

Check the wire harness. (Between terminal A19 of ECM and terminal #2 of EGR valve) Replace the EGR valve. Check the wire harness. (Between terminal A20 of ECM and terminal #1 of EGR valve) Replace the EGR valve. Check the wire harness. Replace the EGR valve.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code DEUTZ HCM

1015

1023

1223

1014

1022

1224

1230

1016

1231

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs 51-5 Abnormal EGR Faulty EGR valve. The output Valve Shorted circuit in wire harness power to the ground. decreases. Faulty wire harness. The output Abnormal EGR Faulty EGR valve. Valve Shorted circuit in wire harness power decreases. to the ground. Faulty wire harness. Abnormal EGR Faulty EGR valve. The output Valve Faulty wire harness. power decreases. The output 51-6 Abnormal EGR Faulty EGR valve. Valve Shorted circuit in wire harness power decreases. to the power source. Faulty wire harness. Abnormal EGR Faulty EGR valve. The output Valve Shorted circuit in wire harness power to the power source. decreases. Faulty wire harness. Abnormal EGR Faulty EGR valve. The output Valve Faulty wire harness. power decreases. EGR Valve Faulty EGR valve. The output High Current Faulty wire harness. power Faulty ECM. decreases. 51-7 EGR Valve Faulty EGR valve. The output High Current Faulty wire harness. power Faulty ECM. decreases. 51-11 EGR Valve Temperature of the EGR valve The output High Current is abnormally high. power Faulty wire harness. decreases.

T5-5-18

Remedy

Check the wire harness. (Between terminal K85 of ECM and terminal #4 of EGR valve) Replace the EGR valve. Check the wire harness. (Between terminal K85 of ECM and terminal #4 of EGR valve) Replace the EGR valve. Check the wire harness. Replace the EGR valve. Check the wire harness. Replace the EGR valve.

Check the wire harness. Replace the EGR valve.

Check the wire harness. Replace the EGR valve. Check the wire harness. Replace the EGR valve. Replace the ECM. Check the wire harness. Replace the EGR valve. Replace the ECM. Check the wire harness. Replace the EGR valve.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code DEUTZ HCM

Trouble

935

Accelerator Pedal Sensor Circuit High Input

940

976

474

472

473

91-3

Cause

Symptoms in Machine Operation When Trouble Occurs The output power decreases.

Faulty accelerator pedal sensor. Shorted circuit in wire harness to the power source. Faulty wire harness. Faulty MC. CAN communication is faulty. The output 91-4 Accelerator Faulty accelerator pedal power Pedal Sensor sensor. decreases. Circuit Low Shorted circuit in wire Input harness to the ground. Faulty wire harness. Faulty MC. CAN communication is faulty. 91-11 Abnormal Faulty accelerator pedal The output Accelerator sensor. power Pedal The accelerator pedal is decreases. damaged. Faulty wire harness. Faulty MC. CAN communication is faulty. 94-1 Abnormal Faulty fuel pressure switch. The output Decrease in The fuel filter is clogged or power Fuel Pressure dirty. decreases. Faulty fuel solenoid pump. Faulty fuel pump relay. Faulty fuse #4 (fuse box A). Faulty wire harness. 94-3 Fuel Pressure Faulty fuel pressure switch No output Switch Circuit Shorted circuit in wire power change. High Input harness to the power source. Faulty wire harness. 94-4 Fuel Pressure Faulty fuel pressure switch. No output Switch Circuit Shorted circuit in wire power change. Low Input harness to the ground. Faulty wire harness.

T5-5-19

Remedy

Check the wire harness. Replace the accelerator pedal sensor. Check the CAN harness. Replace the MC.

Check the wire harness. Replace the accelerator pedal sensor. Repair the accelerator pedal. Check the CAN harness. Replace the MC.

Check the wire harness. Replace the fuel pressure switch. Replace the fuel solenoid pump. Replace the fuel pump relay. Replace fuse #4 (fuse box A). Replace the fuel filter. Check the wire harness. Replace the fuel pressure switch.

Check the wire harness. Replace the fuel pressure switch.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code DEUTZ HCM

736

737

732

733

776

777

Trouble

Cause

100-1 Low Engine Faulty engine oil pressure Oil Pressure sensor. (Warning Engine oil level is low. Threshold) Engine oil leakage. Low Engine Oil Engine oil filter is clogged. Pressure (Shut- Faulty wire harness. Off Threshold)

Symptoms in Machine Operation When Trouble Occurs The output power decreases.

Faulty engine oil pressure No output sensor. power change. Shorted circuit in wire harness to the power source. Faulty wire harness. 100-4 Engine Oil Faulty engine oil pressure No output power change. Pressure sensor. Sensor Circuit Shorted circuit in wire harness Low Input to the ground. Faulty wire harness. 102-2 High Boost Faulty boost pressure sensor No output Pressure The charge air pressure control power change. (Warning is faulty. Threshold) The exhaust gate system operation of turbo charger is High Boost Pressure (Shut- faulty. Off Threshold) Charge air cooler is clogged. Charge air pipe is blocked. Faulty wire harness. 100-3 Engine Oil Pressure Sensor Circuit High Input

102-3 Boost Pressure Faulty boost pressure sensor. Sensor Circuit Shorted circuit in wire harness High Input to the power source. Faulty wire harness. 102-4 Boost Pressure Faulty boost pressure sensor. Sensor Circuit Shorted circuit in wire harness Low Input to the ground. Faulty wire harness.

T5-5-20

Remedy

Check the wire harness. Check engine oil level. Check engine oil leakage. Replace the engine oil filter. Replace the engine oil pressure sensor.

Check the wire harness. Replace the engine oil pressure sensor.

Check the wire harness. Replace the boost pressure sensor. Replace the turbo charger. Replace the charge air cooler. Clean the charge air pipe.

No output Check the wire harness. power change. Replace the boost pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code DEUTZ HCM

996

997

994

995

Trouble

Cause

105-0 Abnormally High Faulty boost temperature Temperature sensor. of Boost Charge air cooler is clogged. Temperature Charge air cooler piping is Sensor (Warning clogged. Threshold) The fan operation is faulty. Abnormally High Faulty wire harness. Temperature of Boost Temperature Sensor (Shut-Off Threshold) 105-3 Boost Faulty boost temperature Temperature sensor Shorted circuit in wire harness Sensor Circuit to the power source. Low Input Faulty wire harness. Faulty boost temperature 105-4 Boost sensor. Temperature Shorted circuit in wire harness Sensor Circuit to the ground. High Input Faulty wire harness. 110-0 Abnormally High Faulty coolant temperature Temperature sensor. of Coolant Clogged radiator Temperature Coolant is insufficient. Sensor (Warning The fan operation is faulty. Threshold) Thermostat is not opened. Abnormally High Faulty wire harness. Temperature of Coolant Temperature Sensor (Shut-Off Threshold) 110-3 Coolant Faulty boost temperature Temperature sensor. Sensor Circuit Shorted circuit in wire harness High Input to the power source. Faulty wire harness. 110-4 Coolant Faulty boost temperature Temperature sensor. Sensor Circuit Shorted circuit in wire harness Low Input to the ground. Faulty wire harness.

T5-5-21

Symptoms in Machine Operation When Trouble Occurs The output power decreases.

Remedy

Check the wire harness. Replace the charge air cooler. Clean the charge air cooler piping. Check the fan operation. Replace the boost temperature sensor.

No output Check the wire harness. power change. Replace the boost temperature sensor.

The output power decreases.

Check the wire harness. Clean the radiator. Check coolant level. Check the fan operation. Replace the thermostat. Replace the coolant temperature sensor.

No output Check the wire harness. power change. Replace the coolant temperature sensor.

Check the wire harness. No output power change. Replace the coolant temperature sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code DEUTZ HCM

101

877

878

1180

1181

47 45

Trouble

111-1 Abnormal Coolant Level Switch

Cause

Symptoms in Machine Operation When Trouble Occurs -

Faulty coolant level switch. Coolant level is too low. Leakage in cooling system Faulty wire harness. Faulty common rail pressure No output 157-3 Common power change. Rail Pressure sensor. Sensor Circuit Shorted circuit in wire High Input harness to the power source. Faulty wire harness. 157-4 Common Faulty common rail pressure No output power change. Rail Pressure sensor. Sensor Circuit Shorted circuit in wire Low Input harness to the ground. Faulty wire harness. Faulty alternator. The output 168-0 Abnormally power High Battery Faulty ECM. Faulty wire harness. decreases. Voltage (Battery voltage is over the limit.) 168-1 Abnormally Faulty battery. No output Low Battery Faulty alternator. power change. Voltage Faulty wire harness. (Battery voltage is below the limit.) 168-2 Abnormal Faulty alternator. No output Alternator Faulty wire harness. power change. 168-3 Alternator Faulty alternator. No output Circuit High Faulty ECM. power change. Input (Battery Faulty wire harness. voltage is over warning threshold.) 168-4 Alternator Faulty alternator. No output Circuit Low Faulty wire harness. power change. Input (Battery voltage is below warning threshold.)

T5-5-22

Remedy

Check the wire harness. Replace the common rail pressure sensor. Check the wire harness. Replace the accelerator pedal sensor. Check the CAN harness. Replace the MC. Check the wire harness. Replace the common rail pressure sensor.

Check the wire harness. Replace the alternator. Replace the ECM.

Check the wire harness. Replace the battery. Check the alternator.

Check the wire harness. Replace the alternator. Check the wire harness. Replace the alternator. Replace the ECM.

Check the wire harness. Replace the alternator.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code DEUTZ HCM

Trouble

Cause

388

190-0

Engine Overrun

421

190-2

Cam Angle Sensor Error

419

190-8

Cam Angle Sensor Error

422

Crank Revolution Sensor Error 190-11 Engine Overrun 190-12 Cam Angle Sensor Error

Engine speed is more than specification (2750 min-1). Engine speed is more than specification (2774 min-1). ECM measures an angle deviation between cam shaft and crank shaft to the target. The offset angle between crank shaft and cam shaft is too large. Offset error between crank revolution sensor and cam angle sensor. Cam angle sensor signal reception is abnormal. Faulty wire harness. Crank revolution sensor signal reception is abnormal. Faulty wire harness. Engine speed is more than specification (2860 min-1). Cam angle sensor signal reception is abnormal. Faulty wire harness. Crank revolution sensor signal reception is abnormal. Faulty wire harness.

389

390 420

423

Crank Revolution Sensor Error

T5-5-23

Symptoms Remedy in Machine Operation When Trouble Occurs No output Check HST pump delivery pressure. power change. Check the HST motor.

No output Check the wire harness. power change. Replace the cam angle sensor.

No output Check the wire harness. power change. Replace the boost temperature sensor. No output Check the wire harness. power change. Replace the crank revolution sensor. No output power change. No output power change.

Check HST pump delivery pressure. Check the HST motor. Check the wire harness. Replace the cam angle sensor.

No output Check the wire harness. power change. Replace the crank revolution sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code DEUTZ HCM

Trouble

391

190-14 Engine Overrun

376 377 378

630-12 Abnormal EEPROM

639-14 CAN Communication Error 651-3 Injector #1 Circuit High Input

580

568

651-5

581

652-3

569

652-5

582

653-3

570

653-5

583

654-3

571

654-5

Injector #1 Low Current Injector #2 Circuit High Input

Injector #2 Low Current Injector #3 Circuit High Input

Injector #3 Low Current Injector #4 Circuit High Input

Injector #4 Low Current

Cause

Engine speed is more than specification (2774min-1). Faulty ECM.

Symptoms in Machine Operation When Trouble Occurs No output power change. No output power change.

Remedy

Check HST pump delivery pressure. Check the HST motor. Replace the ECM.

Faulty ECM. Faulty wire harness.

No output Check the wire harness. power change. Replace the ECM.

Injector #1 is faulty. Shorted circuit in wire harness to the power source. Faulty wire harness. Injector #1 is faulty. Faulty wire harness. Injector #2 is faulty. Shorted circuit in wire harness to the power source. Faulty wire harness. Injector #2 is faulty. Faulty wire harness. Injector #3 is faulty. Shorted circuit in wire harness to the power source. Faulty wire harness. Injector #3 is faulty. Faulty wire harness. Injector #4 is faulty. Shorted circuit in wire harness to the power source. Faulty wire harness. Injector #4 is faulty. Faulty wire harness.

No output Check the wire harness. power change. Replace injector #1.

T5-5-24

No output power change. No output power change.

Check the wire harness. Replace injector #1. Check the wire harness. Replace injector #2.

No output power change. No output power change.

Check the wire harness. Replace injector #2. Check the wire harness. Replace injector #3.

No output power change. No output power change.

Check the wire harness. Replace injector #3. Check the wire harness. Replace injector #4.

No output Check the wire harness. power change. Replace injector #4.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code DEUTZ HCM

Trouble

956 960

Starter Relay 1 Circuit High Input

957 961 958 959 305

946 947

677-3

Cause

Faulty starter relay 1. Shorted circuit in wire harness to the power source. Faulty wire harness. Faulty starter relay 1. 677-4 Starter Relay Shorted circuit in wire harness 1 Circuit Low to the ground. Input Faulty wire harness. 677-5 Starter Relay 1 Faulty starter relay 1. Low Current Faulty wire harness. 677-12 Starter Relay 1 Faulty starter relay 1. Error Faulty wire harness. 898-9 Demand Engine Faulty CAN harness. Speed CAN Communication Error 1079-13 Sensor Supply Faulty ECM. Voltage 1 Error Faulty wire harness. 1080-13 Sensor Supply Faulty ECM. Voltage 2 Error Faulty wire harness.

T5-5-25

Symptoms Remedy in Machine Operation When Trouble Occurs No output Check the wire harness. power change. Replace the starter.

No output Check the wire harness. power change. Replace the starter.

No output power change. No output power change. No output power change.

Check the wire harness. Replace the starter. Check the wire harness. Replace the starter. Check the CAN harness.

No output power change. No output power change.

Check the wire harness. Replace the ECM. Check the wire harness. Replace the ECM.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code DEUTZ HCM

121

565 566 567

980 948

Trouble

1109-2

Engine ShutOff Request Ignorance 1231-14 CAN 1 Communication Error 523350-4 Injector Circuit Low Input 1 523352-4 Injector Circuit Low Input 2 523354-12 Injector High Current 523550-12 Abnormal Engine Start 523601-13 Sensor Supply Voltage 3 Error

Cause

Faulty ECM. Faulty wire harness.

Symptoms Remedy in Machine Operation When Trouble Occurs No output Check the wire harness. power change. Replace the ECM.

Faulty CAN harness.

No output Check the CAN harness. power change.

Faulty injector. Faulty wire harness. Faulty injector. Faulty wire harness. Faulty ECM. Faulty injector. Faulty wire harness. Faulty key switch. Faulty wire harness. Faulty ECM. Faulty wire harness.

No output power change. No output power change. No output power change.

T5-5-26

Check the wire harness. Replace the injector. Check the wire harness. Replace the injector. Check the wire harness. Replace the injector. Replace the ECM. No output Check the wire harness. power change. Replace the key switch. No output Check the wire harness. power change. Replace the ECM.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code DEUTZ HCM

387 612

613 614 615 616

617

618

619

620

621

Trouble

Cause

523612-12 Software Error (Injector Faulty ECM. Shut-Off ) Software Error (Analog Faulty ECM. System) Faulty wire harness.

Software Error (Abnormal A/D Converter)

Faulty ECM. Faulty wire harness.

Software Error Faulty ECM. (Abnormal FC and MM) Software Error (SPI Faulty ECM. Communication Interruption) Software Error Faulty ECM. (Multiple errors occur when completing ROM test with postdrive detected.) Software Error Faulty ECM. (Abnormal CPU) Software Error (The error occurs during SOP test.) Software Error (The error occurs while setting MM response time.) Software Error (The internal communication error occurs.)

Faulty ECM.

T5-5-27

Symptoms in Machine Operation When Trouble Occurs No output power change. No output power change.

Remedy

Replace the ECM.

Check the wire harness between the ECM and sensor. Replace the ECM. No output Check the wire harness power change. between the ECM and sensor. Replace the ECM. No output Replace the ECM. power change. No output Replace the ECM. power change. No output Replace the ECM. power change.

The output power decreases. The output power decreases. The output power decreases.

Replace the ECM.

The output power decreases.

Replace the ECM.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code DEUTZ HCM

623

624

625

627

628

637

1170

973 974 975

Trouble

523612-12 Software Error (Shut-off path test error of low voltage detection and Diagnostic fault check to report low voltage monitoring error) Software Error (Shut-off path test error of monitoring module) Software Error (Time out error canceling alarm task and Faulty setup of alarm task period) Software Error (Time monitoring error of shut-off path test and Diagnostic fault check to report time out during shut-off path test) Software Error (Shut-off path test error of high voltage detection and Diagnostic fault check to report high voltage monitoring error) Software Error (Plausibility error of current energizing time with maximum permitted energizing time and Diagnostic fault check to report error due to engine overrun) Software Error (Error occurs during positive test and Diagnostic fault check to report that the positive test failed) 523612-14 Software Setting Abnormal CPU

Cause

Faulty ECM

Symptoms in Machine Operation When Trouble Occurs The output power decreases.

The output power decreases. The output power decreases.

Remedy

Replace the ECM.

Faulty ECM

The output power decreases.

Replace the ECM.

Faulty ECM

The output power decreases.

Replace the ECM.

Engine overspeed is No output Check HST pump detected by the system power change. delivery pressure. reaction. Check the HST motor.

Faulty ECM

The output power decreases.

Faulty ECM

No output Replace the ECM. power change.

T5-5-28

Replace the ECM.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code DEUTZ HCM

856

857

858

Trouble

523613-10 Combustion pressure in the rail, which is dependant on engine speed, is lower than the target range. Rail pressure increasing is stopped. Positive governor deviation

Cause

Faulty common rail pressure sensor. Faulty wire harness. Faulty supply pump. Faulty fuel system.

Symptoms in Machine Operation When Trouble Occurs The output power decreases.

Remedy

Check the wire harness. Check the supply pump. Check the fuel piping. Replace the common rail pressure sensor. No output Check the wire Combustion pressure in the Faulty common rail pressure sensor. power change. harness. rail, which is dependant on Faulty wire harness. Check the supply engine speed, is lower than pump. the target range. Rail pressure Faulty supply pump. Check the fuel piping. is unstable. Maximum positive Faulty fuel system. Replace the common deviation of rail pressure is rail pressure sensor. large. Combustion pressure in the Faulty ECM. The output Check the fuel drain power piping. rail, which is dependant on Faulty wire harness. decreases. Check the wire engine speed, is higher than Faulty injector. harness. the target range. Rail pressure Faulty fuel drain piping. Replace the injector. increasing is stopped. Fuel Replace the ECM. leakage is detected.

T5-5-29

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code DEUTZ HCM

859

523613-0

862

861

523613-1

864

523613-2

Trouble

Cause

Symptoms Remedy in Machine Operation When Trouble Occurs Combustion pressure in the Faulty ECM. No output Check the fuel drain rail, which is dependant on Faulty wire harness. power change. piping. engine speed, is higher than Faulty injector. Check the wire the target range. Rail pressure Faulty fuel drain piping. harness. is unstable. Maximum negative Replace the injector. deviation of rail pressure is Replace the ECM. large. No output Combustion pressure in Faulty ECM. Check the fuel drain Faulty wire harness. power change. piping. the rail, which is dependant Faulty injector. Check the wire on engine speed, is higher Faulty fuel drain piping. harness. than the target range. Rail Replace the injector. pressure increasing is stopped. Replace the ECM. Maximum rail pressure is exceeded. Faulty common rail The output Check the wire Combustion pressure in the pressure sensor. power harness. rail, which is dependant on Faulty wire harness. decreases. Check the supply engine speed, is lower than Faulty supply pump. pump. the target range. Maximum Faulty fuel system. Check the fuel piping. rail pressure is exceeded. Replace the common Minimum rail pressure is rail pressure sensor. exceeded. Combustion pressure in the Faulty ECM. The output Check the fuel drain rail, which is dependant on Faulty wire harness. power piping. engine speed, is higher than Faulty fuel drain piping. decreases. Check the wire the target range. The set point harness. of metering unit at overrun Replace the ECM. mode is not plausible.

T5-5-30

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code DEUTZ HCM

Trouble

594

523615-3

Fuel HighPressure Metering Unit Circuit High Input

523615-4

Fuel HighPressure Metering Unit Circuit Low Input

Faulty common rail pressure The output power sensor. Faulty wire harness. decreases. Faulty suction control valve. Shorted circuit in wire harness to the ground.

Check the wire harness. Check the suction control valve. Replace the common rail pressure sensor.

592

523615-5

Fuel HighPressure Metering Unit Low Current

122

523698-11 Engine ShutOff from Supervisory Monitoring Function 523776-9 CAN Reception Failure (Time-Out Error) 523777-9 CAN Reception Failure (Passive TimeOut Error)

Faulty ECM. Faulty common rail pressure sensor. Faulty wire harness. Faulty suction control valve. Faulty ECM.

Check the wire harness. Check the suction control valve. Replace the common rail pressure sensor. Replace the ECM. Replace the ECM.

596

595 597

291

292

Cause

Symptoms in Machine Operation When Trouble Occurs Faulty common rail pressure The output sensor. power Faulty wire harness. decreases. Faulty suction control valve. Shorted circuit in wire harness to the power source.

The output power decreases.

The engine stops.

Remedy

Check the wire harness. Check the suction control valve. Replace the common rail pressure sensor.

Faulty ECM. Faulty CAN harness.

No output Check the CAN harness. power change. Replace the ECM.

Faulty ECM. Faulty CAN harness.

No output Check the CAN harness. power change. Replace the ECM.

T5-5-31

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code DEUTZ HCM

559

560

561

562

836

837

834

835

360

361

1505

Trouble

523895-13 Abnormal Adjustment Value Programming of Injector #1 523896-13 Abnormal Adjustment Value Programming of Injector #3 523897-13 Abnormal Adjustment Value Programming of Injector #4 523898-13 Abnormal Adjustment Value Programming of Injector #2 523906-3 Fuel Solenoid Pump Circuit High Input 523906-4 Fuel Solenoid Pump Circuit Low Input 523906-5 Open Circuit in Fuel Solenoid Pump 523906-12 Abnormal Fuel Solenoid Pump Power Source 523982-0 Abnormally High Battery Voltage 523982-1 Abnormally Low Battery Voltage 524057-2 Fuel Pressure Increasing Error

Cause

Injector #1 is faulty.

Symptoms Remedy in Machine Operation When Trouble Occurs No output Check injector #1. power change.

Injector #3 is faulty.

No output Check injector #3. power change.

Injector #4 is faulty.

No output Check injector #4. power change.

Injector #2 is faulty.

No output Check injector #2. power change.

Faulty fuel solenoid pump. Faulty fuel pump relay. Faulty wire harness. Faulty fuel solenoid pump. Faulty fuel pump relay. Faulty wire harness. Faulty fuel solenoid pump. Faulty fuel pump relay. Faulty wire harness.

No output Check the wire harness. power change. Replace the fuel pump relay. Replace the fuel solenoid pump. No output Check the wire harness. power change. Replace the fuel pump relay. Replace the fuel solenoid pump. No output Check the wire harness. power change. Replace the fuel pump relay. Replace the fuel solenoid pump.

Faulty fuel solenoid pump. Faulty fuel pump relay. Faulty wire harness.

No output Check the wire harness. power change. Replace the fuel pump relay. Replace the fuel solenoid pump.

Faulty alternator. Faulty wire harness.

No output Check the wire harness. power change. Replace the alternator.

Faulty alternator. Faulty wire harness.

No output Check the wire harness. power change. Replace the alternator.

Faulty fuel solenoid pump. Faulty fuel pressure switch. Faulty fuel pump relay. Faulty wire harness.

No output Check the wire harness. power change. Replace the fuel pressure switch. Replace the fuel pump relay. Replace the fuel solenoid pump.

T5-5-32

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111004, 111910, 111914 Preparation  Disconnect the connectors from each controller.  Check the wiring connections first.  Check the CAN1 harness between the controllers. (Refer to CAN1 Harness Check on T5-5-34 to 36.) Fault Code 111004-2

Trouble or Message CAN Communication Error 1

111910-2

CAN Engine Speed Reception Failure

111914-2

CAN Coolant Temperature Data Reception Failure

Inspection Method Continuity check (open circuit) Discontinuity check (shorted circuit) Continuity check (open circuit) Discontinuity check (shorted circuit) Continuity check (open circuit) Discontinuity check (shorted circuit)

T5-5-33

Cause Open circuit in wire harness Shorted circuit in wire harness Open circuit in wire harness Shorted circuit in wire harness Open circuit in wire harness Shorted circuit in wire harness

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN1 Harness Check Preparation  Before continuity check, set the key switch to the OFF position. Evaluation Continuity check (open circuit) Discontinuity check (shorted circuit) Inspection

Continuity (0 Ω) Normal

Discontinuity (∞ Ω) Discontinuity

Shorted circuit

Normal

CAN Harness

Continuity check High side between MC and Low side each controller High side Discontinuity check between CAN circuit and ground circuit in each controller

Low side

Main ECM Controller (MC) #40 #K54 #39 #K76

Monitor Controller #2-30 #2-29

Information A/C Controller (ICF) #C-5 #8 #C-11 #9

#40-#2 #40-#28 -

#K54-#K2 #K54-#4 #K54-#6 -

#2-30-#1-28 -

#C-5-#A-13 #C-5-#A-19 #C-5-#A-29 #C-5-#A-30 #C-5-#C-9 #C-5-#C-14

#8-#34 #8-#40 -

#39-#2 #39-#28 -

#K76-#K2 #K76-#K4 #K76-#K6 -

#2-29-#1-28 -

#C-5-#C-15 #C-11-#A-13 #C-11-#A-19 #C-11-#A-29 #C-11-#A-30 #C-11-#C-9 #C-11-#C-14 #C-11-#C-15

#9-#34 #9-#40 -

T5-5-34

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Inspection

CAN Harness

Main ECM Controller (MC)

Monitor Controller

Information A/C Controller (ICF)

Discontinuity check between CAN circuit and power circuit in each controller

High side

#40-#1

#K54-#K1

#2-30-#1-1

#C-5-#C-1

#40-#27

#K54-#K3

#C-5-#C-2

#K54-#K5

#39-#1

#K76-#K1

#2-29-#1-1

#C-11-#C-1

#39-#27

#K76-#K3

#C-11-#C-2

#K76-#K5

#40-#13

#K54-#K88

#2-30-#1-2

#C-5-#C-7

#8-#21

#40-#41

#40-#42

#39-#13

#K76-#K88

#2-29-#1-2

#C-11-#C-7

#9-#21

#39-#41

#39-#42

#40-#39

#K54-#k76

#2-30-#2-29

#C-5-#C-11

#8-#9

Low side

Discontinuity High side check between CAN circuit and key signal circuit in each controller Low side

Discontinuity check between CAN (High side) circuit and CAN (Low side) circuit in each controller

T5-5-35

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Wire harness end)  MC Connector

T4FC-05-05-001

ECM-2 Connector

TNCC-05-07-002

 Monitor Controller 1-A Connector

TNDF-05-05-005

 A/C1 Connector

 Monitor Controller 2-B Connector

TNCC-05-05-002 TNDF-05-05-006

 A/C2 Connector

 ICF-A Connector

TNCC-05-05-003

TNCC-05-05-001

 A/C3 Connector

 ICF-C Connector C2 C1

C11

TNCC-05-05-004 T1V1-05-04-002

T5-5-36

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111103 Preparation  Check the wiring connections first. Fault Code 111103-3

111103-4

Trouble or Message Inspection Method Accelerator Pedal Sensor Measure resistance Circuit High Input between #1 and #2 of accelerator pedal sensor end. Accelerator Pedal Sensor Measure voltage between Circuit Low Input wire harness end terminal #1 of accelerator pedal sensor and the body. Measure voltage between wire harness end terminals #1 and #3 of accelerator pedal sensor. -

Connector (Wire harness end)  Accelerator Pedal Sensor Connector

TNED-05-05-002

T5-5-37

Evaluation 0Ω

Cause Shorted circuit in wire harness between #1 and #2

Normal in above check Less than 0.25 V

Faulty accelerator pedal sensor Open circuit in wire harness #1

Less than 0.25 V

Open circuit in wire harness #3

Normal in above check

Faulty accelerator pedal sensor

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111217 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 111217-3

111217-4

Trouble Inspection Method Primary Pilot Pressure Retry by using MPDr. Sensor Circuit High Input Measure voltage between B and the body.

Evaluation Un-displayed fault code 4.75 V or more

Primary Pilot Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit Low Input code Measure voltage between A Less than 0.25 V and the body. Measure voltage between A Less than 0.25 V and C (GND). Normal in above check

Cause Faulty sensor Shorted circuit in wire harness between #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

2 3

123-

Pressure Sensor (Primary Pilot Pressure) Pilot Shut-Off Solenoid Valve Pilot Accumulator

60TNCC-01-02-13

TDAA-05-06-003

T5-5-38

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111330 Preparation  Check the wiring connections first.  Connect the test harness (ST 6701) and dummy sensor equivalent to #4703324.  Before inspection, set the key switch to the ON position. Fault Code 111330-3

111330-4

Trouble Pressure Sensor (Front Attachment Pressure) Circuit High Input

Pressure Sensor (Front Attachment Pressure) Circuit Low Input

Inspection Method Retry by using MPDr.

Evaluation Un-displayed fault code Measure voltage between B 4.75 V or more and the body. Measure voltage between A Less than 0.25 V and C (GND). Retry by using MPDr. Un-displayed fault code Measure voltage between A Less than 0.25 V and the body. Normal in above check

Cause Faulty sensor Shorted circuit in wire harness between #1 and #2 Open circuit in wire harness #3 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #2

2 1

T4FJ-01-02-016 12-

Pressure Sensor (Front Attachment Pressure) Priority Valve

TDAA-05-06-003

T5-5-39

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111331 Preparation  Check the wiring connections first.  Connect the test harness (ST 6701) and dummy sensor equivalent to #4703324.  Before inspection, set the key switch to the ON position. Fault Code 111331-3

111331-4

Trouble Inspection Method HST Circuit Pressure Retry by using MPDr. Sensor Circuit High Input Measure voltage between B and the body.

Evaluation Un-displayed fault code 4.75 V or more

Measure voltage between A Less than 0.25 V and C (GND). HST Circuit Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit Low Input code Measure voltage between A Less than 0.25 V and the body. Normal in above check

Cause Faulty sensor Shorted circuit in wire harness between #1 and #2 Open circuit in wire harness #3 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #2

123-

HST Circuit Pressure Sensor Transmission HST Motor

T4FJ-01-02-014

TDAA-05-06-003

T5-5-40

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111332 Preparation  Check the wiring connections first. Fault Code 111332-5

Trouble Enable Signal Disconnection Error

Inspection Method Measure voltage between MC harness end #13 and the body. -

Connector (Wire harness end)  MC Connector #13

T4FC-05-05-001

T5-5-41

Evaluation 0V

Cause Open circuit in wire harness

Normal in above check

Faulty MC

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111422 Preparation  Check the wiring connections first. Fault Code 111422-2

Trouble Ride Control Solenoid Valve Abnormal FB

Inspection Method Evaluation Measure resistance 0/∞ Ω between solenoid valve #1 (Specification: and #2. 23.2±0.4 Ω) Measure voltage between 0 V solenoid valve harness end #1 and the body. Monitor Ride Control P/S FB. 0 mA -

Cause Faulty solenoid valve

Open circuit in wire harness #1

Normal in above check

Open circuit in wire harness #2 Shorted circuit in wire harness between #1 and #2

Connector (Wire harness end)  Solenoid Valve Connector

TNED-05-05-020

[ Within Front Chassis ]

2 60TNCC-01-02-14

12-

T5-5-42

Ride Control Solenoid Valve Ride Control Accumulator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111430, 111434 Preparation  Check the wiring connections first. Fault Code 111430-2

111434-2

Trouble Displacement Angle Control Solenoid Valve Abnormal FB

Inspection Method Evaluation Measure resistance 0/∞ Ω between displacement angle control solenoid valve #1 and #2. Measure voltage between 0 V displacement angle control solenoid valve harness end #1 and the body. Monitor Motor 1 Swash 0 mA Angle Control Signal FB. Normal in above check

Driving Control Solenoid Measure resistance 0/∞ Ω Valve Abnormal FB between travel control solenoid valve #1 and #2. Measure voltage between 0 V travel control solenoid valve harness end #1 and the body. ∞Ω Measure resistance between travel control solenoid valve harness end #2 and the body. Normal in above check

Cause Faulty displacement angle control solenoid valve

Open circuit in wire harness #1

Open circuit in wire harness #2 Shorted circuit in wire harness between #1 and #2 Faulty travel control solenoid valve Open circuit in wire harness #1

Open circuit in wire harness #2

Shorted circuit in wire harness between #1 and #2

Connector (Wire harness end)  Solenoid Valve Connector 4 TNED-05-05-020

2 3

T4FJ-01-02-014

1234-

T5-5-43

Displacement Angle Control Solenoid Valve Travel Control Solenoid Valve Transmission HST Motor

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111450, 111451 Preparation  Check the wiring connections first. Fault Code 111450-2

Trouble Forward Side Solenoid Valve Output Error

111451-2

Reverse Side Solenoid Valve Output Error

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and the body. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and the body. -

Evaluation 0/∞ Ω (Specification: 22±0.4 Ω) 0V

Cause Faulty solenoid valve

Open circuit in wire harness #1

Normal in above check ∞Ω (Specification: 22±0.4 Ω) 0V

Open circuit in wire harness #2 Faulty solenoid valve

Normal in above check

Open circuit in wire harness #2

Open circuit in wire harness #1

Connector (Wire harness end) 1a

 Solenoid Valve Connector

TNED-05-05-020

1b 1-

Forward/Reverse Control Solenoid Valve 1a- Forward Side Solenoid Valve 1b- Reverse Side Solenoid Valve

T4FJ-01-02-012 23-

HST Pump Main Pump

T5-5-44

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111455 Preparation  Check the wiring connections first. Fault Code 111455-2

Trouble Inspection Method Shift Switch Signal Monitor Hi/Lo switch. Output Error

Condition Shift Switch: Slow Speed Position Shift Switch: Fast Speed Position

T5-5-45

Evaluation Cause OFF Open circuit in wire harness ON Shorted circuit in wire harness

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111457 Preparation  Check the wiring connections first. Fault Code 111457-2

Trouble Back Buzzer Relay Output Error

Inspection Method Measure voltage at fuse #7 in fuse box A. Measure voltage between fuse box A and back buzzer relay #3. Switch back buzzer relay with other relay. Measure voltage between back buzzer relay #1 and MC (#5).

Evaluation 0V

Cause Faulty fuse #18

Open circuit in wire harness between fuse box A and back buzzer relay Faulty back buzzer relay

Correct operation 0V

Open circuit in wire harness between back buzzer relay and MC (#5)

Connector (Wire harness end)  Back Buzzer Relay Connector

T183-05-04-003

 MC Connector #5

T4FC-05-05-001

TNED-01-02-009 1-

T5-5-46

Back Buzzer Relay

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111622 Preparation  Check the wiring connections first. Fault Code 111622-2

Trouble Vehicle Speed Sensor Error

Inspection Method Disconnect a connector from the machine speed sensor. Retry by using MPDr. Check shorted circuit in wire harness between machine speed sensor harness end #1 and #2. -

Evaluation Cause Fault code 111622- Faulty machine speed 2 is not displayed. sensor

0Ω

Shorted circuit in wire harness between #1 and #2

Normal in above check

Faulty MC

Connector (Wire harness end)  MC Connector

 Machine Speed Sensor Connector

#17 #18

TNDF-05-05-010 T4FC-05-05-001

 Machine Speed Sensor Connector (Harness End) Connection List Terminal No. Terminal No. of MC Remark End #1 #18 Rotation Speed #2 #17 GND 1

2 T4FJ-01-02-014 12-

Machine Speed Sensor Transmission

HST Motor

T5-5-47

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111801 Preparation  Check the wiring connections first. Fault Code 111801-4

Trouble Abnormal Decline in Controller Voltage

Inspection Method Measure voltage between MC harness end #1 and the body. Measure voltage between MC harness end #27 and the body. -

Connector (Wire harness end)  MC Connector #1

#27

T4FC-05-05-001

T5-5-48

Evaluation 0V

Cause Open circuit in wire harness #1

Open circuit in wire harness #27

Normal in above check

Faulty MC

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111904 Preparation  Check the wiring connections first. Fault Code 111904-2

Trouble Abnormal Forward/ Reverse Lever

Inspection Method Disconnect a connector from the forward/reverse lever. Retry by using MPDr. Measure voltage between forward/reverse lever harness end #1 and the body. Check shorted circuit in wire harness between forward/reverse lever harness end #2 and #4. -

Evaluation Cause Fault code 111904- Faulty forward/reverse 2 is not displayed. lever Less than 0.25 V

Open circuit in wire harness #1

0Ω

Shorted circuit in wire harness between #2 and #4

Normal in above check

Faulty MC

Connector (Wire harness end)  MC Connector

 Forward/Reverse Lever Connector

#37

TNDF-05-05-011

 Forward/Reverse Lever Connector (Harness End) Connection List Terminal No. Terminal No. of MC Remark End #1 Fuse #10 in Fuse Box B #2 #48 Reverse #3 Neutral #4 #37 Forward

T5-5-49

#48

T4FC-05-05-001

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111908 Preparation  Check the wiring connections first. Fault Code 111908-3

111908-4

Trouble Slow Speed (L) Select Switch Circuit High Input

Slow Speed (L) Select Switch Circuit Low Input

Inspection Method Measure resistance between slow speed (L) select switch end #1 and #2. -

Evaluation 0Ω

Normal in above check Less than 0.25 V

Measure voltage between slow speed (L) select switch harness end #1 and the body. Measure voltage between Less than 0.25 V slow speed (L) select switch harness end #1 and #3. Normal in above check

Connector (Wire harness end) Slow Speed (L) Select Switch Connector

TNDF-05-05-007

T5-5-50

Cause Shorted circuit in wire harness between #1 and #2 Faulty slow speed (L) select switch Open circuit in wire harness #1 Open circuit in wire harness #3 Faulty slow speed (L) select switch

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111922 Preparation  Check the wiring connections first.  Check the CAN1 harness between the controllers. (Refer to CAN1 Harness Check on T5-5-34 to 36.) Fault Code

Trouble

Inspection Method

Cause

111922-2

HST Oil Temperature Data Reception Failure

Continuity check (open circuit)

Open circuit in wire harness

Discontinuity check (shorted circuit)

Shorted circuit in wire harness

T5-5-51

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller Fault Code 115000 Preparation  Check the wiring connections first.  Check the CAN1 harness between the controllers. (Refer to CAN1 Harness Check on T5-5-54 to 56.) Fault Code

Trouble

Inspection Method

Cause

115000-2

CAN Communication Error 1

Continuity check (open circuit)

Open circuit in wire harness

Discontinuity check (shorted circuit)

Shorted circuit in wire harness

T5-5-52

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-53

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN1 Harness Check Preparation  Before continuity check, set the key switch to the OFF position. Evaluation Continuity (0 Ω)

Discontinuity (∞ Ω)

Continuity check (open circuit)

Normal

Discontinuity

Discontinuity check (shorted circuit)

Shorted circuit

Normal

Inspection

CAN Harness

Main Controller ECM (MC)

Monitor Controller

Information Controller (ICF)

A/C

Continuity check between MC and each controller

High side

#40

#K54

#2-30

#C-5

Low side

#39

#K76

#2-29

#C-11

#40-#2

#K54-#K2

#2-30-#1-28

#C-5-#A-13

#8-#34

#40-#28

#K54-#4

#C-5-#A-19

#8-#40

#K54-#6

#C-5-#A-29

#C-5-#A-30

#C-5-#C-9

#C-5-#C-14

#C-5-#C-15

#39-#2

#K76-#K2

#2-29-#1-28

#C-11-#A-13

#9-#34

#39-#28

#K76-#K4

#C-11-#A-19

#9-#40

#K76-#K6

#C-11-#A-29

#C-11-#A-30

#C-11-#C-9

#C-11-#C-14

#C-11-#C-15

Discontinuity check High side between CAN circuit and ground circuit in each controller

Low side

T5-5-54

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Inspection

CAN Harness

Discontinuity check High side between CAN circuit and power circuit in each controller Low side

High side Discontinuity check between CAN circuit and key signal circuit in each Low side controller

Discontinuity check between CAN (High side) circuit and CAN (Low side) circuit in each controller

Main Controller ECM (MC)

Monitor Controller

Information A/C Controller (ICF)

#40-#1

#K54-#K1

#2-30-#1-1

#C-5-#C-1

#40-#27

#K54-#K3

#C-5-#C-2

#K54-#K5

#39-#1

#K76-#K1

#2-29-#1-1

#C-11-#C-1

#39-#27

#K76-#K3

#C-11-#C-2

#K76-#K5

#40-#13

#K54-#K88

#2-30-#1-2

#C-5-#C-7

#8-#21

#40-#41

#40-#42

#39-#13

#K76-#K88

#2-29-#1-2

#C-11-#C-7

#9-#21

#39-#41

#39-#42

#40-#39

#K54-#K76

#2-30-#2-29

#C-5-#C-11

#8-#9

T5-5-55

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Wire harness end)  MC Connector

T4FC-05-05-001

ECM-2 Connector

TNCC-05-07-002

 Monitor Controller 1-A Connector

TNDF-05-05-005

 A/C1 Connector

 Monitor Controller 2-B Connector

TNCC-05-05-002 TNDF-05-05-006

 A/C2 Connector

 ICF-A Connector

TNCC-05-05-003

TNCC-05-05-001

 A/C3 Connector

 ICF-C Connector C2 C1

C11

TNCC-05-05-004 T1V1-05-04-002

T5-5-56

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller Fault Code 115001 Fault Code 115001-2

Trouble Abnormal REG input H level

Inspection Method Evaluation Measure voltage between terminal 20 to 25 V #2-B28 of monitor controller 2-B connector of wire harness end and the body. Switch alternator indicator relay 1 20 to 25 V with other general relay. Measure voltage between terminal #2-B28 of monitor controller 2-B connector of wire harness end and the body. Measure voltage between terminals 0 V #1, 3 of alternator indicator relay 1 connector of wire harness end and the body. Short-circuit in wire harness between 0 V terminals #3, 4 of alternator indicator relay 1 connector of wire harness end. Measure voltage between terminal #2-B28 of monitor controller 2-B connector of wire harness end and the body. Check continuity between alternator ∞ Ω terminal D and the body.

Normal in above check

Connector (Wire harness end)

Cause Faulty monitor controller

Faulty alternator indicator relay 1

Open circuit in wire harness between alternator indicator relay 1 and key switch Open circuit in wire harness between alternator indicator relay 1 and monitor controller

Shorted circuit in wire harness between alternator and alternator indicator relay 1 Faulty alternator

 Monitor Controller 2-B Connector

TNDB-05-05-013

 Alternator Indicator Relay 1

T183-05-04-003 TNED-01-02-009 1-

T5-5-57

Alternator Indicator Relay 1

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller Fault Code 115011 Fault Code 115011-3

115011-4

Trouble Open circuit in fuel level sensor

Inspection Method Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and the body. -

Evaluation Refer to the table.

Cause Faulty sensor

Open circuit in wire harness #1

Normal in above check Refer to the table.

Open circuit in wire harness #2 Faulty sensor

Shorted circuit in fuel level Measure resistance sensor between sensor #1 and #2. Normal in above check

Fuel Gauge A

No.

Fuel Level (%)

A B C

100(FULL) 50 0(EMPTY)

Shorted circuit in wire harness between #1 and #2 Fuel Level Sensor (Ω) 100/-4 33±5 90+10/0

TNED-05-05-008

Connector (Wire harness end)  Fuel Level Sensor

TNED-05-05-022

2 60TNCC-01-02-03 12-

T5-5-58

Fuel Level Sensor Fuel Tank

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller Fault Code 115014 Preparation  Check the wiring connections first. Fault Code 115014-3

115014-4

Trouble Inspection Method HST Oil Temperature Measure resistance Sensor Circuit High Input between sensor #1 and #2. Measure voltage between sensor harness end #1 and the body. HST Oil Temperature Measure resistance Sensor Circuit Low Input between sensor #1 and #2. -

Evaluation Refer to the table.

Cause Faulty sensor

Open circuit in wire harness #1

Normal in above check Refer to the table.

Open circuit in wire harness #2 Faulty sensor

Normal in above check

Shorted circuit in harness #1

Specification of Hydraulic Oil Temperature Sensor Oil Temperature °C (°F) -30 (-22) -20 (-4)

Resistance (kΩ)

-10 (14) 0 (32) 10 (50) 20 (68)

(9.16) (5.74) (3.70) 2.45+0.14/-0.13

30 (86) 40 (104) 50 (122) 60 (140) 70 (158) 80 (176) 90 (194) 100 (212) 110 (230) 120 (248)

(1.66) (1.15) (0.811) (0.584) (0.428) 0.318±0.008 (0.240) (0.1836) 0.1417±0.0018 (0.1108)

(24.5) 15.04+1.29/-1.20 2

60Z7-05-05-01 12-

Connector (Wire harness end)  HST Oil Temperature Sensor Connector

TNED-05-05-021

T5-5-59

HST Oil Temperature Sensor Hydraulic Tank

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller Fault Code 115015 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 115015-3

115015-4

Trouble Inspection Method Parking Brake Pressure Retry by using MPDr. Sensor Circuit High Input Measure voltage between B and the body.

Evaluation Un-displayed fault code 4.75 V or more

Parking Brake Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit Low Input code Measure voltage between A Less than 0.25 V and the body. Measure voltage between A Less than 0.25 V and C (GND). Normal in above check

Cause Faulty sensor Shorted circuit in wire harness between #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

1 3

2 T4FJ-01-02-014 123-

Parking Brake Pressure Sensor Transmission HST Motor C

TDAA-05-06-003

T5-5-60

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller Fault Codes 120500 to 120502 Fault Code 120500-2

Trouble Overheat Alarm

120501-2

Engine Warning Alarm

120502-2

Engine Oil Pressure Alarm

Inspection Method Diagnose on fault codes of ECM. Diagnose on fault codes of ECM. Diagnose on fault codes of ECM.

T5-5-61

Evaluation -

Cause -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller Fault Codes 120506, 120507, 120510, 120512, 120515, 120518 Fault Code 120506-2 120507-2 120510-2 120512-2 120515-2 120518-2

Trouble Inspection Method Steering Oil Pressure Alarm Diagnose on fault codes of MC. Transmission Error Alarm Diagnose on fault codes of MC. HST Oil Temperature Alarm Diagnose on fault codes of MC. Emergency Steering Alarm Diagnose on (Lighting) Troubleshooting B. Engine Alarm Diagnose on fault codes of ECM. Emergency Steering Alarm Diagnose on (Blinking) Troubleshooting B.

T5-5-62

Evaluation -

Cause -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Codes E11 to E22 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code E11

E12

E13

E14

E18

E21

E22

Trouble Open circuit in recirculated air sensor

Shorted circuit in recirculated air sensor

Open circuit in outdoor ambient temperature sensor

Inspection Method Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and the body. Measure resistance between sensor #1 and #2. Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and the body. -

Shorted circuit in outdoor ambient temperature sensor

Measure resistance between sensor #1 and #2. -

Shorted circuit in solar radiation sensor

Check continuity between sensor harness end #1 and #2. -

Open circuit in frost sensor

Shorted circuit in frost sensor

Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and the body. Measure resistance between sensor #1 and #2. -

T5-5-63

Evaluation ∞ Ω (Specification: 300 to 430 kΩ) 0V

Normal in above check 0 Ω ((Specification: 300 to 430 kΩ) Normal in above check ∞ Ω ((Specification: 100 to 210 kΩ) 0V

Normal in above check 0 Ω ((Specification: 100 to 210 kΩ) Normal in above check 0Ω

Cause Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #2 Faulty sensor Shorted circuit in harness #1 and #2. Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #2 Faulty sensor Shorted circuit in wire harness between #1 and #2 Shorted circuit in wire harness between #1 and #2 Faulty sensor

Normal in above check ∞ Ω ((Specification: Faulty sensor 100 to 115 kΩ) 0V Open circuit in wire harness #1 Normal in above check 0 Ω ((Specification: 100 to 115 kΩ) Normal in above check

Open circuit in wire harness #2 Faulty sensor Shorted circuit in wire harness between #1 and #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Codes E43 to E92 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code E43

E44

Trouble Abnormal air vent damper servo motor

Abnormal air mix damper servo motor

E51

Abnormal high/ low refrigerant pressure

E91

CAN communication error

E92

CAN bus off error

Inspection Method Measure voltage between air vent damper servo motor harness end 7C and the body. (AUTO/OFF switch/blower switch: ON) Measure voltage between air vent damper servo motor harness end 7C and 25D. (AUTO/ OFF switch/blower switch: ON) -

Evaluation 0V

Cause Faulty controller or open circuit in wire harness between controller and air vent damper servo motor

Faulty controller or open circuit in wire harness between controller and air vent damper servo motor Faulty air vent damper servo motor Faulty controller or open circuit in wire harness between controller and air mix damper servo motor

Normal in above check. 0V

Measure voltage between air mix damper servo motor harness end 7D and the body. (AUTO/OFF switch/blower switch: ON) 0V Measure voltage between air mix damper servo motor harness end 7D and 25E. (AUTO/ OFF switch/blower switch: ON) Normal in above check. Measure voltage between High/ 0 V low pressure switch harness end A21 and A05. (AUTO/OFF switch/blower switch: ON) Normal in above check. Check continuity in CAN1 Normal harness. Abnormal

Faulty controller Faulty CAN1 harness

Check continuity in CAN1 harness.

Faulty controller Faulty CAN1 harness

T5-5-64

Normal Abnormal

Faulty controller or open circuit in wire harness between controller and air mix damper servo motor Faulty air mix damper servo motor Faulty controller or open circuit in wire harness between controller and High/low pressure switch Faulty High/low pressure switch

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure Refer to troubleshooting B procedures for diagnosis by using trouble symptom when no fault codes are displayed.  Diagnosis Procedure  The diagnosis procedures for the displayed fault codes are explained in this group.  Perform diagnosis by using MPDr. or the service menu of monitor first.  In case any fault code has not been displayed by diagnosis, perform inspection according to the procedures when diagnosing.  When the fault code is displayed, refer to the troubleshooting A group and diagnose.  On the front section pages of this group, there are the tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if failed. Start the troubleshooting with more probable causes selected by referring to these tables. NOTE: All connector images in this section are viewed from the open end side of wire harness end.

T6L4-05-03-001 1-

Wire Harness End Connector

Wire Harness

T5-6-1

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Contents of Diagnosis

Trouble Symptom Preparation Viewpoints for a diagnosis and contents needing inspection beforehand are explained.

How to Read Table Procedure (A) (F)

Inspection Method (B) (G)

Condition

Evaluation

Cause

(D) (I)

(E) (J)

 A, F: Inspection order  B, G: Inspection method for trouble cause  C, H: Conditions for inspection  D, I: Evaluation specification of check results  E, J: Trouble cause for trouble symptom

Procedure: 1. Perform inspection according to Inspection Method (B) and Condition (C) of Procedure (A). 2. In case the results are applied to Evaluation (D), the trouble cause becomes Cause (E). In case the results are not applied to Evaluation (D), go to the next procedure, Procedure (F).

T5-6-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Relationship between Machine Trouble Symptoms and Related Parts This table indicates the relationship between machine trouble symptoms and the potential problem parts, which may cause trouble if failed, and the evaluation methods of these components. Parts MC (Main Controller) Item Function

Accelerator Pedal (Accelerator Pedal Sensor)

Controls engine, HST pump, HST Instructs target engine speed motor, transmission, and valve according to accelerator pedal operation. depressing amount. Symptoms Depending on trouble situations, MC holds engine speed in 1250 in control control system malfunction may min-1. system when differ.(The following symptoms in trouble occurs machine operation indicates that MC logic circuit has failed.)) Symptoms The engine speed is fixed to 1250 The engine speed is fixed to 1250 min-1. min-1. in Machine As pump displacement is held at Operation When Trouble minimum, all actuator speeds are slow. Occurs Evaluation by 111334 Fault Code Evaluation by MC: Demand Engine Speed Monitoring ECM: Actual Engine Speed Evaluation by using Test Harness Note T2-2 Descriptions T2-2 of Control (Refer to F&S S/M)

T5-6-3

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Power Mode Switch Item Function Turns power mode ON/OFF. Symptoms Same as shown below in control system when trouble occurs Symptoms Power mode (ON/OFF) can not in machine change. operation The power mode indicator on when trouble monitor is not shifted. occurs Evaluation by Fault Code Evaluation by MC: Power Mode Switch Monitoring Evaluation by using Test Harness Note Descriptions T2-2 of Control (Refer to F&S S/M)

Traction Control Switch

Turns traction control ON/OFF. Same as shown below

Traction control (ON/OFF) can not change. The TCS indication on monitor is not shifted. MC: Traction Control Switch -

T2-2

T5-6-4

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Slow Speed (L) Select Switch Item Function

Selects the machine speed at the slow speed within the specified range. Same as shown below

Symptoms in control system when trouble occurs Symptoms When the slow speed (L) select in machine switch is operated with the shift operation switch set in slow speed position, when trouble the maximum speed at the slow occurs speed is fixed to the minimum value. Evaluation by 111908 Fault Code Evaluation by MC: 1st Speed Limit Switch Monitoring Evaluation by using Test Harness Note Descriptions T2-2 of Control (Refer to F&S S/M)

T5-6-5

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Forward/Reverse Lever Item Function

Shifts forward/reverse control solenoid valve in HST pump.

Symptoms MC holds the travel in neutral. in control system when trouble occurs Symptoms Even if forward/reverse lever is in machine operated, the machine does not travel forward/reverse. operation when trouble The FNR indication on monitor is not shifted. occurs Evaluation by Fault Code Evaluation by MC: Forward/Reverse Lever (N)/ Monitoring (F)/(R) Evaluation by using Test Harness Note Descriptions T2-2 of Control (Refer to F&S S/M)

Shift Switch

Quick Shift Switch

Selects travel mode selector solenoid valve in transmission.

Same as shown below

Selects travel mode selector solenoid valve in transmission when the shift switch is in slow speed position and machine speed is less than 10 km/h (6.2 mph). Same as shown below

Even if the shift switch is operated, slow speed is not selected. The machine speed is fixed to fast speed.

Even if the quick shift switch is operated, slow speed is not selected. The machine speed is fixed to fast speed.

111455

MC: Shift Switch

MC: Quick Shift Switch

T2-2

T5-6-6

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Parking Brake Switch Item Function

Shifts parking brake solenoid valve.

Symptoms Same as shown below in control system when trouble occurs Even if parking brake switch Symptoms is turned ON/OFF, the parking in machine operation brake is not released/applied. when trouble (While the engine runs) occurs

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

Descriptions of Control (Refer to F&S S/M)

Control Lever Lock Switch (Option) Shifts control lever lock solenoid valve. Same as shown below

Open circuit: Control lever lock switch is always OFF. Pilot shutoff solenoid valve is not shifted. The lift arm and bucket are not operated even if the control lever is operated with the control lever lock switch set in UNLOCK position. Shorted circuit: Control lever lock switch is always ON. -

Even if the parking brake is turned OFF, the parking brake is applied with the engine stopped. T2-5 T2-4

T5-6-7

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Ride Control Switch (Option) Item Function

Shifts ride control solenoid valve and activates or deactivates the ride control. Same as shown below

Symptoms in control system when trouble occurs Symptoms Open circuit: Ride control switch in machine is always OFF. Even if ride control operation switch is turned ON, the ride when trouble control is not activated. occurs Shorted circuit: Ride control switch is always ON. Evaluation by Fault Code Evaluation by MC: Ride Control Switch Monitoring Evaluation by using Test Harness Note Descriptions T2-2, T2-4 of Control (Refer to F&S S/M)

Secondary Steering Operation Check Switch (Option) Checks operation of secondary steering pump. Same as shown below

Even if secondary steering operation check switch is set to ON side, secondary steering pump is not operated.

MC: Emergency Steering Operation Check Switch -

T2-2

T5-6-8

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts HST Oil Temperature Sensor Item Function

Monitors hydraulic oil temperature. Symptoms MC recognizes that hydraulic in control oil temperature is 120°C (248°F) system when when open circuit occurs. trouble occurs (Hydraulic oil temperature: 120°C (248°F) is not displayed on monitoring.) Symptoms Even if hydraulic oil temperature in machine is 0 °C or less when starting the operation engine, auto-warming up control when trouble is not operated. occurs Evaluation by Fault Code Evaluation by MC: HST Oil Temperature Monitoring Evaluation by using Test Harness Note -

Descriptions of Control (Refer to F&S S/M)

T2-2

HST Circuit Pressure Sensor

Pressure Sensor (Front Attachment Pressure)

Detects HST circuit pressure.

Detects pump delivery pressure (main, steering). When output is 0 V or 5 V, the following symptoms occur.

When output is 0 V or 5 V, the following symptoms occur.

The maximum speed and maximum traction force are limited.

The traction control is not activated.

115014

MC: HST Circuit Pressure

MC: Front Attachment Pressure

Possible to judge if sensor or harness is faulty by switching pressure sensor with other delivery pressure sensor. T2-2

T5-6-9

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Machine Speed Sensor Item Function

Detects fast-speed drive gear Applies and releases parking speed in transmission. brake. Driving mode cannot be changed Same as shown below from fast to slow speed. The maximum speed is limited.

Symptoms in control system when trouble occurs Symptoms Machine speed is insufficient. in machine The machine can travel normally. operation (However, the HST warning when trouble indicator is turned on.) occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Refer to F&S S/M)

Parking Brake Solenoid Valve

Control Lever Lock Solenoid Valve (Option) Opens and closes the front pilot circuit. Same as shown below

When closed: The lift arm and bucket are not operated. (Pilot pressure oil is not supplied to pilot valve.) When open: Pilot pressure oil is always supplied to pilot valve. -

MC: Vehicle Speed Pulse

MC: Parking Brake

T2-2

T2-4, 2-5

T2-4

When closed: The parking brake is not released. When open: The parking brake is applied.

T5-6-10

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Ride Control Solenoid Valve (Option) Shifts spool in ride control valve.

Symptoms Same as shown below in control system when trouble occurs Symptoms High current: The ride control is in machine always activated. operation Low current: The ride control is when trouble not activated. occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Refer to F&S S/M)

Displacement Angle Control Solenoid Valve Controls displacement angle of HST motor. Same as shown below

The maximum speed and maximum traction force are limited.

111434

MC: Motor 1 Swash Angle Control Signal, Motor 1 Swash Angle Control Signal FB -

T2-2, 2-4

T2-2

T5-6-11

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Forward/Reverse Control Solenoid Valve Controls displacement angle direction of HST pump. Same as shown below

Forward Side Solenoid Valve

Reverse Side Solenoid Valve

Shifts HST pump displacement angle to the forward side. Same as shown below

Shifts HST pump displacement angle to the reverse side. Same as shown below

Symptoms in control system when trouble occurs Symptoms The machine can not travel either The machine can not travel in machine forward, in reverse, or in both forward. operation directions. when trouble occurs Evaluation by Fault Code Evaluation by MC: Forward Solenoid Valve Monitoring Evaluation by using Test Harness Note T2-2 Descriptions T2-2 of Control (Refer to F&S S/M)

T5-6-12

The machine can not travel in reverse.

MC: Reverse Solenoid Valve -

T2-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Main Relief Valve (Control Valve) Item Function

Prevents pressure in main pump circuit from exceeding the set pressure when a front attachment control lever is operated. Same as shown below

Symptoms in control system when trouble occurs Symptoms If stuck in fully closed position, in machine hose of front attachment may be operation damaged. when trouble If stuck in fully open position, occurs power is weak during digging operation. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Refer to F&S S/M)

Overload Relief Valve

Prevents actuator circuit pressure generated by external force from exceeding the set pressure with a front attachment control lever set in neutral. Same as shown below

If stuck in fully closed position, hose of front attachment may be damaged by external force. If stuck in fully open position, power is weak during digging operation. -

T2-4

T5-6-13

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Steering Relief Valve (Priority Valve) Prevents pressure in steering pump circuit from exceeding the set pressure when a steering wheel is operated.

Symptoms Same as shown below in control system when trouble occurs Symptoms If stuck in fully closed position, in machine steering hose may be damaged. If stuck in fully open position, operation when trouble steering wheel rotation speed becomes slow. occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Refer to F&S S/M)

Ride Control Spool (Ride Control Valve) (Option)

Back Buzzer Relay

Is shifted by pilot pressure from ride control solenoid valve. Connects the accumulator to lift arm cylinder circuit and increases/decreases the lift arm cylinder bottom pressure. Same as shown below

Sounds the buzzer while driving in reverse.

Same as shown below

If stuck in neutral position, the ride control is not activated. If stuck in ride control operating position, digging operation is not smooth. -

111457

MC: Back Buzzer Relay

T2-4

T2-5

T5-6-14

Even if the forward/reverse lever is set to the (R) position, the buzzer does not sound.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Correlation between Trouble Symptoms and Part Failures This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed. The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom. The marks / in this table indicate the influence to trouble symptom. : Related, required to check : Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.

T5-6-15

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting Trouble Symptom E-1 Starter does not rotate. Parts MC ECM ICF Monitor Controller MPDr. Key Switch Accelerator Pedal Sensor Forward/Reverse Lever Battery Battery Relay Fuse Box A Fuse Box B Neutral Relay Starter Relay 1 Fuel Pump Relay Starter Engine Unit Pressure Sensor (Front Attachment Pressure) Remark

E-2 Even if starter rotates, engine does not start.

 







(N position)    (#13, #14)

E-3 Engine starts with forward/ reverse lever set in the positions except N. 

  (Neutral)

 (#4, #14)

 

 (#10) 

  

Neutral Engine Start Circuit (T2-3)

: Check required : Related

T5-6-16

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom E-4 Even if key switch is turned OFF, engine does not stop.

Parts MC ECM ICF Monitor Controller MPDr. Key Switch Accelerator Pedal Sensor Power Mode Switch Parking Brake Switch Forward/Reverse Lever Battery Battery Relay Fuse Box A Fuse Box B ACC Cut Relay (Option) Starter Relay 1 Fuel Pump Relay Starter Engine Unit Pressure Sensor (Front Attachment Pressure) HST Oil Temperature Sensor Pressure Sensor (Parking Brake) Remark

 





: Check required : Related

T5-6-17

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting

Parts

Trouble Symptom F-1 All front attachment actuator power are weak.

ECM Battery Pilot Shut-Off Relay Control Lever Lock Switch HST Charging Pump Priority Valve (Brake Charge Valve) Pilot Relief Valve (Brake Charge Valve) Pilot Reducing Valve (Manifold Valve) Control Lever Lock Solenoid Valve Pilot Valve Spool (Control Valve) Main Relief Valve (Front Attachment) Overload Relief Valve (Control Valve) Cylinder Main Pump Pressure Sensor (Front Attachment Pressure) Priority Valve (Main) Remark

F-2 Some cylinders are not operated or speed are slow. (Manual Type)

F-3 Some cylinders are not operated or speed are slow. (Hydraulic Pilot Type) (Option)



   

 



   

   

: Check required : Related

T5-6-18



SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom F-4 When lift arm raise or bucket roll-in is operated, lift arm or bucket starts to move after moving slightly down. 

ECM Monitor Lift Arm Angle Sensor (Option) Pilot Pump Brake Charge Valve Manifold Valve Pilot Valve Slow Return Valve Spool (Control Valve) Overload Relief Valve (Control Valve) Load Check Valve (Control Valve) Cylinder Main Pump Remark

 

: Check required : Related

T5-6-19

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom F-5 F-6 F-7 Bucket auto leveler control is Bucket auto leveler control is Lift arm float control is not not activated. (Detent is not not activated. (Detent is not activated. (Detent is not held.) (Manual Type) held.) (Hydraulic Pilot Type) held.) (Hydraulic Pilot Type) (Option) (Option)

MC MPDr. Battery Battery Relay Fuse Box A Lift Arm Angle Sensor (Option) Bucket Leveler Relay Kickout Relay Proximity Switch Pilot Pump Brake Charge Valve Manifold Valve Pilot Valve Spool (Control Valve) Cylinder Main Pump Remark

 (#15)



 (Bucket)

 (Bucket)

 (Bucket)  (Bucket)

: Check required : Related

T5-6-20

 (#15)

 (Lift Arm)  (Lift Arm)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom F-8 Lift arm kickout control is not activated. (Hydraulic Parts Pilot Type) (Option)  MC Information Controller MPDr. (Lift Arm Angle Sensor Learning) Monitor Battery Battery Relay Fuse Box A  (#15) Kickout Relay Proximity Switch Brake Charge Valve Manifold Valve Pilot Valve  (Lift Arm) Spool (Control Valve)  (Lift Arm) Cylinder Main Pump Remark : Check required : Related

T5-6-21

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom F-9 The ride control (optinal) is not activated.

Parts MC HST Controller Information Controller MPDr. Fuse Box B Lift Arm Angle Sensor Machine Speed Sensor HST Circuit Pressure Sensor Power Mode Switch Traction Control Switch Forward/Reverse Lever Shift Switch Ride Control Switch (Option) Pressure Sensor (Primary Pilot Pressure) Ride Control Solenoid Valve (Option) Spool (Ride Control Valve) (Option) Cylinder Accumulator (Ride Control Valve) (Option) Main Pump Pressure Sensor (Front Attachment Pressure) HST Pump Pump Displacement Angle Control Solenoid Valve HST Motor Remark



 (Setting: ON)  

     (Lift Arm) 



: Check required : Related

T5-6-22

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-23

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting Trouble Symptom S-1 Steering cylinder operation is slow. Steering cylinder Parts operation is not operated.  Steering Valve Overload Relief Valve (Steering Valve)  Steering Cylinder  Main Pump  Priority Valve Remark : Check required : Related

T5-6-24

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom S-2 Secondary steering (option) is not operated. (Automatic operation check when the Parts engine starts)  MC  Monitor Controller Battery Fuse Box B  (#4)  Secondary Steering Pump Relay  Machine Speed Sensor Brake Charge Valve Manifold Valve  Secondary Steering Operation Check Switch (Option) Steering Cylinder Main Pump  Secondary Steering Motor  Secondary Steering Pump Remark : Check required : Related

T5-6-25

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting

Parts

Trouble Symptom T-1 Machine does not travel forward.

MC Battery Fuse Box A Fuse Box B Accelerator Pedal Sensor Forward/Reverse Lever HST Pump Transmission Machine Speed Sensor Forward Side Solenoid Valve (HST Pump) Reverse Side Solenoid Valve (HST Pump) Propeller Shaft Axle Pressure Sensor (Parking Brake) Remark

T-2 Machine does not travel in reverse.



 (#10)

  



   

   

T-3 Machine travels forward even if forward/reverse lever is set to the (N) position. 

  

: Check required : Related

T5-6-26

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom T-4 Machine travels in reverse even if forward/reverse lever is set to the (N) position. 

MC Battery Fuse Box A Fuse Box B Accelerator Pedal Sensor Forward/Reverse Lever Shift Switch HST Pump Brake/ Transmission Pump Transmission Travel Mode Selector Solenoid Valve Machine Speed Sensor Forward Side Solenoid Valve (HST Pump) Reverse Side Solenoid Valve (HST Pump) Propeller Shaft Axle Travel Mode Selector Valve Remark

T-5 Slow speed is not selected even if shift switch is set to the (Lo) position. 

T-6 Fast speed is not selected even if shift switch is set to the (Hi) position. 



  

  



  



: Check required : Related

T5-6-27

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom T-7 Quick shift switch function is not activated even if quick shift switch is depressed. 

MC Battery Fuse Box A Fuse Box B Accelerator Pedal Sensor Forward/Reverse Lever Shift Switch Quick Shift Switch Slow Speed (L) Select Switch Transmission Travel Mode Selector Solenoid Valve Machine Speed Sensor Brake/ Transmission Pump Travel Mode Selector Valve Displacement Angle Control Solenoid Valve (HST Motor) Propeller Shaft Axle Displacement Angle Control Cylinder (HST Motor) Remark

 

T-8 Fast speed is not selected even if quick shift switch is released. 

T-9 Travel slow-speed selecting function is not activated. 

  

 

 

  

   



: Check required : Related

T5-6-28

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting Trouble Symptom B-1 Parking brake is not released.

Parts  Monitor Controller Key Switch  (ON) Battery Fuse Box A  (#14, #20) Parking Brake Switch  (Released) Parking Brake Relay 1  (OFF) Parking Brake Relay 2  (ON) Brake Pedal  Parking Brake  Brake/Transmission Pump Parking Brake Solenoid Valve  Brake Valve Axle Remark

B-2 B-3 Parking brake is not applied. Service brake braking force becomes weak.

 (ON)  (#14, #20)  (Applied)  (ON)  (OFF)    

  

: Check required : Related

T5-6-29

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting Trouble Symptom O-1 Clearance light and license plate light are not ON.

Parts Monitor Controller Key Switch Battery Fuse Box A Fuse Box B Light Switch Dimmer Switch Head Light Relay High Beam Relay Head Light Clearance Light License Light (Option) Remark

 (Indicator)   (#11, #17) 

O-2 Head light is not ON.

O-3 Head light is not shifted to high beam.

 (Indicator)  (ON)

 (#9, #17)

 (#17, #19)

  

 

  

: Check required : Related

T5-6-30

  (High Beam)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom O-4 Hazard light circuit is not operated.

Parts Monitor Controller Key Switch Battery Fuse Box A Fuse Box B Hazard Switch Turn Signal Lever Horn Switch Flasher Turn Signal Light Relay (L) Turn Signal Light Relay (R) Horn Relay Turn Signal Light (Hazard Light) Horn Remark

 (Indicator)   (#6)

O-5 Turn signal light is not operated.

O-6 Horn does not sound.

 (Indicator)  (ON)  (#3, #8)

  (#5)

     

   



 

: Check required : Related

T5-6-31

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom O-7 O-8 Reverse light is not ON. Back Brake light is not ON. buzzer does not sound.

Parts MC Monitor Controller Key Switch Battery Fuse Box A Fuse Box B Forward/Reverse Lever Brake Light Switch (Brake Pedal) Light Switch Work Light Switch Back Buzzer Relay Brake Light Relay Front Work Light Relay Rear Work Light Relay Backup Light (Option) Back Buzzer Brake Light Work Light Remark

O-9 Work light does not light.

  (ON)

 (ON)

 (#2)

 (#3)

 (Indicator)  (ON)  (#16)  (#5)

 (Reverse)           

: Check required : Related

T5-6-32

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom O-10 Wiper is not operated. Parts Monitor Controller Key Switch Battery Fuse Box A Fuse Box B Front Wiper, Washer Switch Rear Wiper, Washer Switch Front Cab Light (Switch) Rear Cab Light (Switch) Door Open/Close Switch (Cab) Wiper Relay (F) 1 Wiper Relay (F) 2 Wiper Relay (R) Washer Relay (F) Washer Relay (R) Wiper Motor (F) Wiper Motor (R) Washer Motor (F) Washer Motor (R) Remark

O-11 Washer is not operated.

  (ON)

 (#3)  (#6)  

O-12 Cab light does not light.

  (#11)

     (Fast Speed)       

: Check required : Related

T5-6-33

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-34

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting E-1 Starter does not rotate. Preparation  In case the radio with the key switch set in the ACC position and the horn with the key switch set in the OFF position are operated normally, the wire harness between battery and key switch terminal B is considered normal.

 Check that the forward/reverse lever is in the (N) position (neutral position).  Perform these steps when the fault codes of MC, ECM, and CAN communication are not displayed.  Check the wiring connections first.

Procedure Inspection Method 1 Measure battery voltage and electrolyte density.

Condition -

Key Switch: START

5 6

7 8 9

Measure voltage at wire harness end terminal K35 of ECM-2 connector. Measure voltage at wire harness end terminal #2 of engine connector. Check continuity between terminal K73 of ECM-2 connector of wire harness end and the body. Measure voltage at battery relay terminal C. Measure voltage at wire harness end connector of starter connector (1). Check continuity between key switch #1 and #6. Monitor Forward/Reverse Lever (N). -

Evaluation Cause The measured values Faulty battery are not within the specification. (Specification: Voltage: 24 V or more, Electrolyte density: 1.26 or more) 0V Open circuit in wire harness between key switch and ECM

Key Switch: START

Open circuit in wire harness between ECM and engine

Key Switch: START

0Ω

Open circuit in wire harness between ECM and engine

Key Switch: ON

Faulty battery relay

Key Switch: ON

Key Switch: START

∞Ω

Open circuit in wire harness between starter and battery relay Faulty key switch

Forward/Reverse Lever: N -

OFF is displayed.

Faulty forward/reverse lever

Normal in above check

Faulty starter

Connector (Wire harness end)  Engine Connector

 ECM-2 Connector K35

K73

TNCC-05-07-002

T5-6-35

TNCC-05-06-001

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-2 Even if starter rotates, engine does not start. Preparation  Check that fuses #4 and #14 in fuse box A are normal.  Check the wiring connections first.

Procedure Inspection Method 1 Switch fuel pump relay with other general relay. 2 -

 Check that the fuel pre-filter and fuel main filter are not clogged.  Check that the fuel pump is operated normally when turning the key switch ON.

Condition Key Switch: ON

Evaluation The engine starts.

Cause Faulty fuel pump relay

Normal in above check

Faulty ECM or engine unit

T5-6-36

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-3 Engine starts with forward/reverse lever set in the positions except N. Preparation  Even if the key switch is set to the START position with the forward/reverse lever set in the positions except (N) position (neutral position), the starter does not rotate.  Perform these steps when the fault codes of MC, ECM, and CAN communication are not displayed.  Check fuse #10 in fuse box A.  Refer to SYSTEM/ECM System/Neutral Engine Start Control.  Check the wiring connections first. Procedure Inspection Method Condition 1 Switch the neutral relay with Key Switch: START other general relay. 2 Measure voltage at wire Forward/Reverse harness end #1 of neutral Lever: F or R relay. position 3 -

Evaluation Starter: Not rotating 0V

Cause Faulty neutral relay

Open circuit in wire harness between forward/reverse lever and neutral relay Normal in above check Find out cause of trouble by tracing other trouble symptoms.

Connector (Wire harness end)  Neutral Relay

T183-05-04-003

T5-6-37

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-4 Even if key switch is turned OFF, engine does not stop. 1

Preparation  Remove fusible link A (1) and stop the engine as emergency procedures first.  In case other trouble symptoms occur, perform troubleshooting of these troubles first.  If the fault code is not displayed, the key switch may be faulty.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

TNCC-05-01-001

T5-6-38

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting F-1 All front attachment actuator power are weak.  In case the trouble occurs only when the hydraulic oil temperature is low, high viscosity of hydraulic oil may be the cause.  The main relief valve or overload relief valve in control valve may be faulty if speed is enough but the power is weak.  The front attachment hydraulic system is controlled by the main pump, priority valve, and control valve. When the steering system control is normal, the priority valve should be normal. Therefore, if only the front attachment system is abnormal, the main pump and control valve may be faulty. Main Relief Valve Set Pressure Lift arm and bucket relief operation

Specification (MPa) 20.6 +1.2/−0.5 (2988 +174/−72.5)

Remark

Preparation  If operating speeds are extremely slow, pump control may be faulty. Faulty pilot system may also cause this trouble. Procedure Inspection Method 1 Monitor Pump Delivery Pressure.

Condition Lift arm relief operation

Evaluation The measured value are not within the specification. Normal in above check

T5-6-39

Cause Faulty main relief valve (Front Attachment) (readjust) Find out cause of trouble by tracing other trouble symptoms.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-2 Some cylinders are not operated or speeds are slow. (Manual Type) Overload Relief Specification Valve Set Pressure MPa (PSI) Bucket Dump 16.2 +1.5/−0.5 (2350 +218/-73)

Remark

Preparation  Check if the wire harness between the control lever and the control valve spool is normal (not broken) before starting troubleshooting.  In case only bucket roll-out cannot be operated, moves slowly, or has no power, the overload relief valve may be faulty. Lift Arm Cylinder Procedure Inspection Method 1 Operate lift arm.

Condition Evaluation During full operation The cylinder is not of lift arm raise/lower operated or its speeds is slow.

Cause Stuck control valve spool or faulty cylinder (faulty seal kit)

Bucket Cylinder Procedure Inspection Method 1 Measure overload relief valve set pressure.

Condition During operation of bucket roll back/ dump

Evaluation Cause The value are not Faulty overload relief valve within the specification. (Specification: 15.7~17.7 MPa (2277~2567 PSI)) Normal in above check Stuck control valve spool or faulty cylinder (faulty seal kit)

T5-6-40

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-3 Some cylinders are not operated or speeds are slow. (Hydraulic Pilot Type) (Option) Overload Relief Specification Valve Set Pressure MPa (PSI) Lift Arm Raise 27.9 +1.0/−0 (4047 +145/−0) Bucket 23.5 +1.0/−0 (3408 +145/−0)

Remark

Preparation  When the pilot valve is operated normally, the pilot pump (primary pilot pressure) is considered to be normal.  When bucket operation speed is slow during combined operation of lift arm and bucket, the overload relief valve in control valve may be faulty. Procedure Inspection Method 1 Measure secondary pilot pressure.

Condition During full operation of bucket roll back/ dump and lift arm raise/lower

Switch overload relief valves with other overload relief valve which the set pressure are same. -

Evaluation The measured value values are not within the specification. (Specification: 3.0 ~ 4.4 MPa (435 ~ 638 PSI)) Symptom is reversed.

Cause Faulty pilot valve

Normal in above check

Stuck control valve spool or faulty cylinder (faulty seal kit)

T5-6-41

Faulty overload relief valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-4 When lift arm raise or bucket roll back is operated, lift arm or bucket starts to move after moving slightly down. Procedure Inspection Method 1 Inspect the load check valve in control valve. 2 -

Condition -

Evaluation There is abnormality.

Cause Faulty load check valve

Normal in above check

Oil leaks in cylinder

fNOTE:  During the initial stage of operation, oil pressure and flow rate from the pump is low. Therefore, if the load check valve is faulty, the oil in the bottom side of the lift arm cylinder flows back to the circuit through the load check valve. Therefore, the lift arm cylinder is temporarily retracted.  As oil pressure and flow rate from the pump is low, if oil leaks from bottom side (A) to rod side (B) due to faulty lift arm cylinder piston or cylinder barrel, the lift arm cylinder is temporarily retracted during the initial stage of operation. In addition, cylinder force is reduced. The lift arm cylinder drift increases in this case.

(B) When the load check valve is faulty (A)

T105-07-04-012

T5-6-42

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-5 Bucket auto leveler control is not activated. (Detent is not held.) (Manual Type) Preparation  Refer to SYSTEM/Control System/Bucket Auto Leveler Control.  Check fuse #15 in fuse box A.  Check the wiring connections first. Procedure Inspection Method Condition 1 Measure voltage between Key Switch: ON wire harness end #1 of bucket spool coil in control valve and the body. 2 -

Evaluation 0V

Normal in above check

T5-6-43

Cause Open circuit in wire harness between fuse #15 in fuse box A and bucket spool coil in control valve Faulty bucket proximity switch

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-6 Bucket auto leveler control is not activated. (Detent is not held.) (Hydraulic Pilot Type) (Option) Preparation  Refer to SYSTEM/Control System/Bucket Auto Leveler Control.  Check fuse #15 in fuse box A.  Check the wiring connections first.

Procedure Inspection Method 1 Measure voltage between pilot valve bucket roll back side coil harness end #1 and the body. 2 Check continuity between pilot valve bucket roll back side coil harness end #2 and the body. 3 Measure voltage between bucket leveler relay harness end #2 and the body. 4 -

Condition Key Switch: ON

Evaluation 0V

Cause Open circuit in harness between fuse box A and pilot valve bucket roll back side coil

Bucket roll back, detent control lever operation

Bucket proximity switch: ON: ∞ Ω Bucket proximity switch: OFF: 0 Ω 0V

Faulty pilot valve bucket roll back side coil

Key Switch: ON

Normal in above check

T5-6-44

Open circuit in wire harness between bucket proximity switch and bucket leveler relay Faulty bucket proximity switch

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-7 Lift arm float control (hydraulic pilot type) (option) is not activated. (Detent is not held.) Preparation  Refer to SYSTEM/Control System/Lift Arm Float Control.  Check fuse #15 in fuse box A.  Check the wiring connections first. Procedure Inspection Method 1 Measure voltage between pilot valve lift arm lower side coil harness end #1 and the body. 2 Check continuity between pilot valve lift arm lower side coil harness end #2 and the body. 3 -

Condition Key Switch: ON

Evaluation 0V

Cause Open circuit in wire harness between fuse box A and pilot valve lift arm lower side coil

Lift arm lower, detent control lever operation

0Ω

Faulty ground in pilot valve lift arm lower side coil

Normal in above check

Faulty pilot valve lift arm lower side coil

T5-6-45

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-8 Lift arm kickout control (hydraulic pilot type) (option) is not activated. Preparation  Refer to SYSTEM/Control System/Lift Arm Kickout Control.

Procedure Inspection Method 1 Measure voltage between pilot valve lift arm raise side coil harness end #1 and the body. 2 Check continuity between pilot valve lift arm raise side coil harness end #2 and the body. 3 -

 Check fuse #15 in fuse box A.  Check the wiring connections first.

Condition Key Switch: ON

Evaluation 0V

Lift arm raise, 0Ω detent control lever operation -

Cause Open circuit in wire harness between fuse box A and pilot valve lift arm raise side coil Faulty ground in pilot valve lift arm raise side coil

Normal in above check Faulty pilot valve lift arm raise side coil

T5-6-46

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-9 Ride control (option) is not activated. Preparation  Perform these steps when the fault codes of MC are not displayed.  If the machine speed sensor is abnormal, other travel system controls may be abnormal. When other travel system controls are normal, the machine speed sensor is also normal.  Refer to SYSTEM/Control System/Ride Control.  Check fuse #1 in fuse box A. Procedure Inspection Method Condition 1 Short-circuit in wire harness The machine travels between wire harness end at 6 km/h or more. connector terminals #2 and #4 of ride control switch. 2 Check continuity between Ride Control Switch: terminal #34 of MC ON connector of wire harness end and the body. 3 Measure resistance between ride control solenoid valve #1 and #2. 4 Check continuity between Ride Control Switch: terminal #2 of ride control ON solenoid valve connector of wire harness end and the body. 5 -

 When trouble occurs in the main circuit of the lift arm cylinder and the HST charging pump, this trouble may occur. As the front attachment operation malfunction occurs together, refer to the related pages and execute the remedy.  Check the wiring connections first.

Evaluation The ride control is activated.

Cause Faulty ride control switch

∞Ω

Open circuit in wire harness between ride control switch and MC

0/∞ Ω (Specification: 22±0.4 Ω)

Faulty ride control solenoid valve

∞Ω

Open circuit in wire harness between ride control solenoid valve and MC

Normal in above check Stuck spool of ride control solenoid valve or faulty accumulator

Connector (Wire harness end)  Ride Control Solenoid Valve

 Ride Control Switch

 MC

T4FC-05-05-001

TNED-05-05-020

#34

TNCC-05-06-002

T5-6-47

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-48

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting S-1 Steering cylinder operation is slow. Steering cylinder operation is not operated. Main Relief Valve Set Pressure Steering relief operation

Specification MPa (PSI) 17.2 +1.5/-0.5 (2495 +218/-73)

Remark

Preparation  If the main pump is abnormal, lift arm and bucket operations may be abnormal. Inspect the main pump.  Check if the steering shaft is deformed or stuck. Procedure Inspection Method 1 Measure pump delivery pressure. 2

Condition Steering relief operation

Evaluation The measured value is not within the specification. Measure pressure at port P in Steering relief The measured values the steering valve. operation are not within the specification. Measure pressure at ports L Port L: Steering (left) The measured values and R in the steering valve. relief operation Port are not within the R: Steering (right) specification. relief operation Normal in above check

T5-6-49

Cause Faulty main pump in priority valve Faulty priority valve

Faulty steering valve

Faulty steering cylinder

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-2 Secondary steering (option) is not operated. IMPORTANT: Large capacity of electricity is required in order to operate the secondary steering pump. Check the secondary steering pump within 1 or 2 seconds. Preparation

 Refer to SYSTEM/Control System/Secondary Steering Control (Option).  Check that fuse #4 in fuse box B is not abnormal.  Check the wiring connections first.

 Perform these steps when the fault codes of MC, monitor controller, and CAN communication are not displayed. Procedure Inspection Method Condition 1 Switch secondary steering Key Switch: ON pump relay with other Secondary Steering general relay. Check Switch: ON 2 Connect wire harness end Key Switch: ON connector terminal #4 of secondary steering check switch to the body. 3 Connect terminal #1-33 Key Switch: ON of monitor controller 1-B Connect the terminal connector to the body. to the body by using a pin with the connector connected. 4 Connect terminal #2 of Key Switch: ON secondary steering pump Connect the terminal relay connector to the body. to the body by using a pin with the connector connected. 5 Measure voltage between Key Switch: ON terminals #1, 3 of secondary steering pump relay connector of wire harness end and the body. 6 Measure voltage between Key Switch: ON terminal #1 of secondary Secondary Steering steering motor connector Check Switch: ON of wire harness end and the body. 7 -

Evaluation Cause Secondary Steering Faulty secondary steering Motor: Rotating pump relay Secondary Steering Faulty secondary steering Motor: Rotating operation check switch Secondary Steering Open circuit in wire harness Motor: Rotating between secondary steering check switch and monitor controller Secondary Steering Open circuit in wire harness Motor: Rotating between secondary steering pump relay and monitor controller 0V

Open circuit in wire harness between secondary steering pump relay and fuse box B

Open circuit in wire harness between secondary steering pump relay and secondary steering motor

Normal in above check

Faulty secondary steering motor or faulty secondary steering pump

Connector (Wire harness end)  Secondary Steering Check Switch

TNCC-05-06-003

 Monitor Controller 1-B Connector

TNDB-05-05-013

T5-6-50

 Secondary Steering Pump Relay

T183-05-04-003

 Secondary Steering Motor

T2BC-05-04-031

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting T-1 Machine does not travel forward.  Perform these steps when the fault codes of MC are not displayed.  The machine can not travel unless the following conditions exist. Forward/Reverse Lever : Forward (F) Position Parking Brake Switch: OFF Position  When the actuators (front attachment) is operated normally, the engine is considered to be normal.  Check fuse #10 in fuse box A. Procedure Inspection Method Condition 1 Short-circuit in wire harness Engine: Running between wire harness end connector terminals #1 and #4 of forward/reverse lever/ shift switch. 2 Measure voltage between Key Switch: ON terminal #37 of MC connector of wire harness end and the body. 3 Measure voltage between Key Switch: ON terminal #1 of forward side solenoid valve connector of wire harness end of forward/ reverse control solenoid valve and the body. 4 Check continuity between Key Switch: ON harness end connector terminal #2 of forward side solenoid valve connector of wire harness end of forward/ reverse control solenoid valve and the body. 5 -

 Check the wiring connections first.  If the followings are normal, the brake system, the transmission, and axles (front, rear) may be faulty. Check if the brake system troubleshooting, a noise is emitted from each section.

Evaluation Forward

Cause Faulty forward/reverse lever

Open circuit in wire harness between forward/reverse lever and MC

Open circuit in wire harness between forward side solenoid valve of forward/reverse control solenoid valve and MC

∞Ω

Open circuit in wire harness between forward side solenoid valve of forward/reverse control solenoid valve and the ground

Normal in above check Faulty forward side solenoid valve of forward/reverse control solenoid valve

Connector (Wire harness end)  Forward/Reverse Lever/Shift Switch 1

 Forward Side Solenoid Valve of Forward/Reverse Control Solenoid Valve

T2BC-05-04-002

 MC

#37

T4FC-05-05-001

T5-6-51

T2BC-05-04-031

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-2 Machine does not travel in reverse.  Perform these steps when the fault codes of MC are not displayed.  The machine can not travel unless the following conditions exist. Forward/Reverse Lever : Reverse (R) Position Parking Brake Switch: OFF Position  When the actuators (front attachment) is operated normally, the engine is considered to be normal.  Check fuse #10 in fuse box A. Procedure Inspection Method Condition 1 Short-circuit in wire harness Engine: Running between wire harness end connector terminals #3 and #4 of forward/reverse lever/ shift switch. 2 Measure voltage between Key Switch: ON terminal #48 of MC connector of wire harness end and the body. 3 Measure voltage between Key Switch: ON terminal #1 of reverse side solenoid valve connector of wire harness end of forward/ reverse control solenoid valve and the body. 4 Check continuity between Key Switch: ON terminal #2 of reverse side solenoid valve connector of wire harness end of forward/ reverse control solenoid valve and the body. 5 -

Evaluation Reverse

Cause Faulty forward/reverse lever

Open circuit in wire harness between forward/reverse lever and MC

Open circuit in wire harness between reverse side solenoid valve of forward/reverse control solenoid valve and MC

∞Ω

Open circuit in wire harness between reverse side solenoid valve of forward/reverse control solenoid valve and the ground

Normal in above check Faulty reverse side solenoid valve of forward/reverse control solenoid valve

Connector (Wire harness end)  Reverse Side Solenoid Valve of Forward/Reverse Control Solenoid Valve

 Forward/Reverse Lever/Shift Switch 1

8 T2BC-05-04-002

 MC

#48

T4FC-05-05-001

T5-6-52

T2BC-05-04-031

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-3 Machine travels forward even if forward/ reverse lever is set to the (N) position.  Perform these steps when the fault codes of MC are not displayed.  Check the wiring connections first. Procedure Inspection Method 1 Disconnect the connector of forward/reverse lever/shift switch. 2 Check continuity in wire harness between wire harness end connector terminals #1 and #3 of forward/reverse lever/shift switch. 3 Check continuity between harness end connector terminal #1 of forward side solenoid valve of forward/ reverse control solenoid valve and the body. 4 -

Condition Parking Brake Switch: OFF

Evaluation Machine: Stopped

Cause Faulty forward/reverse lever

Disconnect the connector of MC.

0Ω

Shorted circuit in wire harness between forward/reverse lever and MC

Disconnect the connector of MC.

0Ω

Shorted circuit in wire harness between forward side solenoid valve of forward/reverse control solenoid valve and MC

Normal in above check

Faulty forward side solenoid valve of forward/reverse control solenoid valve or stuck displacement angle control cylinder

Connector (Wire harness end)  Forward Side Solenoid Valve of Forward/Reverse Control Solenoid Valve

 Forward/Reverse Lever/Shift Switch 1

T2BC-05-04-031 T2BC-05-04-002

T5-6-53

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-4 Machine travels in reverse even if forward/ reverse lever is set to the (N) position.  Perform these steps when the fault codes of MC are not displayed.  Check the wiring connections first. Procedure Inspection Method Condition 1 Disconnect the connector of Parking Brake forward/reverse lever/shift Switch: OFF switch. 2 Check continuity in wire Disconnect the harness between wire connector of MC. harness end connector terminals #3 and #4 of forward/reverse lever/shift switch. 3 Check continuity between Disconnect the harness end connector connector of MC. terminal #1 of reverse side solenoid valve of forward/ reverse control solenoid valve and the body. 4 -

Evaluation Machine: Stopped

Cause Faulty forward/reverse lever

0Ω

Shorted circuit in wire harness between forward/reverse lever and MC

0Ω

Shorted circuit in wire harness between reverse side solenoid valve of forward/reverse control solenoid valve and MC

Normal in above check Faulty reverse side solenoid valve of forward/reverse control solenoid valve or stuck displacement angle control cylinder

Connector (Wire harness end)  Reverse Side Solenoid Valve of Forward/Reverse Control Solenoid Valve

 Forward/Reverse Lever/Shift Switch 1

8 T2BC-05-04-002

T5-6-54

T2BC-05-04-031

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-55

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-5 Slow speed is not selected even if shift switch is set to the (Lo) position.  Perform these steps when the fault codes of MC are not displayed.  Check fuse #1 in fuse box A.  Check the wiring connections first. Procedure Inspection Method Condition Evaluation 1 Check continuity in wire Shift Switch: Lo Position ∞ Ω harness between connector terminals #5 and #7 of forward/reverse lever/shift switch. 2 Check continuity between Connect wire harness end ∞ Ω terminal #16 MC connector connector terminal #5 of of wire harness end and the forward/reverse lever/ shift switch to the body. body. 0V 3 Measure voltage between Key Switch: ON terminal #1 of travel mode selector solenoid valve connector of wire harness end and the body. 4 Check continuity between Key Switch: ON ∞Ω terminal #2 of travel mode selector solenoid valve connector of wire harness end and the body. 5 Inspect the travel mode There is abnormality. selector valve. 6 Measure delivery pressure Accelerator Pedal: Full Less than 1.6 MPa (232 of the brake/transmission stroke PSI) pump. Power Mode Switch: ON Parking Brake Switch: ON Forward/Reverse Lever: N 7 Normal in above check

Cause Faulty shift switch

Open circuit in wire harness between shift switch and MC Open circuit in wire harness between travel mode selector solenoid valve and MC Open circuit in wire harness between travel mode selector solenoid valve and the ground Faulty travel mode selector valve Faulty brake/transmission pump

Faulty transmission

Connector (Wire harness end)  Travel Mode Selector Solenoid Valve

 Forward/Reverse Lever/Shift Switch 1

T2BC-05-04-031 T2BC-05-04-002

 MC #16

T4FC-05-05-001

T5-6-56

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-6 Fast speed is not selected even if shift switch is set to the (Hi) position.  Perform these steps when the fault codes of MC are not displayed.  Check the wiring connections first. Procedure Inspection Method Condition 1 Check continuity in wire Shift Switch: Hi harness between connector Position terminals #5 and #7 of forward/reverse lever/shift switch. 2 Check continuity in wire Disconnect the harness between connector connector of MC. terminals #5 and #7 of forward/reverse lever/shift switch. 3 Check continuity between Disconnect the terminal #1 of travel mode connector of MC. selector solenoid valve connector of wire harness end and the body. 4 Inspect the travel mode selector solenoid valve. 5 Inspect the travel mode selector valve. 6 Measure delivery pressure Accelerator Pedal: of the brake/transmission Full stroke pump. Power Mode Switch: ON Parking Brake Switch: ON Forward/Reverse Lever: N 7 -

Evaluation 0Ω

Cause Faulty shift switch

0Ω

Shorted circuit in harness between shift switch and MC

0Ω

Shorted circuit in harness between travel mode selector solenoid valve and MC

There is abnormality.

Faulty travel mode selector solenoid valve There is abnormality. Faulty travel mode selector valve Less than 1.6 MPa (232 Faulty brake/transmission PSI) pump

Normal in above check Faulty transmission

Connector (Wire harness end)  Travel Mode Selector Solenoid Valve

 Forward/Reverse Lever/Shift Switch 1

T2BC-05-04-031 T2BC-05-04-002

T5-6-57

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-7 Quick shift switch function is not activated even if quick shift switch is depressed.  Perform these steps when the fault codes of MC are not displayed.  Conditions that quick-shift control functions Shift Switch: Hi Machine Speed: Less than 10 km/h (6.2 mph)  Check the wiring connections first. Procedure Inspection Method 1 Short-circuit the connector of the quick shift switch. 2 Check continuity between terminal #9 of MC connector of wire harness end and the body. 3 Measure voltage between terminal #1 of travel mode selector solenoid valve connector of wire harness end and the body. 4 Check continuity between terminal #2 of travel mode selector solenoid valve connector of wire harness end and the body. 5 Inspect the travel mode selector valve. 6 Measure delivery pressure of the brake/transmission pump.

Check continuity between terminals #1 and #2 of machine speed sensor. Check continuity between MC harness end connector terminals #17 and #18.

Condition Shift Switch: Hi Position Travel: Fast speed Connect the male end connector of quick shift switch to the body.

Evaluation Travel: Slow speed

Cause Faulty quick shift switch

∞Ω

Open circuit in wire harness between quick shift switch and MC

Key Switch: ON

Open circuit in wire harness between travel mode selector solenoid valve and MC

Key Switch: ON

∞Ω

Open circuit in wire harness between travel mode selector solenoid valve and the ground

There is abnormality.

Faulty travel mode selector valve Less than 1.6 MPa (232 Faulty brake/transmission PSI) pump

Accelerator Pedal: Full stroke Power Mode Switch: ON Parking Brake Switch: ON Forward/Reverse Lever: N 570 Less than 570 Ω or Faulty machine speed 1050 Ω or more sensor Short-circuit in wire harness between wire harness end connector terminals #1 and #2 of machine speed sensor. -

Connector (Wire harness end)

∞Ω

Open circuit in wire harness between machine speed sensor and MC

Normal in above check Faulty transmission  MC Connector

 Quick Shift Switch

T4FC-05-05-001

TNCC-05-06-004

T5-6-58

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-8 Fast speed is not selected even if quick shift switch is released.  Check the wiring connections first. Procedure Inspection Method 1 Disconnect the connector of the quick shift switch.

4 5 6

Check continuity between the male end connector of quick shift switch and the body. Check continuity between terminal #1 of travel mode selector solenoid valve connector of wire harness end and the body. Inspect the travel mode selector solenoid valve. Inspect the travel mode selector valve. Measure delivery pressure of the brake/transmission pump.

Check continuity between terminals #1 and #2 of machine speed sensor. Check continuity between MC harness end connector terminals #17 and #18.

Condition Shift Switch: Hi Position Machine Speed: Slowly accelerate from 10 km/h. Disconnect the connector of MC.

Evaluation Travel: Fast speed

Cause Faulty quick shift switch

0Ω

Shorted circuit in harness between shift switch and MC

Disconnect the connector of MC.

0Ω

Shorted circuit in harness between travel mode selector solenoid valve and MC

There is abnormality.

Faulty travel mode selector solenoid valve There is abnormality. Faulty travel mode selector valve Less than 1.6 MPa (232 Faulty brake/transmission PSI) pump

Accelerator Pedal: Full stroke Power Mode Switch: ON Parking Brake Switch: ON Forward/Reverse Lever: N 570 Less than 570 Ω or Faulty machine speed sensor 1050 Ω or more Short-circuit in wire ∞ Ω harness between wire harness end connector terminals #1 and #2 of machine speed sensor. Normal in above check

Open circuit in wire harness between machine speed sensor and MC

Faulty transmission

Connector (Wire harness end)  Travel Mode Selector Solenoid Valve

 Quick Shift Switch

T2BC-05-04-031

TNCC-05-06-004

T5-6-59

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-9 Travel slow-speed selecting function is not activated.  Perform these steps when the fault codes of MC are not displayed.  Check the wiring connections first. Procedure Inspection Method 1 Check continuity between terminal #46 of MC connector of wire harness end and the body. 2

4 5

Condition Evaluation Cause Connect wire harness ∞ Ω Open circuit in wire harness end connector between slow speed (L) select terminal #2 of slow switch and MC speed (L) select switch to the body. Key Switch: ON Slow Voltage does not reach Faulty slow speed (L) select 1 to 4 V. switch Speed (L) Select Switch: Operated

Measure voltage between terminal #46 of MC connector of wire harness end and the body. Measure voltage between Key Switch: ON terminal #1 of displacement angle control solenoid valve connector of wire harness end and the body. Inspect the displacement angle control solenoid valve. -

Open circuit in wire harness between displacement angle control solenoid valve and MC

There is abnormality.

Faulty displacement angle control solenoid valve Normal in above check Faulty displacement angle control cylinder of HST motor

Connector (Wire harness end)  MC Connector

 Slow Speed (L) Select Switch

TNCC-05-06-012 #46

T5-6-60

T4FC-05-05-001

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting B-1 Parking brake is not released. Preparation  Check fuses #14 and #20 in fuse box A.  Check the wiring connections first. Procedure 1

3 4

11 12

Inspection Method Condition Switch parking brake relay 2 with other Key Switch: ON general relay. Parking Brake Switch: OFF Switch parking brake relay 1 with other Key Switch: ON general relay. Parking Brake Switch: OFF Check continuity between terminals #4 Parking Brake and #6 of the parking brake switch. Switch: OFF Measure voltage between terminal #3 Key Switch: ON of parking brake relay 1 connector of wire harness end and the body. Measure voltage between terminal #1 Key Switch: ON of parking brake relay 1 connector of wire harness end and the body. Measure voltage between terminal #4 Key Switch: ON of parking brake switch connector of wire harness end and the body. Key Switch: ON Connect wire harness end connector terminal #4 of parking brake switch to the body. Key Switch: ON Measure voltage between terminal #1 of parking brake solenoid valve connector of wire harness end and the body. Measure voltage between terminal #3 Key Switch: ON of parking brake relay 2 connector of wire harness end and the body. Key Switch: ON Connect wire harness end connector terminal #3 of parking brake relay 2 to the body. Disassemble and inspect the parking brake solenoid valve. -

Evaluation Cause Parking Brake: Released Faulty parking brake relay 2

Parking Brake: Released Faulty parking brake relay 1

∞Ω

Faulty parking brake switch

Open circuit in wire harness between parking brake relay 1 and fuse box A 0V Open circuit in wire harness between parking brake relay 1 and parking brake relay 2 0V Open circuit in wire harness between parking brake relay 2 and parking brake switch Parking Brake: Released Open circuit in wire harness between parking brake switch and the ground 0V Open circuit in wire harness between parking brake solenoid valve and fuse box A 0V

Open circuit in wire harness between parking brake solenoid valve and parking brake relay 2 Parking Brake: Released Open circuit in wire harness between parking brake relay 2 and the ground There is abnormality. Faulty parking brake solenoid valve Normal in above check Faulty parking brake

Connector (Wire harness end)  Parking Brake Relay 1  Parking Brake Relay 2

 Parking Brake Switch

 Parking Brake Solenoid Valve

T183-05-04-003

T5-6-61

T4FJ-05-06-002

T2BC-05-04-031

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-2 Parking brake is not applied.  Check the wiring connections first. Procedure Inspection Method 1 Switch parking brake relay 1 with other general relay. 2

7 8 9

Check continuity between terminals #1 and #2 of the parking brake switch. Measure voltage between terminal #1 of parking brake relay 1 connector of wire harness end and the body. Measure voltage between terminal #1 of parking brake switch connector of wire harness end and the body. Connect wire harness end connector terminal #1 of parking brake switch to the body. Disconnect the connector of the parking brake solenoid valve.

Condition Key Switch: ON Parking Brake Switch: ON Parking Brake Switch: ON

Evaluation Cause Parking Brake: Applied Faulty parking brake relay 1

∞Ω

Faulty parking brake switch

Key Switch: ON

Open circuit in wire harness between parking brake relay 1 and fuse box A

Key Switch: ON

Open circuit in wire harness between parking brake relay 1 and parking brake switch

Key Switch: ON

Parking Brake: Applied Open circuit in wire harness between parking brake switch and the ground

Key Switch: ON

Parking Brake: Applied Shorted circuit in wire harness between parking brake solenoid valve and parking brake relay 2 Parking Brake: Applied Faulty parking brake relay 2

Switch parking brake relay 2 Key Switch: ON with other general relay. Disassemble and inspect the parking brake solenoid valve. -

There is abnormality.

Faulty parking brake solenoid valve Normal in above check Faulty parking brake

Connector (Wire harness end)  Parking Brake Relay 1

 Parking Brake Switch

T183-05-04-003

#2 T4FJ-05-06-002

T5-6-62

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-3

Service brake braking force becomes weak.

Axle Operating Pressure Front Rear

Specification MPa (PSI) 4.18±0.85 (606±123)

 Check the service brake function beforehand (refer to p. T4-4-4).  Check the service brake wear amount beforehand (refer to p. T4-4-6). Procedure Inspection Method 1 Measure service brake operating pressure of axles (front, rear). 2 -

Condition Engine: Running Brake Pedal: Fully depressed -

Evaluation Within the specified range

Cause Faulty axles (front, rear)

Normal in above check Faulty brake valve or faulty brake pedal

Disconnect brake hose (1) at the axle side and install a pressure gauge to measure the supplied pressure from the brake valve. [ Front Axle ]

[ Rear Axle ]

WNCC-04-04-001

T5-6-63

WNCC-04-04-003

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-64

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting O-1 Clearance light and license plate light are not ON. Preparation

 Failure of the clearance light indicator lighting will be also affected.  Check that the clearance light and license plate light are not broken first.  Refer to SYSTEM/Electrical System.  Check fuses #11 and #17 in fuse box A when the  Check the wiring connections first. clearance lights at both sides and license plate light are not ON at the same time. Procedure Inspection Method Condition Evaluation Cause 1 Measure voltage between 0V Faulty wire harness between terminal #4 of light switch light switch and battery connector of wire harness end and the body. 2 Short-circuit in wire harness Key Switch: ON Clearance Light, Faulty light switch between wire harness end License Plate Light: terminals #3 and #4 of light switch. ON 3 Measure voltage between fuse Key Switch: ON 0V Open circuit in wire harness #11 in fuse box A and the body. Light Switch: S between light switch and Position fuse box A 4 Check continuity between Key Switch: ON ∞Ω Open circuit in wire harness connector (515B) (2) and the body. Light Switch: S between clearance light Position (front) (RH) and fuse box A 5 Check continuity between Key Switch: ON ∞Ω Open circuit in wire harness connector (515C) (1) and the body. Light Switch: S between clearance light Position (front) (LH) and fuse box A 6 Check continuity between Key Switch: ON ∞Ω Open circuit in wire harness terminal #4 of rear combination Light Switch: S between clearance light light (RH) connector of wire Position (rear) (RH) and fuse box A harness end and the body. 7 Check continuity between Key Switch: ON ∞Ω Open circuit in wire harness terminal #4 of rear combination Light Switch: S between clearance light light (LH) connector of wire Position (rear) (LH) and fuse box A harness end and the body. 8 Check continuity between Key Switch: ON ∞Ω Open circuit in wire harness connector (515S) and the body. Light Switch: S between license plate light Position and fuse box A Connector (Wire harness end)  Light Switch 2

 Rear Combination Light (RH)  Rear Combination Light (LH)

T2BC-05-04-001 T2BC-05-04-001

TNCC-05-06-006

TNCC-05-06-005

T5-6-65

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-2 Head light is not ON. Preparation  Check that the head lights are not broken first.  Check fuses #9 and #17 in fuse box A when the head lights at both sides are not ON at the same time.  Check fuses #1 and #5 in fuse box A when only the light at one side is not ON. Procedure Inspection Method 1 Switch the head light relay with other general relay.

Condition Key Switch: ON Light Switch: H Position Dimmer Switch: Lo (Low-Beam) Position Key Switch: ON

Short-circuit in wire harness between wire harness end terminals #1 and #4 of light switch. Key Switch: ON Measure voltage between terminal #1 of head light relay Light Switch: H Position connector of wire harness end and the body. Dimmer Switch: Lo (Low-Beam) Position Key Switch: ON Measure voltage between terminal #3 of head light relay Light Switch: H Position connector of wire harness Dimmer Switch: Lo end and the body. (Low-Beam) Position Check continuity between terminal #2 of head light relay connector of wire harness end and the body. Check continuity between Key Switch: ON connector (512) (4) and the Light Switch: H body. Position Dimmer Switch: Lo (Low-Beam) Position Check continuity between Key Switch: ON connector (512A) (3) and the Light Switch: H body. Position Dimmer Switch: Lo (Low-Beam) Position

T5-6-66

 Check that the light switch is in the head light position.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Evaluation Head Light: ON

Cause Faulty head light relay

Head Light: ON

Faulty light switch or faulty dimmer switch

Open circuit in wire harness between dimmer switch and head light relay

Open circuit in wire harness between fuse box A and head light relay

∞Ω

Open circuit in wire harness between head light relay and the ground

∞Ω

Open circuit in wire harness between head light relay and head light low-beam (RH)

∞Ω

Open circuit in wire harness between head light relay and head light low-beam (LH)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Connector (Wire harness end)  Light Switch

 Head Light Relay

T2BC-05-04-001

T183-05-04-003

TNCC-05-06-005

T5-6-67

TNCC-05-06-006

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-3 Head light is not shifted to high beam. Preparation  Check fuses #17 and #19 in fuse box A when the high beams at both sides are not ON.  Check that the light switch is in the head light position. Procedure Inspection Method 1 Switch the high beam relay with other general relay.

Short-circuit in wire harness between wire harness end terminals #2 and #4 of light switch. Measure voltage between terminal #1 of high beam relay connector of wire harness end and the body.

Measure voltage between terminal #3 of high beam relay connector of wire harness end and the body.

Check continuity between terminal #2 of high beam relay connector of wire harness end and the body. Check continuity between connector (511A) (6) and the body.

Check continuity between connector (511) (5) and the body.

 Failure of the high beam indicator lighting will be also affected.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Condition Evaluation Key Switch: ON High Beam: ON Light Switch: H Position Dimmer Switch: Hi (High-Beam) Position Key Switch: ON High Beam: ON

Key Switch: ON 0V Light Switch: H Position Dimmer Switch: Hi (High-Beam) Position Key Switch: ON 0V Light Switch: H Position Dimmer Switch: Hi (High-Beam) Position ∞Ω

Key Switch: ON ∞Ω Light Switch: H Position Dimmer Switch: Hi (High-Beam) Position Key Switch: ON ∞Ω Light Switch: H Position Dimmer Switch: Hi (High-Beam) Position

T5-6-68

Cause Faulty high beam relay

Faulty light switch or faulty dimmer switch

Open circuit in wire harness between dimmer switch and high beam relay

Open circuit in wire harness between fuse box A and high beam relay

Open circuit in wire harness between high beam relay and the ground Open circuit in wire harness between high beam relay and head light high-beam (RH)

Open circuit in wire harness between high beam relay and head light high-beam (RH)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Connector (Wire harness end)  Light Switch

T2BC-05-04-001

 High Beam Relay

T183-05-04-003

5 TNCC-05-06-005

T5-6-69

TNCC-05-06-006

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-4 Hazard light circuit is not operated. Preparation  Check that the turn signal lights are not broken first.  Check fuse #6 in fuse box A when all turn signal lights do not blink at the same time. Faulty flasher relay may also cause this trouble. Procedure Inspection Method 1 Switch turn signal light relays (R), (L) with other general relays. 2 Short-circuit in wire harness between wire harness end terminals #1 and #2 of hazard light switch. 3 Measure voltage between terminal #1 of hazard light switch connector of wire harness end and the body. 4 Measure voltage between terminal #2 of flasher connector of wire harness end and the body. 5 Short-circuit in wire harness between wire harness end connector terminals #2 and #3 of the flasher. 6 Check continuity between terminal #1 of flasher connector of wire harness end and the body. 7 Measure voltage between terminal #1 of turn signal light relay (R) connector of wire harness end and the body. 8 Measure voltage between terminal #3 of turn signal light relay (R) connector of wire harness end and the body. 9 Check continuity between terminal #2 of turn signal light relay (R) connector of wire harness end and the body. 10 Check continuity between connector (501A) (8) and the body. 11

Check continuity between terminal #1 of rear combination light (RH) connector of wire harness end and the body.

 Failure of blinking of the turn signal light indicators at both sides will be also affected.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Condition Hazard Light Switch: ON

Evaluation Turn Signal Light: Blinking

Cause Faulty turn signal light relays (R), (L)

Key Switch: OFF

Turn Signal Light: Blinking

Faulty hazard light switch

Key Switch: OFF

Open circuit in wire harness between fuse box A and hazard light switch

Key Switch: OFF

Open circuit in wire harness between fuse box A and flasher

Key Switch: OFF Hazard Light Switch: ON

Turn Signal Light: ON Faulty flasher

∞Ω

Open circuit in wire harness between flasher and the ground

Key Switch: OFF Hazard Light Switch: ON

Open circuit in wire harness between turn signal light relay (R) and hazard light switch

Key Switch: OFF Hazard Light Switch: ON

Open circuit in wire harness between turn signal light relay (R) and flasher

∞Ω

Open circuit in wire harness between turn signal light relay (R) and the ground

Key Switch: OFF Hazard Light Switch: ON

∞Ω

Key Switch: OFF Hazard Light Switch: ON

∞Ω

Open circuit in wire harness between turn signal light (right front) and turn signal light relay (R) Open circuit in wire harness between turn signal light (right rear) and turn signal light relay (R)

T5-6-70

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Procedure Inspection Method 12 Measure voltage between terminal #3 of turn signal light relay (L) connector of wire harness end and the body. 13 Check continuity between terminal #2 of turn signal light relay (L) connector of wire harness end and the body. 14 Check continuity between connector (502A) (7) and the body. 15

Check continuity between terminal #1 of rear combination light (LH) connector of wire harness end and the body.

Condition Key Switch: OFF Hazard Light Switch: ON

Evaluation 0V

Cause Open circuit in wire harness between turn signal light relay (L) and flasher

∞Ω

Open circuit in wire harness between turn signal light relay (L) and the ground

Key Switch: OFF Hazard Light Switch: ON

∞Ω

Key Switch: OFF Hazard Light Switch: ON

∞Ω

Open circuit in wire harness between turn signal light (left front) and turn signal light relay (L) Open circuit in wire harness between turn signal light (left rear) and turn signal light relay (L)

Connector (Wire harness end)  Hazard Light Switch

 Turn Signal Light Relay (R)  Turn Signal Light Relay (L)

 Flasher

TNCC-05-06-011

T4GD-05-05-002 T183-05-04-003

 Rear Combination Light (RH)  Rear Combination Light (LH)

8 7

TNCC-05-06-005

TNCC-05-06-006

T5-6-71

T2BC-05-04-001

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-5 Turn signal light is not operated. Preparation  Check fuses #3 and #8 in fuse box A when all turn signal lights do not blink.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method Condition 1 Switch turn signal light relays Turn Signal Lever: (R), (L) with other general Right, Left relays. 2 Short-circuit in wire harness Key Switch: ON between wire harness end terminals #1 and #2, terminals #1 and #4 of the turn signal lever. 3 Measure voltage between Key Switch: ON terminal #1 of the turn signal lever connector of wire harness end and the body. 4 Measure voltage between Key Switch: ON terminal #2 of flasher connector of wire harness end and the body. 5 Short-circuit in wire harness Key Switch: ON between wire harness end Turn Signal Lever: connector terminals #2 and Right or Left #3 of the flasher. 6 Check continuity between terminal #1 of flasher connector of wire harness end and the body. 7 Measure voltage between Key Switch: ON Turn terminal #1 of turn signal Signal Lever: Right light relay (R) connector of wire harness end and the body. 8 Measure voltage between Key Switch: ON Turn terminal #3 of turn signal Signal Lever: Right light relay (R) connector of wire harness end and the body. 9 Check continuity between terminal #2 of turn signal light relay (R) connector of wire harness end and the body. 10 Check continuity between Key Switch: ON Turn connector (501A) (8) and the Signal Lever: Right body.

Evaluation Turn Signal Light: Blinking

Cause Faulty turn signal light relays (R), (L)

Turn Signal Light: Blinking

Faulty turn signal lever

Open circuit in wire harness between fuse box A and the turn signal lever

Open circuit in wire harness between fuse box A and the flasher

∞Ω

Check continuity between terminal #1 of rear combination light (RH) connector of wire harness end and the body.

Key Switch: ON Turn Signal Lever: Right

T5-6-72

Turn Signal Light: ON Faulty flasher

∞Ω

Open circuit in wire harness between the flasher and the ground

Open circuit in wire harness between turn signal light relay (R) and the turn signal lever

Open circuit in wire harness between turn signal light relay (R) and the flasher

∞Ω

Open circuit in wire harness between turn signal light relay (R) and the ground

∞Ω

Check continuity between terminal #1 of rear combination light (LH) connector of wire harness end and the body.

Condition Key Switch: ON Turn Signal Lever: Left

Evaluation 0V

Cause Open circuit in wire harness between turn signal light relay (L) and the flasher

∞Ω

Open circuit in wire harness between turn signal light relay (L) and the ground

Key Switch: ON Turn Signal Lever: Left

∞Ω

Key Switch: ON Turn Signal Lever: Left

∞Ω

Open circuit in wire harness between turn signal light (left front) and turn signal light relay (L) Open circuit in wire harness between turn signal light (left rear) and turn signal light relay (L)

Connector (Wire harness end)  Turn Signal Lever

 Turn Signal Light Relay (R)  Turn Signal Light Relay (L)

 Flasher

TNCC-05-06-011

T4GD-05-05-002 T183-05-04-003

 Rear Combination Light (RH)  Rear Combination Light (LH)

8 7

TNCC-05-06-005

TNCC-05-06-006

T5-6-73

T2BC-05-04-001

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-6 Horn does not sound. Preparation  Check that the horn is not broken first.  Check fuse #5 in fuse box A when the horn does not sound by pushing two horn switches.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method Condition 1 Switch horn relay with other Horn Switch: ON general relay. 2 Short-circuit in wire harness between wire harness end terminals #1 of horn switch and the body. 3 Check continuity between Horn Switch: ON terminal #1 of the horn switch connector of wire harness end and the body. 4 Measure voltage between Key Switch: OFF terminal #1 of horn relay connector of wire harness end and the body. 5 Check continuity between Horn Switch: ON the horn connector and the body. 6 -

Evaluation The horn sounds.

Cause Faulty horn relay

The horn sounds.

Faulty horn switch

∞Ω

Open circuit in wire harness between horn switch and horn relay

Open circuit in wire harness between fuse box A and horn relay

∞Ω

Open circuit in wire harness between horn relay and horn

Normal in above check Open circuit in wire harness between the horn and the ground

Connector (Wire harness end)  Horn Connector

 Horn Switch

 Horn Relay

TNCC-05-06-007

T183-05-04-003

T5-6-74

TNCC-05-06-008

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-7 Reverse light is not ON. Reverse buzzer does not sound. Preparation  Perform these steps when the fault codes of MC are not displayed.  Check that the reverse light and reverse buzzer are not broken first.  Check fuse #2 in fuse box A when the reverse lights at both sides and back buzzer are not operated at the same time. Faulty forward/reverse lever (T-1) may also cause this trouble.

 Check that the forward/reverse lever is in the R position.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Procedure Inspection Method Condition 1 Switch the back buzzer relay with other Key Switch: ON general relay.

Evaluation Reverse light is ON. Back buzzer sounds.

Cause Faulty back buzzer relay

Open circuit in wire harness between fuse box A and back buzzer relay Open circuit in wire harness between MC and back buzzer relay

4 5 6

Measure voltage between terminal #3 of back buzzer relay connector of wire harness end and the body. Check continuity between wire terminal #1 of back buzzer relay connector of wire harness end and the body. Measure voltage between terminal #2 of back buzzer relay connector of wire harness end and the body. Check continuity between terminal #1 of back buzzer connector of wire harness end and the body. Check continuity between terminal #2 of rear combination light (RH) connector of wire harness end and the body. Check continuity between terminal #6 of rear combination light (RH) connector of wire harness end and the body. Check continuity between terminal #2 of rear combination light (LH) connector of wire harness end and the body. Check continuity between terminal #6 of rear combination light (LH) connector of wire harness end and the body.

Connector (Wire harness end)  Back Buzzer Relay

T183-05-04-003

Key Switch: ON

Key Switch: ON ∞Ω Forward/Reverse Lever: Reverse (R) Position Key Switch: ON 0V Forward/Reverse Lever: Reverse (R) Position ∞Ω Key Switch: ON ∞Ω Forward/Reverse Lever: Reverse (R) Position -

Open circuit in wire harness between back buzzer and back buzzer relay Open circuit in wire harness between back buzzer and the ground Open circuit in wire harness between clearance light (rear) (RH) and back buzzer relay

∞Ω

Open circuit in wire harness between clearance light (rear) (RH) and the ground

Key Switch: ON ∞Ω Forward/Reverse Lever: Reverse (R) Position

Open circuit in wire harness between clearance light (rear) (LH) and back buzzer relay

Open circuit in wire harness between clearance light (rear) (LH) and the ground

∞Ω

 Back Buzzer

 Rear Combination Light (RH)  Rear Combination Light (LH)

TNED-05-06-006

T5-6-75

T2BC-05-04-001

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-8 Brake light is not ON. Preparation  Refer to SYSTEM/Electrical System.  Check that the brake lights are not broken first.  Check fuse #3 in fuse box A when the brake lights at  Check the wiring connections first. both sides are not ON. Procedure Inspection Method Condition Evaluation Cause 1 Switch the brake light relay with Key Switch: ON Brake Brake Light: ON Faulty brake light relay other general relay. Light Switch: ON (when the brake pedal is stepped on) 2 Measure voltage between Key Switch: ON 0V Open circuit in wire harness wire harness end connector between fuse box A and brake terminals #3, #1 of brake light light relay relay and the body. Open circuit in wire harness 3 Check continuity between Key Switch: ON Brake ∞ Ω between brake light (RH) and terminal #5 of rear combination Light Switch: ON (when the brake brake light relay light (RH) connector of wire pedal is stepped on) harness end and the body. ∞Ω Open circuit in wire harness 4 Check continuity between between brake light (RH) and terminal #6 of rear combination the ground light (RH) connector of wire harness end and the body. Key Switch: ON Brake ∞ Ω Open circuit in wire harness 5 Check continuity between between brake light (LH) and terminal #5 of rear combination Light Switch: ON (when the brake back buzzer relay light (LH) connector of wire harness end and the body. pedal is stepped on) ∞Ω Open circuit in wire harness 6 Check continuity between between brake light (LH) and terminal #6 of rear combination the ground light (LH) connector of wire harness end and the body. 7 Short-circuit in wire harness Key Switch: ON Brake Light: ON Faulty brake light switch between wire harness end terminals #1 and #2 of brake light switch. 8 Check continuity between Key Switch: ON Brake ∞ Ω Open circuit in wire harness terminal #2 of brake light switch Light Switch: ON between brake light switch connector of wire harness end (when the brake and brake light relay and the body. pedal is stepped on) 9 Check continuity between ∞Ω Open circuit in wire harness terminal #1 of brake light switch between brake light switch connector of wire harness end and the ground and the body. Connector (Wire harness end)  Brake Light Relay

 Rear Combination Light (RH)  Rear Combination Light (LH)

T183-05-04-003

T2BC-05-04-001

T5-6-76

 Brake Light Switch

T2BC-05-04-031

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-77

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-9 Work light does not light. Preparation  Check that the work lights are not broken first.  The light switch may be faulty (O-1) when the work lights at both front and rear sides are not ON at the same time.  Check fuse #16 in fuse box A and fuse #15 in fuse box B when only the light at one side is not ON. Procedure Inspection Method 1 Switch the front work light relay and rear work light relay with other general relays. 2

Condition Key Switch: ON Work Light Switch: Front and Rear Work Light Key Switch: ON

Short-circuit in wire harness between wire harness end terminals #1 and #2, terminals #1 and #5 of the work light switch. Key Switch: ON Measure voltage between terminal #1 of work light switch connector of wire harness end and the body. Key Switch: ON Measure voltage between Work Light Switch: terminal #1 of front work light relay connector of wire Front and Rear Work Light harness end and the body. Check continuity between terminal #2 of front work light relay connector of wire harness end and the body. Measure voltage between Key Switch: ON terminal #3 of front work Work Light Switch: light relay connector of wire Front and Rear Work harness end and the body. Light Measure voltage between Key Switch: ON wire harness end connector Work Light Switch: of front work light and the Front and Rear Work body. Light

 Failure of the work light indicator blinking will be also affected.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Evaluation Work Light: ON

Cause Faulty front work light relay and faulty rear work light relay

Work Light: ON

Faulty work light switch

Open circuit in wire harness between light switch and work light switch

Open circuit in wire harness between front work light relay and work light switch

∞Ω

Open circuit in wire harness between front work light relay and the ground

Open circuit in wire harness between fuse box B and front work light relay

Open circuit in wire harness between front work light relay and the front work light

Connector (Wire harness end)  Work Light Switch

 Front Work Light Relay

TNCC-05-06-009 T183-05-04-003

T5-6-78

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Procedure Inspection Method 8 Measure voltage between terminal #1 of rear work light relay connector of wire harness end and the body. 9 Check continuity between terminal #2 of rear work light relay connector of wire harness end and the body. 10 Measure voltage between terminal #3 of rear work light relay connector of wire harness end and the body. 11 Measure voltage between terminal #1 of rear work light connector of wire harness end and the body.

Condition Key Switch: ON Work Light Switch: Front and Rear Work Light -

Evaluation 0V

Cause Open circuit in wire harness between rear work light relay and work light switch

∞Ω

Open circuit in wire harness between rear work light relay and the ground

Key Switch: ON Work Light Switch: Front and Rear Work Light Key Switch: ON Work Light Switch: Front and Rear Work Light

Open circuit in wire harness between fuse box A and rear work light relay

Open circuit in wire harness between rear work light relay and the rear work light

Connector (Wire harness end)  Rear Work Light Relay

 Rear Work Light

TNED-05-06-006

T183-05-04-003

T5-6-79

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-10 Wiper is not operated. Preparation  Perform these steps when the fault codes of the monitor controller are not displayed.  The wiper is driven by electric power routed via the relay circuit. The relay circuit of front wiper is controlled by the monitor controller.  In case the wiper is not operated, first check if the wiper relay is activated. Next, check if electric power is routed to the wiper motor.

 In case the front washer is also not operated, check fuse #3 in fuse box B. In case the rear washer is also not operated, check fuse #6 in fuse box B.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

 Front Wiper (Slow) Procedure Inspection Method Condition Evaluation 1 Switch wiper relay (F)1 with Key Switch: ON The wiper is other general relay. Wiper Switch: Slow operated. 2 Switch wiper relay (F)2 with Key Switch: ON The wiper is other general relay. Wiper Switch: Slow operated. 3 Short-circuit in wire harness Key Switch: ON The wiper is between wire harness end operated. connector terminals #1 and #3 of the wiper switch. 4 Check continuity between Key Switch: ON ∞Ω terminal #3 of wiper switch connector of wire harness end and the body. ∞Ω 5 Check continuity between terminal #1 of wiper switch connector of wire harness end and the body. 6 Measure voltage between Key Switch: ON 0V terminal #1 of wiper relay (F)1 connector of wire harness end and the body. 7 Check continuity between Key Switch: ON ∞Ω terminal #1 of wiper relay (F)1 Wiper Switch: connector of wire harness Slow end and the body. 8 Check continuity between ∞Ω terminal #5 of wiper relay (F)1 connector of wire harness end and the body. 9 Check continuity between Key Switch: ON ∞Ω terminal #3 of wiper relay (F)2 Wiper Switch: Slow connector of wire harness end and the body.

T5-6-80

Cause Faulty wiper relay (F)1 Faulty wiper relay (F)2 Faulty wiper switch

Open circuit in wire harness between wiper switch and monitor controller (terminal #1-29) Open circuit in wire harness between wiper switch and the ground Open circuit in wire harness between fuse box B and wiper relay (F)1 Open circuit in wire harness between wiper relay (F)1 and monitor controller Open circuit in wire harness between wiper relay (F)1 and the ground Open circuit in wire harness between wiper relay (F)2 and wiper relay (F)1

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Procedure Inspection Method 10 Check continuity between terminal #2 of wiper motor (F) connector of wire harness end and the body. 11 Measure voltage between terminal #5 of wiper motor (F) connector of wire harness end and the body. 12 -

Condition Evaluation Key Switch: ON ∞Ω Wiper Switch: Slow

Cause Open circuit in wire harness between wiper motor (F) and wiper relay (F)2

Key Switch: ON

Open circuit in wire harness between fuse box B and wiper motor (F)

Normal in above check

Faulty wiper motor (F)

Connector (Wire harness end)  Wiper Switch

 Wiper Relay (F)1  Wiper Relay (F)2

TNCC-05-06-010

 Wiper Motor (F)

T183-05-04-003

T5-6-81

T2BC-05-04-001

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B  Front Wiper (Fast) Procedure Inspection Method 1 Switch wiper relay (F)1 with other general relay. 2 Switch wiper relay (F)2 with other general relay. 3 Short-circuit in wire harness between wire harness end connector terminals #1 and #4 of the wiper switch. 4 Check continuity between terminal #4 of wiper switch connector of wire harness end and the body.

Condition Key Switch: ON Wiper Switch: Slow Key Switch: ON Wiper Switch: Slow Key Switch: ON

Evaluation Cause The wiper is operated. Faulty wiper relay (F)1

Key Switch: ON

∞Ω

Open circuit in wire harness between wiper switch and monitor controller (terminal #1-30)

∞Ω

Key Switch: ON

Key Switch: ON Wiper Switch: Fast

∞Ω

Key Switch: ON

Key Switch: ON Wiper Switch: Fast

∞Ω

Key Switch: ON Wiper Switch: Fast

∞Ω

Key Switch: ON Wiper Switch: Fast

∞Ω

Open circuit in wire harness between wiper switch and the ground Open circuit in wire harness between fuse box B and wiper relay (F)1 Open circuit in wire harness between wiper relay (F)1 and monitor controller Open circuit in wire harness between wiper relay (F)1 and the ground Open circuit in wire harness between fuse box B and wiper relay (F)2 Open circuit in wire harness between wiper relay (F)2 and monitor controller Open circuit in wire harness between wiper relay (F)2 and wiper relay (F)1 Open circuit in wire harness between wiper motor (F) and wiper relay (F)2

Key Switch: ON

Normal in above check

Check continuity between terminal #1 of wiper switch connector of wire harness end and the body. Measure voltage between terminal #1 of wiper relay (F)1 connector of wire harness end and the body. Check continuity between terminal #2 of wiper relay (F)1 connector of wire harness end and the body. Check continuity between terminal #5 of wiper relay (F)1 connector of wire harness end and the body. Measure voltage between terminal #1 of wiper relay (F)2 connector of wire harness end and the body. Check continuity between terminal #2 of wiper relay (F)2 connector of wire harness end and the body. Check continuity between terminal #3 of wiper relay (F)2 connector of wire harness end and the body. Check continuity between terminal #3 of wiper motor (F) connector of wire harness end and the body. Measure voltage between terminal #5 of wiper motor (F) connector of wire harness end and the body. -

The wiper is operated. Faulty wiper relay (F)2 The wiper is operated. Faulty wiper switch

Open circuit in wire harness between fuse box B and wiper motor (F) Faulty wiper motor (F)

Connector (Wire harness end)  Wiper Switch

TNCC-05-06-010

 Wiper Relay (F)1  Wiper Relay (F)2

T183-05-04-003

T5-6-82

 Wiper Motor (F)

T2BC-05-04-001

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B  Rear Wiper Procedure Inspection Method 1 Switch wiper relay (R) with other general relay.

Evaluation The wiper is operated.

Cause Faulty wiper relay (R)

The wiper is operated.

Faulty rear wiper switch

∞Ω

Open circuit in wire harness between rear wiper switch and the ground

Condition Key Switch: ON Rear Wiper Switch: Wiper Short-circuit in wire harness Key Switch: ON between wire harness end connector terminals #1 and #9 of the wiper switch. Check continuity between terminal #1 of wiper switch connector of wire harness end and the body.

Measure voltage between Key Switch: ON terminal #1 of wiper relay (R) connector of wire harness end and the body.

Open circuit in wire harness between fuse box B and wiper relay (R)

Key Switch: ON Check continuity between terminal #2 of wiper relay (R) Rear Wiper Switch: Wiper connector of wire harness end and the body. Check continuity between Key Switch: ON terminal #5 of wiper relay (R) connector of wire harness end and the body. Check continuity between Key Switch: ON terminal #2 of wiper motor Rear Wiper Switch: (R) connector of wire Wiper harness end and the body. -

∞Ω

Open circuit in wire harness between wiper relay (R) and rear wiper switch

∞Ω

Open circuit in wire harness between wiper relay (R) and fuse box B

∞Ω

Open circuit in wire harness between wiper motor (R) and wiper relay (R)

Normal in above check Faulty wiper motor (R)

Connector (Wire harness end)  Wiper Switch

 Wiper Relay (R)

 Wiper Motor (R)

TNCC-05-06-010 T183-05-04-003

T5-6-83

T2BC-05-04-001

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-11 Washer is not operated. Preparation  Refer to SYSTEM/Electrical System.  Check the wiring connections first.  Front Washer Procedure Inspection Method 1 Switch washer relay (F) with other general relay. 2

Short-circuit in wire harness between wire harness end connector terminals #1 and #6 of the wiper switch. Check continuity between terminal #1 of wiper switch connector of wire harness end and the body. Measure voltage between terminals #1, #3 of washer relay (F) connector of wire harness end and the body. Check continuity between terminal #2 of washer relay (F) connector of wire harness end and the body. Measure voltage between terminal #2 of washer motor (F) connector of wire harness end and the body. Measure voltage between terminal #1 of washer motor (F) connector of wire harness end and the body. -

Condition Key Switch: ON Washer Switch: ON (Keep pushing) Key Switch: ON

Evaluation Cause Washer is operated. Faulty washer relay (F)

∞Ω

Open circuit in wire harness between wiper switch and the ground

Key Switch: ON

Open circuit in wire harness between fuse box B and washer relay (F)

Key Switch: ON Washer Switch: ON (Keep pushing)

∞Ω

Key Switch: ON Washer Switch: ON (Keep pushing)

∞Ω

Open circuit in wire harness between washer relay (F) and the washer switch part of the wiper switch Open circuit in wire harness between washer motor (F) and washer relay (F)

∞Ω

Open circuit in wire harness between washer motor (F) and the ground

Normal in above check

Faulty washer motor (F)

Washer is operated. Faulty washer switch part of the wiper switch

Connector (Wire harness end)  Wiper Switch

 Washer Relay (F)

TNCC-05-06-010

 Washer Motor (F)

T183-05-04-003

T5-6-84

TNED-05-06-006

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B  Rear Washer Procedure Inspection Method 1 Switch washer relay (R) with other general relay. 2

Short-circuit in wire harness between wire harness end connector terminals #1 and #11 of the wiper switch. Check continuity between terminal #1 of wiper switch connector of wire harness end and the body. Measure voltage between terminals #1, #3 of washer relay (R) connector of wire harness end and the body. Check continuity between terminal #2 of washer relay (R) connector of wire harness end and the body. Measure voltage between terminal #2 of washer motor (R) connector of wire harness end and the body. Measure voltage between terminal #1 of washer motor (R) connector of wire harness end and the body. -

Condition Key Switch: ON Rear Wiper Switch: Washer Key Switch: ON

Evaluation Washer is operated.

Cause Faulty washer relay (R)

Washer is operated.

Faulty rear wiper switch part of the wiper switch

∞Ω

Open circuit in wire harness between wiper switch and the ground

Key Switch: ON

Open circuit in wire harness between fuse box B and washer relay (R)

Key Switch: ON Rear Wiper Switch: Washer

∞Ω

Key Switch: ON Rear Wiper Switch: Washer

∞Ω

Open circuit in wire harness between washer relay (R) and the rear wiper switch part of the wiper switch Open circuit in wire harness between washer motor (R) and washer relay (R)

∞Ω

Open circuit in wire harness between washer motor (R) and the ground

Normal in above check

Faulty washer motor (R)

Connector (Wire harness end)  Wiper Switch

 Washer Relay (R)

TNCC-05-06-010

T183-05-04-003

T5-6-85

 Washer Motor (R)

TNED-05-06-006

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-12 Cab light is not ON. Preparation  Check fuse #11 in fuse box B when the front cab light and rear cab light are not ON at the same time.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Set front cab light switch to ON position.

Condition -

Evaluation Front cab light is not ON.

Door open/close switch: ON -

Front cab light is not ON. Rear cab light is not ON.

Set front cab light switch to Door Interlocking Position. Set rear cab light switch to ON position.

T5-6-86

Cause Faulty front cab light, open circuit in wire harness between cab light and fuse box B Faulty door open/close switch Faulty rear cab light, open circuit in wire harness between rear cab light and fuse box B

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Transporting Wheel Loader (Urgent Situation) The following procedures shall only be applied to cases when urgently moving the wheel loader a short distance is required. When required to transport the wheel loader long distance, use a trailer. Precautions for Self-Traveling Avoid driving the wheel loader long distances at high-speed as much as possible as it may overheat the tires, possibly resulting in premature tire damage and/or wear. Keep the following points in mind when transporting the wheel loader by self-traveling.  Observe the rules and regulations associated to this wheel loader, and travel carefully.  Recommended tire pressures and traveling speeds may vary depending on the type of tires used and the road conditions. Consult your nearest authorized dealer.  Check the tire pressure before self-traveling when the tires are cool.  After driving the wheel loader for one hour, allow the wheel loader to park for 30 minutes and meanwhile, check the tires and every part of the machine for any abnormality, and also check the oil and coolant levels.  Keep the bucket empty when traveling.  Do not drive the machine with the tires containing calcium chloride or dry ballast, which accelerate heating.

T5-6-87

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Precautions for Towing Never attempt to tow the machine if dCAUTION: the brake system is in need of repair. Avoid towing the machine as much as possible. If the machine is to be unavoidably towed, beware of the following points. IMPORTANT: Do not tow the machine with the parking brake applied. Damage to the parking brake may result.  If the engine is operable: Keep the engine running so that the steering and brake system are operable. Release the parking brake.  If the engine is inoperable: Removal of the propeller shaft  When the parking brake cannot be released, manually release the parking brake. (Refer to the "How to Release Parking Brake" on p. T5-6-90.) Then, Remove the front and rear propeller shafts. At this time, wedge wheel stoppers to all tires to prevent the machine from moving.  The steering system is inoperable when the engine is stopped. Changing the hydraulic hose connections between the rod end side and the head end side only of one steering cylinder enables the steering wheel operation. NOTE: Take care not to spill oil when disconnecting the hoses.

Steering Cylinder

Hose

M4GB-06-007

T5-6-88

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-89

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B How to Release Parking Brake in Case of Emergency and When Engine Stops

In case the engine has stopped suddenly and it can not restart, release the parking brake and tow the machine. 1. Remove plug (2) from parking brake cover (1). l : 6 mm (0.24 in) 2. Remove the plug located at the diagonal position of plug (2) which has been removed. l : 6 mm (0.24 in) 3. Remove release bolts (3) (2 used). j : 17 mm (0.67 in) 4. Insert release bolts (3) (2 used) to the plug holes of parking brake cover (1). Evenly tighten the release bolts by inches. j : 17 mm (0.67 in) 5. Tighten release bolts (3) two to three turns after they come in contact with parking brake cover (1). As spring (4) is compressed and brake piston (5) is moved, the parking brake is released.

M4FJ-06-001

j : 17 mm (0.67 in) 5

4 123-

T5-6-90

Parking Brake Cover Plug Release Bolt

45-

T4FJ-05-06-003 Spring Brake Piston

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Recovery After Parking Brake Release 1. Remove release bolts (3) (2 used) from parking brake cover (1).

j : 17 mm (0.67 in) 2. As brake piston (5) is pushed to end plate (6) by spring (4), the parking brake is applied. 3. Insert release bolts (3) (2 used) into the bolt holes on and under parking brake cover (1). Tighten them. j : 17 mm (0.67 in) m : 53 N·m (5.3 kgf·m) (39 lbf·ft) 4. Insert the plugs (2 used) to parking brake cover (1). l : 6 mm (0.24 in) 6 3

T4FJ-05-06-003

M4FJ-06-001

123-

T5-6-91

Parking Brake Cover Plug Release Bolt

456-

Spring Brake Piston End Plate

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-92

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Troubleshooting C (Monitor Diagnosis) Procedure This procedure is used when there are malfunctions on components regarding monitor, such as gauges or indicators.

 Diagnosis Procedure  The diagnosis procedures for components regarding monitor, such as gauges, or indicators are explained in this group.  When the fault code is displayed, refer to the troubleshooting A group and diagnose. NOTE: All connector images in this section are viewed from the open end side of wire harness end.

T6L4-05-03-001

Wire Harness End Connector

Wire Harness

Column Monitor (Gauges and Indicators) 40

39 38

37 12 36 35

14 15

33 32

1234-

16 31 30

12131415161718192021-

29 28 27 26

25 24 23 22 21 20 19 18 17

T5-7-1

MNDB-01-034

32- Engine Oil Low Pressure Indicator 33- (Unused) 34- (Unused) 35- (Unused) 36- (Unused) 37- (Unused) 38- HST Warning Indicator 39- HST Oil Temperature Indicator 40- HST Oil Temperature Gauge

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Contents of Diagnosis

Trouble Symptom Preparation Viewpoints for a diagnosis and contents needing inspection beforehand are explained.

How to Read Table Procedure (A) (F)

Inspection Method (B) (G)

Condition

Evaluation

Cause

(D) (I)

(E) (J)

T5-7-2

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Monitor Buzzer  Check the wiring connections first. After the engine starts, the buzzer continues sounding. Procedure Inspection Method 1 Check the engine oil pressure indicator. 2 Check the overheat indicator. 3 Check the brake oil low level indicator. 4 -

Condition Engine: Running

Evaluation Indicator: ON

Engine: Running Engine: Running

Indicator: ON Indicator: ON

Normal in above check

Cause Faulty engine lubrication oil pressure system Engine overheating Faulty brake circuit Faulty monitor controller

The buzzer does not sound even when the engine oil pressure indicator, overheat indicator, or brake oil low level indicator, lights with the engine running. Procedure Inspection Method 1 Measure engine speed. 2 Check the alternator indicator.

Condition -

Engine: Running 13 to 33.5V 900 min-1 or more Engine: Running 13 to 33.5V 900 min-1 or more

Measure voltage at alternator terminal L. Measure voltage between terminal #28 of monitor controller 2-B connector of wire harness end and the body. -

Evaluation Less than 900min-1 Indicator: OFF

Normal in above check

Connector (Wire harness end)  Monitor Controller 2-B Connector

TNDB-05-05-013

T5-7-3

Cause Normal Perform the troubleshooting for the lighting indicator. Faulty alternator Faulty monitor controller

Open circuit in wire harness between alternator and monitor controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Coolant Temperature Gauge  The coolant temperature is sent from ECM to the monitor controller by using CAN communication.  Perform these steps when the fault codes of ECM and CAN are not displayed.  Check the wiring connections first. The coolant temperature gauge pointer does not move at all. Procedure Inspection Method 1 Connect the coolant temperature sensor harness end connector #2 terminal to the body. 2 Check continuity between terminal A28 of ECM-1 connector of wire harness end and the body.

Condition Key Switch: ON

Evaluation The gauge pointer reaches the (H) side.

Cause Faulty coolant temperature sensor

Connect the coolant temperature sensor harness end connector #2 terminal to the body. -

∞Ω

Open circuit in wire harness between ECM and coolant temperature sensor

Normal in above check Faulty monitor controller

The coolant temperature gauge pointer swings over scale. Procedure Inspection Method Condition Evaluation Cause 1 Disconnect the coolant Key Switch: ON The gauge pointer Faulty coolant temperature sensor connector. returns to zero. temperature sensor 2 Check continuity between Key Switch: ON 0Ω Shorted circuit in wire terminal A28 of ECM-1 connector Disconnect harness between ECM of wire harness end and the the coolant and coolant temperature body. temperature sensor sensor connector. 3 Normal in above check Faulty monitor controller The coolant temperature gauge pointer keeps moving unstably. Procedure Inspection Method 1 Visually inspect the coolant temperature gauge.

Condition Evaluation Connect the coolant The gauge pointer temperature reaches the (H) side sensor harness end and is stabilized. terminal to the body. Key Switch: ON Normal in above check

Cause Faulty coolant temperature sensor

Faulty monitor controller

Connector (Wire harness end)  ECM-1 Connector

 Coolant Temperature Sensor

A28

T1J1-05-07-006 TNCC-05-07-001

T5-7-4

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Fuel Gauge  Perform these steps when the fault codes of monitor controller are not displayed.  Check the wiring connections first. The fuel gauge pointer does not move at all. Procedure Inspection Method Condition 1 Short-circuit in wire harness Key Switch: ON between fuel level sensor harness end #1 and #2. 2 Check continuity between Connect fuel level terminal #35 of monitor sensor harness end controller 2-B connector of wire terminal #1 to the harness end and the body. body. 3 -

Evaluation The gauge pointer reaches the (FULL) side. ∞Ω

Cause Faulty fuel level sensor

Evaluation The gauge pointer returns to zero. 0Ω

Cause Faulty fuel level sensor

Open circuit in wire harness between monitor controller and fuel level sensor Normal in above check Faulty monitor controller

The fuel gauge pointer swings over scale. Procedure Inspection Method 1 Disconnect the fuel level sensor connector. 2 Check continuity between terminal #35 of monitor controller 2-B connector of wire harness end and the body. 3 -

Condition Key Switch: ON Key Switch: ON Disconnect the fuel level sensor connector. -

Shorted circuit in wire harness between monitor controller and fuel level sensor Normal in above check Faulty monitor controller

The fuel gauge pointer keeps moving unstably. Procedure Inspection Method 1 Visually inspect the fuel gauge.

Condition Short-circuit in wire harness between fuel level sensor harness end terminals #1 and #2. -

Connector (Wire harness end)  Monitor Controller 2-B Connector

TNDB-05-05-013

 Fuel level Sensor

T6LE-05-05-017

T5-7-5

Evaluation Cause The gauge pointer Faulty fuel level sensor reaches the (FULL) side and is stabilized.

Normal in above check Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of HST Oil Temperature Gauge  Perform these steps when the fault code of monitor controller is not displayed.  Check the wiring connections first. The HST oil temperature gauge pointer does not move at all. Procedure Inspection Method Condition Evaluation Cause 1 Short-circuit in wire harness Key Switch: ON The gauge pointer Faulty HST oil between HST oil temperature reaches the (H) side. temperature sensor sensor harness end terminals #1 and #2. ∞Ω Open circuit in wire 2 Check continuity between Connect the HST harness between terminal #24 of monitor controller oil temperature monitor controller and 2-B connector of wire harness end sensor harness end and the body. terminal #1 to the HST oil temperature body. sensor 3 Normal in above check Faulty monitor controller The HST oil temperature gauge pointer swings over scale. Procedure Inspection Method 1 Disconnect the HST oil temperature sensor terminal. 2 Check continuity between terminal #24 of monitor controller 2-B connector of wire harness end and the body. 3

Condition Key Switch: ON

Evaluation The gauge pointer returns to zero. 0Ω

Cause Faulty HST oil temperature sensor Key Switch: ON Shorted circuit in wire Disconnect the HST harness between oil temperature monitor controller and sensor terminal. HST oil temperature sensor Normal in above check Faulty monitor controller

The HST oil temperature gauge pointer keeps moving unstably. Procedure Inspection Method 1 Visually inspect the HST oil temperature gauge.

Condition Short-circuit in wire harness at HST oil temperature sensor harness end terminals #1 and #2. Key Switch: ON -

Evaluation The gauge pointer reaches the (H) side and is stabilized.

Cause Faulty HST oil temperature sensor

Normal in above check Faulty monitor controller

Connector (Wire harness end)  HST Oil Temperature Sensor

 Monitor Controller 2-B Connector

TNCC-05-05-013

T5-7-6

TCJB-05-06-004

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C (Blank)

T5-7-7

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Monitor Display  The data on monitor display is not displayed by the signal directly input from the sensors except one part. The signal data which has input to other controllers from the sensors once is input to the monitor controller by using CAN communication and is proceeded in the logic circuit of monitor controller. Therefore, check if CAN communication is normal first and check if the controller and sensors corresponding to the trouble are normal. Trouble Data on FNR Indicator Liquid Crystal Shift Position Indicator Display Speedometer Traction Control Indicator ECO Indicator Ride Control Indicator (Option)

Cause If the data of monitoring function can be displayed on MPDr., CAN communication between monitor controller and other controllers is faulty. If the data cannot be displayed on MPDr., 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.)

T5-7-8

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Trouble Data on Machine Information

Cause Clock (time, 24-hour) If the data of monitoring function can be displayed on MPDr., CAN communication between monitor Hour Meter controller and other controllers is faulty. If the Odometer data cannot be displayed on MPDr., the sensor Engine Speed Displayed only when system detecting the related signal is faulty. (As starting on service mode for the machine, some trouble must occur. Refer to Engine Coolant Displayed only when Troubleshooting A and conduct the remedy.) Temperature starting on service mode HST Oil Temperature Displayed only when starting on service mode Fault Code Displayed only when starting on service mode Fuel Consumption Displayed only when starting on normal mode Average Fuel Displayed only when Consumption starting on service mode Hydraulic Oil Hour Meter As for these troubles, the liquid crystal display in monitor panel may be faulty or the logic circuit may Hydraulic Oil Filter 1 Hour Meter (Hydraulic Oil be faulty. Return Filter) Hydraulic Oil Filter 3 Hour Meter (HST Charge Oil Filter) Transmission Oil Hour Meter Transmission Oil Filter Hour Meter Engine Oil Hour Meter Engine Oil Filter Hour Meter Fuel Filter Hour Meter Axle Oil Hour Meter

T5-7-9

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Light Bulb Check System  Check the wiring connections first.  Check that fuse #13 (fuse box A) is normal.  When there is an indicator which does not light at the light bulb check, perform the troubleshooting of each indicator. All indicators do not light. Procedure Inspection Method Condition Evaluation 1 Check continuity between terminal Key Switch: ON ∞ Ω #2 of monitor controller 1-A connector of wire harness end and the body. 2 Normal in above check Connector (Wire harness end)  Monitor Controller 1-A Connector

TNDF-05-05-005

T5-7-10

Cause Open circuit in wire harness between monitor controller and key switch Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Left And Right Turn Signal Light Indicators  Check the wiring connections first.  If the left and right turn signal lights do not blink, the flasher may be faulty. Even when the turn signal lever is shifted, the turn signal light and turn signal light indicator at one side do not blink. 1

2 3

Inspection Method Shift the hazard light switch.

Switch right turn signal light relay with left turn signal light relay. -

Condition Evaluation Hazard Light Switch: Turn Signal Light: ON Lighting, Blinking Turn Signal Light Indicator: Lighting, Blinking Hazard Light Switch: The symptom is ON switched. Normal in above check

Cause Faulty turn signal lever

Faulty turn signal light relay Open circuit in wire harness between turn signal lever and turn signal light relay

Even when the turn signal lever is not shifted, the turn signal light and turn signal light indicator blink. 1 2

Inspection Method Switch right turn signal light relay with left turn signal light relay. -

Condition Evaluation Hazard Light Switch: The symptom is ON switched. Normal in above check

T5-7-11

Cause Faulty turn signal light relay Faulty turn signal lever or shorted circuit in wire harness between turn signal lever and turn signal light relay

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Hazard Light Indicator  When the excited signals of left and right turn signal relays are sent to the hazard light switch, left and right turn signal light indicators are turned on. Therefore, when both turn signal lights are lighting or blinking and if left and right turn signal light indicators are not turned on, the wire harness between turn signal light relay and monitor controller may be faulty or the monitor controller may be faulty.  If the turn signal light indicator at one side is not lighting or blinking, refer to troubleshooting that the wire harness between turn signal light relay and hazard light switch is faulty or left and right turn signal light indicators are faulty in order to conduct the remedy.  Check the wiring connections first.

T5-7-12

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of High Beam Indicator  Check the wiring connections first.  If the high beams of head lights also do not light, check the dimmer switch and high beam relay.  If the head lights do not light, check fuse #17 (fuse box A) and the light switch.  If the high beam do not light, check fuse #19 (fuse box A). Even when the dimmer switch is set to the High beam position, the high beam indicator does not light. 1

Inspection Method Measure voltage at the wire harness end of monitor controller 2-A connector terminal #13.

Condition Light Switch: H Dimmer Switch: Hi

Evaluation 0V

Cause Open circuit in wire harness between high beam relay and monitor controller Normal in above check Faulty monitor controller

Even when the dimmer switch is not in the High beam position, the high beam indicator lights. 1

Inspection Method Measure voltage at the wire harness end of monitor controller 2-A connector terminal #13. -

Condition Light Switch: H Dimmer Switch: Hi

Evaluation 0V

Normal in above check Shorted circuit in wire harness between high beam relay and monitor controller

Connector (Wire harness end)  Monitor Controller 2-A Connector

TNDF-05-05-005

T5-7-13

Cause Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Work Light Indicator  Check that the light switch is in the S or H position.  If the clearance light indicator also does not light, the common circuit for clearance light indicator and work light indicator may be faulty. Refer to "Malfunction of Clearance Light Indicator".  Check that fuse #5 (fuse box B) is normal.  Check the wiring connections first. Even when the work light switch is shifted to the front work light position, the work light indicator does not light. Work Light: ON 1

Inspection Method Measure voltage at the wire harness end of monitor controller 2-A connector terminal #12.

Condition Work Light Switch: Front work light position

Evaluation 0V

Cause Open circuit in wire harness between front work light relay and monitor controller Normal in above check Faulty monitor controller

Condition Key Switch: ON

Evaluation 0V

Work Light: OFF 1

Inspection Method Measure voltage between the wire harness end of front work light relay connector terminal #3 and the body. Switch front work light relay with rear work light relay.

Work Light Switch: Front work light position Check continuity between Work Light Switch: terminals #1 and #2 of work light Front work light position switch end connector. Measure voltage between the wire Work Light Switch: harness end of front work light Front work light relay connector terminal #1 and position the body. Measure voltage at the wire Work Light Switch: harness end of monitor controller Front work light 2-A connector terminal #12. position -

T5-7-14

Indicator: ON

∞Ω

Cause Open circuit in wire harness between front work light relay and battery relay Faulty front work light relay Faulty work light switch

Open circuit in wire harness between front work light relay and work light switch 0V Open circuit in wire harness between front work light relay and monitor controller Normal in above check Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Even when the work light switch is in the OFF position, the work light indicator lights. 1

2 3 4

Inspection Method Check the work light.

Condition Work Light Switch: OFF

Evaluation Work Light: OFF

Switch front work light relay with rear work light relay. Disconnect connectors of work light switch. -

Work Light Switch: OFF -

Indicator: OFF

Normal in above check Shorted circuit in wire harness between front work light relay and work light switch

Indicator: OFF

Cause Shorted circuit in wire harness between front work light relay and monitor controller Faulty front work light relay Faulty work light switch

Connector (Wire harness end)  Monitor Controller 2-A Connector

 Work Light Switch

 Work Light Relay

TNCC-05-05-005 T4FJ-05-07-002

T5-7-15

T183-05-04-003

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Maintenance Light  The maintenance light lights when the hour meter reaches the set replacement interval for lubrication system and filter. (Refer to the operator’s manual.) The maintenance light lighting is controlled in the logic circuit of monitor controller. Therefore, if the maintenance light lights during the time when it must go out, the monitor may be faulty.  If the maintenance light does not light during the time when it must light, the monitor controller may be faulty.

T5-7-16

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Preheat Indicator  Check the wiring connections first. The preheat indicator lights even when the heater plug is not operated. 1 2

Inspection Method Condition Disconnect ECM-2 connector from Key Switch: ON ECM. Check continuity between terminal Key Switch: ON K48 of ECM-2 connector of wire harness end and the body. -

Evaluation Cause Preheat Indicator: OFF Faulty ECM 0Ω

Shorted circuit in wire harness between ECM and monitor controller Normal in above check Faulty monitor controller

The preheat indicator does not light even when the heater plug is operated. 1

Inspection Method Condition Disconnect ECM-2 connector from Key Switch: ON ECM. Connect the wire harness end of ECM-2 connector terminal K48 to the body. Connect the wire harness end of Key Switch: ON monitor controller 1-B connector terminal #21 to the body. -

Evaluation Preheat Indicator: ON

Cause Faulty ECM

Preheat Indicator: ON

Open circuit in wire harness between ECM and monitor controller Normal in above check Faulty monitor controller

Connector (Wire harness end)  ECM-2 Connector

 Monitor Controller 1-B Connector

K48

TNDF-05-05-006

TNCC-05-07-002

T5-7-17

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of HST Oil Temperature Indicator  Perform these steps when the fault code of monitor controller is not displayed.  Check the wiring connections first. The indicator does not light even when the engine overheats. 1

Inspection Method Short-circuit in wire harness between HST oil temperature sensor harness end #1 and #2. Connect the wire harness end of monitor controller 2-B connector terminal #24 to the body.

Condition Key Switch: ON

Evaluation Indicator: ON

Key Switch: ON

Indicator: ON

Cause Faulty HST oil temperature sensor

Open circuit in wire harness between monitor controller and HST oil temperature sensor Normal in above check Faulty monitor controller

The indicator lights even when HST oil temperature is low. 1 2

Inspection Method Disconnect the terminal of HST oil temperature sensor. Disconnect monitor controller 2-B connector.

Condition Key Switch: ON Engine: Stopped Key Switch: ON

Connector (Wire harness end)  Monitor Controller 2-B Connector

TNCC-05-05-013

T5-7-18

Evaluation Indicator: OFF

Cause Faulty HST oil temperature sensor Indicator: OFF Shorted circuit in wire harness between monitor controller and HST oil temperature sensor Normal in above check Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of HST Warning Indicator  Check the wiring connections first. Even when MC is abnormal, the indicator does not light. 1

Inspection Method Measure voltage at the wire harness end of monitor controller 1-A connector terminal #13. -

Condition Key Switch: ON

Evaluation 0V

Cause Open circuit in wire harness between MC and monitor controller Normal in above check Faulty monitor controller

Even when MC is not abnormal, the indicator lights. 1

Inspection Method Condition Check continuity between terminal Key Switch: ON #13 of monitor controller 1-A connector of wire harness end and the body. -

Connector (Wire harness end)  Monitor Controller 1-A Connector

TNDF-05-05-005

T5-7-19

Evaluation 0Ω

Cause Shorted circuit in wire harness between MC and monitor controller

Normal in above check Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Engine Oil Pressure Indicator  Check the wiring connections first. Even when engine oil pressure is insufficient, the indicator does not light. Procedure Inspection Method 1 Connect the wire harness end of monitor controller 1-A connector terminal #7 to the body. 2 -

Condition Key Switch: ON

Evaluation Indicator: ON

Cause Open circuit in wire harness between ECM and monitor controller Normal in above check Faulty monitor controller

Even when the engine runs, the indicator is not turned off. Procedure Inspection Method 1 Disconnect ECM-2 connector. 2

Disconnect monitor controller 1-A connector.

Condition Evaluation Cause Key Switch: ON Indicator: OFF Faulty ECM Engine: Stopped Key Switch: ON Indicator: OFF Shorted circuit in wire Connect only to harness between ECM and terminal #2. monitor controller Normal in above check Faulty monitor controller

Connector (Wire harness end)  Monitor Controller 1-A Connector

TNDF-05-05-005

T5-7-20

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Overheat Indicator  Perform these steps when the fault codes of ECM are not displayed.  Check the wiring connections first. Even when the engine overheats, the indicator does not light. Procedure Inspection Method

Condition

Evaluation

Cause

Key Switch: ON

Indicator: ON

Faulty coolant temperature sensor

Key Switch: ON

Indicator: ON

Faulty coolant level switch

Key Switch: ON

∞Ω

Open circuit in wire harness between ECM and monitor controller

Normal in above check Faulty monitor controller

Connect the wire harness end of coolant temperature sensor connector terminal #2 to the body. Connect the wire harness end of coolant level switch connector terminal #1 to the body. Connect the wire harness end of ECM-2 connector terminal K69 to the body. Check continuity between terminal #8 of monitor controller 1-A connector of wire harness end and the body. -

Even when coolant temperature is low, the indicator lights. Procedure Inspection Method 1 Disconnect the coolant temperature sensor connector. 2 Disconnect the coolant level switch connector. 3 Disconnect the monitor controller 1-A connector. 4

Condition Key Switch: ON

Evaluation Indicator: OFF

Key Switch: ON Key Switch: ON Connect only to terminal #2. -

Cause Faulty coolant temperature sensor Indicator: OFF Faulty coolant level switch Indicator: OFF Shorted circuit in wire harness between ECM and monitor controller Normal in above check Faulty monitor controller

Connector (Wire harness end)  Coolant Temperature Sensor

 Monitor Controller 1-A Connector

TNDF-05-05-005

T1J1-05-07-006

 ECM-2 Connector K69

TNCC-05-07-002

T5-7-21

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Engine Warning Indicator  Perform these steps when the fault codes of ECM are not displayed.  Check the wiring connections first. Even when the engine is abnormal, the indicator does not light. Procedure Inspection Method 1 Disconnect ECM-2 connector from ECM. Connect the wire harness end of ECM-2 connector terminal K70 to the body. 2 Connect the wire harness end of monitor controller 1-A connector terminal #14 to the body. 3 -

Condition Key Switch: ON

Evaluation Indicator: ON

Key Switch: ON

Indicator: ON

Cause Faulty ECM

Open circuit in wire harness between ECM and monitor controller Normal in above check Faulty monitor controller

Even when the engine is not abnormal, the indicator lights. Procedure Inspection Method 1 Disconnect the ECM-2 connector. 2 Disconnect the monitor controller 1-A connector. 3

Condition Key Switch: ON Key Switch: ON Connect only to terminal #2. -

Evaluation Indicator: OFF Indicator: OFF

Cause Faulty ECM Shorted circuit in wire harness between ECM and monitor controller Normal in above check Faulty monitor controller

Connector (Wire harness end)  ECM-2 Connector K70

TNCC-05-07-002

 Monitor Controller 1-A Connector

TNCC-05-05-005

T5-7-22

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Service Indicator  When the following troubles occur, the service indicator lights in order to announce the trouble to the operator, stop the machine, and maintain the machine.  Even when the machine is maintained and if the service indicator does not go out, other indicator on the monitor panel must light. Refer to the pages corresponding to the indicator in this group or conduct the remedy according to Troubleshooting A.  Even when there is no trouble and if the service indicator does not go out, the logic circuit in monitor controller may be faulty. Items when the service indicator lights  Faulty generation of the alternator  Lighting the engine warning indicator  Lighting the HST warning indicator  High temperature of HST oil (Within a short time)  Secondary steering operation (Only machine with the optional parts equipped)

T5-7-23

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Parking Brake Indicator  Perform these steps when the fault code of monitor controller is not displayed.  Refer to Troubleshooting B as for the parking brake troubleshooting. Even when the parking brake switch is not set to the ON position, the indicator lights. 1 2

Inspection Method Condition Remove the parking brake pressure Key Switch: ON sensor. Check continuity between terminal Key Switch: ON #25 of monitor controller 2-B connector of wire harness end and the body. -

Evaluation Indicator: OFF

Cause Faulty parking brake pressure sensor 0Ω Shorted circuit in wire harness between parking brake pressure sensor and monitor controller Normal in above check Faulty monitor controller

Even when the parking brake switch is in the ON position, the indicator does not light. 1

Inspection Method Condition Check continuity between terminal Key Switch: ON Parking Brake #25 of monitor controller 2-B connector of wire harness end and Switch: ON the body. -

Connector (Wire harness end)  Monitor Controller 2-B Connector

TNDB-05-05-013

T5-7-24

Evaluation ∞Ω

Cause Open circuit in wire harness between parking brake pressure sensor and monitor controller Normal in above check Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 7 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 wire harness between light switch and clearance light or monitor controller may be shorted.  Check the wiring connections first. The indicator does not light. 1

Inspection Method Check if the clearance light lights.

Measure voltage at the wire harness end of monitor controller 1-B connector terminal #25.

Condition Light Switch: S or H position Key Switch: ON

Connector (Wire harness end)  Monitor Controller 1-B Connector

TNDF-05-05-006

T5-7-25

Evaluation Light is ON. 0V

Cause Faulty light switch

Open circuit in wire harness between light switch and monitor controller Normal in above check Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Secondary Steering Indicator (Option)  Check that fuse #4 (fuse box B) is normal.  Refer to Troubleshooting B as for the secondary steering troubleshooting.  When there is no trouble, the monitor controller may be faulty.

T5-7-26

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Low Steering Oil Pressure Indicator (Option)  When this trouble occurs, the fault corresponding to the secondary steering pressure switch in MC must be displayed. Refer to Troubleshooting A and conduct the remedy.  When there is no trouble, the monitor controller may be faulty.

T5-7-27

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Alternator Indicator  Perform these steps when the fault code of monitor controller is not displayed.  Check the wiring connections first. Even when the engine runs, the alternator indicator is not turned off. Procedure Inspection Method Condition 1 Switch alternator indicator Engine: Running relay 1 with other general relay. 2 Measure voltage at alternator Engine: Running terminal B. 3 Check continuity between the Engine: Running wire harness end of alternator indicator relay 1 terminal #2 and the body. 4 Check voltage between the Engine: Running wire harness end of alternator indicator relay 1 terminal #1 and the body. Engine: Running 5 Check voltage between terminal #28 of monitor controller 2-B connector of wire harness end and the body. 6 -

Evaluation Cause Alternator Indicator: OFF Faulty alternator indicator relay 1 Less than 13V or 33.5V Faulty alternator or more 0Ω Shorted circuit in wire harness between alternator indicator relay 1 and alternator 0V Open circuit in wire harness between alternator indicator relay 1 and fuse box A 0V Open circuit in wire harness between alternator indicator relay 1 and monitor controller Normal in above check Faulty monitor controller

Even when charging is low, the alternator indicator does not light. Procedure Inspection Method Condition 1 Check if the engine has started. Key Switch: ST 2 Switch alternator indicator Engine: Stopped relay 1 with other general relay. 3 Measure voltage at alternator Engine: Running terminal B. 4 Check continuity between the Engine: Running wire harness end of alternator indicator relay 1 terminal #2 and the body. 5 Check voltage between Engine: Running terminal #28 of monitor controller 2-B connector of wire harness end and the body. 6 -

Evaluation Cause The engine does not start. To Troubleshooting B Alternator Indicator: ON Faulty alternator indicator relay 1 Less than 13V or 33.5V or Faulty alternator more ∞Ω Open circuit in wire harness between alternator indicator relay 1 and alternator 24 V Shorted circuit in wire harness between alternator indicator relay 1 and monitor controller Normal in above check Faulty monitor controller

 Alternator Indicator Relay 1

Connector (Wire harness end)  Monitor Controller 2-B Connector

TNDB-05-05-013

T5-7-28

T183-05-04-003

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Control Lever Lock Indicator (Option) Malfunction of Power Mode Indicator The indicator does not light.  When the fault codes of the controller and CAN are displayed, refer to Troubleshooting A and conduct the remedy.  When the fault codes of the controller and CAN are not displayed, the logic circuit in monitor controller may be faulty. The indicator does not go out.  Even when there is no trouble and if the indicator does not go out, the logic circuit in monitor controller may be faulty.

T5-7-29

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Seat Belt Indicator (Option) The indicator does not light. 1

Inspection Method Measure voltage between terminal #28 of monitor controller 2-B connector of wire harness end and the body. -

Condition Key Switch: ON Engine: Stopped

Evaluation Voltage: 24V

Cause Shorted circuit in wire harness between alternator indicator relay 1 and monitor controller Normal in above check Faulty monitor controller

The indicator does not go out. 1

Inspection Method Condition Measure voltage between terminal Engine: Running #28 of monitor controller 2-B connector of wire harness end and the body. -

Connector (Wire harness end)  Monitor Controller 2-B Connector

TNDB-05-05-013

T5-7-30

Evaluation Voltage: 0V

Cause Open circuit in wire harness between alternator indicator relay 1 and monitor controller Normal in above check Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Outline Operation layout of the air conditioning system is illustrated below. Either fresh or re-circulated air is induced into the air conditioner unit by operating fresh / re-circulated air damper servo motor (6). The induced air flows out of the vents through evaporator (5) or heater (15) by blower motor (11). Evaporator (5) is a device used to cool the air. Heater (15) is a device used to warm the air. In the air conditioning system, after the refrigerant is compressed by the compressor, it is sent to evaporator (5) in which the refrigerant expands to cool the air. Heater (15) warms air by first absorbing heat from warmed engine coolant. Evaporator (5) and heater (15) allow the introduced air to circulate in the system to maintain the temperature at the set temperature.

The vents (operator’s front/rear vent, foot vent, and the front window) can be simultaneously or independently selected by air vent damper servo motor (1) in accordance with the set-ventilation mode. The air conditioning controller controls the air conditioning system. The air conditioning controller controls the damper operation by corresponding to the job site conditions such as atmospheric and cab inside air temperatures, coolant temperature, operator’s set-temperature, and the selected ventilation mode. In addition, the air conditioning controller displays the air conditioning system operation status on the monitor.

6 1

5 2

15 12345-

Air Vent Damper Servo Motor Defroster Vent Rear Vent Front Vent Evaporator

6789-

Fresh/Re-circulated Air Damper Servo Motor Re-circulated Air Sensor Fresh Air Induction Port Re-circulated Air Filter

10- Re-circulated Air Induction Port 11- Blower Motor 12- Power Transistor 13- Frost Sensor

T5-8-1

TDAA-05-07-001

14- Air Mix Damper Servo Motor 15- Heater Core 16- Foot Vent

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Component Layout

11 5

TNDF-05-07-001

13 TNCC-05-08-002

27 1568-

Solar Radiation Sensor Accelerator Pedal Key Switch Air Conditioner Unit

9- Fresh Air Filter 10- Air Conditioner Controller (Switch Panel)

11- Outdoor Ambient Temperature Sensor 12- High/Low Pressure Switch 13- Air Conditioner Condenser

T5-8-2

14- Receiver Tank 27- Compressor 28- Screen (2 used)

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner  Air Conditioner Unit 19

16 15

20 21

22 23 24 25

TNDB-05-07-028

15- Re-circulated Air Filter 16- Compressor Relay 17- Re-circulated Air Sensor

18- Fresh/Re-circulated Air Damper Servo Motor 19- Frost Sensor 20- Evaporator

21222324-

T5-8-3

Heater Core Air Mix Damper Servo Motor Air Vent Damper Servo Motor Blower Motor Relay

25- Power Transistor 26- Blower Motor

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner  Air Conditioner Condenser

TNCC-05-08-003

29- Condenser

30- Electric Fan

T5-8-4

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner (Blank)

T5-8-5

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Functions of Main Parts The functions of the main parts for the air conditioner are described below. The connector No. is shown in the parentheses after the part name.  Controller Controls the air conditioning system. According to the operator’s requests sent via the switches, and the information regarding the air and refrigerant temperature sent from the sensors, the controller judges the air conditioner operating status and controls the blower motor and/or compressor operation as needed by operating the relays. In addition, the controller informs the operator of the air conditioner operating status by displaying the information on the monitor panel.

TNDB-05-07-002

 Power Transistor (CN7) An electric switch to control blower motor voltage.

TDAA-05-07-003

 Blower Motor Relay (CN3) Supplies 24 volts of electricity to the blower motor when the air conditioner is operated. The blower motor relay is turned ON when excited by the current from terminal #30 in controller. TDAA-05-07-004

 Compressor Relay (CN4) Supplies 24 volts of electricity to the compressor clutch when the air conditioner is operated. The compressor relay is turned ON when excited by the current from terminal #29 in controller. TDAA-05-07-005

T5-8-6

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner  Frost Sensor (CN12) Monitors the fin temperature which is cooled by the evaporator. When the temperature is higher than 3 °C (approx. 4.2 kΩ), the controller turns the compressor relay ON. When the temperature is lower than 2 °C (approx. 4.5 kΩ), the controller turns the compressor relay OFF. Therefore, the evaporator in the air conditioner unit is prevented from freezing. The electrical resistance in the frost sensor is 100 Ω to 115 kΩ.

 High/Low Pressure Switch (CN14) Controls the compressor clutch solenoid while monitoring the compressor circuit pressure. The high/ low pressure switch consists of a pressure gauge and a switch. The pressure gauge detects the lower pressure range (0.196 ~ 0.216 MPa (28.4 ~ 31.3 PSI)) and the surge pressure range (2.55 ~ 3.14 MPa (370 ~ 455 PSI)). When the circuit pressure is reduced to the lower pressure range or increases to the surge pressure range, the pressure gauge turns the switch OFF so that the compressor operation stops. If the pressure is reduced to the lower range, a lack of refrigerant is suspected. Therefore, damage to the compressor due to a lack of refrigerant is prevented. In case the pressure increases to the surge range, damage to the air conditioner circuit parts due to excessively high circuit pressure is prevented.

 Re-circulated Air Sensor (CN11) Monitors the temperatures (0 ~ 25 °C (32 ~ 77 °F)) around the re-circulated air inlet as the interior air temperatures and converts them to the electrical resistance values. The temperatures 0 ~ 25 °C (32 ~ 77 °F) corresponds to a resistance of 1.645 kΩ (0 °C (32 °F)) to 5 kΩ (25 °C (77 °F)) respectively. The electrical resistance in the air circulation sensor is 300 Ω to 430 kΩ.

TDAA-05-07-006

#A052 #A211 TDAA-05-07-007

TDAA-05-07-014

TDAA-05-07-008

TDAA-05-07-009

 Outdoor Ambient Temperature Sensor (CN15) Monitors the temperature around the rear side of the machine as the fresh air temperature, and converts the temperature to the electrical resistance value. The electrical resistance in the fresh air sensor is 100 Ω to 210 kΩ.

T5-8-7

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner  Solar Radiation Sensor (CN16) Converts the amount of solar radiation (illumination intensity) at the cab front to the current values. TDAA-05-07-010

 Fresh/Re-circulated Air Damper Servo Motor (CN10) Opens or closes the fresh/re-circulated air selection louvers. The damper consists of a motor, link mechanism, and position sensing switch. The motor opens or closes the fresh/re-circulated air selection louvers via the link mechanism. TDAA-05-07-011

T5-8-8

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner  Air Mix Damper Servo Motor (CN9) Controls opening/closing of the air mixing door in response to the set temperature. The damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes the air mix door via the link mechanism. The potentiometer converts the link movements (the mix door strokes) to the voltage. Both ends of the potentiometer are energized by 5 V from terminals #7 (+) and #25 (-) in controller so that the potentiometer outputs voltage of 0.5 to 4.5 V from the center terminal to terminal #19 in controller corresponding to the link movement. When the set temperature is determined by temperature UP/DOWN signal from the controller, the controller calculates voltage (Vr) corresponding the link position. Further more, the controller checks the air mix door position by voltage (Vf ) from the potentiometer. Then, after the controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf, the controller sends out the current from terminals #15 and #16. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr).

TDAA-05-07-012

T5-8-9

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner  Air Vent Damper Servo Motor (CN8) Opens or closes the front and rear air vent, foot vent, and defroster vent louvers. The damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes vent louvers via the link mechanism. The potentiometer converts the link movements (vent louvers strokes) to the voltage. Both ends of the potentiometer are energized by 5 V from terminals #7 (+) and #25 (-) in controller so that the potentiometer outputs voltage of 0.5 to 4.5 V from the center terminal to terminal #20 in controller corresponding to the link movement. Depending on the MODE switch set position, vent louvers are operated as shown below: When the front and rear air vent louvers positions are selected, the controller calculates potentiometer voltage (Vr). Furthermore, the controller checks the vent louvers positions by receiving voltage (Vf ) from the potentiometer. Then, after the controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf, the controller sends out the current from terminals #31 and #32. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr). MODE switch position

Front air vent

Rear air vent

Foot air vent

Defroster vent























TNED-05-07-005

TNED-05-07-006

TNED-05-07-007

TNED-05-07-008

TNED-05-07-009

TNED-05-07-010

: Open : Closes

T5-8-10

TDAA-05-07-013

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Troubleshooting IMPORTANT:  When replacing the compressor due to the breakage of compressor from internal lock, sufficiently clean the air conditioner circuit or replace all the parts.  When cleaning is insufficient or all the parts are not replaced, the air conditioner may be broken due to contaminants remaining in the circuit.  Using deteriorated LLC (long life coolant) or low-concentration LLC, the heater core will receive a bad influence and it may lead water leaks and shorten the service life of machine. Replace coolant and manage LLC concentration according to the Operator's Manual.

MNEC-01-052

How to Display and Delete Air Conditioner Controller Fault Code

The fault code of air conditioner controller is displayed on LCD panel (4) of air conditioner controller (1). How to Display 1. Push OFF switch (2) and stop the air conditioner. MNDB-01-011

2. Push Up and Down buttons of temperature control switch (3) beyond three seconds at the same time. 3. The current fault code is displayed at temperature display (a) on LCD panel (4). Example: E11 4. When some fault codes exist and whenever pushing Up or Down button of temperature control switch (3), other fault codes are displayed.

a 123-

How to Delete 1. Push Up and Down buttons of blower switch (5) beyond three seconds at the same time. 2. The fault code displayed at temperature display (a) on LCD panel (4) is deleted. E-- is displayed. How to Return to Normal Display 1. When pushing OFF switch (2) or setting the key switch to the ON position from the OFF position, the fault code displayed at temperature display (a) on LCD panel (4) is changed into the normal temperature display.

T5-8-11

Air Conditioner Controller OFF Switch Temperature Control Switch

45-

LCD Panel Blower Switch

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Air Conditioner Controller Fault Code List Fault Code

Trouble

Cause

E11

Open circuit in recirculated air sensor

Voltage: more than 4.95 V

E12

E13

E14

E18

E21

E22

E43

E44

E51

E91

E92

Symptoms in Machine Operation When Trouble Occurs. Operation is controlled under such circumstance as no recirculated air sensor is provided.

Remedy

Check the harness. Replace the recirculated air sensor. Shorted circuit in reVoltage: less than 0.3 V Operation is controlled under Check the harness. circulated air sensor such circumstance as no reReplace the recirculated air sensor is provided. circulated air sensor. Open circuit in Voltage: more than Operation is controlled under Check the harness. outdoor ambient 4.88 V such circumstance as no outdoor Replace the temperature sensor ambient temperature sensor is outdoor ambient temperature provided. sensor. Check the harness. Shorted circuit in Voltage: less than Operation is controlled under outdoor ambient 0.096 V such circumstance as no outdoor Replace the outdoor ambient temperature sensor ambient temperature sensor is temperature provided. sensor. Shorted circuit in solar Voltage: more than Operation is controlled under Check the harness. radiation sensor 5.04 V such circumstance as no solar Replace the solar radiation sensor is provided. radiation sensor. Open circuit in frost Voltage: more than The compressor clutch is Check the harness. sensor 4.79 V disengaged. (The compressor Replace the frost stops.) sensor. Shorted circuit in frost Voltage: less than The compressor clutch is Check the harness. sensor 0.096 V disengaged. (The compressor Replace the frost stops.) sensor. Abnormal air vent Shorted circuit: Air vent damper servo motor Check the harness. damper servo motor Voltage: 0 V becomes inoperable. Replace the air Open circuit: Voltage: vent damper servo more than 5 V motor. Abnormal air mix Shorted circuit: Air mix damper servo motor Check the harness. damper servo motor Voltage: less than 0.2 V servo motor becomes inoperable. Replace the air Open circuit: Voltage: vent damper servo more than 4.8 V motor. Abnormal high/low Voltage: 0 V The compressor clutch is Check the harness. refrigerant pressure disengaged. (The compressor Replace the high/ stops.) low pressure switch. Check the CAN1 CAN communication Faulty CAN1 harness Air conditioner stops. harness. error between monitor controller and air Replace air conditioner controller conditioner controller. CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1 controller harness. Faulty CAN1 harness Replace air conditioner controller.

T5-8-12

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Air Conditioner Controller Fault Codes E11 to E22 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code E11

E12

E13

E14

E18

E21

E22

Trouble Open circuit in recirculated air sensor

Shorted circuit in recirculated air sensor

Open circuit in outdoor ambient temperature sensor

Inspection Method Measurement of resistance between sensor #1 and #2. Measurement of voltage between sensor harness end #1 and body. Measurement of resistance between sensor #1 and #2. Measurement of resistance between sensor #1 and #2. Measurement of voltage between sensor harness end #1 and body. -

Shorted circuit in outdoor ambient temperature sensor

Measurement of resistance between sensor #1 and #2. -

Shorted circuit in solar radiation sensor

Continuity check between sensor harness end #1 and #2. -

Open circuit in frost sensor

Shorted circuit in frost sensor

Measurement of resistance between sensor #1 and #2. Measurement of voltage between sensor harness end #1 and body. Measurement of resistance between sensor #1 and #2. -

T5-8-13

Evaluation Cause ∞ Ω (Normal value: Faulty sensor. 300 to 430 kΩ) 0V Open circuit in harness #1.

Normal in above check. 0 Ω (Normal value: 300 to 430 kΩ) Normal in above check. ∞ Ω (Normal value: 100 to 210 kΩ) 0V

Normal in above check. 0 Ω (Normal value: 100 to 210 kΩ) Normal in above check. 0Ω

Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2. Faulty sensor. Open circuit in harness #1.

Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2. Shorted circuit in harness #1 and #2.

Normal in above Faulty sensor. check. ∞ Ω (Normal value: Faulty sensor. 100 to 115 kΩ) 0V Open circuit in harness #1.

Normal in above check. 0 Ω (Normal value: 100 to 115 kΩ) Normal in above check.

Open circuit in harness #2. Faulty sensor. Shorted circuit in harness #1 and #2.

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Air Conditioner Controller Fault Codes E43 to E92 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code E43

E44

E51

E91

E92

Trouble Abnormal air vent damper servo motor

Abnormal air mix damper servo motor

Abnormal high/ low refrigerant pressure

CAN communication error CAN bus off error

Inspection Method Evaluation Measurement of voltage 0V between air vent damper servo motor harness end 7C and body. (AUTO/OFF switch / blower switch: ON) Measurement of voltage 0V between air vent damper servo motor harness end 7C and 25D. (AUTO/OFF switch / blower switch: ON) Normal in above check. 0V Measurement of voltage between air mix damper servo motor harness end 7D and body. (AUTO/OFF switch / blower switch: ON) 0V Measurement of voltage between air mix damper servo motor harness end 7D and 25E. (AUTO/OFF switch / blower switch: ON) Normal in above check. Measurement of voltage 0V between high/low pressure switch harness end A21 and A05. (AUTO/OFF switch / blower switch: ON) Normal in above check. Continuity check in CAN1 Normal harness. Abnormal

Faulty controller. Faulty CAN1 harness.

Continuity check in CAN1 harness.

Faulty controller. Faulty CAN1 harness.

T5-8-14

Normal Abnormal

Cause Faulty controller or open circuit in harness between controller and air vent damper servo motor. Faulty controller or open circuit in harness between controller and air vent damper servo motor. Faulty air vent damper servo motor. Faulty controller or open circuit in harness between controller and air mix damper servo motor.

Faulty controller or open circuit in harness between controller and air mix damper servo motor.

Faulty air mix damper servo motor. Faulty controller or open circuit in harness between controller and high/low pressure switch.

Faulty high/low pressure switch.

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner (Blank)

T5-8-15

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Faulty cooling (1) Condition:  Fault code: Un-displayed  Airflow volume: faulty Blower motor rotates

Normal speed

Slow speed

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Frosted evaporator Adhered dirt on evaporator surface Power source decreases

Poor battery terminal contact Faulty blower motor Faulty power transistor Blower motor Faulty blower motor relay does not rotate Faulty blower motor Faulty power transistor Blower interferes with case Faulty controller Faulty ground in body Faulty wiring, disconnection of connector Blowout of power transistor thermal fuse due to locked motor Blowout of fuse Replace with the Blower motor is locked same capacity fuse Faulty wiring Shorted circuit

T5-8-16

Filter cleaning Filter cleaning Remove obstacles Replacement of blower To A Evaporator surface cleaning Check battery charging system Repair Replace Replace Replace Replace Replace Repair Replace the controller Make sure to ground Wirings inspection Replace motor Replace blower motor Refer to wiring diagram and check Wirings inspection

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of frost sensor Faulty frost sensor characteristics Frost sensor is out of evaporator range (faulty sensitivity) No voltage applied to magnet clutch

T5-8-17

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor.

Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace magnet clutch

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Faulty cooling (2) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Normal Fresh air enters

Disconnection of air mix dumper servo motor link

Close window and door Readjust fresh/re-circulated air selection damper Setting link again

T5-8-18

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner (Blank)

T5-8-19

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Faulty cooling (3) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Abnormal Pressure on lowpressure side is too high (approx. 0.29 MPa (42 PSI) or more)

Pressure on highpressure side is too low (pressure is not approx. 0.98 MPa (142 PSI) or more)

Pressure on lowpressure side is too low (pressure is approx. 0.05 MPa (7.25 PSI) or less) Pressure is high on both sides of highpressure and lowpressure Pressure is low on both sides of highpressure and lowpressure

Overcharge air conditioner with refrigerant Faulty compressor

Remove refrigerant thoroughly and recharge refrigerant to proper level after purging Breakage of head gasket Replace compressor Breakage of inlet valve Replace compressor Clogged foreign matter into inlet Replace compressor valve Faulty valve Replace valve

Excessive open of expansion valve Abnormally low ambient temperature Low refrigerant Faulty compressor Swash plate shoe is locked Piston is locked Faulty suction discharge valve Faulty expansion valve Clogged valve (foreign matter) Temporary clogged due to freezing valve (water intrusion)

To B Replace compressor Replace compressor Replace compressor Replace valve Thoroughly perform purging after replacing valve and receiver

Abnormally low ambient temperature Low refrigerant To B Clogged during refrigeration cycle To C Faulty expansion valve To D Frosted evaporator To A Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing) Overcharge air conditioner Remove refrigerant thoroughly and recharge refrigerant to proper with refrigerant level after purging Lack of refrigerant

T5-8-20

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor

Reinsert (floating distance from evaporator is 3 mm (0.12 in) or less) Faulty magnet clutch

Replace magnet clutch

B: Low refrigerant Low refrigerant

Low refrigerant quantity Gas leak

Charge refrigerant to proper level Check leak and charge with refrigerant after repairing faulty

C: Clogged during refrigeration cycle Clogged during refrigeration cycle

Clogged receiver dryer Clogged foreign matter in piping

Replace Replace

D: Faulty expansion valve Faulty expansion valve

Clogged valve (foreign matter) Replace valve Temporary clogged due to freezing valve Thoroughly perform purging after (water intrusion) replacing valve and receiver

T5-8-21

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Faulty cooling (4) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor does not rotate normally Broken V belt or slipping Faulty compressor (locked) Faulty magnet Repair or clutch replace.

Clutch does not operate due to faulty electrical system

Check wiring

Replace V belt Replace Open circuit in stator coil Replace Air gap between rotor and stator is too large Repair or Replacement Clutch slipping Slip caused by key breakage or inserting no key Replace key Greasy clutch surface Remove oil Layer shorted coil Replace Battery voltage drop Charge Clogged foreign matter between rotor and stator Overhaul Faulty controller Replace the controller Faulty compressor clutch relay Replace Faulty frost sensor Replace Faulty high/low refrigerant pressure switch Replace Abnormally high ambient temperature Abnormal high Too high pressure (2.54 MPa Lack of Clogged fin with Cleaning of fin (368 PSI) or condenser dirt or mud (washing) more) cooling Overcharge air Remove refrigerant thoroughly and conditioner with recharge refrigerant to proper level refrigerant after purging Air incorporation Remove refrigerant thoroughly and in refrigeration recharge refrigerant to proper level cycle after purging Too low Abnormally low ambient temperature (0.98 MPa Low refrigerant To B (142 PSI) or Clogged during refrigeration cycle To C less) Faulty expansion valve To D Frosted evaporator To A

T5-8-22

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor

Reinsert (floating distance from evaporator is 3 mm (0.12 in) or less) Faulty magnet clutch

Replace magnet clutch

B: Low refrigerant Low refrigerant

Low refrigerant quantity Gas leak

Charge refrigerant to proper level Check leak and charge with refrigerant after repairing faulty

C: Clogged during refrigeration cycle Clogged during refrigeration cycle

Clogged receiver dryer Clogged foreign matter in piping

Replace Replace

D: Faulty expansion valve Faulty expansion valve

Clogged valve (foreign matter) Replace valve Temporary clogged due to freezing valve Thoroughly perform purging after (water intrusion) replacing valve and receiver

T5-8-23

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Faulty cooling (5) Condition:  Fault Code: 44 (Abnormal air mix damper servo motor) Faulty wiring, open circuit, disconnection of connector Faulty servo motor Clogged foreign matter

Wirings inspection

Replace Remove foreign matter

Condition:  Fault Code: 51 (Abnormal high/low refrigerant pressure) High pressure cut is operated

Low pressure cut is operated

Abnormally high ambient temperature Lack of condenser Clogged fin with dirt or mud Cleaning of fin (washing) cooling Overcharge air Remove refrigerant thoroughly and recharge refrigerant to proper conditioner with level after purging refrigerant Air incorporation in Remove refrigerant thoroughly and recharge refrigerant to proper refrigeration cycle level after purging Abnormally low ambient temperature Low refrigerant Low refrigerant quantity Charge refrigerant to proper level Gas leak Check leak and charge with refrigerant after repairing faulty Faulty compressor Swash plate shoe is locked Replace compressor Piston is locked Replace compressor Faulty suction discharge valve Replace compressor Faulty expansion valve Clogged valve (foreign matter) Replace valve Temporary clogged due to Thoroughly perform purging freezing valve (water intrusion) after replacing valve and receiver

T5-8-24

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner (Blank)

T5-8-25

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Faulty heating (1) Condition:  Fault code: Un-displayed Faulty air flow volume

Blower motor rotates

Normal speed

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Frosted evaporator Adhered dirt on evaporator surface

Slow speed

Power source decreases

Poor battery terminal contact Faulty blower motor Faulty power transistor Blower motor Blowout of fuse Replace with the Blower motor is does not rotate same capacity fuse locked Faulty wiring Shorted circuit Faulty blower motor relay Faulty blower motor Faulty power transistor Blower interferes with case Faulty controller Faulty ground in body Faulty wiring, disconnection of connector Blowout of power transistor thermal fuse due to locked motor Air flow volume Coolant temperature is low is normal Coolant Disconnection of air mix damper link temperature is Air incorporation in hot-water circuit normal Clogging, breakage and bending of piping Extremely low ambient temperature Low engine coolant level Broken heater core

T5-8-26

Filter cleaning Filter cleaning Remove obstacles Replacement of blower To A Evaporator surface cleaning Check battery charging system Repair Replace Replace Replace blower motor Refer to wiring diagram and check Wirings inspection Replace Replace Replace Repair Replace the controller Make sure to ground Wirings inspection Replace motor

Setting link again Air Bleeding Circuit Repair or replace. Charge engine coolant to proper level Replace heater core

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of evaporator sensor Faulty the frost sensor characteristics Frost sensor is out of evaporator range (faulty sensitivity) No voltage applied to magnet clutch

T5-8-27

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor

Reinsert (floating distance from evaporator is 3 mm (0.12 in) or less) Faulty magnet clutch

Replace magnet clutch

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Faulty heating (2) Condition:  Fault Code: 44 (Abnormal air mix damper servo motor) Clogged foreign matter Faulty wiring, open circuit, disconnection of connector Faulty damper

Remove foreign matter Wirings inspection Replace

T5-8-28

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Others  Faulty air vent switch Fault code is un-displayed Disconnection of link Fault code 43 (Abnormal air vent damper Faulty wiring, open circuit, servo motor) disconnection of connector Faulty servo motor Clogged foreign matter

Setting link again Wirings inspection Replace Remove foreign matter

 Faulty fresh/re-circulated air selection Fault code is un-displayed

Disconnection of link Faulty wiring, open circuit, disconnection of connector Faulty servo motor Clogged foreign matter

Setting link again Wirings inspection Replace Remove foreign matter

 Ambient temperature is higher or lower than set-temperature Fault code 11 (Open circuit in recirculated air sensor) Fault code 12 (Shorted circuit in recirculated air sensor) Fault code is un-displayed (Normal recirculated air sensor)

Open circuit in harness, disconnection Wirings inspection of connector Open circuit in air circulation sensor Replace Shorted circuit in harness Wirings inspection Shorted circuit in air circulation sensor Replace Faulty cooling, faulty heating Check by referring to the items of faulty cooling and faulty heating

T5-8-29

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner  Noise Case connection. Blower fan motor connection.

Gas blowing sound (roaring). Expansion valve connection. Whistle sound. Gas blowing sound. Clutch disengaging sound.

Compressor rotating sound.

Louver resonance. Fan contacts case. Foreign matter enters case. Brush friction noise, metal and/or thrust washer contact. Gas vibration noise (compressor discharge and/or suction gas noise). Abnormal noise from expansion valve. Expansion valve is normally functioning. Faulty clutch bearing, and/or idle pulley bearing. Contact of clutch amature due to resonance. Loose belt. Loose screws. Noisy compressor. Vibration due to V belt looseness. Loose screws.

Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud. No functional problem exists. Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard. Replace. Repair or replace clutch. Re-tighten screws. Repair or replace. Re-adjust belt. Re-tighten screws.

 Others Water leak. Water splash.

Abnormal smell.

Broken heater core. Broken hose. Clogged case drain port and/or drain hose. Absorbed cigarette and dust smell on evaporator fins.

T5-8-30

Replace. Clean. Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L mode for more than 10 minutes, flush smell out by condensed water.

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner (Blank)

T5-8-31

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Blower motor does not operate. Preparation  Check the wiring connections first. Procedure Inspection Method Condition 1 Switch compressor relay with Key Switch: ON blower motor relay. Blower Switch: ON 2 Measurement of voltage Key Switch: ON between terminal #41B of blower motor relay harness end and body. 3 Measurement of voltage Key Switch: ON between terminal #43B of blower Blower Switch: ON motor harness end and body. 4 Continuity check between terminals #1 and #2 of blower motor harness end. 5 Measurement of voltage Key Switch: ON between terminal #44B of power Blower Switch: ON transistor harness end and body. 6 Measurement of voltage Key Switch: ON between terminal #9B of power Blower Switch: ON transistor harness end and body. 7 -

Connector (Harness end)  Blower Motor Relay

Evaluation Cause (check point) Blower motor Faulty blower motor relay. does not operate. 0V Open circuit in harness between fuse #3 and blower motor relay. 0V

0Ω

Open circuit in harness between blower motor relay and blower motor. Faulty blower motor.

Open circuit in harness between blower motor and power transistor. Faulty air conditioner controller.

Procedures as Faulty power transistor. steps 1 to 6 above are normal.

 Blower motor

TDAB-05-07-020

 Power Transistor

TDAB-05-07-028

T5-8-32

TDAB-05-07-027

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Compressor clutch does not operate. Preparation  Check that fresh air temperature is 0 °C (32 °F) or higher first. When fresh air temperature is lower than 0 °C (32 °F), the air conditioner controller turns the compressor clutch OFF in order to protect the compressor.  Check that fault code 21 or 22 (abnormal frost sensor) is not displayed. When the frost sensor is abnormal, the compressor clutch does not operate.  Check the wiring connections first. Procedure Inspection Method 1 Switch compressor relay with blower motor relay. 2 Measurement of voltage between terminal #48A of compressor relay harness end and body. 3 Measurement of voltage between terminal #42A of compressor clutch relay harness end and body. 4 -

Condition Key Switch: ON Blower Switch: ON Key Switch: ON

Evaluation Cause (check point) Compressor is not Faulty compressor relay. operable. 0V Open circuit in harness between fuse #3 and compressor relay.

Key Switch: ON Blower Switch: ON

Procedures as Faulty compressor clutch. steps 1 to 3 above are normal.

Connector (Harness end)  Compressor Relay

Open circuit in harness between compressor relay and compressor clutch.

 Compressor Clutch

TDAB-05-07-019

T5-8-33

TDAB-05-07-024

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Cooling circuit check by using manifold gauge Condition:  Engine Speed: 1500 min-1  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh / re-circulated air selection: Re-circulated Air  Air conditioner inlet temperature: 30 ~ 35°C (86 ~ 95°F) 1. In normal  Low-pressure side pressure: 0.15 ~ 0.25 MPa (21.8 ~ 36.3 PSI)  High-pressure side pressure: 1.37 ~ 1.57 MPa (198.7 ~ 227.7 PSI) NOTE: The reading of manifold gauge may depend on conditions.

TDAA-05-07-018

2. Lack of refrigerant quantity Trouble

Pressure is low on both sides of high-pressure and low-pressure. Cooling performance is low. Cause Refrigerant quantity is low. Gas leak. Remedy Check and repair of gas leak. Charge air conditioner with refrigerant.

TDAA-05-07-019

3. Excessive refrigerant, lack of condenser cooling Trouble

Pressure is high on both sides of highpressure and low-pressure. Cooling performance is low. Cause Overcharge air conditioner with refrigerant. Faulty condenser cooling. Remedy Adjust refrigerant quantity. Clean condenser. Check for machine cooling system.

TDAA-05-07-020

4. Water incorporation in circuit. Trouble

After using a certain period of time, lowpressure side gradually indicates negative pressure. Cause Water is mixed in circuit. Remedy Replace receiver tank. Thoroughly perform purging before charging refrigerant to remove water.

TDAA-05-07-021

T5-8-34

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner 5. Faulty compression of compressor Trouble

Low-pressure side is high and high-pressure side is low. High-pressure becomes equal to low-pressure immediately after stopping the air conditioner. Cause Faulty compressor. Remedy Check and repair of compressor. TDAA-05-07-022

6. Refrigerant does not circulate (clogged circuit) Trouble

When absolutely clogging, low-pressure side indicates negative pressure quickly. When slightly clogging, low-pressure side gradually indicates negative pressure. Cause Dirt or water adheres or freezes to expansion valves, refrigerant does not flow. Remedy Replace receiver tank. Perform purging.

TDAA-05-07-023

7. Air incorporation in circuit Trouble

Pressure is high on both sides of highpressure and low-pressure. When touching low-pressure piping, it is not cold. Cause Air is mixed in system. Remedy Replace refrigerant. Perform purging. TDAA-05-07-024

8. Excessive open of expansion valve Trouble

Pressure is high on both sides of highpressure and low-pressure. Frost (dew) adheres to low-pressure piping. Cause Faulty expansion valve. Remedy Check for installation of thermal cylinder. TDAA-05-07-025

T5-8-35

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Work after Replacing Components The following work is required after replacing compressor, high pressure hose, low pressure hose, condenser, receiver tank, liquid hose, and air conditioner unit. The same work is required when gas leakage is found. 1. Refill Compressor Oil 2. Charge Air Conditioner with Refrigerant  Purging  Charge air conditioner with refrigerant  Warm-up operation  Inspection

T5-8-36

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Refill Compressor Oil When replacing the cooling circuit parts, refill compressor oil to the specified level. Replacement Compressor parts

Condenser

Evaporator

Receiver

D hose (between compressor and condenser)

L hose (between condenser and unit)

S hose (between unit and compressor)

Oilreplenishing quantity

40 cm3 (2.4 in3)

20 cm3 (1.2 in3)

6 to 9 cm3/m (0.4 to 0.5 in3/m)

2 to 4 cm3/m (0.1 to 0.2 in3/m)

8 to 11 cm3/m (0.5 to 0.7 in3/m)

Refer to the following.

 In case of replacing compressor New compressor (1) is charged with oil required for cooling circuit. When replacing new compressor (1), drain excess oil from new compressor (1). Adjust oil level so that it is the same level as oil (B) in compressor (2) to be replaced. NOTE: Compressor oil quantity: 160 cm3 (9.8 in3)

 Compressor oil refill container Oil type ND-OIL8

Quantity 40 cm3 (2.4 in3)

TDAA-05-07-015

New Compressor

Replacing Compressor

T5-8-37

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Charge Air Conditioner with Refrigerant Necessity of Purging Be sure to purge the air conditioner circuit with a vacuum before charging with refrigerant (R134a) because the following problems can arise if air or other gases remain in the A/C circuit. 1. Pressure rise in the high pressure side If air remains in the air conditioner circuit, this disturbs the heat exchange between refrigerant and air in the condenser, causing pressure to rise in the high pressure side (compressor side). Usually, refrigerant gas is easily liquefied; however, air cannot be liquefied and remains as a gas in the condenser because the temperature at which air liquefies is extremely low. That is, liquidation of the refrigerant gas in the condenser decreases by the amount of air in the circuit, and the gas pressure in the high pressure side increases accordingly.

W115-02-10-001

2. Metal corrosion If air remains in the air conditioner circuit, a chemical reaction between refrigerant and moisture in the air takes place, and as a result, hydrochloric acid, that corrodes metals such as aluminum, copper and iron, is produced.

W115-02-10-002

3. Plugging of the expansion valve by moisture When high pressure refrigerant gas passes through the expansion valve, gas pressure decreases and temperature drops. Moisture included in high pressure refrigerant gas in the air conditioner circuit freezes at the expansion valve orifice, plugging refrigerant flow. Operation of the air conditioner becomes unstable and cooling efficiency lowers.

W115-02-10-003

T5-8-38

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Procedures for charging air conditioner with refrigerant

IMPORTANT: Do not mistake the charge hose connections. 1. Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Connect high-pressure side charge hose (3) and low-pressure side charge hose (6) on manifold gauge (1) to the high-pressure side charge valve (“D” marked) and to the lowpressure side charge valve (“S” marked) located on the compressor, respectively. Connect charge hose (5) located on the center of manifold gauge (1) to vacuum pump (4).

7 6 2 3 5 4

W115-02-10-005

2. Open high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Perform purging for 10 minutes or more by operating vacuum pump (4).

1 7

W115-02-10-005

T5-8-39

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner IMPORTANT: If the pointer returns to 0, retighten the line connections and perform purging again. 3. When the low pressure gauge reading falls below -0.1 MPa (-750 mmHg (-14.5 PSI)), close high pressure valve (2) and low pressure valve (7) and stop vacuum pump (4). Wait for approximately five minutes and confirm that the pointer does not return to 0.

W115-02-10-005

4. With high pressure valve (2) and low pressure valve (7) on manifold gauge (1) closed, connect charge hose (5) to refrigerant container (8).

 Refrigerant Specification R134a

Volume (g) 200 250 300

W115-02-10-007

5. Open valve (9) of refrigerant container (8). Push air bleed valve (10) on manifold gauge (1) to purge air in charge hose (5) with the refrigerant pressure. When draining refrigerant, immediately release air bleed valve (10).

W115-02-10-007

T5-8-40

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner IMPORTANT:  Always stop the engine when charging the air conditioner with refrigerant.  Do not position the refrigerant container upside down during charging operation.  When changing the refrigerant container during charging operation, be sure to purge air from the charge hose, as shown in step 10.  Charge the low-pressure side hose first. 6. Fully tighten charge hose (5) connection to gauge manifold (1). Open high pressure valve (2) and valve (9) of refrigerant container (8). Charge with refrigerant (R134a). Close high pressure valve (2) and valve (9) of refrigerant container (8) when high pressure gauge (11) reading reaches 98 kPa (1 kgf/cm2) (14.2 PSI).

W115-02-10-008

fNOTE: Use warm water of 40˚C (104˚F) or less to warm refrigerant container (8) to aid in charging operation.

11 2

5 9 8

IMPORTANT: Use the leak tester for R134a. 7. After charging, check the line connections for gas leaks using leak tester.

W115-02-10-007

T5-8-41

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner 8. Confirm that high pressure valve (2) and low pressure valve (7) on gauge manifold (1) and valve (9) of refrigerant container (8) are closed. Start the engine and operate the air conditioner.

1 7

Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool

9 8

W115-02-10-007

IMPORTANT: Do not open high pressure valve (2) on manifold gauge (1). 9. Open low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8) to charge with refrigerant.

1 7

fNOTE: Required refrigerant quantity: 800±50 g (1.76 ± 0.1 lb)

10. If refrigerant container (8) becomes empty during the charging work, replace refrigerant container (8) with a new refrigerant container as follows:  Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1).  Replace the empty container with new refrigerant container (8).  Tighten, then slightly loosen refrigerant container (8) joint.  Slightly open low pressure valve (7) on manifold gauge (1).  When refrigerant container (8) joint starts to leak, immediately tighten refrigerant container (8) joint and close low-pressure valve (7) on manifold gauge (1). 11. After charging, close low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8), and stop the engine.

T5-8-42

9 8

W115-02-10-007

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner IMPORTANT: If the air conditioner is operated with very low refrigerant, a bad load will be exerted on the compressor. If the air conditioner is overcharged with refrigerant, cooling efficiency will lower and abnormal high pressure will arise in the air conditioner circuit, causing danger. 12. Start the engine and operate the air conditioner again. Check that cold air blow out from the vents. Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool When attempting to disconnect the dCAUTION: high-pressure-side charge hose, refrigerant and

compressor oil may spout. Disconnect the highpressure side charge hose after the high-pressure side pressure drops to less than 980 kPa (10 kgf/ cm2, 142 psi).

13. After checking refrigerant quantity, disconnect the low-pressure-side charge hose first. Disconnect the low-pressure-side charge hose. Wait for the highpressure-side pressure to drop to less than 980 kPa (10 kgf/cm2, 142 psi). Disconnect the high-pressureside charge hose.

T5-8-43

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Warm-up Operation After charting the air conditioner, carry out warmup operation five minute to lubricate system with compressor oil. Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool Inspection After warm-up operation, carry out gas leak check and performance check. CAUTION: Refrigerant will produce poisonous material if exposed to heat of 1000 °C or more. Never bring refrigerant close to a fire. 1. Check the air conditioner for gas leaks using a leak tester.

 Perform checking under well-ventilated conditions.  Thoroughly wipe off dust from the charge hose connections of the compressor.  Pay special attention to check the line connections.  If any gas leaks are found, retighten the line connections. 2. Performance Check. Carry out performance check of the air conditioner after checking each air conditioner component.

W115-02-10-013

 Check each component for abnormalities.  Carry out ON-OFF check of the compressor clutch.  Check compressor fan belt tension.  Check the coolant level in the radiator.  Operate the air conditioner and check the performance.

W115-02-10-014

T5-8-44

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner 3. The checklist before the summer season is as follows:  Check each air conditioner component for abnormalities.  Check the line connections for oil leaks.  Check refrigerant quantity.  Check the engine cooling circuit.  Check V belt for wear. Replace if necessary.  Check for clogged condenser. 4. Off-Season Maintenance  During off-season, operate the idler pulley and compressor at least once a month for a short time to check for any abnormal sounds.  Do not remove the compressor belts during offseason. Operate the compressor occasionally at slow speed for 5 to 10 minutes with the belt slightly loosened in order to lubricate the machine parts. NOTE: When the machine is in normal and the air conditioner is operated with the following conditions, air vent temperature decrease approx. 20 °C or less. (it may be different under special environment.) Operating Conditions of the Air Conditioner  Engine Speed: Fast Idle  Cab Window: Fully closed  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh / re-circulated air selection: Re-circulated Air  Season: Summer

T5-8-45

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Hose and Pipe Tightening Torque

Use the following tightening torque values when connecting the pipes. Joint Location Nut type (Fig. A)

Block joint (Fig. B)

Tube or Bolt Size Tightening Torque N·m (kgf·m) (lbf·ft) Pipe with dia. 8 11.8 to 14.7 (1.2 to 1.5) (8.7 to 10.8) Pipe with D1/2 19.6 to 24.5 (2.0 to 2.5) (14.5 to 18.1) Pipe with D5/8 29.4 to 34.3 (3.0 to 3.5) (21.7 to 25.3) Receiver M6 Bolt 4.0 to 6.8 (4T) (0.4 to 0.7) (3.0 to 5.0) M6 Bolt (6T) 7.9 to 11.8 for other than (0.8 to 1.2) Receiver (5.8 to 8.7)

TDAA-05-07-016 B

TDAA-05-07-017

T5-8-46

INDEX 111004.........................................................................................T5-5-33 111103.........................................................................................T5-5-37 111217.........................................................................................T5-5-38 111330.........................................................................................T5-5-39 111331.........................................................................................T5-5-40 111332.........................................................................................T5-5-41 111422.........................................................................................T5-5-42 111430.........................................................................................T5-5-43 111434.........................................................................................T5-5-43 111450.........................................................................................T5-5-44 111451.........................................................................................T5-5-44 111455.........................................................................................T5-5-45 111457.........................................................................................T5-5-46 111622.........................................................................................T5-5-47 111801.........................................................................................T5-5-48 111904.........................................................................................T5-5-49 111908.........................................................................................T5-5-50 111910.........................................................................................T5-5-33 111914.........................................................................................T5-5-33 111922.........................................................................................T5-5-51 115000.........................................................................................T5-5-52 115001.........................................................................................T5-5-57 115011.........................................................................................T5-5-58 115014.........................................................................................T5-5-59 115015.........................................................................................T5-5-60 120500 to 120502...................................................................T5-5-61 120506, 120507........................................................................T5-5-62 120510.........................................................................................T5-5-62 120512.........................................................................................T5-5-62 120515.........................................................................................T5-5-62 120518.........................................................................................T5-5-62 24-Volt Circuit...........................................................................T5-1-18 5-Volt Circuit..............................................................................T5-1-22 A Accumulator Gas Pressure...................................................T4-5-24 Accumulator Gas Pressure Adjustment (Option), Ride Control.........................................................................T4-5-26 Air Conditioner Controller Fault Code List....T5-5-13, T5-8-12 Air Conditioner Controller Fault Codes E11 to E22............................................................T5-5-63, T5-8-13 E43 to E92............................................................T5-5-64, T5-8-14 Air Conditioner, Outline.......................................................... T5-8-1 Alarm List...................................................................................... T5-3-5 Alternator Check......................................................................T5-1-15 Alternator Indicator, Malfunction......................................T5-7-28 B Backup Alarm/Light, Troubleshooting............................T5-6-74 Battery Voltage Check...........................................................T5-1-14 Bell Crank Stopper Clearance................................................ T4-4-8 Brake Light, Troubleshooting.............................T5-6-32, T5-6-76 Brake System Troubleshooting..........................T5-6-29, T5-6-61 Brake/Transmission Pump Delivery Pressure.................. T4-5-4 Bucket Levelness.....................................................................T4-4-13 Bucket Stopper Clearance...................................................... T4-4-8

C Cab Dome Light, Troubleshooting...................T5-6-32, T5-6-86 CAN1 Harness Check.............................................T5-5-34, T5-5-54 Charge Air Conditioner with Refrigerant........................T5-8-38 Check by False Signal.............................................................T5-1-23 Clearance Light, Troubleshooting....................T5-6-30, T5-6-65 Clearance Light Indicator, Malfunction...........................T5-7-25 Column Monitor (Gauges and Indicators)........................ T5-7-1 Communication System......................................................... T5-3-6 Communication Terminal Fault Code List......................T5-5-15 Component Layout................................................................... T5-4-1 Component Layout, Air Conditioner.................................. T5-8-2 Continuity Check.....................................................................T5-1-16 Control Lever Lock Indicator (Option), Malfunction...T5-7-29 Control Lever Operating Force...........................................T4-4-14 Control Lever Stroke...............................................................T4-4-16 Control Valve.............................................................................T5-4-13 Coolant Temperature............................................................... T5-2-4 Coolant Temperature Gauge................................................. T5-2-7 Coolant Temperature Gauge, Malfunction...................... T5-7-4 Correlation between Trouble Symptoms and Part Failures..........................................................................T5-6-15 Cylinder Drift Check...............................................................T4-4-12 D Daily Report Data...................................................................... T5-3-2 Diagnosing Procedure, Introduction.................................. T5-1-1 Diagnosis Procedure................................................................ T5-1-2 Dome Light, Troubleshooting............................T5-6-32, T5-6-86 E e-Service, Outline...................................................................... T5-3-1 ECM Fault Code List................................................................T5-5-17 Electric System Inspection..................................................... T5-1-5 Electrical System Cab............................................................................................ T5-4-5 Components Related with Engine................................. T5-4-4 Components Related with Relays.................................. T5-4-4 Overview................................................................................. T5-4-3 Engine..........................................................................................T5-4-10 Engine Oil Pressure Indicator, Malfunction....................T5-7-20 Engine Speed................................................................T4-3-1, T5-2-4 Engine System Troubleshooting.......................T5-6-16, T5-6-35 Engine Test................................................................................... T4-3-1 Engine Warning Indicator, Malfunction..........................T5-7-22 F Fault Code.................................................................................... T5-2-5 Fault Code List, Air Conditioner Controller...T5-5-13, T5-8-12 Fault Code List, Communication Terminal.....................T5-5-15 Fault Code List, ECM...............................................................T5-5-17 Fault Code List, ICF..................................................................T5-5-10 Fault Code List, Information Controller...........................T5-5-10 Fault Code List, MC................................................................... T5-5-7 Fault Code List, Monitor Controller...................................T5-5-11 Fault Code List, MPDr............................................................... T5-5-3 Faulty cooling...........................................................................T5-8-16 60Z7 Trbl

INDEX Faulty heating...........................................................................T5-8-26 Frequency Distribution Data................................................. T5-3-3 Front Attachment System Troubleshooting .................................................................................T5-6-18, T5-6-39 Front Console.............................................................................. T5-4-6 Front Washer, Troubleshooting.........................T5-6-32, T5-6-84 Front Wiper, Troubleshooting............................T5-6-32, T5-6-82 Fuel Consumption..................................................................... T5-2-5 Fuel Gauge................................................................................... T5-2-8 Fuel Gauge, Malfunction........................................................ T5-7-5 Functions of Main Parts, Air Conditioner.......................... T5-8-6 Fuse Box A..................................................................................T5-1-11 Fuse Box B..................................................................................T5-1-12 Fuse Inspection........................................................................T5-1-10 Fusible Link Inspection..........................................................T5-1-13 H Hazard Light Indicator, Malfunction.................................T5-7-12 Hazard Light, Troubleshooting..........................T5-6-31, T5-6-70 Head Light, Troubleshooting............T5-6-30, T5-6-66, T5-6-68 High Beam, Troubleshooting.............................T5-6-30, T5-6-68 High Beam Indicator, Malfunction....................................T5-7-13 Horn, Troubleshooting.........................................T5-6-31, T5-6-74 Hose and Pipe Tightening Torque.....................................T5-8-46 How to display service menu................................................ T5-2-4 How to Release Parking Brake in Case of Emergency ..................................................................................................T5-6-90 HST Charging Pump Delivery Pressure.............................. T4-5-3 HST Charging Pump Relief Pressure................................... T4-5-3 HST Motor..................................................................................T5-4-12 HST Motor Displacement Angle Control Pressure.......T4-5-16 HST Oil Temperature................................................................ T5-2-4 HST Oil Temperature Gauge.................................................. T5-2-7 HST Oil Temperature Gauge, Malfunction........................ T5-7-6 HST Oil Temperature Indicator, Malfunction.................T5-7-18 HST Pump Delivery Pressure................................................. T4-5-2 HST Pump Displacement Angle Control Pressure.......T4-5-14 HST Pump Relief Pressure....................................................... T4-5-8 HST Warning Indicator, Malfunction................................T5-7-19 Hydraulic Cylinder Cycle Time............................................T4-4-10 Hydraulic Oil Temperature Sensor, Specification.........T5-5-59 I ICF Fault Code List...................................................................T5-5-10 Information Controller Fault Code List............................T5-5-10 Instructions for Disconnecting Connectors..................... T5-1-8 L Lever Stopper Clearance......................................................... T4-4-8 License Plate Light, Troubleshooting..............T5-6-30, T5-6-65 Light Bulb Check System, Malfunction............................T5-7-10 List of Alarm................................................................................ T5-3-5 List of Daily Report Data......................................................... T5-3-2 List of Frequency Distribution Data.................................... T5-3-3 List of Operation Data.............................................................. T5-3-2 List of Service Menu Display................................................. T5-2-6 List of Total Operating Hours................................................ T5-3-4

Loading Circuit Main Relief Set Pressure.......................... T4-5-6 Low Steering Oil Pressure Indicator (Option), Malfunction..........................................................................T5-7-27 Lubricant Consumption.......................................................... T4-3-3 M Machine Performance Test..................................................... T4-4-1 Main Component (Overview)............................................... T5-4-1 Main Component (Travel System)....................................... T5-4-2 Main Pump Delivery Pressure............................................... T4-5-1 Maintenance Light, Malfunction.......................................T5-7-16 Malfunction of Alternator Indicator...........................................................T5-7-28 Clearance Light Indicator................................................T5-7-25 Control Lever Lock Indicator (Option)........................T5-7-29 Coolant Temperature Gauge........................................... T5-7-4 Engine Oil Pressure Indicator........................................T5-7-20 Engine Warning Indicator...............................................T5-7-22 Fuel Gauge............................................................................. T5-7-5 HST Oil Temperature Gauge............................................. T5-7-6 HST Oil Temperature Indicator......................................T5-7-18 HST Warning Indicator.....................................................T5-7-19 Hazard Light Indicator.....................................................T5-7-12 High Beam Indicator.........................................................T5-7-13 Left And Right Turn Signal Light Indicators..............T5-7-11 Light Bulb Check System.................................................T5-7-10 Low Steering Oil Pressure Indicator (Option)..........T5-7-27 Maintenance Light............................................................T5-7-16 Monitor Buzzer..................................................................... T5-7-3 Monitor Display.................................................................... T5-7-8 Overheat Indicator............................................................T5-7-21 Parking Brake Indicator....................................................T5-7-24 Preheat Indicator................................................................T5-7-17 Seat Belt Indicator (Option)............................................T5-7-30 Secondary Steering Indicator (Option)......................T5-7-26 Service Indicator................................................................T5-7-23 Turn Signal Light Indicators...........................................T5-7-11 Work Light Indicator.........................................................T5-7-14 MC Fault Code 111004...................................................................................T5-5-33 111103...................................................................................T5-5-37 111217...................................................................................T5-5-38 111330...................................................................................T5-5-39 111331...................................................................................T5-5-40 111332...................................................................................T5-5-41 111422...................................................................................T5-5-42 111430...................................................................................T5-5-43 111434...................................................................................T5-5-43 111450...................................................................................T5-5-44 111451...................................................................................T5-5-44 111455...................................................................................T5-5-45 111457...................................................................................T5-5-46 111622...................................................................................T5-5-47 111801...................................................................................T5-5-48 111904...................................................................................T5-5-49 111908...................................................................................T5-5-50 60Z7 Trbl

INDEX MC Fault Code 111910...................................................................................T5-5-33 111914...................................................................................T5-5-33 111922...................................................................................T5-5-51 MC Fault Code List.................................................................... T5-5-7 Monitor, Outline......................................................................... T5-2-1 Monitor Buzzer, Malfunction................................................. T5-7-3 Monitor Controller Fault Code 115000...................................................................................T5-5-52 115001...................................................................................T5-5-57 115011...................................................................................T5-5-58 115014...................................................................................T5-5-59 115015...................................................................................T5-5-60 120500 to 120502..............................................................T5-5-61 120506, 120507, 120510.................................................T5-5-62 120512, 120515, 120518.................................................T5-5-62 Monitor Controller Fault Code List....................................T5-5-11 Monitor Display.......................................................................... T5-2-2 Monitor Display, Malfunction............................................... T5-7-8 Monitor Panel............................................................................. T5-4-9 MPDr. Fault Code Reference Table...................................... T5-5-3 O Operating Procedures of Service Menu............................ T5-2-3 Operation Data........................................................................... T5-3-2 Operational Performance Standard Table........................ T4-2-1 Operational Performance Tests............................................ T4-1-1 Other System Troubleshooting.........................T5-6-30, T5-6-65 Overheat Indicator, Malfunction........................................T5-7-21 Overload Relief Valve Set Pressure....................................T4-5-12 P Parking Brake Function Check.............................................. T4-4-7 Parking Brake Indicator, Malfunction...............................T5-7-24 Parking Brake Manual Release............................................T5-6-90 Parking Brake Release, Recovery.......................................T5-6-91 Pilot Shut-Off Solenoid Valve (Hydraulic Operated Type)(Option).............................T5-4-17 Precautions for Inspection and Maintenance................. T5-1-6 Precautions for Self-Traveling.............................................T5-6-87 Precautions for Towing..........................................................T5-6-88 Preheat Indicator, Malfunction...........................................T5-7-17 Preparation for Performance Tests...................................... T4-1-2 Primary Pilot Pressure (Hydraulic Operated Type: Option).............................T4-5-20 Priority Valve.............................................................................T5-4-14 Pump Device.............................................................................T5-4-11 R Rear Console............................................................................... T5-4-8 Rear Wiper, Troubleshooting..............................T5-6-32, T5-6-83 Rear Washer, Troubleshooting...........................T5-6-32, T5-6-85 Recovery after Parking Brake Release..............................T5-6-91 Refill Compressor Oil..............................................................T5-8-37 Refrigerant, Charge Air Conditioner.................................T5-8-38 Reverse Buzzer/Light, Troubleshooting.........T5-6-32, T5-6-74

Relationship between Machine Trouble Symptoms and Related Parts................................................................. T5-6-3 Ride Control Accumulator (Option)..................................T4-5-25 Ride Control Accumulator Gas Pressure Adjustment (Option).................................................................................T4-5-26 Ride Control Valve (Option).................................................T5-4-15 Right Console.............................................................................. T5-4-7 S Seat Belt Indicator (Option), Malfunction.......................T5-7-30 Secondary Pilot Pressure (Hydraulic Operated Type: Option).............................T4-5-22 Secondary Steering Block (Option)...................................T5-4-16 Secondary Steering Indicator (Option), Malfunction..........................................................................T5-7-26 Secondary Steering Pump (Option).................................T5-4-16 Self-Traveling, Precautions...................................................T5-6-87 Sensor Activating Range........................................................ T4-2-8 Service Brake Function Check............................................... T4-4-4 Service Brake Wear Amount.................................................. T4-4-6 Service Indicator, Malfunction............................................T5-7-23 Standard Table............................................................................ T4-2-1 Steering Circuit Relief Pressure...........................................T4-5-10 Steering System Troubleshooting....................T5-6-24, T5-6-49 T Test Harness..............................................................................T5-1-24 Total Operating Hours............................................................. T5-3-4 Towing, Precautions...............................................................T5-6-88 Transmission.............................................................................T5-4-12 Transmission Clutch Pressure.............................................T4-5-18 Transporting Wheel Loader (Urgent Situation)............T5-6-87 Travel Speed................................................................................ T4-4-1 Travel System Troubleshooting.........................T5-6-26, T5-6-51 Troubleshooting A (by Fault Codes)................................... T5-5-1 Troubleshooting B (by Troubleshooting Symptom)..... T5-6-1 Troubleshooting C (Monitor Diagnosis)............................ T5-7-1 Troubleshooting, Air Conditioner......................................T5-8-11 Turn Signal Light, Troubleshooting.................T5-6-31, T5-6-72 Turn Signal Light Indicators, Malfunction......................T5-7-11 V Vehicle Information Display.................................................. T5-2-2 Voltage and Current Measurement..................................T5-1-18 W Washer, Troubleshooting.....................................T5-6-32, T5-6-84 Wiper, Troubleshooting........................................T5-6-32, T5-6-80 Work Light, Troubleshooting.............................T5-6-32, T5-6-78 Work Light Indicator, Malfunction....................................T5-7-14 Work after Replacing Components, Air Conditioner ..................................................................................................T5-8-36

60Z7 Trbl

INDEX (Blank)

60Z7 Trbl