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62Z7/67Z7/67TM7 SHOP MANUAL Operational Performance Test Troubleshooting

Printed in Japan (K) ( アメリカ用 )

93207-01031

93207-01031 April 2015

SHOP MANUAL WHEEL LOADER

62Z7/67Z7/ 67TM7 Operational Performance Test Troubleshooting

93207-01031 April 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

Group 6

Adjustment .............................................................................................................. T4-6-1

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.

62Z7/67Z7/67TM7

INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. y 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 y 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. y 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.

y 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: y Technical Manual: T 1-3-5 T 1 3 5

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

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

IN-01

Workshop Manual (Disassembly & Reassembly) Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

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

CAUTION:

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

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.

NOTE:

Indicates supplementary technical information.

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

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

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

Quantity

To Convert From

Into

Multiply By

Length

0.03937

0.003281

Volume

US gal

0.2642

US qt

1.057

L 3

1.308

Weight

2.205

Force

kgf

0.10197

lbf

0.2248

N·m

kgf·m

Torque Pressure

0.10197 2

MPa

kgf/cm

10.197

MPa

psi

145.0

1.360

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

-1

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Power

Flow rate

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

IN-02

Symbol and Abbreviation Symbol and Abbreviation Symbol / Name Abbreviation T/M Transmission S/M Shop Manual

MC ECM VGS VGT

HST Controller

GSM

GPS CAN

A/C OPT MPDr. A/I, A/S WU Li ATT

Explanation

Transmission Shop manual (Function and Structure, Operational Performance Test / Troubleshooting, Disassembly and Reassembly). Main Controller Main controller. MC controls the engine, pump, and valve according to the machine operating condition. Engine Control Module Engine controller. ECM controls fuel injection amount according to the machine operating condition. Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged Variable Geometry Turbo controller system to supercharge the exhaust energy while running the engine at slow idle speed. VGS optimizes the turbine rotation, improves the performance at slow-speed torque and the acceleration, reduces fuel consumption, and reduces particulate matter (PM) by adjusting the nozzle opening of turbine housing. Hydrostatic Transmission Controller Hydrostatic transmission controller. Hydraulic pump and motors drive the clutch where all power is transmitted by hydraulic fluid. HST controller controls the transmission, HST pump and HST motors 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. Auto-idling Stop Auto-idling stop function Warming-Up Warming-up. Low (Slow) Idle Slow idle engine speed. Attachment Attachment.

SY-1

Symbol and Abbreviation Symbol / Name Abbreviation DPF Diesel Particulate Filter

DPD

Diesel Particulate Diffuser

DOC

Diesel Oxidation Catalyst

CSF

Catalyzed Soot Filter

PM EGR

Particulate Matter Exhaust Gas Recirculation

Explanation DPF is a filter which removes particulate matter (PM) including the toxic substance of exhaust gas of the diesel engine. Exhaust particulate removal equipment. DPD is an exhaust emission control system, a type of DPF, which cleans up particulate matter (PM) of diesel engine exhaust gas. DPD is a ceramic filter which traps and filters PM of exhaust gas. DPD burns up accumulated PM when PM increases and regenerates the filter. Oxidation catalyst for the diesel engine. Diesel oxidation catalyst oxidizes unburnt fuel and raises exhaust temperature. Filter. The filter traps, burns, and remove particulate matter (PM) by using high-temperature-exhaust gas with diesel oxidation catalyst. Catalyst is applied onto the filter. This advances PM burning. Particulate matter in gas 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-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 Clearance, 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

Loading/Steering Overload Relief Valve Set Pressure ...................................................................T4-5-18 Overload Relief Valve Pressure Adjustment Procedure ....................................................................T4-5-21 Service Brake Pressure (Front and Rear) ...................T4-5-22 Parking Brake Pressure ....................................................T4-5-24 Service Brake Accumulator Pressure..........................T4-5-26 Brake Warning Pressure (Pressure-Decreasing) .....T4-5-28 Brake Warning Pressure (Pressure-Increasing) .......T4-5-30 Transmission Clutch Pressure .......................................T4-5-32 Accumulator Gas Pressure .............................................T4-5-34 Service Brake Circuit ...................................................T4-5-36 Steering Circuit.............................................................T4-5-38 Gas Pressure Adjustment Procedure of Accumulator (Service Brake Circuit, Steering Circuit) ...............T4-5-40 Ride Control Circuit (Option) ...................................T4-5-41 Gas Pressure Adjustment Procedure of Accumulator (Ride Control Circuit (Option)) ................................T4-5-42

Group 6 Adjustment Measuring Method of No-Load-Max Differential Pressure ............................................................................. T4-6-1 Zero-Point Calibration (Correction) .............................. T4-6-3 Rewrite of Exhaust Filter Serial No. ............................... T4-6-4 Maintenance of Exhaust Filter ........................................ T4-6-5 Clutch Learning ................................................................... T4-6-6 Brake Pedal Angle Learning ..........................................T4-6-10 Lift Arm Angle Sensor Learning...................................T4-6-14

Primary Pilot Pressure (Including Brake Circuit) ...... T4-5-1 Primary Pilot Pressure Adjustment Procedure .... T4-5-3 Secondary Pilot Pressure .................................................. T4-5-4 Combined Delivery Pressure of Main Pump and Steering Pump ................................................................ T4-5-5 HST Pump Delivery Pressure........................................... T4-5-6 HST Charging Pump Delivery Pressure ....................... T4-5-7 Transmission Charge Pump Delivery Pressure ......... T4-5-8 Loading Circuit Main Relief Set Pressure ..................T4-5-10 Main Relief Valve Pressure Adjustment Procedure ....................................................................T4-5-12 HST Pump Relief Pressure ..............................................T4-5-14 Steering Circuit Main Relief Set Pressure..................T4-5-16

62Z7/67Z7/67TM7

(Blank)

62Z7/67Z7/67TM7

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

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

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

Definition of “Performance Standard”

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

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

3. To economically operate the machine under optimal conditions.

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

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

T4-1-1

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

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

T4-1-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard 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

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: x Accelerator Pedal: Full Stroke x Power Mode Switch: ON x Hydraulic Oil Temperature: 55±5 °C (131±9 °F) Performance Standard

Remarks

Reference Page

Power mode switch: OFF

T4-3-1

Low Idle Speed (without load)

800±25

Value indicated on MPDr.

High Idle Speed (without load)

2150±30

Value indicated on MPDr.

High Idle Speed (with HST relieved)

2120±50

Value indicated on MPDr.

High Idle Speed (with front attachment relieved)

2040±50

Value indicated on MPDr.

Engine Speed

min-1

Power mode switch: ON

Low Idle Speed (without load)

800±25

Value indicated on MPDr.

High Idle Speed (without load)

2420±30

Value indicated on MPDr.

High Idle Speed (with HST relieved)

2380±50

Value indicated on MPDr.

High Idle Speed (with front attachment relieved)

2300±50

Value indicated on MPDr.

T4-3-1

Valve Clearance (In, Ex)

mm (in)

0.4 (0.016)

With the engine cold

Refer to Engine Manual

Lubricant Consumption (Rated output)

mL (quart)/h

20 (0.02) or less

Hour meter: 2000 hours or less

T4-3-3

T4-2-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Travel Speed

km/h (mph)

Performance Standard

Remarks

Reference Page

Power mode switch: OFF

T4-4-1

First Speed (Forward/Reverse)

7.0±1.0/7.0±1.0 (4.4±0.6/4.4±0.6)

Value indicated on MPDr.

Second Speed (Forward/Reverse)

11.5±1.2/11.5±1.2 (7.1±0.7/7.1±0.7)

Value indicated on MPDr.

Third Speed (Forward/Reverse)

20.0±2.0/20.0±2.0 Value indicated on MPDr. (12.4±1.2/12.4±1.2)

Fourth Speed (Forward) (62Z7)

34.6±3.5 (21.5±2.2)

Value indicated on MPDr.

Fourth Speed (Forward) (67Z7/67TM7)

39.0±3.9 (24.2±2.4)

Value indicated on MPDr.

Travel Speed

km/h (mph)

Power mode switch: ON

First Speed (Forward/Reverse)

7.0±1.0/7.0±1.0 (4.4±0.6/4.4±0.6)

Value indicated on MPDr.

Second Speed (Forward/Reverse)

12.2±1.2/11.5±1.2 (7.6±0.7/7.1±0.7)

Value indicated on MPDr.

Third Speed (Forward/Reverse)

20.0±2.0/20.0±2.0 Value indicated on MPDr. (12.4±1.2/12.4±1.2)

Fourth Speed (Forward)

34.6±3.5 (21.5±2.2)

Value indicated on MPDr.

14 (45) or less

Machine speed: 32 km/h (19.9 mph)

Service Brake Function Check

m (ft)

Service Brake Wear Amount

mm (in) 9.2 (0.4)

Allowable limit: 7.9 (0.31)

Steel Plate

8.0 (0.3)

Allowable limit: 7.5 (0.29)

mm/5 min

Parking Brake Wear Amount

mm (in)

T4-4-4 T4-4-6

Friction Plate Parking Brake Function Check

T4-4-1

T4-4-7 -

Brake Disc

2.5 (0.1)

Allowable limit: 2.2 (0.09)

Brake Pad

1.6 (0.06)

Allowable limit: 1.4 (0.06)

Bucket Stopper Clearance

mm (in)

T4-4-8

Lever (Bell Crank) Stopper Clearance (62Z7/67TM7)

mm (in)

0 to 3 (0 to 0.12)

T4-4-8

Lever (Bell Crank) Stopper Clearance (67Z7)

mm (in)

2 (0.08

T4-4-8

Front Pin Wear Amount

mm (in)

Allowable limit: -1.0 (-0.03) -

Front Bushing Wear Amount

mm (in)

Allowable limit: -1.5 (-0.05) -

Clearance Between Front Pin and Bushing

mm (in)

0.3 (0.01)

T4-2-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Hydraulic Cylinder Cycle Time (62Z7)

sec

Performance Standard

Lift Arm Raise

5.2±0.3

Lift Arm Lower (Float)

3.0±0.3

Bucket Dump

1.1±0.3

Steering (engine: high idle speed)

3.4±0.4

Hydraulic Cylinder Cycle Time (62Z7)

sec 4.5±0.3

Lift Arm Lower (Float)

3.0±0.3

Bucket Dump

1.1±0.3

Steering (engine: high idle speed)

3.0±0.3 sec

Lift Arm Raise

6.4±0.3

Lift Arm Lower (Float) (67Z7)

3.8±0.3

Lift Arm Lower (Float) (67TM7)

3.5±0.5

Bucket Dump (67Z7)

1.4±0.3

Bucket Dump (67TM7)

3.5±0.4

Steering (engine: high idle speed)

3.4±0.4

Hydraulic Cylinder Cycle Time (67Z7/67TM7)

sec

Lift Arm Raise

5.7±0.3

Lift Arm Lower (Float) (67Z7)

3.8±0.3

Lift Arm Lower (Float) (67TM7)

3.4±0.5

Bucket Dump (67Z7)

1.4±0.3

Bucket Dump (67TM7)

3.4±0.5

Steering (engine: high idle speed)

3.4±0.4

Dig Function Drift Check

mm (in)/15 min 45 (1.8) or less

Bucket Cylinder

15 (0.6) or less

Bucket Bottom (62Z7)

75 (3) or less

Bucket Bottom (67Z7)

150 (6) or less mm (in)

Power mode switch: OFF

T4-4-10

Power mode switch: OFF

T4-4-10

Power mode switch: ON

T4-4-10

T4-4-12

Lift Arm Cylinder

Bucket Levelness

Reference Page

Power mode switch: ON

Lift Arm Raise

Hydraulic Cylinder Cycle Time (67Z7/67TM7)

Remarks

14 (0.6) or less

T4-2-3

T4-4-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Control Lever Operating Force

N (kgf ) (lbf )

Performance Standard

Remarks

Reference Page T4-4-14

Lift Arm Raise

27 (2.8) (6.1) or less

Joystick type lever

Lift Arm Raise (Detent)

54 (5.5) (12.1) or less

Joystick type lever

Lift Arm Raise (Detent Release)

40 (4.1) (9.0) or less

Joystick type lever

Lift Arm Lower

27 (2.8) (6.1) or less

Joystick type lever

Lift Arm Lower (Float)

54 (5.5) (12.1) or less

Joystick type lever

Lift Arm Lower (Float Release)

40 (4.1) (9.0) or less

Joystick type lever

Bucket Control Lever Roll Back

20 (2.0) (4.5) or less

Joystick type lever

Bucket Control Lever Roll Back (Detent)

40 (4.1) (9.0) or less

Joystick type lever

Bucket Control Lever Roll Back (Detent Release)

50 (5.1) (11.2) or less

Joystick type lever

Bucket Control Lever Dump

30 (3.1) (6.7) or less

Joystick type lever

Steering

29 (0.3) (6.5) or less

With steering wheel operated

Forward/Reverse Lever

12 (+3/-2) (1.2(+0.3/-0.2)) (2.7(+0.7/-0.45))

Accelerator Pedal

22±6 (2.2±0.6) (4.95±1.35)

Brake/Declutch Pedal (Right/Left)

298 (+38/-27) (30.4(+3.9/-2.8)) (67(+8.5/-6.1)) When operating brake pedal (fully)

T4-2-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Control Lever Stroke

mm (in)

Performance Standard

Remarks

Reference Page T4-4-16

Lift Arm Raise

58±10 (2.3±0.4)

Joystick type lever

Lift Arm Raise (Detent)

79±10 (3.1±0.4)

Joystick type lever

Lift Arm Lower

58±10 (2.3±0.4)

Joystick type lever

Lift Arm Lower (Float)

79±10 (3.1±0.4)

Joystick type lever

Bucket Control Lever Roll Back

58±10 (2.3±0.4)

Joystick type lever

Bucket Control Lever Roll Back (Detent)

79±10 (3.1±0.4)

Joystick type lever

Bucket Control Lever Dump

79±10 (3.1±0.4)

Joystick type lever 60 rpm (with steering wheel operated)

Steering Wheel Rotation (Right Max. to Left Max.)

(Turn)

3.6 to 4.1

Forward/Reverse Lever

mm (in)

50±5 (2.0±0.2)

Steering Wheel Play

5 to 15 (0.2±0.6)

Brake Pedal Play

0 to 5 (0±0.2)

T4-2-5

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Pedal Depressing Angle

deg.

Performance Standard

Accelerator Pedal

17±2

Brake/Inching Pedal (Right/Left)

22.6±1.5

Electrolyte Density (Specification at 20 °C (68 °F)) Tire Inflation (62Z7)

1.26

Remarks

Reference Page

(without play)

T4-4-16

Allowable limit: 1.16

kPa (kgf/cm2) (psi)

Bias Tire

350 (+50/-0) (3.6 (+0.5/-0)) (50.8 (+7.25/-0))

Size of tires: 17.5-25-12 PR

Radial Tire

425 (+50/-0) (4.3 (+0.5/-0)) (61.6 (+7.25/-0))

Size of tires: 17.5 R25

Tire Inflation (67Z7)

kPa (kgf/cm2) (psi)

Bias Tire

Radial Tire

280 (+50/-0) (2.9 (+0.5/-0)) (40.6 (+7.25/-0))

Size of tires: 20.5-25-12 PR

350 (+50/-0) (3.6 (+0.5/-0)) (50.8 (+7.25/-0))

Size of tires: 20.5-25-16 PR

400 (+50/-0) (4.1 (+0.5/-0)) (58 (+7.25/-0))

Size of tires: 20.5 R25

NOTE: Tire inflation is different depending on size of tires.

T4-2-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Primary Pilot Pressure

MPa (kgf/cm2) (psi) 3.7±0.7 (38±7) (537±101.5)

Secondary Pilot Pressure

Performance Standard

Remarks

Reference Page T4-5-1

T4-5-4

In neutral, Value T4-5-5 indicated on MPDr.

MPa (kgf/cm ) (psi) 3.7±0.7 (38±7) (537±101.5)

Combined Delivery Pressure of Main Pump and Steering Pump

MPa (kgf/cm ) (psi) 1.5 (+1.0/-0.5) (15 (+10/-5)) (217.6 (+145/-72.5))

HST Pump Delivery Pressure

MPa (kgf/cm2) (psi) 2.4±0.3 (25±3) (348±43.5)

T4-5-6

HST Charging Pump Delivery Pressure

MPa (kgf/cm ) (psi) 3.5±0.3 (36±3) (507.6±43.5)

T4-5-7

Transmission Charge Pump Delivery Pressure

MPa (kgf/cm2) (psi) 1.8 to 2.1 (18 to 21) (261 to 305)

T4-5-8

Main Relief Set Pressure

MPa (kgf/cm2) (psi)

T4-5-10

Relief Operation of Lift Arm

20.6 (+1.2/-0.5) (210 (+12/-5)) (2988 (+174/-72.5))

Relief Operation of Bucket

20.6 (+1.2/-0.5) (210 (+12/-5)) (2988 (+174/-72.5))

Value indicated on MPDr.

HST Pump Relief Pressure

MPa (kgf/cm2) (psi) 41.2±1.9 (420±19) (5976±275.6)

T4-5-14

Steering Relief Pressure

MPa (kgf/cm2) (psi) 19.6 (+1.9/-0) (200 (+19/-0)) (2843 (+275.6/-0))

T4-5-16

Overload Relief Pressure

MPa (kgf/cm2) (psi)

Lift Arm Raise

27.4 (+1.0/-0) (280 (+10/-0)) (3974 (+145/-0))

Bucket Roll Back

22.6 (+1.0/-0) (230 (+10/-0)) (3278 (+145/-0))

Bucket Dump (62Z7/67Z7)

22.6 (+1.0/-0) (230 (+10/-0)) (3278 (+145/-0))

Bucket Dump (67TM7)

14.9 (+1.0/-0) (152 (+10/-0)) (2161 (+145/-0))

Service Brake Pressure (Front/ Rear)

MPa (kgf/cm2) (psi) 3.63±0.6 (37±6) (526.5±87)

Parking Brake Pressure

MPa (kgf/cm2) (psi) 3.7±0.7 (38±7) (537±101.5)

Brake Accumulator Pressure

(Reference)

T4-5-18

at brake pedal (left)

T4-5-22 T4-5-24

MPa (kgf/cm ) (psi)

Service Brake

T4-5-26 10.8 to 17.0 (110 to 173) (1566 to 2466)

Parking Brake

3.7±0.7 (38±7) (537±101.5) 2

Brake Warning Pressure (Pressure-Decreasing)

MPa (kgf/cm ) (psi) 8.1±0.5 (82±5) (1175±72.5)

T4-5-28

Brake Warning Pressure (Pressure-Increasing)

MPa (kgf/cm2) (psi) 10±0.5 (102±5) (1450±72.5)

T4-5-30

Transmission Clutch Pressure

MPa (kgf/cm2) (psi) 1.8 to 2.1 (18 to 21) (261 to 305)

T4-5-32

Accumulator Gas Pressure

MPa (kgf/cm2) (psi)

T4-5-34

Service Brake

6.7 to 7.0 (68.3 to 71.4) (972 to 1015)

20 °C (68 °F)

Steering

1.9 to 2.2 (19.4 to 22.4) (276 to 319)

20 °C (68 °F)

T4-2-7

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

Power Mode Switch

High Idle Speed

t .POJUPS FBDI TFOTPS CZ VTJOH .1%S

2. Sensor Activating Range Item HST Pump Delivery Pressure Main Relief Pressure Parking Brake Pressure

Operation

Unit

Specification 2

Neutral

MPa (kgf/cm ) (psi) 2.1 to 2.7 (21 to 28) (305 to 392)

HST Relieved

MPa (kgf/cm2) (psi) 39.3 to 43.1 (401 to 439) (5700 to 6251)

Neutral

MPa (kgf/cm2) (psi) 1.0 to 2.5 (10 to 25) (145 to 362.6)

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) 3.0 to 4.4 (31 to 45) (435 to 638)

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.

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

other performance data will be unreliable. Consequently, measure the engine speed before performing all other tests in order to check that the engine speed meets specification. Preparation: 1. Select the service menu of monitor (In case of MPDr., connect MPDr. first). 2. Warm up the machine until coolant temperature reaches 50 °C (122 °F) or more and hydraulic oil temperature is 55±5 °C (131±9 °F).

T4-3-1

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

and rear tires in order not to move the machine 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

Forward/Reverse Lever, Shift Switch N

Low Idle Speed (with no load) High Idle Speed (with no Third speed/fourth load) speed forward High Idle Speed (with HST Third speed/fourth relieved) speed forward High Idle Speed (with front Third speed forward attachment relieved)

Accelerator Pedal

Parking Brake Switch Power Mode Switch

No depression

ON/OFF

Full stroke

ON/OFF

Full stroke

OFF

ON/OFF

Full stroke

OFF

ON/OFF

Item Control Lever (Bucket) Low Idle Speed (with no Transporting position, load) No control lever operation High Idle Speed (with no Transporting position, load) No control lever operation High Idle Speed (with HST Transporting position, relieved) No control lever operation High Idle Speed (with front Transporting position, attachment relieved) Bucket is rolled back and relieved. Evaluation: Refer to Operational Performance Standard (p.T4-2-1). Remedy: Refer to Troubleshooting B. NOTE: Engine System Troubleshooting (T5-6-28).

T4-3-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 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 lower 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 lower 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.

NOTE: 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: 1. 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).

NOTE: The machine speed can be read on the MPDr or monitor.

Preparation: 1. Adjust air pressure of the tires evenly in advance. (62Z7) x Bias Tire: 350 kPa (3.6 kgf/cm2, 51 psi) x Radial Tire: 425 kPa (4.3 kgf/cm2, 62 psi) (67Z7/67TM7) x Bias Tire: 280 kPa (29 kgf/cm2, 41 psi) x Radial Tire: 400 kPa (4.1 kgf/cm2, 58 psi)

a c

e T4GB-04-04-001

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. (For measurement at fourth speed, a 300 m (984 ft) acceleration zone is needed.)

abc-

3. Empty the bucket and hold the lift arm with it floated 0.3 m (12 in) above the ground. 4. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicator of the coolant temperature monitor should rise above the horizontal position.

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 CAUTION: reverse travel to avoid accident. 1. Measure in each mode (first speed to fourth speed). 2. Select the conditions as follows. Shift Switch

Parking Brake Switch

Accelerator Pedal

Power Mode Switch

1 st Speed Limit Switch

First Speed

OFF

Full Stroke

ON/OFF

OFF

Second Speed

OFF

Full Stroke

ON/OFF

OFF

Third Speed

OFF

Full Stroke

ON/OFF

OFF

Fourth Speed

OFF

Full Stroke

ON/OFF

OFF

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

4. Measure the travel speed (sec) of each travel mode. 5. Repeat the measurement three times and calculate the mean values. 6. Convert the measurement value to be expressed in km/h. Measurement value (seconds) = S (sec) Converted value (hourly speed) = A (km/h) A = (50×3600)/(S×1000) Evaluation: Refer to Operational Performance Standard (p.T4-2-2). TNDF-01-02-005

Remedy:

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

T4-4-2

Machine Speed Sensor

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. (62Z7) x Bias Tire: 350 kPa (3.6 kgf/cm2, 51 psi) x Radial Tire: 425 kPa (4.3 kgf/cm2, 62 psi) (67Z7/67TM7) x Bias Tire: 280 kPa (29 kgf/cm2, 41 psi) x Radial Tire: 400 kPa (4.1 kgf/cm2, 58 psi) a

2. On a paved dry road, prepare a 150 m (492 ft) straight travel course (100 m (328 ft) of acceleration zone + 50 m (164 ft) of test track) and set the brake starting point. 3. Empty the bucket and hold the lift arm with it floated 0.3 m (12 in) above the ground.

b c

abc-

4. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicator of the coolant temperature monitor should rise above the horizontal position.

T4-4-4

0.3 m (12 in) Braking Distance Stop Position

T4GB-04-04-002

Brake Starting Point

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

2. Select the switches as follows. Shift Switch

Parking Brake Switch

Accelerator Pedal

Power Mode Switch

Fourth Speed

OFF

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 32 km/h (20 mph). 4. Release the accelerator pedal and step on the right service brake pedal at the brake starting point. Completely stop the machine. 5. Measure the distance from the brake starting point to the point where the front tire is contacting. 6. Repeat the measurement three times and calculate the mean values. Add traveling distance 0.97 m (3 ft 2 in) to the mean value. This is stopping distance. Evaluation: Stopping distance: 14 m (45 feet) or less Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-44)

T4-4-5

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

Summary: 1. Check the extent of wear of friction plate (1) at the service brake of the axle by using the wear gauge (ST 7919). Preparation: 1. Clean around drain plug (5) of the axle and loosen it.

3 2

2. Remove drain plug (5) and drain axle oil.

Measurement:

1. Operate the service brake by stepping on the brake pedal. 2. Insert wear gauge (b) into drain port (6), turn wear gauge (b), and measure wear limit (a).

TNDF-04-04-001

Evaluation:

1. In case wear gauge (b) turns, wear amount of friction plate (1) does not reach the allowable limit. In case wear gauge (b) can not turn, wear amount of friction plate (1) is beyond the allowable limit. 2. In the method above, in case the wear amount is beyond the maximum allowable limit of use or in case the service brake portion has been disassembled, refer to Operational Performance Standard in T4-2.

TNDF-04-04-002 123-

Friction Plate Brake Piston Brake Retainer

456-

Steel Plate Drain Plug Drain Port

ab-

Wear Limit Wear Gauge (ST 7919)

ф 7.9 mm (0.31 in)

x Wear Limit (a): 7.9 mm (0.31 in)

T4-4-6

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

Preparation: 1. Measure on a 1/5 slope of paved surface (11.31°). 2. Empty the bucket and hold the bucket with it floated 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 55±5 °C (131±9 °F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicator of the coolant temperature monitor should rise above the horizontal position.

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. Put a mark (white line) on the tire and the road surface respectively. 4. After five minutes, measure the amount of movement between white lines of tire and road surface. 5. Repeat the measurement three times and calculate the mean values.

Evaluation: No movement. Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-44)

T4-4-7

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

11.31° (20 % Slope)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Bucket Stopper Clearance, Lever (Bell Crank) Stopper Clearance

y 62Z7/67Z7 a b

Summary: 1. Measure wear and deformation conditions of the bucket stopper (dump side and roll back side) and the clearance between lever (bell crank) stopper and cross tube. Preparation: 1. Stop the machine on a plane road surface and operate the parking brake. Measurement: y Bucket Dump Stopper (a) 1. Raise the lift arm to the highest lifting position and stop the engine.

T4GB-04-04-008

2. Dump the bucket calmly with the engine stopped until the bucket contacts dump stopper (a). At this time, measure strokes (A and B) of the bucket cylinder and the lift arm and dump angle (C) of the bucket. In addition, measure the clearance between cross pipe dump (bell crank) stopper (b) and the cross tube.

2 c

NOTE: In case of 67TM7, measure strokes (A, B) of the

bucket cylinder and angle (C) of the bucket. 3. At the same time, measure the contact condition of bucket dump stopper (a) (left and right). 1

y Bucket Roll Back Stopper (c) 1. Raise the lift arm until lift arm cylinder stroke (E) becomes the length of the standard dimension. 2. Set the engine at idling speed and make roll back operation until the bucket calmly contacts bucket roll back stopper (c).

NOTE: In case of 67TM7, tilt until the bucket link (1)

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

T4GB-04-04-010

ab-

Bucket Dump Stopper Cross Pipe Dump (Bell Crank) Stopper

Bucket Roll Back Stopper

Bucket Link

Bell Crank (Lever)

y 67TM7

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

3 M4GB-07-183 1-

T4-4-8

Bucket Link

Guide

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

2. Bucket Roll Back Stopper

x Cylinder Strokes (A, B)

x Cylinder Strokes (D, E)

Model

Bucket Cylinder (A)

Lift Arm Cylinder (B)

mm (in)

320±1.5 (12.6±0.60)

810±2 (31.9±0.08)

67Z7

300±1.5 (11.8±0.60)

950±2 (37.4±0.08)

67TM7

1027±1.5 (40.4±0.60)

950±2 (37.4±0.08)

62Z7

Model

Bucket Cylinder Lift Arm Cylinder D (mm) (in)

E (mm) (in)

62Z7

600 (23.6)

270 (10.6)

67Z7

610 (24.1)

300 (11.8)

67TM7

403 (15.9)

262 (10.3)

x Bucket Roll Back Angle (F) degree 50

x Bucket Dump Angle (C) Model

degree

62Z7/67Z7

49±2

Model

mm (in)

67TM7

45±2

62Z7

380 (15)

67Z7

445 (17.5)

67TM7

400 (15.7)

x Height from Ground to Bucket Lowest Portion (G)

x Clearance between Lever Stopper and Cross Tube (b) Clearance between Stopper and Tube mm (in) Standard

2.0 (0.08)

Limit

x Clearance between Bucket Roll Back Stopper and Lift Arm (c) Clearance at Unsymmetrical Contact

x Clearance between Bucket Dump Stopper and Lift Arm (a) Clearance at Unsymmetrical Contact mm (in) 0 (0) Standard 0.2 (0.008) Limit

mm (in) 0 (0) Standard 3.0 (0.12) Limit

Longitudinal and Lateral Clearance of Each Stopper mm (in) 0 (0) 4.0 (0.16)

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

NOTE:

x Clearance at Unsymmetrical Contact (left stop compared to right stop)

x Longitudinal and Lateral Clearance of Each Stopper

Clearance limit Clearance limit Left stop

Longitudinal contact

Right stop

T4-4-9

Lateral contact

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 drive system (main pump to each cylinder). 2. The bucket should be empty. T4GB-04-04-016

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

(Lowering)

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

T487-04-03-005

Bucket Cylinder:

Select ground filled with sand or CAUTION: 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

Parking Brake Forward/ Power Mode Switch Reverse Lever Switch

Lift Arm (Raising)

Full stroke (engine: high idle speed)

ON/OFF

Lift Arm (Lowering)

Neutral (engine: low idle speed)

ON/OFF

Bucket

Full stroke (engine: high idle speed)

ON/OFF

Steering

Full stroke (engine: high idle speed)

OFF

ON/OFF

Prevent personal injury. Always make CAUTION: 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.)

x 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. x 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. x Measurement of Bucket Cylinder Operate the bucket control lever to the stroke end. Measure the time of movement of the bucket from the full roll back position to the full dump position. x 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.T56-34)

T4-4-11

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. 62Z7: 3200 kg (7055 lb) 67Z7: 3680 kg (8113 lb) 67TM7: 3400 kg (7496 lb)

Never allow any personnel to be CAUTION: under the bucket. 2. In the front position, extend the lift arm to the maximum reach and hold the bucket at an angle of about 5 degrees declined forward from full tilting (rolling back). 2

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

Measurement: 1. Stop the engine. 2. In 15 minutes after the engine has been stopped, measure the change in position of lift arm cylinder (2) (b), bucket cylinder (1) (b), and bottom of the bucket (a).

Bucket Cylinder

Dig Function Drift Amount

T4GB-04-04-014 Lift Arm Cylinder

3. Repeat the measurement three times and calculate the mean values. Evaluation: Drift amount: Lift Arm Cylinder: 45 mm (1.8 in) or less Bucket Cylinder: 15 mm (0.6 in) or less Bucket Bottom (a): 62Z7: 75 mm (3 in) or less Bucket Bottom (a): 67Z7/TM7: 150 mm (6 in) or less

b TNEE-04-04-001 b-

Remedy: Refer to Troubleshooting B. NOTE: Front Attachment System Troubleshooting (p.T56-34)

T4-4-12

Dig Function Drift Amount

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

Measurement: Never put hands, feet, and measuring CAUTION: instruments under the bucket. 1. Float 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: 14 mm (0.55 in) or less

T4-4-13

T4GB-04-04-011

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

Travel Position

3. Measure at the grip center of each control lever. Measure at 150 mm (6 in) from the pedal support of each pedal. Preparation: 1. In the front position, empty the bucket in advance. 2. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

a M4GB-04-001 a-

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

Accelerator Pedal (engine: low idle speed)

Parking Brake Switch

Forward/Reverse Lever

Front Attachment Control Lever Lock

Each Control Lever

Neutral

OFF

Each Pedal

Neutral

Steering Wheel

Neutral

OFF

Prevent personal injury. Always make CAUTION: 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.

TNDF-04-04-003

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

5. In case of the steering wheel, attach a spring balance scale (tension type) onto knob (1). Measure the maximum operating force when it is moved. 6. Repeat the measurement three times and calculate the mean values. Evaluation: 3

Refer to Operational Performance Standard (p.T4-2-4). 12-

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 55±5 °C (131±9 °F). Measurement: 1. Measure as follows. y Measurement of Control Lever x Lower the bucket bottom onto the ground. x Stop the engine. x 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. y Measurement of Pedal x Lower the bucket bottom onto the ground. x Stop the engine. x Measure the stroke from neutral to the stroke end of the pedal at the pedal top. y Measurement of Steering Wheel x Start the engine. (Low idle) x Float the bucket slightly above the ground. x 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.T4-2-4).

T4-4-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure (Including Brake Circuit) If air is mixed in the brake system, CAUTION: the brake function is reduced and serious hazard

may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. (Refer to Troubleshooting B.)

Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Disconnect hose (1) from pilot filter (2). Install tee (3) (ST 6688), nipple (4) (ST 6069), coupling (5) (ST 6332), and pressure gauge (6) (ST 6315) between pilot filter (2) and hose (1). : 14, 19, 27 mm (0.55, 0.75, 1.06 in)

TNDF-04-05-001

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

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

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

TNDF-04-05-003

6 1234-

T4-5-1

Hose Pilot Filter Tee Nipple

56-

Coupling Pressure Gauge

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

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

2. Read pressures on the pressure gauge with no load. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Standard: 3.7±0.7 MPa (537±101.5 PSI)

T4-5-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure Adjustment Procedure 1

Adjustment:

Adjust the set pressure of pilot reducing valve (1) if necessary.

1. Loosen lock nut (2). Turn adjusting screw (3) and adjust the set pressure. 2. After adjustment, tighten lock nut (2). : 17 mm (0.67 in)

TNDF-03-09-003

: 15.7 N·m (1.6 kgf·m, 11.6 lbf·ft) 1-

: 5 mm (0.2 in)

Pilot Reducing Valve

3. After adjustment, check the set pressure.

NOTE: Standard Change in Pressure (Reference) Screw Turns 1/4 Change in kPa 125 Pressure 2 (kgf/cm ) (1.3) (PSI)

(18.1)

1/2 250

3/4 375

1 500

(2.5)

(3.8)

(5.1)

(36.3)

(54.4)

(72.5)

d c

W107-02-05-129 c-

Pressure Increase

Pressure Decrease

Lock Nut

Adjusting Screw

T4-5-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Measure pressure between pilot valve and control valve. Disconnect pilot hose (1) from the circuit to be measured. Install tee (4) (ST 6450), nipple (3) (ST 6069), and pressure gauge (2) (ST 6932).

1 1

: 19, 22 mm (0.75, 0.87 in)

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

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

TNDF-04-05-005

Measurement: 1. Select the following conditions: Accelerator Power Pedal Mode Switch Full stroke ON

Parking Forward/ Brake Switch Reverse Lever ON N

Control Lever Lock Switch

Unlock 3

2. Measure pilot pressure by using a pressure gauge with the lift arm and bucket control levers operated to full stroke.

1 TNDF-04-05-004

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

4 12-

Evaluation: Standard. 3.7±0.7 MPa (537±101.5 PSI) Remedy: Refer to Troubleshooting A for any accompanied error code. Refer to Troubleshooting B for observed phenomena.

NOTE: All Actuator System Troubleshooting (p.T5-6-30) Front Attachment System Troubleshooting (p.T5-6-34) Steering System Troubleshooting (p.T5-6-40) Brake System Troubleshooting (p.T5-6-44)

T4-5-4

Pilot Hose Pressure Gauge

34-

Nipple Tee

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Combined Delivery Pressure of Main Pump and Steering Pump

NOTE: Measure the pressure by using the MPDr. Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Disconnect main hose (1) in the control valve. Install tee (2) (263E7-62331), nipple (3) (ST 6069), and pressure gauge (4) (ST 6932). : 19, 36 mm (0.75, 1.42 in)

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. TNDF-04-05-005

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

Measurement: 1. Select the following conditions: Accelerator Power Pedal Mode Switch Full stroke ON

Parking Brake Switch ON

Forward/ Reverse Lever N

Steering 4

Neutral

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

Evaluation: Standard: 1.5 MPa (217.6 PSI) Remedy:

TNDF-04-05-006

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

12-

NOTE: All Actuator System Troubleshooting (p.T5-6-30) Front Attachment System Troubleshooting (p.T5-6-34) Steering System Troubleshooting (p.T5-6-40) Brake System Troubleshooting (p.T5-6-44)

T4-5-5

Main Hose Tee

34-

Nipple Pressure Gauge

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test HST Pump Delivery 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 (1) of the HST motor. Install nipple (2) (ST 6069) and pressure gauge (3) (ST 6932). : 6 mm (0.24 in) : 19 mm (0.75 in)

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

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 55±5 °C (131±9 °F).

2 TNDF-04-05-007

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

Evaluation: Standard: 2.4 MPa (348 PSI) TNDF-01-02-005

Remedy:

12-

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

NOTE: All Actuator System Troubleshooting (p.T5-6-30) Front Attachment System Troubleshooting (p.T5-6-34) Steering System Troubleshooting (p.T5-6-40) Brake System Troubleshooting (p.T5-6-44

T4-5-6

Pressure Check Port Nipple

Pressure Gauge

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test HST Charging Pump Delivery Pressure Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Disconnect hose (1) from HST charge oil filter (2). Install tee (3) (ST 6688), nipple (4) (ST 6069), coupling (5) (ST 6332), and pressure gauge (6) (ST 6315) between HST charge oil filter (2) and hose (1).

: 14, 19, 27 mm (0.55, 0.75, 1.06 in)

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

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

TNDF-04-05-002

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

TNDF-04-05-003

1234-

Evaluation: Standard: 3.5 MPa (507.6 PSI) Remedy: Refer to Troubleshooting A for any accompanied error code. Refer to Troubleshooting B for observed phenomena.

NOTE: All Actuator System Troubleshooting (p.T5-6-30) Front Attachment System Troubleshooting (p.T5-6-34) Steering System Troubleshooting (p.T5-6-40) Brake System Troubleshooting (p.T5-6-44)

T4-5-7

Hose HST Charge Oil Filter Tee Nipple

56-

Coupling Pressure Gauge

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Transmission Charge Pump Delivery Pressure Preparation: 1. Stop the engine. 2. Disconnect hose (1) from transmission charge filter (2). Install tee (3) (ST 6477), nipple (4) (ST 6069), coupling (5) (ST 6332), and pressure gauge (6) (ST 6315) between transmission charge filter (2) and hose (1).

: 14, 19, 27 mm (0.55, 0.75, 1.06 in) 2

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

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

TNDF-04-05-002

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

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

Evaluation: Standard: 1.8 to 2.1 MPa (261 to 305 PSI)

TNDF-04-05-003

1234-

Remedy: Low clutch mode is not available.

T4-5-8

Hose Transmission Charge Filter Tee Nipple

56-

Coupling Pressure Gauge

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

T4-5-9

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

Summary: Measure the main relief valve set pressure at port P in the control valve. NOTE: Measure the pressure by using the MPDr.

Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Disconnect main hose (1) in the control valve. Install tee (2) (263E7-62331), nipple (3) (ST 6069), pressure gauge (4) (ST 6313), coupling (5) (ST 6332), and hose (6) (ST 6943). : 14, 19, 36 mm (0.55, 0.75, 1.42 in)

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

TNDF-04-05-005

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F). 1 4, 5

3 2

TNDF-04-05-006

123-

T4-5-10

Main Hose Tee Nipple

456-

Pressure Gauge Coupling Hose

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

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

2. Operate the bucket or lift arm control levers slowly, operate each cylinder to the stroke end, and relieve each function. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Standard (relief operation): 20.6 MPa (2988 PSI)

T4-5-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Valve Pressure Adjustment Procedure 1. While holding lock nut (1), remove nut (3). : 17 mm (0.67 in) 2. While holding screw (2), loosen lock nut (1). : 17 mm (0.67 in) 3. Turn adjusting screw (2) in order to adjust the relief pressure to the specification. 3

4. While holding screw (2), tighten lock nut (1). : 17 mm (0.67 in)

: 19.5 N·m (2 kgf·m, 14.4 lbf·ft)

T4GB-04-05-010

5. While holding lock nut (1), tighten nut (3). 12-

: 17 mm (0.67 in)

Lock Nut Adjusting Screw

Nut

6. Check the relief set pressures.

NOTE: Standard Change in Pressure (Reference) Adjusting Screw (2) 1/4 Turns Change in MPa 2.79 2 Pressure (kgf/cm ) (28.5) (PSI) (405)

1/2

3/4

5.59 (57) (811)

8.36 11.2 (85.2) (114) (1213) (1624)

T105-06-05-002 a-

T4-5-12

Pressure Increase

Pressure Decrease

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

T4-5-13

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

Summary: Measure the HST relief valve set pressure at the delivery port 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 (1) of the HST motor. Install nipple (2) (ST 6069), hose (3) (ST 6943), and pressure gauge (4) (ST 6941). : 6 mm (0.24 in) 1

: 14, 19 mm (0.55, 0.75 in)

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

3 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 55±5 °C (131±9 °F).

TNDF-01-02-005 12-

T4-5-14

Pressure Check Port Nipple

34-

Hose Pressure Gauge

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

Parking Brake Switch OFF

Forward/Reverse Shift Switch Lever F First 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: 41.2 MPa (5976 PSI) Remedy: Refer to Troubleshooting B for observed phenomena. NOTE: Traval System Troubleshooting (p.T5-6-42)

T4-5-15

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Steering Circuit Main Relief Set Pressure Summary: Measure the steering relief valve set pressure at the steering cylinder inlet and check performance of the steering relief valve.

1 2, 3

Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Install hose (4) (ST 6943), pressure gauge (2) (ST 6313), and coupling (3) (ST 6332) to check port (1) at the bottom side of the steering cylinder.

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

T4FC-04-05-006

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

12-

T4-5-16

Check Port at Bottom Side Pressure Gauge

34-

Coupling Hose

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

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

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

Evaluation: Standard: 19.6 MPa (2843 PSI) Remedy: Refer to Troubleshooting B for observed phenomena. NOTE: Steering System Troubleshooting (p.T5-6-40)

T4-5-17

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Loading/Steering 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 relieving. In this case, its pre-leaking 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. Assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range.

T4-5-18

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Preparation:

1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Disconnect main hose (1) in the control valve. Install tee (2) (263E7-62331), nipple (3) (ST 6069), and pressure gauge (4) (ST 6941). : 14, 19, 36 mm (0.55, 0.75, 1.42 in)

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

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

TNDF-04-05-005

1 4

3 2

TNDF-04-05-006

12-

T4-5-19

Main Hose Tee

34-

Nipple Pressure Gauge

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

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

2. Slowly operate the bucket or lift arm control lever, operate each cylinder 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 pressure falls within the main relief normal pressure range. Standard: Lift arm raise: 27.4 MPa (3974 PSI) Bucket roll back: 22.6 MPa (3278 PSI) Bucket dump (Z7): 22.6 MPa (3278 PSI) Bucket dump (TM7): 14.9 MPa (2161 PSI)

T4-5-20

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

NOTE: Adjust the overload relief valve pressure on a test stand. Loosen lock nut (1) and adjust pressure by using adjusting screw (2) as follows. 1. Loosen lock nut (1).

2 W107-02-05-128

: 17 mm (0.67 in) 2. Turn adjusting screw (2) in order to adjust the pressure.

Lock Nut

Adjusting Screw

: 6 mm (0.24 in) 3. Tighten lock nut (1). : 17 mm (0.67 in) : 29.5 N·m (3.0 kgf·m) 4. After adjustment, check the set pressure. 1

NOTE: Standard Change in Pressure (Reference) Adjusting Screw (2) 1/4 Turns Change in MPa 5.2 Pressure 2 (kgf/cm ) (53) (PSI)

(754)

1/2

3/4

10.6

15.9

21.1

(108)

(162)

(215)

(1537) (2306) (3060) W107-02-05-129 a-

T4-5-21

Pressure Increase

Pressure Decrease

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

T4GB-04-05-017

Summary:

Measure the pressure at the outlet port of brake valve (3) when the brake pedal is depressed. Preparation: Set blocks (4) onto the front and rear CAUTION: tires in order not to move the machine. Keep away from the machine. 1. Stop the engine.

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

T4FC-04-05-007

4. Install a pressure gauge to the front and rear wheel brake circuits.

x Front wheel brake circuit pressure: Remove plug (1) from brake valve (3). Install nipple (6) (ST 6069) and pressure gauge (5) (ST 6932) to brake valve (3). : 6 mm (0.24 in) : 19 mm (0.75 in) x Rear wheel brake circuit pressure: Remove plug (2) from brake valve (3). Install nipple (6) (ST 6069) and pressure gauge (5) (ST 6932) to brake valve (3). : 6 mm (0.24 in) : 19 mm (0.75 in) 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 6. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

To 1

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

6 TNDF-04-05-007 123-

T4-5-22

Plug (Front) Plug (Rear) Brake Valve

456-

Block Pressure Gauge Nipple

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

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

2. Measure the pressure when fully depressing the brake pedal at left side to the floor. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Standard: 3.63 MPa (526.5 PSI) Remedy: Refer to Troubleshooting B. Normally, the front and rear wheel brake pressures become equal. If not, malfunction of the brake valve and dirt caught in the valve are suspected. NOTE: Brake System Troubleshooting (p.T5-6-44)

T4-5-23

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Parking Brake Pressure Summary: Measure the parking brake release pressure in the parking brake release circuit. Preparation: Set blocks (1) onto the front and rear CAUTION: tires in order not to move the machine. Keep away from the machine. 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Depress the brake pedal at least 50 strokes in order to release the pressure left in accumulator (5) of the brake circuit. 4. Disconnect hose (2) at the parking brake side. Install tee (3) (ST 6451), nipple (4) (ST 6069), and pressure gauge (5) (ST 6932).

T4GB-04-05-017

Block

: 19 mm (0.75 in)

NOTE: "ST xxxx" is tool number. Available equivalent

parts and pressure gauge can be used.

IMPORTANT: When the parking brake disc is dirty with hydraulic oil, the parking brake function is reduced. Clean hydraulic oil off the parking brake disc. 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 6. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

TNDF-04-05-008

23-

T4-5-24

Brake Hose Tee

45-

Nipple Pressure Gauge

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

Forward/Reverse Lever N

2. Release the parking brake and measure the pressure at this time. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard: 3.7 MPa (537 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-44)

T4-5-25

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

Summary: Measure the accumulated brake pressure at the accumulator (5) output port. The accumulated brake pressure varies according to operation of the brake. Record the maximum value. Preparation: Set blocks (1) onto the front and rear CAUTION: tires in order not to move the machine. Keep away from the machine. 1. Stop the engine.

T4GB-04-05-017

Block

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Depress the brake pedal at least 50 strokes in order to release the accumulated pressure left in accumulator (5) of the brake circuit. 4. Disconnect hoses (3, 4) from brake charge valve (2). Install tee (6) (ST 6451), nipple (7) (ST 6069), and pressure gauge (8) (ST 6933) between brake charge valve (2) and hoses (3, 4). : 19 mm (0.75 in)

NOTE: "ST xxxx" is tool number. Available equivalent

parts and pressure gauge can be used. 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

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

3, 4

6 TNDF-04-05-009

2345-

T4-5-26

Brake Charge Valve Hose Hose Accumulator

678-

Tee Nipple Pressure Gauge

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Select the following conditions: Power Mode Switch ON

Parking Brake Switch ON

Forward/Reverse Lever N

2. Measure the maximum pressure when depressing the brake pedal slowly several times. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard: 10.8 to 17.0 MPa (1566 to 2466 PSI)

NOTE: Cut-in: 11.8 MPa (1711 PSI)

Cut-out: 15.5 MPa (2248 PSI)

Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-44)

T4-5-27

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

Summary: Measure the pressure at the accumulator (5) output port when the buzzer sounds while decreasing the accumulated brake pressure. Preparation: Set blocks (1) onto the front and rear CAUTION: tires in order not to move the machine. Keep away from the machine. 1. Stop the engine.

T4GB-04-05-017

Block

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Depress the brake pedal at least 50 strokes in order to release the accumulated pressure left in accumulator (5) of the brake circuit. 4. Disconnect hoses (3, 4) from brake charge valve (2). Install tee (6) (ST 6451), nipple (7) (ST 6069), and pressure gauge (8) (ST 6932) between brake charge valve (2) and hoses (3, 4). : 19 mm (0.75 in)

NOTE: "ST xxxx" is tool number. Available equivalent

parts and pressure gauge can be used.

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

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

3, 4

6 TNDF-04-05-009

2345-

T4-5-28

Brake Charge Valve Hose Hose Accumulator

678-

Tee Nipple Pressure Gauge

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

Parking Brake Switch ON

2. Stop the engine. Set the key switch to the ON position. 3. Depress the brake pedal several times. Measure the pressure when the buzzer sounds. 4. Repeat the measurement three times and calculate the mean values. Evaluation: Standard: 8.1±0.5 MPa (1175±73 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-44)

T4-5-29

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

Summary: Measure the pressure at the accumulator (5) output port when the buzzer stops sounding while increasing the accumulated brake pressure. Preparation: Set blocks (1) onto the front and rear CAUTION: tires in order not to move the machine. Keep away from the machine. 1. Stop the engine.

T4GB-04-05-017

Block

NOTE: "ST xxxx" is tool number. Available equivalent

parts and pressure gauge can be used.

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

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

3, 4

6 TNDF-04-05-009

2345-

T4-5-30

Brake Charge Valve Hose Hose Accumulator

678-

Tee Nipple Pressure Gauge

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

Parking Brake Switch ON

2. Stop the engine. Set the key switch to the ON position. 3. Depress the brake pedal several times. Sound the buzzer. 4. Start the engine. Measure the pressure when the buzzer stops sounding. Notice that it is difficult to read the gauge as the pressure increases rapidly. 5. Repeat the measurement three times and calculate the mean values. Evaluation: Standard: 10±0.5 MPa (1450±73 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-44)

T4-5-31

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Transmission Clutch Pressure Summary: Measure the operating pressure of the transmission clutch at the check port of the transmission.

Preparation: 1. Stop the engine. 2. Remove plug (1) from the check port. Install nipple (2) (ST 6069) and pressure gauge (3) (ST 6932). : 19 mm (0.75 in)

NOTE: "ST xxxx" is tool number. Available equivalent parts and pressure gauge can be used.

3. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 4. Maintain the transmission oil temperature at 60 to 80 °C (140 to 176 °F).

TNDF-03-10-004

To 1

2 TNDF-04-05-007

12-

T4-5-32

Plug Nipple

Pressure Gauge

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: Set blocks (5) onto the front and rear CAUTION: tires in order not to move the machine. Keep away from the machine. 1. Select the following conditions:

Brake Pedal Full stroke

Power Mode Switch ON

Parking Brake Switch OFF

T4GB-04-05-017

2. Operate the forward/reverse lever and the shift switch. Measure the clutch pressure.

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

Evaluation: Standard: 1.8~2.1 MPa (261~305 PSI) Remedy: Refer to Troubleshooting B. NOTE: Travel System Troubleshooting (p.T5-6-42)

T4-5-33

Block

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

CAUTION:

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

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

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

y Release pressure before starting any work on the piping lines. Summary: Measure the gas pressure of each accumulator in the service brake circuit, steering circuit, and ride control circuit (OPT) at the accumulator gas enclosed port. Preparation: Set blocks (1) onto the front and rear CAUTION: tires in order not to move the machine. Keep away from the machine.

T4-5-34

Block

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

T4-5-35

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Service Brake Circuit 3

1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Depress the brake pedal at least 50 strokes in order to release the pressure left in accumulator (1) of the service brake circuit. 4. Remove cap (3) from gas charging port (2) in accumulator (1).

IMPORTANT: If seal bolt (4) is loosened more than 1/2 turn, the gas will leak and the gas pressure cannot be confirmed correctly. 5. Loosen seal bolt (4) of gas charging port (2) by 1/2 turn.

: 6 mm (0.24 in) TNDF-01-02-007

IMPORTANT: Use sealing tool (5) (ST 7918). When installing it to gas enclosed port (2), turn nut (a) by hands.

12-

Accumulator Gas Charging Port

Cap

NOTE: "ST xxxx" is a tool number. 6. Install sealing tool (5) to gas charging port (2).

2 T4FC-04-05-104

8 5 6

a T4FC-04-05-103 a-

Nut

456-

Seal Bolt Sealing Tool Release Valve

T4-5-36

78-

Pressure Gauge Valve

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 7. Turn release valve (6) clockwise and set it to the completely closed status. 6

8. Turn valve (8) counterclockwise and loosen seal bolt (4).

9. If the pointer in pressure gauge (7) has moved, turn valve (8) counterclockwise furthermore by one turn.

10. Confirm that the gas is not leaking from check valve (9) and release valve (6). 9

Measurement: Confirm the charging pressure by using pressure gauge (7). Evaluation:

T4FC-04-05-102

567-

Standard: 6.7~7.0 MPa (972~1015 PSI)

T4-5-37

Sealing Tool Release Valve Pressure Gauge

89-

Valve Check Valve

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Steering Circuit 1. Stop the engine. 3

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

3. Operate the steering wheel right and left several times in order to release the pressure left in accumulator (1) of the steering circuit. 4. Remove cap (3) from gas charging port (2) in accumulator (1). 1

IMPORTANT: If seal bolt (4) is loosened more than 1/2 turn, the gas will leak and the gas pressure cannot be confirmed correctly. 5. Loosen seal bolt (4) of gas charging port (2) by 1/2 turn.

12-

Accumulator Gas Charging Port

TNDF-04-05-010

Cap

: 6 mm (0.24 in) IMPORTANT: Use sealing tool (5) (ST 7918). When installing it to gas charging port (2), turn nut (a) by hands.

NOTE: "ST xxxx" is a tool number. 2

6. Install sealing tool (5) to gas charging port (2).

T4FC-04-05-104

8 5 6

a T4FC-04-05-103 a-

Nut

456-

Seal Bolt Sealing Tool Release Valve

T4-5-38

78-

Pressure Gauge Valve

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 7. Turn release valve (6) clockwise and set it to the completely closed status. 6

8. Turn valve (8) counterclockwise and loosen seal bolt (4).

9. If the pointer in pressure gauge (7) has moved, turn valve (8) counterclockwise furthermore by one turn.

10. Confirm that the gas is not leaking from check valve (9) and release valve (6). 9

Measurement: Confirm the charging pressure by using pressure gauge (7). Evaluation:

T4FC-04-05-102

567-

Standard: 1.9~2.2 MPa (276~319 PSI)

T4-5-39

Sealing Tool Release Valve Pressure Gauge

89-

Valve Check Valve

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Gas Pressure Adjustment Procedure of Accumulator (Service Brake Circuit, Steering Circuit)

6 7

The pressure is reduced or increased according to the results.

When the pressure is reduced: Loosen release valve (6) and discharge the charging gas into the atmosphere.

When the pressure is increased: IMPORTANT: Check the specified pressure of charging gas cylinder as the gas cannot be accumulated in the accumulator beyond its specified pressure. 1. Connect check valve (9) to charging gas cylinder (b) with the hose.

T4FC-04-05-102

b 7

8 5 6

2. Set release valve (6) to the completely closed status. 3. Slowly loosen the valve of charging gas cylinder (b) and accumulate the gas until the pressure is increased to the specified value. 4. Tighten the valve of charging gas cylinder (b). Check the charging gas pressure by using pressure gauge (7).

a T4FC-04-05-103

5. Turn valve (8) clockwise by hands and tighten seal bolt (4). 6. Loosen release valve (6) and release the pressure from sealing tool (5).

7. Turn nut (a) counterclockwise and remove sealing tool (5) from gas charging port (2). 8. Tighten seal bolt (4).

: 6 mm (0.24 in)

T4FC-04-05-104

: 20 N·m (2 kgf·m, 14.8 lbf·ft) a-

Nut

From Charging Gas Cylinder

2456-

Gas Charging Port Seal Bolt Sealing Tool (ST 7918) Valve

789-

Pressure Gauge Valve Check Valve

T4-5-40

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Ride Control Circuit (Option) 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Operate the lift arm control lever up and down at least 30 times in order to release the pressure left in accumulator (1) of the ride control circuit. 2

4. Remove cap (3) from gas charging port (2) in accumulator (1). : 20 mm (0.79 in)

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

NOTE: "ST xxxx" is tool number. Available equivalent

TNDF-01-02-008

parts and pressure gauge can be used.

12-

5. Install sealing tool (4) to gas charging port (2).

Accumulator Gas Charging Port

Cap

6. Turn valve (5) clockwise until it stops. IMPORTANT: Do not turn valve (7) excessively as sealing tool (4) is damaged. 7. Turn valve (7) clockwise. When the pointer of pressure gauge (6) starts moving, stop turning it.

Measurement:

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

2 1

Evaluation: Standard: 2.0 MPa (290 PSI)

TNDF-04-05-011

Nut

Joint

45-

Sealing Tool Valve

67-

Pressure Gauge Valve

T4-5-41

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Gas Pressure Adjustment Procedure of Accumulator (Ride Control Circuit (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-

T4-5-42

Accumulator Gas Charging Port Cap Sealing Tool (ST 7917)

567-

Valve Pressure Gauge Valve

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test When the pressure is increased: Check the specified pressure of CAUTION: charging gas cylinder as the gas cannot be

4 5

accumulated in the accumulator beyond its specified pressure. 1. Install hose (8) to sealing tool (4).

3 a

2. Turn valves (5, 7) of sealing 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 sealing 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). 7. Open the cock of charging gas cylinder (10). 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 sealing tool (4). Then, stop turning valve (c) of reducing valve (9) and stop increasing the pressure.

10. Turn valve (5) of sealing tool (4) clockwise until it stops.

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

TNDF-04-05-012

ab-

Nut Joint

Valve

123456-

Accumulator Gas Charging Port Cap Sealing Tool (ST 7917) Valve Pressure Gauge

78910-

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

T4-5-43

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).

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

4 5

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.

b 2

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

17. Loosen nut (1) of sealing tool (4). Turn joint (b) and remove sealing tool (4) from gas enclosed port (2).

18. Install cap (3) to gas charging port (2). 10

TNDF-04-05-012

ab-

Nut Joint

Valve

123456-

Accumulator Gas Charging Port Cap Sealing Tool Valve Pressure Gauge

78910-

Valve Hose Reducing Valve Charging Gas Cylinder

T4-5-44

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Measuring Method of No-Load-Max Differential Pressure When ECM fault code 10026, Muffler Filter PM OverRestriction is displayed, measure No-Load-Max differential pressure and check the exhaust filter condition. After inspection, handle it according to the result.

Refer to Measurement of No-Load-Max Differential Pressure (Functions-Engine/Muffler Filter) on MPDr. and measure No-Load-Max differential pressure while monitoring the following items.  Coolant Temperature (ECM)  Actual Engine Speed (ECM)  Muf/Fltr Inlet EGT (ECM)  Muf/Fltr EGP DP (ECM)

Measuring Procedure Step 1 2 3 4 5

Content Warm up the machine until coolant temperature reaches 70 °C or more. Return the accelerator pedal (not depressed) and set engine speed to the low idle speed. Lower CSF exhaust temperature to 210 °C (410 °F) under the state at step 2. Depress the accelerator pedal (fully depressed) and set engine speed to the high idle speed. Raise CSF exhaust temperature under the state at step 4. Measure differential pressure (A) when CSF exhaust temperature is 230 °C (446 °F).

Condition -

Monitoring Item Coolant Temperature (ECM) Actual Engine Speed (ECM) Muf/Fltr Inlet EGT (ECM)

* * **

Actual Engine Speed (ECM) Muf/Fltr Inlet EGT (ECM), Muf/Fltr EGP DP (ECM)

* Coolant temperature: 70 °C (158 °F) or more

*: Parking Brake: Applied, Front Attachment Control Lever: Not operated, Forward/Reverse Lever: N **: Parking Brake: Applied, Front Attachment Control Lever: Not operated, Forward/Reverse Lever: F, Power Mode: ON Timing Chart of No-Load-Max Differential Pressure

b a c d

e f

h i

k l

n m

A t TDAA-04-06-001

A-

Measuring Point

abcd-

Coolant Temperature 70 °C (158 °F) or more Ordinary Temperature Front Attachment Control Lever Operation

efghi-

Operated Not Operated Engine Speed High Idle Low Idle

jklm-

CSF Exhaust Temperature 230 °C (446 °F) 210 °C (410 °F) Exhaust Filter Exhaust Differential Pressure

12-

Step 1 Step 2

34-

Step 3 Step 4

Step 5

T4-6-1

nt-

No-Load-Max Differential Pressure Time

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Evaluation (Specification of Differential Pressure) Item Condition for Differential Pressure Check Differential pressure whether has been cleaned up

Regeneration starting differential pressure (press3)

PM over-restriction differential pressure (press5)

Filter replacement differential pressure

Engine speed: 2420 min-1 CSF temperature: 230 °C (446 °F) Muffler filter 0 maintenance (h) 1000 2000 3000 4000 4500 Muffler filter 0 maintenance (h) 1000 2000 3000 4000 4500 Muffler filter 0 maintenance (h) 1000 2000 3000 4000 4500 Muffler filter 0 maintenance (h) 1000 2000 3000 4000 4500

Differential Pressure (kPa) 3.6 3.6 3.6 3.6 3.6 3.6 4.3 4.3 4.3 4.4 4.4 4.4 6.2 6.2 6.3 6.3 6.3 6.3 6.8 6.9 6.9 7.0 7.0 7.0

Remarks Differential pressure whether has been cleaned up after completing regeneration.

Differential pressure will be regenerated.

The engine alarm is displayed on the monitor.

Allowable limit value.

Remedy Step 1

Content Measure No-Load-Max differential pressure and check the filter replacement differential pressure.

Evaluation Less than filter replacement differential pressure Filter replacement differential pressure or more

fNOTE: Manual Exhaust Filter Regeneration: Slow Regeneration is performed for about two hours.

T4-6-2

Remedy Perform Manual Exhaust Filter Regeneration: Slow Regeneration of Engine Setting on the monitor. Then, change the engine oil. Replace the filter (CSF).

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Zero-Point Calibration (Correction) Perform Zero-point calibration of the differential pressure sensor after the following repairs and inspections.  When the differential pressure sensor has been replaced  When ECM has been replaced  When the ECM software has been rewritten Zero-Point Calibration 1. Connect MPDr. 2. Set the key switch to the ON position. 3. Select Functions-Engine/Muffler Filter-Muffler Filter Differential Pressure Sensor Learning with MPDr. Select Learning Starting. In case learning is performed normally, Learning State is displayed with MPDr. 4. Hold this state for 30 seconds.

fNOTE: When operating the key switch during Zero-

point calibration, calibration is interrupted. (Calibration Failure) 5. When Zero-point calibration is completed normally, OK is displayed with MPDr.

fNOTE: When Zero-point calibration is interrupted (Calibration Failure), NG is displayed with MPDr. Repeat the procedures from step 3. 6. Set the key switch to the OFF position.

7. Hold this state for 60 seconds or more (until the ECM main relay is turned OFF). Calibration Conditions:  CSF Exhaust Temperature: Less than 100 °C (212 °F)  Coolant Temperature: Less than 100 °C (212 °F) IMPORTANT: After Zero-point calibration is completed normally, download all data with MPDr. In addition, upload the downloaded data to e-Service.

T4-6-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Rewrite of Exhaust Filter Serial No. When the exhaust filter has been replaced, rewrite the serial No. of exhaust filter and upload the data to e-Service. 1. Connect MPDr. 2. Set the key switch to the ON position. 3. Select Functions-Engine/Muffler Filter-Muffler Filter NO. with MPDr. 4. Input the following items of Oxidation Catalyst (DOC) and Filter (CSF).  ASM  SUB  Serial No. 5. After inputting, select Setting. IMPORTANT: After inputting Exhaust Filter Serial No. is completed, upload the data to e-Service.

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

TNDF-04-06-014

T4-6-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Maintenance of Exhaust Filter IMPORTANT: When the filter (CSF) has been replaced or cleaned, perform ASH Sedimentation Signal Reset in order to reset Muffler Filter maintenance history on the monitor. 1. Connect MPDr.

IMPORTANT: After Setting Exhaust Filter No. and ASH ASH Sedimentation Signal Reset are performed, upload the data to e-Service.

fNOTE: When the set data is uploaded to e-Service,

the M-Find product specification and history will be updated.

2. Set the key switch to the ON position.

3. Select Functions-Engine/Muffler Filter-Muffler Filter maintenance with MPDr. (Fig A) 4. Perform the followings. Item Change (1) the DOC Change (2) the CSF or Change the DOC and CSF Cleaning (3)

Content Setting Exhaust Filter No. Setting Exhaust Filter No. and ASH Sedimentation Signal Reset Setting Exhaust Filter No. and ASH Sedimentation Signal Reset

5. Set or check the exhaust filter serial No. (Refer to Rewrite for Exhaust Filter Serial No.) 6. Perform ASH Sedimentation Signal Reset. (Fig B)

TNDF-04-06-015 B

TNDF-04-06-016

T4-6-5

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Clutch Learning IMPORTANT: When transmission or transmission control valve has been repaired/replaced, and the HST controller or MC has been replaced, perform clutch learning. Preparation: 1. When the key switch is in the OFF position, connect MPDr. to MPDr. connector (1) at the body end (relay box). 2. Start the engine. 3. Select the Service Menu screen on the monitor and HST oil temperature (2) appears. (Refer to T5-2.) 4. Make a warm up operation with the front attachment relieved and increase HST oil temperature (2) to 50 to 55 °C (122 to 131 °F).

fNOTE: Change the relief position of front attachment

whenever HST oil temperature (2) increases (approx. 5 °C (41 °F)). (Example: Relieve the operation of bucket tilt, lift arm raise, and bucket dump in sequence.) 5. Then, make travel operation of the machine on a test track at the max. speed (20 km/h (12.4 mph)) at 3rd speed for 15 minutes.

Detail A

TNDB-01-02-029

6. When HST oil temperature (2) reaches 50 to 55 °C (122 to 131 °F), park the machine in a safe place. Hold the engine speed at low idle speed.

TNDB-01-02-005

TNDB-04-06-011

T4-6-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment MPDr. Operation: 1

IMPORTANT: Do not operate control levers and other switches when learning is performed. 1. Start MPDr. Select Wheel Loader, ZW-5, Functions, Machine Body, Main Setting, Constant Change, Calibration Value Setting, and Clutch Learning in sequence. Then, the Clutch Learning screen appears. (Fig. A)

2. When HST oil temperature (3) increases 50 to 55 °C (122 to 131 °F), select Start (1) from the pull-down menu on the Clutch Learning screen on MPDr. and click Set (2).

TNDF-04-06-017

TNDB-04-06-011

3. The inquiry window is displayed on the Clutch Learning screen on MPDr. Click Yes (4). (Fig. B)

3 B

4. The learning starts and Progress (C1 to C5) of learning is displayed on the monitor. (Fig C)

TNDF-04-06-018

T4-6-7

TNDF-04-06-001

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment D

5. When the learning is completed, the Learning End screen appears on the monitor. (Fig. D)

T4GB-04-06-006

6. The message, "Writing process in controller is complete." is displayed on the Clutch Learning screen on MPDr. Click OK (5). (Fig. E) E

7. Set the key switch to the OFF position, and finish the learning.

fNOTE: When the machine is in deactivation condition

while learning, the learning is stopped on the way. At this time, the message on the error is displayed on the Clutch Learning screen on MPDr. Perform the learning again. (Fig. F)

TNDF-04-06-019

8. Make travel operation of the machine on a test track with the following conditions. Check the clutch learning results. When abnormal shock occurs when connecting the clutch, perform clutch learning again.

TNDF-04-06-020

T4-6-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Condition:  Connecting the slow speed clutch 1. Accelerate the machine to the max. speed (20 km/h (12.4 mph)) at 3rd speed. 2. When the machine speed reaches the max. speed (20 km/h (12.4 mph)), return the accelerator pedal and make inertia travel operation. At this time, do not depress the brake pedal. 3. When the machine speed decreases to 3 to 5 km/h (1.9 to 3.1 mph), fully depress the accelerator pedal again. 4. Then, check if there is abnormality with the clutch connected.  Connecting the fast speed clutch 1. When the machine speed decreases to 7 to 9 km/h (4.3 to 5.6 mph), fully depress the accelerator pedal again in the same way as the slow speed clutch. 2. Then, check if there is abnormality with the clutch connected.

T4-6-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Brake Pedal Angle Learning IMPORTANT: When the brake pedal or brake valve has been repaired/replaced, and the brake angle sensor, HST controller, or MC has been replaced, perform brake pedal angle learning. Preparation: 1. When the key switch is in the OFF position, connect MPDr. to MPDr. connector (1) at the body end (relay box). 2. Set the key switch to the ON position. (The engine does not start. ) 3. Depress and release the brake pedal several times. Check that the brake pedal depressing angle is normal. (Refer to Machine Performance Test.) 4. Release the brake pedal. (Not Depressed) A

Detail A

TNDB-01-02-029

TNDB-01-02-005

T4-6-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment MPDr. Operation: 1

IMPORTANT: Do not operate control levers and other switches when learning is performed. 1. Start MPDr. Select Wheel Loader, ZW-5, Functions, Machine Body, Main Setting, Constant Change, Calibration Value Setting, and Brake Pedal Angle Learning in sequence. Then, the Brake Pedal Angle Learning screen appears. (Fig. A)

2. Select Start (1) from the pull-down menu on the Brake Pedal Angle Learning screen on MPDr. and click Set (2).

TNDF-04-06-021

3. The inquiry window is displayed on the Brake Pedal Angle Learning screen on MPDr. Click Yes (3). (Fig. B)

4. Check that the buzzer has sounded. Fully depress the brake pedal and hold it for approx. 5 seconds. 5. Check that the second buzzer has sounded. Release the brake pedal. 6. Set the key switch to the OFF position, and finish the learning. 7. Set the key switch to the ON position after 30 seconds when setting it to the OFF position.

T4-6-11

TNDF-04-06-022

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment 8. The message, "Writing process in controller is complete." is displayed on the Brake Pedal Angle Learning screen on MPDr. Click OK (4). (Fig. C)

TNDF-04-06-023

fNOTE: When the machine is in deactivation condition

while learning, the learning is stopped on the way. At this time, the message on the error is displayed on the Brake Pedal Angle Learning screen on MPDr. Perform the learning again. (Fig. D)

9. Select "Retry" on the Trouble shooting screen on MPDr. Check that the message, "Brake Pedal Angle Uncalibration" has disappeared.

10. Set the key switch to the OFF position, and finish the learning. TNDF-04-06-024

fNOTE: When the message in step 8 is displayed, perform the learning again.

T4-6-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment (Blank)

T4-6-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Lift Arm Angle Sensor Learning 1

IMPORTANT: When lift arm angle sensor or MC has been replaced, perform lift arm angle sensor learning. Preparation: 1. Connect MPDr. (Refer to clutch Learning.) 2. Start the engine. 3. Set control lever lock switch (1) to UNLOCK position (3). 4. Raise the lift arm to the highest level by lift arm raise operation.

MNDF-01-006

5. Set control lever lock switch (1) to LOCK position (2). 6. Set the key switch to the OFF position.

3 MNEC-01-015 2-

T4-6-14

LOCK

UNLOCK

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment MPDr. Operation: A

IMPORTANT: Do not operate control levers and other switches when learning is performed. 1. Set the key switch to the ON position. 2. Start MPDr. Select Wheel Loader, ZW-5, Functions, Machine Body, Main Setting, Constant Change, Calibration Value Setting, and Arm Angle Sensor Calibration in sequence. Then, the Arm Angle Sensor Calibration screen appears. (Fig. A)

3. Select Start (1) from the pull-down menu on the Arm Angle Sensor Calibration screen and click Set (2).

TNDF-04-06-025

4. The inquiry window is displayed on the Arm Angle Sensor Calibration screen on MPDr. Click Yes (3). (Fig. B)

IMPORTANT: The learning can not be performed when the value of lift arm angle sensor is out of range from 3.3 V to 4.3 V. 5. When the learning is completed correctly, the buzzer sounds. 6. Set the key switch to the OFF position, and finish the learning. 7. Set the key switch to the ON position again after 30 seconds when setting it to the OFF position. 8. Select "Retry" on the Trouble shooting screen on MPDr. When the message, "Lift arm angle sensor in uncalibrated" disappeared, the learning is completed normally.

fNOTE: When the buzzer sounds in step 5 or when the message in step 8 is displayed, perform the learning again.

T4-6-15

TNDF-04-06-026

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment (Blank)

T4-6-16

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 ..................................................................T5-1-24 Check by False Signal ......................................................T5-1-25 Test Harness ........................................................................T5-1-26

Group 2 Monitor Outline .................................................................................... T5-2-1 Monitor Panel ................................................................. T5-2-1 Monitor Display.............................................................. T5-2-2 Operating Procedures of Service Menu ...................... T5-2-3 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 ........................ T5-3-4 List of Total Operating Hours .................................... T5-3-5 Snapshot Data...................................................................... T5-3-6 Communication System ................................................... T5-3-7

Group 4 Component Layout Main Component Layout (Overview) .......................... T5-4-1 Main Component Layout (Hydraulic System)........... T5-4-3 Main Component Layout (Travel System).................. T5-4-5 Electrical System (Overview) .......................................... T5-4-6 Electrical System (Cab) ...................................................... T5-4-7 Front Console.................................................................. T5-4-8 Right Console.................................................................. T5-4-9 Rear Console .................................................................T5-4-11 Monitor Panel ...............................................................T5-4-12 Engine ...................................................................................T5-4-13 Exhaust Filter ......................................................................T5-4-15 HST Pump, 4-Gear Pump Unit ......................................T5-4-16 Transmission, HST Motor................................................T5-4-17 Control Valve.......................................................................T5-4-17 Manifold Valve....................................................................T5-4-18 Brake Charge Valve ...........................................................T5-4-18 Fan Valve ..............................................................................T5-4-19 Fan Valve (with Fan Reverse Rotation) (Option).....T5-4-19 Ride Control Valve (Option) ...........................................T5-4-20 Secondary Steering Block (Option) ............................T5-4-21 Secondary Steering Pump (Option) ...........................T5-4-21 Solenoid Valve (In Front Chassis).................................T5-4-22

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 .............................................................. T5-5-9 HST Controller Fault Code List......................................T5-5-19 Information Controller Fault Code List......................T5-5-25 Column Display Controller Fault Code List ..............T5-5-26 Air Conditioner Controller Fault Code List ...............T5-5-28 Communication Terminal Fault Code List ................T5-5-30 ECM Fault Code List..........................................................T5-5-32 MC Fault Codes 111000 to 111002 .............................T5-5-57 MC Fault Code 111003 ....................................................T5-5-58 MC Fault Codes 111006, 111007, 111030 ................T5-5-61 CAN1 Harness Check .......................................................T5-5-62 CAN3 (Engine) Harness Check......................................T5-5-66 MC Fault Codes 111008, 111014, 111025 ................T5-5-69 CAN2 Harness Check ......................................................T5-5-70 MC Fault Code 111103 ....................................................T5-5-73 MC Fault Codes 111205, 111207 .................................T5-5-74 MC Fault Code 111217 ....................................................T5-5-75 62Z7/67Z7/67TM7

MC Fault Code 111206 ....................................................T5-5-76 MC Fault Code 111208 ....................................................T5-5-77 MC Fault Code 111311 ....................................................T5-5-78 MC Fault Code 111406 ....................................................T5-5-79 MC Fault Code 111411 ....................................................T5-5-80 MC Fault Code 111412 ....................................................T5-5-81 MC Fault Code 111422 ....................................................T5-5-82 MC Fault Code 111908 ....................................................T5-5-83 MC Fault Code 111909 ....................................................T5-5-84 MC Fault Codes 120003, 120004, 120014 ................T5-5-85 HST Controller Fault Codes 111027, 111028 ...........T5-5-86 HST Controller Fault Code 111332..............................T5-5-88 HST Controller Fault Codes 111330, 111331, 111333 .............................................................................T5-5-89 HST Controller Fault Code 111334..............................T5-5-90 HST Controller Fault Codes 111430, 111431, 111432 .............................................................................T5-5-91 HST Controller Fault Code 111433..............................T5-5-92 HST Controller Fault Code 111457..............................T5-5-93 HST Controller Fault Codes 111450, 111451 ...........T5-5-94 HST Controller Fault Codes 111620, 111621 ...........T5-5-95 HST Controller Fault Code 111622..............................T5-5-96 HST Controller Fault Code 111904..............................T5-5-97 HST Controller Fault Code 111905..............................T5-5-98 Column Display Controller Fault Code 115001 ......T5-5-99 Column Display Controller Fault Code 115011 ... T5-5-100 Column Display Controller Fault Code 115015 ... T5-5-101 Column Display Controller (Information) Fault Codes 120500 to 120505 ............................ T5-5-102 Column Display Controller Fault Codes 120506, 120507, 120510 to 120513, 120515, 120517, 120518 .. T5-5-103 Air Conditioner Controller Fault Codes E11 to E22.................................................................... T5-5-104 Air Conditioner Controller Fault Codes E43 to E92.................................................................... T5-5-105

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 ...................................................................T5-6-27 Engine System Troubleshooting ............................T5-6-28 All Actuator System Troubleshooting ..................T5-6-30 Front Attachment System Troubleshooting ......T5-6-34 Steering System Troubleshooting .........................T5-6-40 Travel System Troubleshooting ..............................T5-6-42 Brake System Troubleshooting...............................T5-6-44 Other System Troubleshooting ..............................T5-6-46 Engine System Troubleshooting .................................T5-6-51 All Actuator System Troubleshooting........................T5-6-57 Front Attachment System Troubleshooting............T5-6-63 Steering System Troubleshooting ..............................T5-6-75 Travel System Troubleshooting ...................................T5-6-79 Brake System Troubleshooting ....................................T5-6-83

Other System Troubleshooting....................................T5-6-87 Exchange Inspection .................................................... T5-6-101 Air Bleeding Procedures for Brake (Axle) ............... T5-6-103 Transporting Wheel Loader (Urgent Situation)... T5-6-105 Precautions for Self-Traveling .............................. T5-6-105 Precautions for Towing ........................................... T5-6-106 Hydraulic Circuit Bypass......................................... T5-6-107 Releasing Parking Brake ......................................... T5-6-108 Parking Brake Manual Release Procedures ..... T5-6-109

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 (OPT) ................................................................................T5-7-26 Malfunction of Low Steering Oil Pressure Indicator (OPT) ................................................................................T5-7-27 Malfunction of Alternator Indicator ...........................T5-7-28 Malfunction of Air Filter Restriction Indicator ........T5-7-29 Malfunction of Fuel Filter Restriction Indicator .....T5-7-30 Malfunction of Low Brake Oil Pressure Indicator ..T5-7-31 Malfunction of Hydraulic Oil Level Indicator ..........T5-7-32 Malfunction of Exhaust Filter Indicator.....................T5-7-33 Malfunction of Exhaust Filter Regeneration Inhibit Indicator ...........................................................T5-7-33 Malfunction of Water Separator Indicator (OPT) ...T5-7-33 Malfunction of Exhaust Filter Regeneration Inhibit Indicator ...........................................................T5-7-33 Malfunction of Control Lever Lock Indicator ..........T5-7-33 Malfunction of Power Mode Indicator ......................T5-7-33 Malfunction of Fan Reverse Rotation Indicator (OPT) ................................................................................T5-7-33 Malfunction of Seat Belt Indicator ..............................T5-7-34

62Z7/67Z7/67TM7

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

62Z7/67Z7/67TM7

(Blank)

62Z7/67Z7/67TM7

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 (base machine diagnosis starting with inspection of abnormal operational status), 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 Troubleshooting Symptom) Refer to troubleshooting B for diagnosis by using trouble symptom. Refer to these procedures when no fault codes are displayed after diagnosing the machine by using MPDr. (or the service menu of monitor). Example: Even if accelerator pedal is operated, engine speed does not change.  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.

T4GB-05-01-002

Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine. If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result, wasting time. Check for blown fuses before troubleshooting. Even if a fuse looks normal by visual inspection, a fine crack is difficult to find. Always use a 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 harnesses or dCAUTION: hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Stop the engine before disconnecting harnesses or hydraulic lines. Perform diagnosis by connecting MPDr. to the machine or by using the service menu of monitor. In case any fault code has been displayed by diagnosis by using MPDr. (the service menu of monitor), check the cause of the trouble by referring to Troubleshooting A in this section. In case any fault code has been displayed by diagnosis by using MPDr. (the service menu of monitor), write the fault code. Delete the fault code once and retry self-diagnosis again. If the fault code is displayed again, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code (displayed by the service menu of monitor) will be deleted. Therefore, in case the problems which are not easily re-predicable are encountered, check the fault code by using MPDr. In case the fault code is not displayed, check operating condition of each component by referring to Troubleshooting B in this section and by using MPDr. (the service menu of monitor). 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 harnesses, grasp them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate connectors, if a lock is provided. (Refer to Instructions for Disconnecting Connector on T5-1-8.)  The water-resistant connectors keep water out. If water enters them, water will not easily drain from them. When checking the water-resistant connectors, take extra care not to allow water to enter the connectors. In case water should enter the connectors, reconnect only after the connectors are thoroughly dried.  Before connecting the terminal connectors, check that no terminals are bent (3) or coming off. In addition, as most connectors are made of brass, check that no terminals are rusting (2).  When connecting terminal connectors provided with a lock, insert them together until the lock "clicks."  Pull the harness near the connector in order to check if it is correctly connected.

TDAA-05-08-002

1 2 3

4 TDAA-05-08-003

12-

Correct Rust

34-

Incorrect (Deformation) Incorrect (Deformation)

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

TDAA-05-08-004

T5-1-7

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

T107-04-05-002

 Raise Lock, Pull, and Separate Type

T107-04-05-003

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 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: Check the glow plug relay circuit fuse with

the key switch set in the ON position and follow the procedure in step 3.

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 except the glow plug relay circuit. (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 a

10 9 8 7 6

20 19 18 17 16

5 4 3 2 1

15 14 13 12 11

c MNEC-01-047 ab-

Fuse Box A Fuse Box B

Relay Box

M178-07-034

T5-1-10

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Box A Fuse 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 Head Light Relay (Right) (Power) 10 A Cigar Lighter 15 A Front Wiper Motor, Front Wiper Relay 1, Front Wiper Relay 2, Front Washer Relay (Power) 20 A Work Light (Front) Relay (Power) 5A Head Light Relay (Left) (Power) 5A Forward/Reverse Switch, Shift Switch, Machine Speed 1 Sensor 5A Back Buzzer Relay (Power) 5A Turn Signal Lever, Brake Light Relay (Power) 10 A Compressor Relay (Air Conditioner) 5A Parking Brake Solenoid Valve 15 A DC/DC Converter 20 A Option 2 20 A Seat Heater (OPT) 10 A Beacon Light Switch (OPT) 20 A Blower Motor Relay (Air Conditioner) 15 A Glass Heater (Front) (OPT) 15 A Glass Heater (Rear) (OPT) 20 A Glass Heater (Side) (OPT) 10 A Option 3 10 A Option 4

T5-1-11

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Box 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 Light Switch 5A Radio (Power), Cab Light, Tachograph 15 A Option 1 10 A Horn Relay 10 A Flasher, Hazard Switch 10 A Load Dump Relay, MC (Power), Column Display Controller, Information Controller, GSM (Power) 30 A ECM Main Relay (Power), Fuel Pump Relay (Power) 10 A MC (Solenoid Valve Power) 15 A HST Controller (Power), Forward/Reverse Lever, Forward/Reverse Select Switch 5A Tail Light (Left), License Light (OPT), Clearance Light (Right), Control Lever Lock Switch, Power Mode Switch, Traction Control Switch, Fan Reversing Switch (OPT), Ride Control Switch (OPT), Secondary Steering Operation Check Switch (OPT), Creeper Switch, Forward/Reverse Select Switch 5A Tail Light (Right), Clearance Light (Left), Parking Brake Switch, Work Light Switch, Hazard Light Switch 10 A Main Controller (MC), Column Display Controller, Information Controller, Air Conditioner Controller, GSM, Buzzer, Battery Relay, Auto idling Stop Switch, Tachograph 10 A HST Controller, Parking Brake Relay 1 5A Auto Idling Stop Relay 10 A Control Lever Lock Relay, Lift Arm Kickout Relay, Bucket Leveler Relay, Coil (Lift Arm Lower Side), Coil (Lift Arm Raise Side), Coil (Bucket Tilting Side) 20 A Work Light (Rear) Relay 10 A Rear Wiper Motor, Rear Wiper Relay, Rear Washer Relay 10 A High-Beam Relay (Power) 5A Secondary Steering Relay (OPT)

T5-1-12

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fusible Link Inspection

3 4 5

Inspection 1. Visually inspect fusible links (2, 3, 4, 5). Replacement 1. Disconnect the negative cable from the battery. 2. Pull out fusible links (2, 3, 4, 5). Replace fusible links (2, 3, 4, 5). 3. Connect the negative cable to the battery. TNDF-05-01-001

T111-04-05-015 1234-

T5-1-13

Battery Relay Fusible Link (100 A) Fusible Link (OPT) Fusible Link B (65 A)

Fusible Link A (65 A)

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.

TNEE-05-01-002

T5-1-14

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Alternator Check Generally, if the alternator has generated electricity, alternator alarm (1) will disappear. If discharge warning indicator (1) is displayed while the engine is running, the alternator might be defective. How to Check Alternator 1. Set the key switch to the ON position. Confirm that discharge warning indicator (1) is displayed. 2. Measure voltage between terminals B and E of the alternator. 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.

3. Next, start the engine and measure voltage generated while the alternator rotates. As described above, measure voltage between terminals B and E on the alternator side.

MNDB-01-008

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. E

T157-07-06-003

T5-1-15

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

 Single-line continuity check

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

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

 Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the body:

T107-07-05-003

 0 Ω = Short-circuit is present.  ∞ Ω = No short-circuit is present.

T5-1-16

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure  Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the short-circuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c). By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c).

A B C

a b c

T107-07-05-004

 0 Ω = Line (B) - (b) has discontinuity.  ∞ Ω = Line (A) - (a) has discontinuity. A B C

 Multi-line short-circuit check

a b c

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

T5-1-17

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

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 (11) and Ground: Key Switch Between (7) and Ground: Glow 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

Fast Speed Surge Voltage Prevention Circuit Idle Speed Idle Speed Idle Speed Idle Speed Accessory Circuit Stopped Stopped

Between (9) and Ground: Alternator (B)/Generating Voltage Between (8) and Ground: Battery Relay/Generating Voltage Between (17) and Ground: Fusible Link (100 A)/Generating Voltage Between (14) and Ground: Information Controller (A15)

ON ON ON ON

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

26 to 30 V 20 to 25 V 26 to 30 V 26 to 30 V

ON ON

Stopped Stopped Stopped

ON ON ON

Between (12) and Ground: ACC Cut Relay (Option) Between (15) and Ground: Monitor Controller, Information Controller, Air Conditioner Unit, MC Between (18) and Ground: Radio Between (19) and Ground: Fusible Link (100 A) Between (6) and Ground: Battery Relay

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

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

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

T5-1-18

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

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 f

5 k

19 n

3 2

1 A

A15 a

17 14 6 12

j(#1)

9 A e

7 TNDF-05-01-002

abcd-

Battery Alternator Fusible Link A (65A) Battery Relay

A-

To Terminal A15

efgh-

Glow Plug Load Dump Relay Key Switch ACC Cut Relay (Option)

ijk-

T5-1-19

Key Switch ON Cut Relay (Option) Fuse Box B Information Controller

Fusible Link (100 A)

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

Between (20) and Ground: Between (21) and Ground: Between (22) and Ground: Between (23) and Ground: Between (24) and Ground: Between (25) and Ground: Between (26) and Ground: Between (27) and Ground: Between (28) and Ground: Between (29) and Ground: Between (30) and Ground: Between (32) and Ground: Between (33) and Ground:

Battery Relay (Coil) Battery Relay (Switch) Starter (#B) Starter (#S) Starter Relay 1 (C) Starter Cut Relay Fuse Box B (#8) Key Switch Neutral Relay Information Controller (A17) MC (E10) ECM Main Relay (Switch) ECM Main Relay (Coil)

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 20 to 25 V 20 to 25 V

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

f(#8)

29 A17

e j

27 30 E10

28 k

25 d

22 23

TNDF-05-01-003

abc-

Starter Starter Relay 1 Battery Relay

def-

Starter Cut Relay Key Switch Fuse Box B

gij-

T5-1-21

Information Controller ECM MC

Neutral Relay

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Engine Neutral Engine Start Circuit * Stopped Stopped Stopped Stopped Stopped Stopped

Key Switch

Location to be Measured

ON ON ON ON ON ON

Between (34) and Ground: Between (35) and Ground: Between (36) and Ground: Between (37) and Ground: Between (38) and Ground: Between (39) and Ground:

Specification

Key Switch Key Switch ON Cut Relay (Option) Fuse Box B (#10) HST Controller (#10) Neutral Relay (Coil) Neutral Relay (Switch)

* Before measurement, set the forward/ reverse lever to the neutral position.

T5-1-22

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

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure e

c(#10)

37 d B

35 b

34 39 B

38 f

TNDF-05-01-004

ab-

Key Switch Key Switch ON Cut Relay (Option)

B-

To Starter Cut Relay Terminal #1

cde-

Fuse Box B Forward/ Reverse Lever HST Controller

fg-

T5-1-23

Neutral Relay ECM

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5-Volt Circuit  Voltage between terminal #1 and the body

Two Polarities 1

Disconnect the connector with the key switch OFF. Measure voltage between terminal #1 on the body harness end connector and the body (ground).

 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 Two Polarities

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

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

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

T5-1-24

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

T5-1-25

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Test Harness

Part 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.  Part 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

Part Number (ST 7226)

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

4 3

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

150

50 50

1 T107-07-06-015

Connect a test harness to the 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

T5-1-26

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

fNOTE: The connecting procedures of test harness of

HST circuit pressure 1 pressure sensor (1) are explained.

1. Disconnect a connector of HST circuit pressure 1 sensor (1).

TNDF-05-01-005

2. Connect the male end connector of test harness (3) (ST 6701) to harness end connector (4) of pump 2 delivery 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

T5-1-27

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure (Blank)

T5-1-28

SECTION 5 TROUBLESHOOTING Group 2 Monitor Outline Basic Screen Monitor Panel

7 8

9 10

37 12 36 35

14 15

33 16

32 31 30

12345-

Left Turn Signal Light Indicator High Beam Indicator Work Light Indicator Right Turn Signal Indicator Exhaust Filter Warning Indicator 6- Exhaust Filter Regeneration Inhibited Warning Indicator 7- Service Indicator 8- Maintenance Indicator 9- Parking Brake Indicator 10- Clearance Light Indicator 11- Control Lever Lock Indicator

29 28 27 26

25 24 23 22 21 20 19 18 17

12- (Not used) 13- Low Brake Oil Pressure Indicator 14- (Not used) 15- Secondary Steering Indicator (Option) 16- Low Steering Oil Pressure Indicator (Option) 17- Seat Belt Indicator 18- Discharge Warning Indicator 19- Fuel Gauge 20- Power Mode Indicator 21- Monitor Display Mode Selector

22- Exhaust Filter Regeneration Inhibited Indicator 23- Monitor Display Selector (Up) 24- Preheat Indicator 25- Monitor Display Selector (Down) 26- Forward/Reverse Selector Switch Indicator 27- Monitor Display 28- Fan Reverse Rotation Indicator 29- Engine Warning Indicator 30- Overheat Indicator 31- Coolant Temperature Gauge

f NOTE: Refer to the Operator’s Manual for details of the monitor panel.

T5-2-1

MNDB-01-034

32- Low Engine Oil Pressure Indicator 33- Air Filter Restriction Indicator 34- Fuel Filter Restriction Indicator 35- Water Separator Indicator (Option) 36- Hydraulic Oil Level Indicator 37- (Not used) 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 Mode Selector 3- Monitor Display Selector (Up) 4- Monitor Display Selector (Down) 5- Speedometer 6- Information Display 7- Traction Control Indicator (TCS) 8- F-N-R/Shift Position Indicator

MNDB-01-008

9- Ride Control Indicator (Option) 10- ECO Indicator

MNDB-01-033

Machine Information Display (6)

12- Engine Speed Display 13- Coolant Temperature Display 14- HST Oil Temperature Display

15- (Not used) 17

16- Fuel Consumption Display 17- Exhaust Filter Regeneration Display

18- Hour Meter Display 19- Average Fuel Consumption Display 20- Odometer Display MNDB-01-033

21- Fault Code Display

22- PM Accumulating Amount Display

T5-2-2

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 *  PM Accumulating Amount *  INFO (Information) *  Engine Speed  Coolant Temperature  HST Oil Temperature  Fault Code  Fuel Consumption  Average Fuel Consumption

f NOTE: The normal menu with the mark * is displayed on Service Menu.

f NOTE: Refer to the Operator’s Manual for details of operation for the normal menu with the 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 Machine 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 Machine 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

5 B

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 C

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.

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. 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, '-----' (dash) is displayed.

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

MNDB-01-008

TNDB-05-02-006

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 PM Accumulating Amount * 5 INFO (Information) * 6 Engine Speed 7 Coolant Temperature 8 HST Oil Temperature 9 Fault Code 10 Fuel Consumption 11 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 MC -

f NOTE: The normal menu with the mark * is displayed on Service Menu.

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)

C B

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

A 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

No. A B C D

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

Fuel Level (%) 100 (FULL) 50 12 0 (EMPTY)

Fuel Sensor (Ω) 100-4 32.9 77±3 90+100

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

T5-3-1

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

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

T5-3-2

SECTION 5 TROUBLESHOOTING Group 3 e-Service

Item Engine Operating Hour Distribution Data Latitude Longitude

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

fNOTE: The daily operation in this table is equivalent

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

T5-3-3

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Frequency Distribution Data Item Details Radiator Coolant Temperature (79 °C or Total hours when coolant temperature is less than 80 °C (176 °F) during a less) day. Radiator Coolant Temperature (80 to 93 °C) Total hours when coolant temperature is 80 °C (176 °F) or more and less than 94 °C (201.2 °F) during a day. Radiator Coolant Temperature (94 to 104 Total hours when coolant temperature is 94 °C (201.2 °F) or more and less °C) than 105 °C (221 °F) during a day. Radiator Coolant Temperature (105 °C or Total hours when coolant temperature is 105 °C (221 °F) or more during a more) day. Hydraulic Oil Temperature (49 °C or less) Total hours when hydraulic oil temperature is less than 50 °C (122 °F) during a day. Hydraulic Oil Temperature (50 to 89 °C) Total hours when hydraulic oil temperature is 50 °C (122 °F) or more and less than 90 °C (194 °F) during a day. Hydraulic Oil Temperature (90 to 99 °C) Total hours when hydraulic oil temperature is 90 °C (194 °F) or more and less than 100 °C (212 °F) during a day. Hydraulic Oil Temperature (100 °C or more) Total hours when hydraulic oil temperature is 100 °C (212 °F) or more during a day.

T5-3-4

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

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

T5-3-5

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

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

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

fNOTE: The data on machine body system including

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

T5-3-6

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

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

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

T5-3-7

SECTION 5 TROUBLESHOOTING Group 3 e-Service (Blank)

T5-3-8

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Main Component Layout (Overview) 6

5 4 3 2 1

TNDF-01-02-001

123-

Bucket Bell Crank (Lever) Bucket Cylinder

56-

Head Light (Turn Signal Light/ Hazard Light/Clearance Light) (2 used) Front Work Light (2 used) Cab

78910-

T5-4-1

Lift Arm Cylinder (2 used) Lift Arm Bucket Link Hydraulic Oil Tank

TNDF-01-02-002

11- Rear Combination Light (Turn Signal/Hazard Light/Clearance Light/Brake Light/Backup Light) (2 used) 12- Rear Work Light (2 used)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout y 67TM7 Only

12 7 9

8 TNDF-01-02-021

TNDF-01-02-022

123-

Bucket Bell Crank (Lever) (2 used) Bucket Cylinder (2 used)

789-

Lift Arm Cylinder (2 used) Lift Arm Bucket Link (2 used)

12- Link (2 used) 13- Guide (2 used) 14- Quick Coupler Cylinder

T5-4-2

15- Quick Coupler

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Main Component Layout (Hydraulic System) 1

7 8 9

12345678-

Ride Control Valve (Option) Steering Valve Pilot Valve Auxiliary Pilot Valve (Option) Priority Valve Hydraulic Oil Tank Air Cleaner Exhaust Filter

910111213141516-

11 23

Fan Motor Oil Cooler Radiator Intercooler Fuel Tank Fan Valve Coolant Reservoir Engine

10 20

17181920212223-

T5-4-3

18 17

16 15

HST Pump 4-Gear Pump Unit Manifold Valve Transmission Oil Filter HST Charge Filter Brake Charge Valve Service Brake Accumulator

TNDF-01-02-003

24- Secondary Steering Pump (Option) 25- Pilot Filter 26- Brake Valve 27- Control Valve 28- Ride Control Accumulator (Option)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout y 67TM7 Only

Front Side of Machine

29- Bucket Regenerative Selector Valve

Front Frame

30- Bucket Regenerative Valve

T5-4-4

TNDF-01-02-023

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

2 9 8 7

123-

Front Axle Steering Cylinder HST Motor 1

456-

Transmission Rear Propeller Shaft Rear Axle

789-

T5-4-5

Steering Accumulator HST Motor 2 Front Propeller Shaft

TNDF-01-02-010

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Electrical System (Overview) 1

14 13

9 8

Electrical System (Cab) (Refer to T5-4-5.)

Exhaust Filter (Refer to T5-412.)

12-

Horn Lift Arm Proximity Switch, Lift Arm Angle Sensor (Option) MAF Air Cleaner Restriction Switch

56789-

Reverse Buzzer Battery Fuel Level Sensor Battery Relay Fusible Link (100A) (2 Used)

34-

7 6

10- Fusible Link A (65A) / Fusible Link B (65A) 11- Glow Plug Relay 12- Starter Relay 1 13- Hydraulic Oil Level Switch

T5-4-6

TNDF-01-02-011

14- Hydraulic Oil Temperature Sensor 15- Bucket Proximity Switch

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

TNDB-01-02-032

Detail E D

c TNDB-01-02-029

13 14

15 TNDF-05-04-002

Components Related with Front Console (Refer to T5-4-6.)

Components Related with Right Console (Refer to T5-4-7.)

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

1234-

Radio Upper Switch Panel (Option) Speaker Rear Wiper Motor

5678-

Accelerator Pedal Sensor Brake Angle Sensor Brake Light Switch Front Wiper Motor

9101112-

Air Conditioner Controller Front Wiper (1) Relay (WR1) Front Wiper (2) Relay (WR2) GSM (OPT) / GPS (OPT)

T5-4-7

13- Flasher Relay 14- MC (Main Controller) 15- HST 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 Front Vent Hazard Light Switch Work Light Switch Parking Brake Switch Neutral Lever Lock (Forward / Reverse Lever) Steering Wheel

78910-

Monitor Panel Horn Switch Accelerator Pedal Brake / Declutch Pedal (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

T5-4-8

171819202122-

1st Speed Limit Switch Auto Idling Stop Switch Auxiliary Auxiliary Ash Tray Cigar Lighter

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Right Console x Multi-Function Joystick Type

7 8

11 12 13

21 22

1234567-

Forward / Reverse Switch Multi-Function Joystick Lever Auxiliary Auxiliary Auxiliary Control Lever (Option) Control Lever Lock Switch Creep Switch

17 16

15 MNEC-01-044

MNDB-01-005

8- Traction Control Switch 9- Power Mode Switch 10- Forward / Reverse Selector Switch 11- Fan Reverse Rotation Switch (Option) 12- Auxiliary 13- Auxiliary

14- Secondary Steering Operation Check Switch (Option) 15- Exhaust Filter Switch 16- Lift Arm Auto Lever Switch (Upward Set) 17- Lift Arm Auto Lever Switch (Downward Set) 18- Ride Control Switch (Option)

T5-4-9

19202122-

Armrest Adjust Handle Armrest Adjustment Auxiliary Horn Switch (Under the Lever)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout

x Fingertip Control Type

3 (2)* 2 (1)*

6 7

20 8 9

1 (3)*

11 12

1234567-

* Bucket Control Lever * Lift Arm Control Lever * Auxiliary Control Lever (Option) Forward/Reverse Switch Control Lever Lock Switch Creep Switch Traction Control Switch

14 MNEC-01-042

MNDB-01-004

89-

Power Mode Switch Forward/Reverse Selector Switch 10- Fan Reverse Rotation Switch (Option) 11- Auxiliary

12- Quick Coupler Switch (62/67Z7: Option, 67TM7: Standard) 13- Secondary Steering Operation Check Switch (Option) 14- Exhaust Filter Switch 15- Lift Arm Auto Lever Switch (Upward Set)

NOTE: * The location of control levers may be changed depending on the specification.

T5-4-10

16- Lift Arm Auto Lever Switch (Downward Set) 17- Ride Control Switch (Option) 18- Armrest Adjust Handle 19- Armrest Adjustment 20- 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

123456789-

Fuse Box B Fuse Box A MPDr. Connector Main Relay Fuel Pump Relay Back Buzzer Relay Starter Cut Relay Head Light Relay (Left) (A-R1) Head Light Relay (Right) (A-R2)

101112131415-

High Beam Relay (A-R3) Bucket Leveler Relay (A-R4) Lift Arm Kickout Relay (A-R5) Work Light (Front) Relay (A-R6) Work Light (Rear) Relay (A-R7) Right Turn Signal Light Relay (A-R8) 16- Horn Relay (A-R9)

17- Secondary Steering Relay (OPT)(A-R10) 18- Parking Brake Relay 1 (B-R1) 19- Parking Brake Relay 2 (B-R2) 20- Control Lever Lock Relay (B-R3) 21- Brake Light Relay (B-R4) 22- Load Dump Relay (B-R5) 23- Neutral Relay (B-R6)

T5-4-11

TNED-01-02-009

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

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- Exhaust Filter Warning Indicator 6- Exhaust Filter Regeneration Inhibit Indicator 7- Service Indicator 8- Maintenance Indicator 9- Parking Brake Indicator 10- Clearance Light Indicator 11- Control Lever Lock Indicator

16 31 30

29 28 27 26

25 24 23 22 21 20 19 18 17

12- (Unused) 13- Brake Oil Low Pressure Indicator 14- (Unused) 15- Secondary Steering Indicator (Option) 16- Low Steering Oil Pressure Indicator (Option) 17- Seat Belt Indicator 18- Discharge Warning Indicator 19- Fuel Gauge 20- Power Mode Indicator 21- Monitor Display Selection Switch

22- Exhaust Filter Regeneration Inhibit Indicator 23- Monitor Display Selection Switch (Up) 24- Preheat Indicator 25- Monitor Display Selection Switch (Down) 26- Forward/Reverse Selector Switch Indicator 27- Monitor Display 28- Fan Reverse Rotation Indicator (Option) 29- Engine Warning Indicator 30- Overheat Indicator

T5-4-12

MNDB-01-034

31- Coolant Temperature Gauge 32- Engine Oil Low Pressure Indicator 33- Air Filter Restriction Indicator 34- Fuel Filter Restriction Indicator 35- Water Separator Indicator (Option) 36- Hydraulic Oil Level Indicator 37- (Unused) 38- HST Warning Indicator 39- HST Oil Temperature Indicator 40- HST Oil Temperature Gauge

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Engine 6

1 2 3 9

TNDF-01-02-012

TNDF-01-02-013

13 16

TNDF-01-02-014

12345-

VGS Actuator Coolant Temperature Sensor Overheat Switch Glow Plug Intake Throttle

678910-

Common Rail Pressure Sensor Boost Pressure Sensor Boost Temperature Sensor) Crank Revolution Sensor Fuel Temperature Sensor

TNDF-01-02-015

11121314-

T5-4-13

Supply Pump Engine Oil Pressure Sensor Cam Angle Sensor Injector

15- Intake Manifold Temperature Sensor 16- EGR Valve

SECTION 5 TROUBLESHOOTING Group 4 Component Layout

TNDF-05-04-001

9 10

MNDF-07-019

Machine Front Side

123-

MAF Air Cleaner Restriction Switch Atmospheric Pressure Sensor

456-

VGS Controller ECM Fuel Pump

789-

T5-4-14

Fuel Main Filter Fuel Pre-Filter Water Separator (Option)

10- Engine Oil Filter

MNDF-07-005

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Exhaust Filter

TNED-02-03-001

DOC Exhaust Temperature Sensor

CSF Exhaust Temperature Sensor

T5-4-15

Differential Pressure Sensor

SECTION 5 TROUBLESHOOTING Group 4 Component Layout HST Pump, 4-Gear Pump Unit

TNDF-01-02-016

12-

Displacement Angle Control Cylinder Pump Displacement Angle Control Solenoid Valve

345-

Reverse Selection Solenoid Valve Forward Selection Solenoid Valve Shuttle Valve

678910-

T5-4-16

High-Pressure Relief Valve Low-Pressure Relief Valve Cutoff Valve HST Circuit Pressure 1 Sensor HST Circuit Pressure 2 Sensor

TNDF-01-02-017

1112131415-

HST Charging Pump Steering Pump Main Pump Pilot Pump Transmission Charge Pump

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

12-

Clutch Pressure Control Solenoid Valve Transmission

345-

TNDF-01-02-005

Vehicle Speed Sensor 1 Vehicle Speed Sensor 2 HST Motor 2

67-

Motor 2 Displacement Angle Control Solenoid Valve HST Motor 1

Motor 1 Displacement Angle Control Solenoid Valve

Control Valve 9

10 11 12 13

14 TNDF-01-02-018

19 9-

Orifice (Muffler Filter Regeneration Circuit) 10- Pressure Sensor (Implement Pressure) 11- Overload Relief Valve (Bucket: Rod Side)

17 16

12- Make-Up Valve (Lift Arm: Rod Side) 13- Slow Return Valve (Lift Arm: Rod Side) 14- Main Relief Valve 15- Low-Pressure Relief Valve

15 16- Overload Relief Valve (Lift Arm: Bottom side) 17- Overload Relief Valve (Bucket: Bottom Side) 18- Slow Return Valve (Lift Arm: Bottom Side)

T5-4-17

19- Overload Relief Valve (Quick Coupler Circuit) (OPT))

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Manifold Valve 1

7 6 4 5

TNDF-01-02-007

123-

Pilot Accumulator (Front) Pilot Reducing Valve Parking Brake Accumulator

Pressure Sensor (Primary Pilot Pressure)

Control Lever Lock Solenoid Valve

67-

Pressure Sensor (Parking Brake ) Parking Brake Solenoid Valve

Brake Charge Valve 9

TNDF-01-02-007

Pressure Sensor (Brake Primary Pressure)

Service Brake Accumulator

T5-4-18

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Fan Valve

TNDF-01-02-019

Fan Speed Control Solenoid Valve

Fan Control Valve

Fan Valve (with Fan Reverse Rotation) (Option)

2 1

TNDF-01-02-020

12-

Fan Speed Control Solenoid Valve Fan Control Valve

Fan Reverse Rotation Control Solenoid Valve (Option)

T5-4-19

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

TNDF-01-02-008

12-

Overload Relief Valve Ride Control Solenoid Valve

Ride Control Accumulator

T5-4-20

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

1 TNDB-01-02-014

Secondary Steering Pump Delivery Pressure Sensor (Option)

Steering Pressure Switch (Option)

Secondary Steering Pump (Option) 3

TNED-01-02-019

Relief Valve

Gear Pump

T5-4-21

Electric Motor

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Solenoid Valve (In Front Chassis) 1

Machine Front

Quick Coupler Pilot Solenoid Valve (Option)

Exhaust Filter Regeneration Control Solenoid Valve

T5-4-22

Coupler Cylinder Selector Solenoid Valve (Option)

TNDF-01-02-024

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure

fNOTE: The engine controller (ECM) judges the engine

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

1 2

T6L4-05-03-001

Harness End Connector

Harness

T5-5-1

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Contents of Diagnosis

Fault Code

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

How to Read Table Fault Code (A)

    

A: B: C, D, E,

Trouble or MP Inspection Dr. Message Method (B) (C) (F)

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

111000-2

Abnormal EEPROM

T5-5-9

T5-5-57

111001-2

Abnormal RAM

T5-5-9

T5-5-57

111002-2

Abnormal A/D Converter

T5-5-9

T5-5-57

111003-3

Abnormal Sensor Voltage

T5-5-9

T5-5-58

111006-2

Engine Controller Communication Error

T5-5-10

T5-5-61

111007-2

(CAN1) Information Controller Communication Error 1

T5-5-10

T5-5-61

111008-2

(CAN2) Information Controller Communication Error 2

T5-5-10

T5-5-69

111014-2

Air Conditioner Controller Communication Error (CAN2)

T5-5-10

T5-5-69

111025-2

Column Monitor Controller Communication Error (CAN2) MC

T5-5-10

T5-5-69

111027-2

MC Communication Error

HST

T5-5-19

T5-5-87

111028-2

ECM Communication Error

HST

T5-5-19

T5-5-87

111030-2

HST Controller Communication Error (CAN1)

T5-5-10

T5-5-61

111103-3

Accelerator Pedal Sensor Circuit High Input

T5-5-11

T5-5-73

111103-4

Accelerator Pedal Sensor Circuit Low Input

T5-5-11

T5-5-73

111205-3

Lift Arm Angle Sensor Circuit High Input

T5-5-17

T5-5-74

111205-4

Lift Arm Angle Sensor Circuit Low Input

T5-5-17

T5-5-74

111206-3

Pressure Sensor (Fan Circuit Pressure) Circuit High Input

T5-5-17

T5-5-76

111206-4

Pressure Sensor (Fan Circuit Pressure) Circuit Low Input

T5-5-17

T5-5-76

111207-3

Refrigerant Pressure Sensor Circuit High Input

T5-5-17

T5-5-74

111207-4

Refrigerant Pressure Sensor Circuit Low Input

T5-5-17

T5-5-74

111208-3

T5-5-12

T5-5-77

T5-5-12

T5-5-77

111217-3

Emergency Steering Pump Delivery Pressure Sensor Circuit High Input Emergency Steering Pump Delivery Pressure Sensor Circuit Low Input Primary Pilot Pressure Sensor Circuit High Input

T5-5-13

T5-5-75

111217-4

Primary Pilot Pressure Sensor Circuit Low Input

T5-5-13

T5-5-75

111208-4

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

111311-3

Service Brake Primary Pressure Sensor Circuit High Input

T5-5-13

T5-5-78

111311-4

Service Brake Primary Pressure Sensor Circuit Low Input

T5-5-13

T5-5-78

111330-3

Pressure Sensor (Front Attachment Pressure) Circuit High Input HST

T5-5-20

T5-5-89

111330-4

Pressure Sensor (Front Attachment Pressure) Circuit Low Input HST

T5-5-20

T5-5-89

111331-3

HST Circuit Pressure 1 Sensor Circuit High Input

HST

T5-5-20

T5-5-89

111331-4

HST Circuit Pressure 1 Sensor Circuit Low Input

HST

T5-5-20

T5-5-89

111332-5

Enable Signal Disconnection Error

HST

T5-5-20

T5-5-88

111333-3

HST Circuit Pressure 2 Sensor Circuit High Input

HST

T5-5-20

T5-5-89

111333-4

HST Circuit Pressure 2 Sensor Circuit Low Input

HST

T5-5-20

T5-5-89

111334-3

Brake Angle Sensor Circuit High Input

HST

T5-5-20

T5-5-90

111334-4

Brake Angle Sensor Circuit Low Input

HST

T5-5-20

T5-5-90

111406-2

T5-5-14

T5-5-79

T5-5-14

T5-5-79

T5-5-14

T5-5-79

111411-2

Muffler Filter Regeneration Control Solenoid Valve Abnormal FB Muffler Filter Regeneration Control Solenoid Valve FB High Current Muffler Filter Regeneration Control Solenoid Valve FB Low Current Fan Reverse Rotation Control Solenoid Valve Abnormal FB

T5-5-14

T5-5-80

111411-3

Fan Reverse Rotation Control Solenoid Valve FB High Current

T5-5-14

T5-5-80

111411-4

Fan Reverse Rotation Control Solenoid Valve FB Low Current

T5-5-14

T5-5-80

111412-2

Fan Speed Control Solenoid Valve Abnormal FB

T5-5-14

T5-5-81

111412-3

Fan Speed Control Solenoid Valve FB High Current

T5-5-14

T5-5-81

111412-4

Fan Speed Control Solenoid Valve FB Low Current

T5-5-14

T5-5-81

111422-2

Ride control Solenoid Valve Abnormal FB

T5-5-15

T5-5-82

111422-3

Ride control Solenoid Valve FB High Current

T5-5-15

T5-5-82

111422-4

Ride control Solenoid Valve FB Low Current

T5-5-15

T5-5-82

111406-3 111406-4

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

111430-2

Motor 1 Displacement Angle Control Solenoid Valve Abnormal FB Motor 2 Displacement Angle Control Solenoid Valve Abnormal FB Clutch Pressure Control Solenoid Valve Abnormal FB

HST

T5-5-21

T5-5-91

HST

T5-5-21

T5-5-91

HST

T5-5-21

T5-5-91

T5-5-21

T5-5-92

111450-2

Pump Displacement Angle Control Solenoid Valve Abnormal HST FB Forward Side Solenoid Valve Output Error HST

T5-5-21

T5-5-94

111451-2

Reverse Side Solenoid Valve Output Error

HST

T5-5-21

T5-5-94

111457-2

Back Buzzer Relay Output Error

HST

T5-5-22

T5-5-93

111620-2

Vehicle Speed 1 Sensor (Rotation Direction) Error

HST

T5-5-22

T5-5-95

111621-2

Vehicle Speed 1 Sensor (Rotation Speed) Error

HST

T5-5-22

T5-5-95

111622-2

Vehicle Speed 2 Sensor Error

HST

T5-5-22

T5-5-96

111706-20

Clutch Learning Un-Calibration

T5-5-16

111720-2

Lift Arm Angle Sensor Un-Calibration

T5-5-16

111722-2

Brake Angle Sensor Un-Calibration

T5-5-16

111904-2

Abnormal Forward/Reverse Lever

HST

T5-5-23

T5-5-97

111905-2

Abnormal Forward/Reverse Switch

HST

T5-5-23

T5-5-98

111908-3

1st Speed Limit Switch Circuit High Input

T5-5-17

T5-5-83

111908-4

1st Speed Limit Switch Circuit Low Input

T5-5-17

T5-5-83

111909-3

HST Oil Temperature Sensor Circuit High Input

T5-5-17

T5-5-84

111909-4

HST Oil Temperature Sensor Circuit Low Input

T5-5-17

T5-5-84

111431-2 111432-2 111433-2

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

114001-2

Flash Memory Read/Write Error

Information

T5-5-25

114002-2

External RAM Read/Write Error

Information

T5-5-25

114003-2

Abnormal EEPROM

Information

T5-5-25

114006-2

Communication Terminal : Communication Error

Information

T5-5-25

114008-2

Abnormal Internal RAM

Information

T5-5-25

114100-2

Communication Terminal: Abnormal EEPROM

T5-5-30

114101-2

Communication Terminal: Abnormal IB/OB Queue

T5-5-30

114102-2

Communication Terminal: Abnormal Local Loop Back

T5-5-30

114103-2

Communication Terminal: No Satellite Found

T5-5-30

114104-2

Communication Terminal: Remote Loop Back Error 1

T5-5-30

114105-2

Communication Terminal: Remote Loop Back Error 2

T5-5-30

114106-2

Communication Terminal: Transmission/Receiving Data Unmatched

Communication Terminal Communication Terminal Communication Terminal Communication Terminal Communication Terminal Communication Terminal Communication Terminal

T5-5-30

T5-5-6

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

MPDr. Message

Category

Reference 1

Reference 2

115001-2

Abnormal REG input H level

Column Display

T5-5-26

T5-5-99

115003-2

Abnormal EEPROM

Column Display

T5-5-26

115011-3

Open circuit in fuel level sensor

Column Display

T5-5-26

T5-5-100

115011-4

Shorted circuit in fuel level sensor

Column Display

T5-5-26

T5-5-100

115015-3

Parking Brake Pressure Sensor High Voltage

Column Display

T5-5-26

T5-5-101

115015-4

Parking Brake Pressure Sensor Low Voltage

Column Display

T5-5-26

T5-5-101

115018-2

24 V Output Error

Column Display

T5-5-26

120003-2

Emergency Steering Operation Alarm

T5-5-85

120004-2

Emergency Steering Operating Pressure Error

T5-5-18

T5-5-85

120014-2

Overrun Alarm

T5-5-18

T5-5-85

120101-2

Exhaust Temperature Alarm

T5-5-18

120102-2

Intake Air Temperature Alarm

T5-5-18

120103-2

Boost Temperature Increase Alarm

T5-5-18

120104-2

Fuel Temperature Increase Alarm

T5-5-18

120106-2

EGR Gas Temperature Alarm

T5-5-18

fNOTE:

Refer to page T5-5-29 for the air conditioner controller fault code list. Refer to page T5-5-32 for the ECM fault code list.

T5-5-7

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

Column Display

T5-5-27

T5-5-102

120501-2

Engine Warning Alarm

Column Display

T5-5-27

T5-5-102

120502-2

Engine Oil Pressure Alarm

Column Display

T5-5-27

T5-5-102

120503-2

Air Cleaner Restriction Alarm

Column Display

T5-5-27

T5-5-102

120504-2

Hydraulic Oil Level Alarm

Column Display

T5-5-27

T5-5-102

120505-2

Brake Pressure Alarm

Column Display

T5-5-27

T5-5-102

120506-2

Steering Oil Pressure Alarm

Column Display

T5-5-27

T5-5-103

120507-2

Transmission Error Alarm

Column Display

T5-5-27

T5-5-103

120510-2

HST Oil Temperature Alarm

Column Display

T5-5-27

T5-5-103

120511-2

Fuel Filter Restriction Alarm

Column Display

T5-5-27

T5-5-103

120512-2

Emergency Steering Alarm (Lighting)

Column Display

T5-5-27

T5-5-103

120513-2

Muffler Filter Alarm

Column Display

T5-5-27

T5-5-103

120515-2

Engine Alarm

Column Display

T5-5-27

T5-5-103

120517-2

Water Separator Alarm

Column Display

T5-5-27

T5-5-103

120518-2

Emergency Steering Alarm (Blinking)

Column Display

T5-5-27

T5-5-103

fNOTE:

Refer to page T5-5-28 for the air conditioner controller fault code list. Refer to page T5-5-32 for the ECM fault code list.

T5-5-8

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code List Controller Hardware Failure Fault Code

Trouble

Cause

111000-2 111001-2 111002-2

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

Faulty MC Faulty MC Faulty MC

111003-3

Faulty MC Faulty sensor Faulty harness

Symptoms in Machine Operation When Trouble Occurs. -

Remedy

Replace MC. Replace MC. Replace MC.

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

T5-5-9

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN Data Reception Failure Fault Code

Trouble

111006-2

Engine Controller Faulty harness Communication Error

111007-2

Information Faulty information Controller controller Communication Error Faulty CAN1 harness 1 (CAN 1) Faulty information The information for e-Service Information controller cannot be collected. Controller Communication Error Faulty CAN2 harness 2 (CAN 2) Faulty air conditioner The air conditioner is not effective. Air Conditioner controller Controller Communication Error Faulty CAN2 harness (CAN2) Column Display Faulty column display The alarms and meters on column Controller controller display cannot be displayed Communication Error Faulty CAN2 harness correctly. (CAN2) HST Controller Faulty HST controller The machine can not travel. Communication Error Faulty CAN1 harness (CAN1)

111008-2

111014-2

111025-2

111030-2

Cause

Symptoms in Machine Operation When Trouble Occurs. Even if accelerator pedal is operated, engine speed does not change. The information for e-Service cannot be collected.

T5-5-10

Remedy Check the harness.

Check the CAN1 harness. Replace the information controller. Check the CAN2 harness. Replace the information controller. Check the CAN2 harness. Replace the air conditioner controller. Check the CAN2 harness. Replace the column display controller. Check the CAN1 harness. Replace the HST controller.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Engine Failure Fault Code

Trouble

Cause

111103-3

Accelerator Pedal Sensor Circuit High Input Accelerator Pedal Sensor Circuit Low Input

Voltage: more than 4.74 V

Symptoms in Machine Operation When Trouble Occurs. The engine speed is fixed to 1300 min-1.

Voltage: less than 0.25 V

The engine speed is fixed to 1300 min-1.

111103-4

T5-5-11

Remedy

Check the harness. Replace the accelerator pedal sensor. Check the harness. Replace the accelerator pedal sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pump Failure Fault Code

Trouble

Cause

111208-3

Emergency Steering Voltage: or Pump Delivery more 4.75 V Pressure Sensor Circuit High Input

111208-4

Emergency Steering Voltage: less than 0.25 V Pump Delivery Pressure Sensor Circuit Low Input

Symptoms in Machine Operation When Trouble Occurs. The initial automatic check for secondary steering operation cannot be performed. (When the engine starts) The secondary steering indicator (OPT) blinks. The initial automatic check for secondary steering operation cannot be performed. (When the engine starts) The secondary steering indicator (OPT) blinks.

T5-5-12

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

Check the harness. Replace the secondary steering pump delivery pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pilot System Failure Fault Code

Trouble

Cause

111217-3

Primary Pilot Pressure Sensor Circuit High Input Primary Pilot Pressure Sensor Circuit Low Input Service Brake Primary Pressure Sensor Circuit High Input Service Brake Primary Pressure Sensor Circuit Low Input

Voltage: or more 4.75 V

Symptoms in Machine Operation When Trouble Occurs. The control lever lock indicator (OPT) is always OFF.

Voltage: less than 0.25 V

The control lever lock indicator (OPT) is always OFF.

Voltage: or more 4.75 V

The low brake oil pressure indicator is always ON.

Voltage: less than 0.25 V

The low brake oil pressure indicator is always ON.

111217-4

111311-3

111311-4

T5-5-13

Remedy Check the harness. Replace the pressure sensor (primary pilot pressure). Check the harness. Replace the pressure sensor (primary pilot pressure). Check the harness. Replace the pressure sensor (brake primary pressure). Check the harness. Replace the pressure sensor (brake primary pressure).

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code 111406-2

111406-3

111406-4

111411-2

111411-3

111411-4

111412-2

111412-3

111412-4

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs. Muffler Filter Solenoid valve Regeneration may not complete as Regeneration Control output: 140 mA the load cannot be applied during Solenoid Valve or more, feedback manual or auto regeneration of the Abnormal FB current: More exhaust filter. than 920 mA or Or, the load is always applied. less than 70 mA; both are detected. Current: more Regeneration may not complete as Muffler Filter Regeneration Control than 920 mA the load cannot be applied during Solenoid Valve FB High manual or auto regeneration of the Current exhaust filter. Or, the load is always applied. Muffler Filter Current: less than Regeneration may not complete as Regeneration Control 70 mA the load cannot be applied during Solenoid Valve FB Low manual or auto regeneration of the Current exhaust filter. Or, the load is always applied. Fan Reverse Rotation Solenoid valve The fan reverse rotation control becomes ineffective. Control Solenoid Valve output: 140 mA Abnormal FB or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Fan Reverse Rotation Current: more Fan rotation direction is fixed in Control Solenoid Valve than 920 mA reverse. FB High Current Fan Reverse Rotation Current: less than The fan reverse rotation control (OPT) Control Solenoid Valve 70 mA is not activated. FB Low Current Fan Speed Control Solenoid valve The fan speed is fixed to the Solenoid Valve output: 140 mA maximum or minimum. Abnormal FB or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Fan Speed Control Current: more The fan speed is fixed to the Solenoid Valve FB High than 920 mA minimum. Current Fan Speed Control Current: less than The fan speed is fixed to the Solenoid Valve FB Low 70 mA maximum. Current

T5-5-14

Remedy Check the harness.

Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

111422-2

Ride control Solenoid Valve Abnormal FB

111422-3

Ride control Solenoid Valve FB High Current Ride control Solenoid Valve FB Low Current

Solenoid valve output: 140 mA or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Current: more The ride control (OPT) is always than 920 mA activated. Current: less than The ride control (OPT) is not always 70 mA activated.

111422-4

Symptoms in Machine Operation When Trouble Occurs. The ride control (OPT) becomes ineffective.

T5-5-15

Remedy Check the harness.

Check the harness. Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Learning Failure Fault Code

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs. The speed shift is impossible.

111706-20

Clutch Learning UnCalibration

111720-2

Lift Arm Angle Sensor Un-Calibration

111722-2

Brake Angle Sensor Un-Calibration

The clutch calibration is not performed. Or, it fails. The lift arm angle The lift arm auto leveler height/ sensor calibration is lower kickout control (OPT) can not not performed. Or, be set. it fails. The brake angle The inching control is impossible. sensor calibration is not performed. Or, it fails.

T5-5-16

Remedy Perform the clutch calibration.

Perform the lift arm angle sensor calibration. Perform the brake angle sensor calibration.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Other Failures Fault Code

Trouble

Cause

111205-3

Lift Arm Angle Sensor Circuit High Input

Voltage: more than 4.75 V

111205-4

Lift Arm Angle Sensor Circuit Low Input

Voltage: less than The lift arm auto leveler height/lower 0.25 V kickout control (OPT) is not activated.

111206-3

Pressure Sensor (Fan Voltage: more Circuit Pressure) Circuit than 4.74 V High Input

111206-4

Pressure Sensor (Fan Voltage: less than The fan reverse rotation control (OPT) Circuit Pressure) Circuit 0.25 V is not activated. Low Input

111207-3

Refrigerant Pressure Sensor Circuit High Input

111207-4

111908-3

111908-4

111909-3

111909-4

Symptoms in Machine Operation When Trouble Occurs. The lift arm auto leveler height/lower kickout control (OPT) is not activated.

The fan reverse rotation control (OPT) is not activated.

Voltage: more than 4.74 V

Remedy Check the harness. Replace the lift arm angle sensor. Check the harness. Replace the lift arm angle sensor. Check the harness. Replace the pressure sensor (fan circuit pressure). Check the harness. Replace the pressure sensor (fan circuit pressure). Check the harness. Replace the refrigerant pressure sensor. Check the harness. Replace the refrigerant pressure sensor. Check the harness.

The fan speed is always fixed to the maximum. The fan reverse rotation control (OPT) is not activated. Refrigerant Pressure Voltage: less than The fan speed is always fixed to the Sensor Circuit Low 0.25 V maximum. Input The fan reverse rotation control (OPT) is not activated. 1st Speed Limit Switch Voltage: more The speed limit control is not Circuit High Input than 4.74 V activated. The maximum speed is fixed to the minimum value. 1st Speed Limit Switch Voltage: less than The speed limit control is not Check the harness. Circuit Low Input 0.25 V activated. The maximum speed is fixed to the minimum value. HST Oil Temperature Voltage: more When hydraulic oil temperature is Check the harness. Sensor Circuit High than 4.35 V less than 0 °C, the auto-warming up Input control is not activated. The fan speed is always fixed to the maximum. The fan reverse rotation control (OPT) is not activated. HST Oil Temperature Voltage: less than When hydraulic oil temperature is Check the harness. Sensor Circuit Low 0.1 V less than 0 °C, the auto-warming up Input control is not activated. The fan speed is always fixed to the maximum. The fan reverse rotation control (OPT) is not activated.

T5-5-17

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

120004-2

Emergency Steering Operating Pressure Error

120014-2

120101-2

120102-2

120103-2

120104-2

120106-2

Cause

Secondary steering pump delivery pressure does not increase up to the specified value. (When the engine starts) Overrun Alarm The machine speed is beyond the upper limit. Exhaust Temperature Exhaust Alarm temperature around the muffler is high. Intake Air Temperature Intake air Alarm temperature increases. Boost Temperature Boost Increase Alarm temperature increases. Fuel Temperature Fuel temperature Increase Alarm increases. EGR Gas Temperature Alarm

EGR gas temperature increases.

Symptoms in Machine Operation When Trouble Occurs. The secondary steering indicator (OPT) blinks.

Remedy

The buzzer sounds.

Check the harness. Replace the machine speed sensor. Check the harness. Replace the exhaust temperature sensor.

T5-5-18

Check the harness. Replace the pressure sensor.

Check the harness. Replace the intake-air temperature sensor. Check the harness. Replace the boost temperature sensor. Check the harness. Replace the fuel temperature sensor. Check the harness. Replace the intake manifold temperature sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller Fault Code List CAN Data Reception Failure Fault Code

Trouble

Cause

111027-2

MC Communication Error

Faulty harness

111028-2

ECM Communication Error

Faulty harness

Symptoms in Machine Operation When Trouble Occurs. Although the accelerator pedal is operated, the engine speed does not change. Although the accelerator pedal is operated, the engine speed does not change.

T5-5-19

Remedy Check the harness. Replace MC. Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pilot System Failure Fault Code

Trouble

111330-3

Pressure Sensor Voltage: (Front Attachment more than Pressure) Circuit 4.75 V High Input Voltage: less Pressure Sensor (Front Attachment than 0.25 V Pressure) Circuit Low Input HST Circuit Pressure Voltage: 1 Sensor Circuit more than High Input 4.75 V HST Circuit Pressure Voltage: less 1 Sensor Circuit Low than 0.25 V Input Enable Signal Faulty Disconnection Error harness HST Circuit Pressure Voltage: 2 Sensor Circuit more than High Input 4.75 V HST Circuit Pressure Voltage: less 2 Sensor Circuit Low than 0.25 V Input Brake Angle Sensor Voltage: Circuit High Input more than 4.75 V Brake Angle Sensor Voltage: less Circuit Low Input than 0.25 V

111330-4

111331-3

111331-4

111332-5 111333-3

111333-4

111334-3

111334-4

Cause

Symptoms in Machine Operation When Trouble Occurs. The matching control cannot be activated.

Remedy

The matching control cannot be activated.

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

The maximum speed and maximum Check the harness. traction force are limited. (while Replace the HST circuit driving in forward direction) pressure 1 sensor. The maximum speed and maximum Check the harness. traction force are limited. (While Replace the HST circuit driving in forward direction) pressure 1 sensor. The travel operation is impossible. Check the harness. The maximum speed and maximum Check the harness. traction force are limited. (While Replace the HST circuit driving in reverse direction) pressure 2 sensor. The maximum speed and maximum Check the harness. traction force are limited. (While Replace the HST circuit driving in reverse direction) pressure 2 sensor. The inching control is not activated. Check the harness. Replace the brake angle sensor. The inching control is not activated. Check the harness. Replace the brake angle sensor.

T5-5-20

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code

Trouble

111430-2

Motor 1 Displacement Solenoid valve Angle Control Solenoid output: 140 mA Valve Abnormal FB or more, feedback current: More than 920 mA or less than 70 mA; both are detected. The maximum speed and maximum Motor 2 Displacement Solenoid valve Angle Control Solenoid output: 140 mA traction force are limited. Valve Abnormal FB or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Clutch Pressure Solenoid valve The maximum speed and maximum Control Solenoid Valve output: 140 mA traction force are limited. Abnormal FB or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Pump Displacement Solenoid valve The machine can not travel. Angle Control Solenoid output: 140 mA Valve Abnormal FB or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Forward Side Solenoid Faulty harness The maximum speed and maximum Valve Output Error Faulty forward traction force are limited. (While side solenoid driving in forward direction) valve Reverse Side Solenoid Faulty harness The maximum speed and maximum Valve Output Error Faulty reverse side traction force are limited. (While solenoid valve driving in reverse direction)

111431-2

111432-2

111433-2

111450-2

111451-2

Cause

Symptoms in Machine Operation When Trouble Occurs. The maximum speed and maximum traction force are limited.

T5-5-21

Remedy Check the harness.

Check the harness.

Check the harness. Replace the forward side solenoid valve. Check the harness. Replace the reverse side solenoid valve.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

111457-2

Back Buzzer Relay Output Error

111620-2

111621-2

111622-2

Cause

Faulty harness Faulty back buzzer relay Vehicle Speed 1 Sensor When machine (Rotation Direction) speed is less than Error 2 km/h or 5 km/h or more, the state that the rotation direction is different from the signal from the forward/reverse lever is detected. Vehicle Speed 1 Sensor The detected (Rotation Speed) Error value is 5 km/h slower than the machine speed 2 sensor. Vehicle Speed 2 Sensor The detected Error value is 5 km/h slower than the machine speed 1 sensor.

Symptoms in Machine Operation When Trouble Occurs. The back buzzer does not sound while driving in reverse direction. Machine speed is insufficient.

Remedy Check the harness. Replace the back buzzer relay. Check the harness. Replace the machine speed 1 sensor.

The machine can travel normally. (However, the HST warning indicator is turned on.)

Check the harness. Replace the machine speed 1 sensor.

The machine can travel normally. (However, the HST warning indicator is turned on.) The overrun control is not activated.

Check the harness. Replace the machine speed 2 sensor.

T5-5-22

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

111904-2

Abnormal Forward/ Reverse Lever

111905-2

Abnormal Forward/ Reverse Switch

The forward and reverse travel signals are detected at the same time. The forward and reverse travel signals are detected at the same time.

Symptoms in Machine Operation Remedy When Trouble Occurs. The travel operation is impossible. Check the harness.

When the forward/reverse switch (OPT) is effective, travel direction (forward/reverse) cannot be shifted.

T5-5-23

Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-24

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Information Controller Fault Code List Fault Code 114001-2

114002-2

114003-2

114006-2

114008-2

Trouble Cause Remedy Flash Memory Read/ The internal memory After initializing the information controller by using MPDr., Write Error of information retry the troubleshooting. If the fault code is displayed after controller is abnormal. retry, the information controller may be broken. Replace the information controller. When initializing the information controller, all stored data is deleted. External RAM Read/ The internal memory After initializing the information controller by using MPDr., Write Error of information retry the troubleshooting. If the fault code is displayed after controller is abnormal. retry, the information controller may be broken. Replace the information controller. When initializing the information controller, all stored data is deleted. Abnormal EEPROM The internal memory Retry the troubleshooting by using MPDr. If the fault code of information is displayed after retry, the information controller may be controller is abnormal. broken. Replace the information controller. Communication error Check the communication line, power line, and fuses for Communication with communication communication terminal. Then, retry the troubleshooting Terminal : equipment by using MPDr. If the fault code is displayed after retry, the Communication Error communication equipment may be broken. Replace the communication equipment. Abnormal Internal The internal memory Retry the troubleshooting by using MPDr. If the fault code RAM of information is displayed after retry, the information controller may be controller is abnormal. broken. Replace the information controller.

T5-5-25

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display Controller Fault Code List Fault Code

115001-2

115003-2 115011-3

115011-4

115015-3

115015-4

115018-2

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs. Abnormal REG input Alternator generating The alternator Check the harness. H level voltage: 33.5 V or more indicator is ON. Check the battery. Check the alternator. Abnormal EEPROM Faulty column display Replace the column controller. display controller. The fuel gauge Check the harness. Open circuit in fuel 131±5 Ω or less level sensor continues for 5 (pointer) points to E. Replace the fuel level seconds. sensor. The fuel gauge Check the harness. Shorted circuit in fuel 4±2 Ω or less (pointer) points to E. Replace the fuel level level sensor continues for 5 seconds. sensor. Parking Brake Pressure 4.75 V or more The parking brake Check the harness. Sensor continues for 200 indicator is tuned off. Replace pressure High Voltage msec. sensor (Parking brake) Parking Brake Pressure 0.25 V or less The parking brake Check the harness. Sensor continues for 200 indicator is tuned off. Replace pressure Low Voltage msec. sensor (Parking brake) 24 V Output Error Faulty column display Check the harness. controller. Replace the column display controller.

T5-5-26

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code 120500-2

Trouble Overheat Alarm

120501-2

Engine Warning Alarm Engine Oil Pressure Alarm Air Cleaner Restriction Alarm Hydraulic Oil Level Alarm Brake Pressure Alarm

120502-2 120503-2 120504-2 120505-2

120506-2 120507-2 120510-2 120511-2 120512-2

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

Steering Oil Faulty steering pressure switch Pressure Alarm (OPT) Transmission Error Faulty transmission system Alarm HST Oil Temperature HST oil temperature is high while Alarm the engine runs. Fuel Filter Supply pump inlet pressure is Restriction Alarm reduced. Emergency Steering Faulty secondary steering system Alarm (Lighting) (OPT)

120513-2

Muffler Filter Alarm

Faulty exhaust filter

120515-2 120517-2

Engine Alarm Water Separator Alarm

Faulty engine system The water separator (OPT) is full.

120518-2

Emergency Steering Faulty secondary steering pump Alarm (Blinking) (OPT)

T5-5-27

Check the harness. Replace the engine oil pressure switch. Check the harness. Replace the air cleaner restriction switch. Check the harness. Replace the hydraulic oil level switch. Check the harness. Replace the pressure sensor (brake primary pressure). Check the harness. Replace the steering pressure switch (OPT). Check the harness. Check the harness. Replace the HST oil temperature sensor. Check the harness. Replace the fuel filter. Check the harness. Replace the secondary steering pump delivery pressure sensor. Check the harness. Replace the exhaust filter differential pressure sensor. Refer to Engine Troubleshooting Manual. Check the harness. Replace the water separator alarm switch (OPT). Check the harness. Replace the secondary steering operation check switch (OPT).

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. Voltage: less than 0.3 V Operation is controlled under such circumstance as no recirculated air sensor is provided. Voltage: more than 4.88 V Operation is controlled under such circumstance as no outdoor ambient temperature sensor is provided.

Remedy

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

T5-5-28

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

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 harness. 0V motor becomes inoperable. Replace the air vent Open circuit: Voltage: damper servo motor. more than 5 V Check the harness. Shorted circuit: Voltage: Air mix damper servo 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 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 controller and air conditioner controller. conditioner controller Faulty air conditioner Air conditioner stops. Check the CAN1 controller harness. Replace air Faulty CAN1 harness conditioner controller.

T5-5-29

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.

T5-5-30

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)

T5-5-31

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code ISUZU KCM P2453 81-0

Trouble

Cause

High Muffler Filter Differential Pressure

Exhaust filter pressure difference is more than 60 kPa. Low Muffler Filter Differential Pressure Exhaust filter pressure difference is less than 0.5 kPa. Zero-point calibration of Muffler Filter differential Learning value is 4.5 kPa or more. pressure sensor is abnormal. Muffler Filter Differential Pressure Sensor Circuit Voltage at the exhaust filter pressure difference High Input sensor is more than 4.89 V. Muffler Filter Differential Pressure Sensor Circuit Voltage at the exhaust filter pressure difference Low Input sensor is less than 0.18 V. Accelerator Pedal Position Sensor 1-2 Correlation Opening amount difference between accelerator sensors 1 and 2 is 45 % or more.

P2452

81-1

P2456

81-2

P2455

81-3

P2454

81-4

P2138

91-2

P2123

91-3

Accelerator Pedal Position Sensor 1 High Input

Voltage at accelerator sensor 1 is more than 4.9 V.

P2128

91-3

Accelerator Pedal Position Sensor 2 High Input

Voltage at accelerator sensor 2 is more than 4.9 V.

P2122

91-4

Accelerator Pedal Position Sensor 1 Low Input

Voltage at accelerator sensor 1 is less than 0.2 V.

P2127

91-4

Accelerator Pedal Position Sensor 2 Low Input

Voltage at accelerator sensor 2 is less than 0.2 V.

P0523

100-3

Engine Oil Pressure Sensor Circuit High Input

P0522

100-4

Engine Oil Pressure Sensor Circuit Low Input

P0234 P0238

102-0 102-3

Over Boost-Pressure Boost Pressure Sensor Circuit High Input

P0237

102-4

Boost Pressure Sensor Circuit Low Input

P1113

105-3

Boost Temperature Sensor Circuit High Input

P1112

105-4

Boost Temperature Sensor Circuit Low Input

P2229

108-3

Atmospheric Pressure Sensor Circuit High Input

P2228

108-4

Atmospheric Pressure Sensor Circuit Low Input

P0217

110-0

Overheat

Voltage at the engine oil pressure sensor is more than 4.85 V. Voltage at the engine oil pressure sensor is less than 0.1 V. Boost pressure is more than 270 kPa. Voltage at the boost pressure sensor is more than 4.9 V. Voltage at the boost pressure sensor is less than 0.1 V. Voltage at the boost temperature sensor is more than 4.94 V. Voltage at the boost temperature sensor is less than 0.1 V. Voltage at the atmospheric pressure sensor is more than 4 V. Voltage at the atmospheric pressure sensor is less than 0.5 V. Coolant temperature is more than 110 °C.

T5-5-32

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

The output power decreases.

Regenerative control is impossible.

The output power decreases.

Regenerative control is impossible.

The output power decreases.

Exhaust filter pressure difference is 0 kPa.

The output power decreases.

Exhaust filter pressure difference is 0 kPa.

The output power decreases.

Exhaust filter pressure difference is 0 kPa.

Abnormal system 1: No backup Abnormal system 2: The accelerator opening amount is limited to 0 %. Abnormal system 1: No backup Abnormal system 2: The accelerator opening amount is limited to 0 %. Abnormal system 1: No backup Abnormal system 2: The accelerator opening amount is limited to 0 %. Abnormal system 1: No backup Abnormal system 2: The accelerator opening amount is limited to 0 %. Abnormal system 1: No backup Abnormal system 2: The accelerator opening amount is limited to 0 %. Nothing special.

The output power decreases. Nothing special.

The accelerator opening amount signal cannot be used. (The limited value is changed according to the quantity of faulty systems.) The accelerator opening amount signal cannot be used. (The limited value is changed according to the quantity of faulty systems.) The accelerator opening amount signal cannot be used. (The limited value is changed according to the quantity of faulty systems.) The accelerator opening amount signal cannot be used. (The limited value is changed according to the quantity of faulty systems.) The accelerator opening amount signal cannot be used. (The limited value is changed according to the quantity of faulty systems.) Engine oil pressure is 120 kPa. Hydraulic oil pressure alarm stop. Engine oil pressure is 120 kPa. Hydraulic oil pressure alarm stop. Malfunction of VGS turbo Boost pressure is 100 kPa.

Nothing special.

Boost pressure is 100 kPa.

The rotation speed does not increase.

The output power decreases.

Boost temperature is 50 °C. Boost temperature alarm stop. Boost temperature is 50 °C. Boost temperature alarm stop. Atmospheric pressure is 95 kPa.

The output power decreases.

Atmospheric pressure is 95 kPa.

The output power decreases.

Injection amount is regulated by overheat protection.

Nothing special.

The rotation speed does not increase.

T5-5-33

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P2453 81-0 P2452 81-1 P2456 81-2

Trouble

Influence to Engine Performance (Presumption)

High Muffler Filter Differential Pressure Low Muffler Filter Differential Pressure Zero-point calibration of Muffler Filter differential pressure sensor is abnormal. Muffler Filter Differential Pressure Sensor Circuit High Input Muffler Filter Differential Pressure Sensor Circuit Low Input Accelerator Pedal Position Sensor 1-2 Correlation

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

P2455

81-3

The output power decreases.

P2454

81-4

P2138

91-2

P2123

91-3

Accelerator Pedal Position Sensor 1 High Input

P2128

91-3

Accelerator Pedal Position Sensor 2 High Input

P2122

91-4

Accelerator Pedal Position Sensor 1 Low Input

P2127

91-4

Accelerator Pedal Position Sensor 2 Low Input

P0523

100-3

P0522

100-4

P0234 P0238

102-0 102-3

Engine Oil Pressure Sensor Circuit High Input Engine Oil Pressure Sensor Circuit Low Input Over Boost-Pressure Boost Pressure Sensor Circuit High Input

Rotation speed is limited, the output power decreases. The output power decreases.

P0237

102-4

Boost Pressure Sensor Circuit Low Input

The output power decreases.

P1113

105-3

P1112

105-4

P2229

108-3

P2228

108-4

P0217

110-0

Boost Temperature Sensor Circuit High No output power change Input Boost Temperature Sensor Circuit Low No output power change Input Atmospheric Pressure Sensor Circuit High The output power decreases. Input Atmospheric Pressure Sensor Circuit Low The output power decreases. Input Overheat Rotation speed is limited, the output power decreases.

The output power decreases. Abnormal system 1: No output power change Abnormal system 2: Idle speed operation No influence while operating CAN Communication Abnormal system 1: No output power change Abnormal system 2: Idle speed operation No influence while operating CAN Communication Abnormal system 1: No output power change Abnormal system 2: Idle speed operation No influence while operating CAN Communication Abnormal system 1: No output power change Abnormal system 2: Idle speed operation No influence while operating CAN Communication Abnormal system 1: No output power change Abnormal system 2: Idle speed operation No influence while operating CAN Communication No output power change No output power change

T5-5-34

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B   

Remark C

D Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



In case accelerator sensor system 2 is connected



In case accelerator sensor system 2 is connected



In case accelerator sensor system 2 is connected



In case accelerator sensor system 2 is connected

     

The boost pressure is reduced due to turbo control and the output power decreases. The boost pressure is reduced due to turbo control and the output power decreases. Diagnosing starts over 3 minutes after the engine starts or coolant temperature is beyond 50 °C.

 

Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



The indicator does not light due to overheat switch alarm in the same way as Tier 3. Send the CAN fault code.

Operating Rank A: Digging / travel is operable. B: The machine can travel on a level ground and a downhill. C: The engine only runs. (Travel and digging operations are impossible even in light load.) D: The engine cannot stop/start.

T5-5-35

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P0118 110-3

Trouble

Cause

Engine Coolant Temperature Circuit High Input

P0117

110-4

Engine Coolant Temperature Circuit Low Input

P0103 P0102 P0088

132-3 132-4 157-0

Air Flow Sensor Circuit High Input Air Flow Sensor Circuit Low Input Pressure Increase in Common Rail (Secondary)

Voltage at the coolant temperature sensor is more than 4.85 V. Voltage at the coolant temperature sensor is less than 0.1 V. Voltage at the air flow sensor is more than 4.9 V. Voltage at the air flow sensor is less than 0.1 V. The first stage "Abnormal common rail pressure" is approved and common rail pressure is 190 MPa or more.

P0193

157-3

Common Rail Pressure Sensor Circuit High Input

P0192

157-4

P0089

157-15

P0088

157-16

Pressure Increase in Common Rail (Primary)

Rail pressure is 185 MPa or more.

P0563 P0113

158-3 172-3

Abnormally High Battery System Voltage Intake Air Temperature Sensor Circuit High Input

P0112

172-4

Intake Air Temperature Sensor Circuit Low Input

IG-KEY voltage is more than 32 V. Voltage at the intake-air temperature sensor is more than 4.85 V. Voltage at the intake-air temperature sensor is less than 0.1 V.

Voltage at the common rail pressure sensor is more than 4.8 V. Common Rail Pressure Sensor Circuit Low Input Voltage at the common rail pressure sensor is less than 0.7 V. Abnormal Common Rail Pressure (Over Pumping) Actual rail pressure is more than 40 MPa higher than the target rail pressure.

T5-5-36

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

The output power decreases.

When starting: Coolant temperature is -20 °C. When operating: Coolant temperature is 90 °C. When starting: Coolant temperature is -20 °C. When operating: Coolant temperature is 90 °C. The MAF sensor value is 250 g/sec. The MAF sensor value is 250 g/sec. Prevent fuel leaks.

The output power decreases. The output power decreases. The output power decreases. Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large. The engine may be stalled. The output power decreases.

Rail pressure is 80 MPa.

The engine may be stalled. The output power decreases.

Rail pressure is 80 MPa.

Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large. Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large. The battery may be faulty. The output power decreases.

Prevent fuel leaks.

Intake-air temperature is -10 °C.

The output power decreases.

Intake-air temperature is -10 °C.

Prevent fuel leaks.

T5-5-37

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P0118 110-3

Trouble

Influence to Engine Performance (Presumption)

Engine Coolant Temperature Circuit High Input

The output power decreases.

P0117

110-4

Engine Coolant Temperature Circuit Low Input

The output power decreases.

P0103

132-3

Air Flow Sensor Circuit High Input

The output power decreases.

P0102

132-4

Air Flow Sensor Circuit Low Input

The output power decreases.

P0088 P0193

157-0 157-3

Pressure Increase in Common Rail (Secondary) Common Rail Pressure Sensor Circuit High Input

The output power decreases. The output power decreases.

P0192

157-4

Common Rail Pressure Sensor Circuit Low Input

The output power decreases.

P0089 P0088 P0563 P0113

157-15 157-16 158-3 172-3

Abnormal Common Rail Pressure (Over Pumping) The output power decreases. Pressure Increase in Common Rail (Primary) The output power decreases. Abnormally High Battery System Voltage No output power change. Intake Air Temperature Sensor Circuit High Input The output power decreases.

P0112

172-4

Intake Air Temperature Sensor Circuit Low Input

T5-5-38

The output power decreases.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B 



      

Remark C

D Limit Q is performed as regeneration stops. The boost pressure is reduced due to turbo control and the output power decreases. Diagnosing starts over 3 minutes after the engine starts. Limit Q is performed as regeneration stops. The boost pressure is reduced due to turbo control and the output power decreases. Limit Q is performed just in case as regeneration evaluation stops. Limit Q is performed just in case as regeneration evaluation stops. Limit Q is performed as regeneration stops. Limit Q is performed as rail pressure cannot be controlled and regeneration stops. Limit Q is performed as rail pressure cannot be controlled and regeneration stops. Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops.

  

Limit Q is performed. Diagnosing starts over 3 minutes after the engine starts. Limit Q is performed.

T5-5-39

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P0426 173-0

Trouble

Cause

Abnormally High Exhaust Temperature Sensor 1 (CSF Inlet) Exhaust Temperature Sensor 1 Circuit High Input (CSF Inlet)

Temperature of exhaust temperature sensor 1 is 880 °C or more. Voltage at exhaust temperature sensor 1 is more than 4.85 V. Voltage at exhaust temperature sensor 1 is less than 0.2 V. (Exhaust temperature is equivalent to 1000 °C.) Voltage at the fuel temperature sensor is more than 4.85 V. Voltage at the fuel temperature sensor is less than 0.1 V. Engine speed is more than specification (2800 min-1). Check sum is NG. It is judged by rail pressure change pattern. The signal from cam sensor is not present.

P0428

173-3

P0427

173-4

Exhaust Temperature Sensor 1 Circuit Low Input (CSF Inlet)

P0183

174-3

P0182

174-4

P0219

190-0

Combustion Temperature Sensor Circuit High Input Combustion Temperature Sensor Circuit Low Input Engine Overrun

P0601 P0087 P0340

628-2 633-7 636-2

Abnormal ROM Common Rail Pressure Limiter Open Abnormal Cam Angle Sensor (No Signal)

P0016

636-7

Phase Difference between Cam and Sensor

The correct cam pulse is not present at the gap in the crank.

U0101 U0073

639-2 639-19

Abnormal CAN Time-out Abnormal CAN Bus

TSC1 message from SA=228 is not received. The bus line OFF is detected.

T5-5-40

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

The output power decreases.

Regenerative control is impossible.

The output power decreases.

Exhaust temperature sensor 2 is substituted for exhaust filter regeneration evaluation temperature. Exhaust temperature 1 is 0 °C. Exhaust temperature alarm stop. Exhaust temperature sensor 2 is substituted for exhaust filter regeneration evaluation temperature. Exhaust temperature 1 is 0 °C. Exhaust temperature alarm stop. When starting: Coolant temperature is -20 °C. When operating: Coolant temperature is 50 °C. When starting: Coolant temperature is -20 °C. When operating: Coolant temperature is 50 °C. Protect the engine.

The output power decreases.

Nothing special. Nothing special. Engine speed may not increase 2800 min-1 or more. The engine cannot start. The output power decreases. While the engine runs, there is nothing abnormal with machine operation. After the engine is stalled, the re-start is impossible. While the engine runs, there is nothing abnormal with machine operation. After the engine is stalled, the re-start is impossible. The engine runs at 1000 min-1. The engine runs at idle speed.

Malfunction of ROM Limitter open status While the engine runs, operate according to standard of the crank speed sensor. When the engine stops, the start is impossible (in order to prevent the engine from damaging). While the engine runs, operate according to standard of the crank speed sensor. When the engine stops, the start is impossible (in order to prevent the engine from damaging). CAN communication is impossible. CAN communication is impossible.

T5-5-41

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P0426 173-0

Trouble

Influence to Engine Performance (Presumption)

Abnormally High Exhaust Temperature Sensor 1 (CSF Inlet) Exhaust Temperature Sensor 1 Circuit High Input (CSF Inlet)

The output power decreases.

P0428

173-3

P0427

173-4

P0183

174-3

P0182

174-4

P0219 P0601 P0087 P0340

190-0 628-2 633-7 636-2

Exhaust Temperature Sensor 1 Circuit Low Input (CSF Inlet) Combustion Temperature Sensor Circuit High Input Combustion Temperature Sensor Circuit Low Input Engine Overrun Abnormal ROM Common Rail Pressure Limiter Open Abnormal Cam Angle Sensor (No Signal)

P0016

636-7

Phase Difference between Cam and Sensor

U0101 U0073

639-2 639-19

Abnormal CAN Time-out Abnormal CAN Bus

T5-5-42

The output power decreases.

No output power change No output power change No output power change The engine cannot start. The output power decreases. No influence during operation. After stopping, the re-start is impossible. No influence during operation. After stopping, the re-start is impossible. Engine speed is fixed. Idle speed

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B 

Remark C

D Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops. Diagnosing starts when coolant temperature is beyond 70 °C over 30 seconds to 10 minutes after the engine starts. Limit Q is performed as regeneration stops.

 

Diagnosing starts over 3 minutes after the engine starts.

   

Limit Q is performed as regeneration stops.



  

T5-5-43

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P0201 651-5

Trouble

Cause

Cylinder 1 Injector Circuit Open

No input signal of injector 1 monitor.

P0202

652-5

Cylinder 2 Injector Circuit Open

No input signal of injector 2 monitor.

P0203

653-5

Cylinder 3 Injector Circuit Open

No input signal of injector 3 monitor.

P0204

654-5

Cylinder 4 Injector Circuit Open

No input signal of injector 4 monitor.

P0335

723-2

Crank Position Sensor Failure (No Signal)

Engine speed: 90 min-1 or more, even if the cam signal is present, the crank signal is not present.

P0336

723-2

Crank Position Sensor Failure (Abnormal Signal)

Engine speed: 750 min-1 or more, the pulse of crank signal is not matched.

P0606

1077-2

Abnormal CPU

P0641

1079-2

Abnormal 5V-Electric Power Circuit #1

P0651

1080-2

Abnormal 5V-Electric Power Circuit #2

P041C

1131-3

P041D

1131-4

P0093

1239-1

Manifold Temperature Sensor Circuit High Input Manifold Temperature Sensor Circuit Low Input Pressure Decline in Common Rail (No Pumping Pressure)

Failure of main CPU is detected by sub CPU. (Sub CPU resets CPU.) Voltage of 5 V1 or 5 V5 power source is 5.5 V or more or 4.5 V or less. Voltage of 5 V2 or 5 V6 power source is 5.5 V or more or 4.5 V or less. Voltage at the manifold temperature sensor is more than 4.94 V. Voltage at the manifold temperature sensor is less than 0.1 V. Engine speed: 900 min-1 or more, rail pressure: 15 MPa or less

P1093

1239-31 (Fuel temperature < 5 °C) 1239-17 Pressure Decline in Common Rail (Lack of Pumping Pressure) 1239-31 (Fuel temperature < 5 °C)

T5-5-44

Actual rail pressure is 50 MPa or lower than the target rail pressure.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. The output power may decrease, white smoke may occur and vibration may occur, the engine may be stalled. (If the cam senor is normal, the engine can re-start.)

The injector cannot be controlled.

The output power may decrease, white smoke may occur and vibration may occur, the engine may be stalled. (If the cam senor is normal, the engine can re-start.) The output power decreases, or the engine cannot start.

The injector cannot be controlled.

The engine is operated according to the cam sensor standard. Rotation speed cannot be detected by the crank speed sensor. The engine is operated according to the cam sensor standard. Rotation speed cannot be detected by the crank speed sensor. Malfunction of CPU 

Same to when accelerator sensor, crank speed sensor, and rail pressure sensor are abnormal. Same to when atmospheric pressure sensor, cam angle sensor, and boost temperature sensor are abnormal. Nothing special.

Manifold temperature is 60 °C.

Nothing special.

Manifold temperature is 60 °C.

Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large.

Fuel leakage is too much.

Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large.

Fuel leakage is too much.



T5-5-45

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P0201 651-5

Trouble

Influence to Engine Performance (Presumption)

Cylinder 1 Injector Circuit Open

P0202

652-5

Cylinder 2 Injector Circuit Open

P0203

653-5

Cylinder 3 Injector Circuit Open

P0204

654-5

Cylinder 4 Injector Circuit Open

P0335 P0336

723-2 723-2

P0606

1077-2

Crank Position Sensor Failure (No Signal) Crank Position Sensor Failure (Abnormal Signal) Abnormal CPU

The output power decreases. Three cylinders in operation The output power decreases. Three cylinders in operation The output power decreases. Three cylinders in operation The output power decreases. Three cylinders in operation The output power decreases. The output power decreases.

P0641

1079-2

Abnormal 5V-Electric Power Circuit #1

P0651

1080-2

Abnormal 5V-Electric Power Circuit #2

P041C

1131-3

P041D

1131-4

P0093

Manifold Temperature Sensor Circuit High Input Manifold Temperature Sensor Circuit Low Input Pressure Decline in Common Rail (No Pumping Pressure)

1239-1 1239-31 (Fuel temperature < 5 °C) 1239-17 Pressure Decline in Common Rail (Lack of Pumping Pressure) 1239-31 (Fuel temperature < 5 °C)

P1093

T5-5-46

Rotation speed limit control, the output power decreases, or the engine cannot start. Same to when accelerator sensor, crank speed sensor, and rail pressure sensor are abnormal. Same to when atmospheric pressure sensor, cam angle sensor, and boost temperature sensor are abnormal. No output power change No output power change The output power decreases.

The output power decreases.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B 

Remark C

D Although regeneration stops, limit Q is not performed as the output power decreases too much. Although regeneration stops, limit Q is not performed as the output power decreases too much. Although regeneration stops, limit Q is not performed as the output power decreases too much. Although regeneration stops, limit Q is not performed as the output power decreases too much. Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops.

     



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Diagnosing starts over 3 minutes after the engine starts.

 

Limit Q is performed as rail pressure control is impossible and regeneration stops.



Limit Q is performed as rail pressure control is impossible and regeneration stops.

T5-5-47

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P0092 1347-3

Trouble

Cause

SCV Drive Circuit + Short Circuit B

SCV current is 2400 mA or more or difference between SCV current and target current is 1000 mA or more. SCV Drive Circuit Open or Short Circuited to GND SCV current is 50 mA or less or difference between SCV current and target current is 1000 mA or more.

P0091

1347-4

P1294

1381-3

Fuel Filter Restriction Sensor Circuit High Input

P1293

1381-4

Fuel Filter Restriction Sensor Circuit Low Input

P0685

1485-5

Abnormal Main Relay Circuit (Inactivation)

P0687

1485-6

Abnormal Main Relay Circuit (Kept closed)

P0409

10001-2

EGR Position Sensor Error

P1404

10001-13 Abnormal EGR Zero-point calibration

P0404

10002-2

Abnormal EGR Valve Control Circuit

P2146

10003-2

Abnormal Injector Common 1 Circuit

Voltage at the restriction sensor is more than 4.9 V. Voltage at the restriction sensor is less than 0.1 V. Voltage in the main relay system is 1 V or less with the main relay coil output ON. Even if the main relay coil output is turned OFF, the main relay is kept ON. The condition which the output signal of EGR position sensor cannot be present in. Zero point calibration value is beyond the specification. Difference between the target valve lift and actual position is more than 20 %. No monitor input signal of injectors 1, 4.

P2149

10004-2

Abnormal Injector Common 2 Circuit

No monitor input signal of injectors 2, 3.

P1261

10005-1

Abnormal Charge Circuit (Bank 1)

Voltage at bank 1 of charge circuit in ECM is low.

P1262

10006-1

Abnormal Charge Circuit (Bank 2)

Voltage at bank 2 of charge circuit in ECM is low.

P0606 P060B P0697

10007-2 10008-2 10009-2

Abnormal CPU Monitor IC Abnormal A/D Converter Abnormal 5V-Electric Power Circuit #3

No change of RUN-SUB pulse in 20 msec. A/D conversion cannot be done. Voltage of 5 V3 or 5 V7 power source is 5.5 V or more or 4.5 V or less.

P1655

10010-2

Abnormal 5V-Electric Power Circuit #4

Voltage of 5 V4 or 5 V8 power source is 5.5 V or more or 4.5 V or less.

P0560

10012-2

Abnormal 12V Circuit

P1621

10013-2

Abnormal EEPROM

Voltage of 12 V power source is 19 V or more or 7 V or less. Abnormal EEPROM is detected.

T5-5-48

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

The output power decreases, there is influence to exhaust gas.

The supply pump can not be controlled.

The output power decreases, there is influence to exhaust gas, the supply pump can not be controlled, the engine may increase the rotation speed automatically and abnormally. Nothing special.

The engine cannot start.

The supply pump can not be controlled.  Prevent the engine from increasing the rotation speed automatically and abnormally. (The engine is protected from damage.) Fuel pressure is 0 kPa. Fuel filter restriction alarm stop. Fuel pressure is 0 kPa. Fuel filter restriction alarm stop. -

Electrical power is kept supplying to the machine.

The output power decreases.

EGR opening amount is not certain.

The output power decreases.

EGR cannot be controlled.

The output power decreases.

EGR cannot be controlled.

Nothing special.

Vibration of the engine may be large, rough idle, output The injector cannot be controlled. power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled. Vibration of the engine may be large, rough idle, output The injector cannot be controlled. power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled. Vibration of the engine may be large, rough idle, output The injector cannot be controlled. power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled. Vibration of the engine may be large, rough idle, output The injector cannot be controlled. power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled. The output power decreases. Malfunction of sub CPU Output power decrease, dark smoke occurs. All analogue sensor cannot be used. Same to when coolant temperature sensor, engine oil  pressure sensor, exhaust filter differential pressure sensor, exhaust temperature sensor, and fuel filter restriction sensor are abnormal. Same to when boost pressure sensor, EGR position sensor,  intake throttle position sensor, and fuel temperature sensor are abnormal. Same to when air flow sensor is abnormal.  Nothing special.

Learning value and correction value cannot be used.

T5-5-49

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code Trouble ISUZU KCM P0092 1347-3 SCV Drive Circuit + Short Circuit B P0091 1347-4 SCV Drive Circuit Open or Short Circuited to GND P1294 1381-3 Fuel Filter Restriction Sensor Circuit High Input P1293 1381-4 Fuel Filter Restriction Sensor Circuit Low Input P0685 1485-5 Abnormal Main Relay Circuit (Inactivation) P0687 1485-6 Abnormal Main Relay Circuit (Kept closed) P0409 10001-2 EGR Position Sensor Error P1404 10001-13 Abnormal EGR Zero-point calibration P0404 10002-2 Abnormal EGR Valve Control Circuit P2146 10003-2 Abnormal Injector Common 1 Circuit

The output power decreases. The output power decreases. No output power change No output power change The engine stops. No output power change The output power decreases. The output power decreases. The output power decreases. Two cylinders in operation

P2149

10004-2

Abnormal Injector Common 2 Circuit

Two cylinders in operation

P1261

10005-1

Abnormal Charge Circuit (Bank 1)

Two cylinders in operation

P1262

10006-1

Abnormal Charge Circuit (Bank 2)

Two cylinders in operation

P0606 P060B P0697

10007-2 10008-2 10009-2

Abnormal CPU Monitor IC Abnormal A/D Converter Abnormal 5V-Electric Power Circuit #3

P1655

10010-2

Abnormal 5V-Electric Power Circuit #4

P0560 P1621

10012-2 10013-2

Abnormal 12V Circuit Abnormal EEPROM

The output power decreases. The output power decreases. Same to when coolant temperature sensor, engine oil pressure sensor, exhaust filter differential pressure sensor, exhaust temperature sensor, and fuel filter restriction sensor are abnormal. Same to when boost pressure sensor, EGR position sensor, intake throttle position sensor, and fuel temperature sensor are abnormal. Same to when air flow sensor is abnormal. No output power change

T5-5-50

Influence to Engine Performance (Presumption)

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B    

Remark C

D Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops.

        

The battery may run out. Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops. Although regeneration stops, limit Q is not performed as the output power decreases too much. Although regeneration stops, limit Q is not performed as the output power decreases too much. Although regeneration stops, limit Q is not performed as the output power decreases too much. Although regeneration stops, limit Q is not performed as the output power decreases too much.

  

Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops.

 Operating Rank A: Digging / travel is operable. B: The machine can travel on a level ground and a downhill. C: The engine only runs. (Travel and digging operations are impossible even in light load.) D: The engine cannot stop/start.

T5-5-51

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P0638 10022-2

Trouble

Cause

P0602 P0604 U0001

Difference between the target valve lift and actual position is more than 40 %. 10022-3 Intake Throttle Position Sensor Circuit High Input Voltage at the intake throttle position sensor is more than 4.9 V. 10022-4 Intake Throttle Position Sensor Circuit Low Input Voltage at the intake throttle position sensor is less than 0.3 V. 10023-2 Abnormal CAN VNT Time-out The message from turbo controller is not received. 10023-12 Abnormal VNT Turbo The abnormal message from turbo controller has been received. 10023-19 VNT Communication Error The abnormal communication message from turbo controller has been received. 10024-3 Exhaust Temperature Sensor 2 Circuit High Input Voltage at exhaust temperature sensor 2 is more (DOC Inlet) than 4.85 V. 10024-4 Exhaust Temperature Sensor 2 Circuit Low Input Voltage at exhaust temperature sensor 2 is less (DOC Inlet) than 0.2 V. (Exhaust temperature is equivalent to 800 °C.) 10025-5 Muffler Filter Light Failure No exhaust filter lamp monitor signal. 10026-0 Muffler Filter PM Over-Restriction 2 In case it is evaluated that PM trapping amount is out of exhaust filter regeneration level (evaluated by the operating period) 10026-15 Muffler Filter PM Over-Restriction In case it is evaluated that PM trapping amount is out of exhaust filter regeneration level (evaluated by a pressure difference) 10027-0 Muffler Filter Cleaning Decision Error In case cleaning evaluation after regeneration is NG continuously twice 10028-0 Abnormally High Exhaust Temperature Sensor 2 Temperature of exhaust temperature sensor 2 is (DOC Inlet) 870 °C or more. 10029-0 Over Frequent Muffler Filter Regeneration Time- In case regeneration time out is continuously Out three times 10032-2 QR Code Error QR code and Q adjust have not been written. 10033-2 Abnormal RAM Abnormal RAM is detected. 10040-19 Abnormal ISO-CAN Bus The bus line OFF is detected.

U2106

10034-2

P0123 P0122 U0110 P0045 U0411 P042D P042C

P1669 P1455

P242F

P1471 P042B P2458

Abnormal Intake Throttle Control Circuit

Abnormal Wheel Loader CAN Time -Out

T5-5-52

The TS1 message from SA=3 is not received.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs.

Assumptive Conditions at Backup

The output power decreases.

The intake throttle cannot be controlled.

The output power decreases.

The intake throttle opening amount is not certain.

The output power decreases.

The intake throttle opening amount is not certain.

The output power decreases.

The information from turbo controller cannot be received.

The output power decreases.

Turbo controller performs fail-safe control and boost pressure decreases. Turbo controller performs fail-safe control and boost pressure decreases. Exhaust temperature 2 is 0 °C.

The output power decreases.

Exhaust temperature 2 is 0 °C.

There is no influence when operating the machine. The output power decreases.

Regenerative control is impossible.

The output power decreases.

Regenerative control is impossible.

The output power decreases.

Regenerative control is impossible.

The output power decreases.

Regenerative control is impossible.

The output power decreases.

Regenerative control is impossible.

Combustion sound may change. The engine cannot start. The output power decreases.

The injector cannot be corrected. Malfunction of RAM Turbo controller performs fail-safe control and boost pressure decreases. CAN communication is impossible.

The output power decreases.

There is no influence when operating the machine.

T5-5-53

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code ISUZU KCM P0638 10022-2 P0123 10022-3 P0122 10022-4 U0110 10023-2 P0045

Influence to Engine Performance (Presumption) Abnormal Intake Throttle Control Circuit The output power decreases. Intake Throttle Position Sensor Circuit High Input The output power decreases. Intake Throttle Position Sensor Circuit Low Input The output power decreases. Abnormal CAN VNT Time-out Rotation speed is limited, the output power decreases. 10023-12 Abnormal VNT Turbo The output power decreases.

U0411

10023-19 VNT Communication Error

The output power decreases.

P042D

10024-3

Exhaust Temperature Sensor 2 Circuit High Input (DOC Inlet)

The output power decreases.

P042C

10024-4

The output power decreases.

P0602 P0604 U0001

Exhaust Temperature Sensor 2 Circuit Low Input (DOC Inlet) 10025-5 Muffler Filter Light Failure 10026-0 Muffler Filter PM Over-Restriction 2 10026-15 Muffler Filter PM Over-Restriction 10027-0 Muffler Filter Cleaning Decision Error 10028-0 Abnormally High Exhaust Temperature Sensor 2 (DOC Inlet) 10029-0 Over Frequent Muffler Filter Regeneration TimeOut * 10032-2 QR Code Error 10033-2 Abnormal RAM 10040-19 Abnormal ISO-CAN Bus

No output power change The engine cannot start. The output power decreases.

U2106

10034-2

The engine speed is fixed.

P1669 P1455 P242F P1471 P042B P2458

Trouble

Abnormal Wheel Loader CAN Time -Out

IMPORTANT: In case fault code 10029-0 is displayed, delete it once. Measure exhaust temperature of diesel oxidation catalyst (DOC) and filter (CSF) under the following conditions. Then, when difference between two exhaust temperature is beyond 15 °C (59 °F), the temperature sensor at lower-temperature side may be faulty. Condition after warming-up  Power Mode : ON  Parking Brake: ON  Forward/Reverse Lever: F  Bucket relief operation  The engine runs at high idle speed without load for six minutes. Normal value of exhaust temperature (reference) Temperature °C (°F)

380 (716)

T5-5-54

No output power change The output power decreases. The output power decreases. The output power decreases. The output power decreases. The output power decreases.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Operating Rank (Current) A B    

Remark C

D Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops.



Limit Q and rotation speed limit control are not performed as boost pressure decreases. Limit Q and rotation speed limit control are not performed as boost pressure decreases. Limit Q is performed as regeneration stops. Diagnosing starts when coolant temperature is beyond 70 °C over 30 seconds to 10 minutes after the engine starts. Limit Q is performed as regeneration stops.

   

Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops. Limit Q is performed as regeneration stops.



Limit Q is performed as regeneration stops. (Refer to T5-67.)

 



  

Limit Q and rotation speed limit control are not performed as boost pressure decreases.

T5-5-55

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-56

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111000 to 111002 Fault Code 111000-2 111001-2 111002-2

Trouble Abnormal EEPROM Abnormal RAM Abnormal A/D Converter

Cause Faulty MC Faulty MC Faulty MC

fNOTE: Even if the engine and the machine are operated normally with the fault code displayed after retrial, the machine can be operated as it is.

T5-5-57

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111003 IMPORTANT: When fault code 111003-3 (Abnormal Sensor Voltage) is displayed with other fault code, diagnose on fault code 111003-3 first. Fault Code 111003-3

Trouble Abnormal Sensor Voltage

Inspection Method Evaluation Disconnect connectors from Fault code 111003-3 is all sensors and accelerator not displayed. pedal sensor. Retry the troubleshooting by using MPDr. Measure voltage between Voltage: less than 0.25 V sensor harness end #1 and body. Check shorted circuit in harness 0 Ω between sensor harness end #1 and #3. Normal in above check.

Cause Faulty sensor

Open circuit in harness #1. Shorted circuit in harness #1 and #3. Faulty MC

123-

MC Pressure Sensor (Refrigerant Pressure) Pressure Sensor (Primary Pilot Pressure)

4567-

Pressure Sensor (Brake Primary Pressure) 1st Speed Limit Switch Accelerator Pedal Sensor Lift Arm Angle Sensor (OPT)

Pressure Sensor (Fan Circuit Pressure) 9- Secondary Steering Pump Delivery Pressure Sensor (OPT) 10- Steering Pressure Switch (OPT)

T5-5-58

TNDF-05-05-001

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Harness end of connector viewed from the open end side)  Pressure Sensor (Primary Pilot Pressure)  Steering Pressure Switch (OPT)

T6LE-05-05-011

 Pressure Sensor (Brake Primary Pressure)  Pressure Sensor (Fan Circuit Pressure)  Secondary Steering Pump Delivery Pressure Sensor (OPT)  Lift Arm Angle Sensor (OPT)  Pressure Sensor (Refrigerant Pressure)

T6LE-05-05-010

 Accelerator Pedal Sensor

TNED-05-05-002

 1st Speed Limit Switch

TNDF-05-05-007

T5-5-59

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-60

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111006, 111007, 111030 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 T5-5-54 to 56.) Fault Code 111006-2

111007-2

111030-2

Trouble Engine Controller Communication Error Information Controller Communication Error 1 (CAN1) HST Controller Communication Error (CAN1)

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)

T5-5-61

Cause Open circuit in harness Shorted circuit in harness Open circuit in harness Shorted circuit in harness Open circuit in harness Shorted circuit in 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) Correct

Discontinuity (∞ Ω) Discontinuity

Shorted circuit

Correct

CAN Harness

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

ECM #154 #132

HST Controller #40 #39

#A28 #A29 #A28-#D1 #A28-#E1 #A28-#E2 #A28-#E5 #A28-#E6 #A29-#D1 #A29-#E1 #A29-#E2 #A29-#E5 #A29-#E6

#A24 #A23

#154-#137 #154-#119 #154-#97 #132-#137 #132-#119 #132-#97 -

#40-#28 #40-#2 #39-#28 #39-#2 -

#A24-#B36 #A24-#B36 #A23-#B36 #A23-#B36 -

T5-5-62

Information Controller

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Inspection

CAN Harness

ECM

Discontinuity check between CAN circuit and power circuit in each controller

High side

#A28-#E3 #A28-#E4 #A28-#D2 #A28-#D5 #A28-#D6 #A29-#E3 #A29-#E4 #A29-#D2 #A29-#D5 #A29-#D6 #A28-#E10

#154-#67 #154-#89 #154-#111 #154-#133 #132-#67 #132-#89 #132-#111 #132-#133 #154-#134

Low side

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

#A29-#E10 #132-#134

#A28-#A29 #154-#132

HST Controller #40-#1 #40-#27 #39-#1 #39-#27 #40-#13 #40-#41 #40-#42 #39-#13 #39-#41 #39-#42 #40-#39

T5-5-63

Information Controller #A24-#B18 #A23-#B18 #A24-#B17

#A23-#B17

#A24-#A23

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Harness end)  MC-D Connector

 MC-A Connector

TNDB-05-05-005

 MC-E Connector

TNDF-05-05-002

 HST Controller Connector

T4FC-05-05-001 TNDB-05-05-006

 ECM-2 Connector

TDAB-05-06-021

 Information Controller-A Connector

TNDF-05-05-003

 Information Controller-B Connector

TNDF-05-05-004

T5-5-64

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-65

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN3 (Engine) Harness Check Preparation  Disconnect the connectors from ECM and VGS.  Before continuity check, set the key switch to the OFF position. Evaluation Continuity check (open circuit) Discontinuity check (shorted circuit)

Continuity (0 Ω) Correct

Discontinuity (∞ Ω) Discontinuity

Shorted circuit

Correct

Inspection CAN Harness Continuity check between ECM High side and VGS controller Low side Discontinuity check between CAN High side circuit and ground circuit in each controller

Low side

ECM #110 #88 #110-#61 #110-#62 #110-#63 #110-#64 #110-#65 #110-#66 #110-#97 #110-#119 #110-#137 #88-#61 #88-#62 #88-#63 #88-#64 #88-#65 #88-#66 #88-#97 #88-#119 #88-#137

T5-5-66

VGS #C07 #D06 #C07-#C02 #C06-#C02 -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

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

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

ECM #110-#67 #110-#89 #110-#111 #110-#133 #88-#67 #88-#89 #88-#111 #88-#133 #110-#134 #88-#134

VGS #1-#3 #1-#4 -

#110-#88

#3-#4

Connector (Harness end)  ECM-2 Connector

TDAB-05-06-021

 VGS Connector (Engine harness end)

TNDF-05-05-012

T5-5-67

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-68

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111008, 111014, 111025 Preparation  Disconnect the connectors from each controller.  Check the wiring connections first.  Check the CAN2 harness between the controllers. (Refer to CAN2 Harness Check on T5-5-62 to 64.) Fault Code 111008-2

111014-2

111025-2

Trouble Information Controller Communication Error 2 (CAN2) Air Conditioner Controller Communication Error (CAN2) Column Display Controller Communication Error (CAN2)

T5-5-69

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN2 Harness Check Preparation  Before continuity check, set the key switch to the OFF position. Evaluation Continuity check (open circuit) Discontinuity check (shorted circuit) Inspection

Continuity (0 Ω) Correct

Discontinuity (∞ Ω) Open circuit

Shorted circuit

Correct

CAN Harness

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

MC #E15 #E24

Information Controller #A26 #A25

Column Display A/C Controller #2-B30 #8 #2-B29 #9

#E15-#D1 #E15-#E1 #E15-#E2 #E15-#E5 #E15-#E6 #E24-#D1 #E24-#E1 #E24-#E2 #E24-#E5 #E24-#E6

#A26-#B36 #A25-#B36 -

#2-B30-#1-B28 #2-B29-#1-B28 -

T5-5-70

#8-#40 #9-#40 -

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

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

MC #E15-#E3 #E15-#E4 #E15-#D2 #E15-#D5 #E15-#D6 #E24-#E3 #E24-#E4 #E24-#D2 #E24-#D5 #E24-#D6 #E15-#E10

Information Controller #A26-#B18 #A25-#B18 #A26-#A17

Column Display A/C Controller #2-B28-#1-A1 #8-#21 #8-#21 #2-B30-#1-A1 #9-#21 #9-#21 #2-B28-#1-A2

#E24-#E10

#A25-#A17

#2-B30-#1-A2

#E15-#E24

#A26-#A25

#2-B28-#2-B30

T5-5-71

#8-#9

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Harness end)  MC-D Connector

 Column Display Controller 1-A Connector

TNDF-05-05-005 TNDB-05-05-005

 MC-E Connector

 Column Display Controller 1-B Connector

TNDF-05-05-006 TNDB-05-05-006

 Information Controller-A Connector

 Column Display Controller 2-B Connector

TNDF-05-05-003

 Information Controller-B Connector

TNDB-05-05-013

 A/C Connector

TNDF-05-05-004

T5-5-72

TNDB-05-05-018

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

111103-4

Trouble Inspection Method Accelerator Pedal Sensor Measure resistance Circuit High Input between accelerator pedal sensor end #1 and #2. Accelerator Pedal Sensor Measure voltage between Circuit Low Input accelerator pedal sensor harness end #1 and body. Measure voltage between accelerator pedal sensor harness end #1 and #3. -

Connector (Harness end)  Accelerator Pedal Sensor Connector

TNED-05-05-002

T5-5-73

Evaluation 0Ω

Cause Shorted circuit in harness #1 and #2

Normal in above check Voltage: less than 0.25 V

Faulty accelerator pedal sensor Open circuit in harness #1

Voltage: less than 0.25 V

Open circuit in harness #3

Normal in above check

Faulty accelerator pedal sensor

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111205, 111207 Preparation  Check the wiring connections first. Fault Code 111205-3

111205-4

111207-3

111207-4

Trouble Lift Arm Angle Sensor Circuit High Input

Lift Arm Angle Sensor Circuit Low Input

Inspection Method Measure resistance between lift arm angle sensor end #1 and #2. Measure voltage between lift arm angle sensor harness end #1 and body. Measure voltage between lift arm angle sensor harness end #1 and #3. -

Evaluation 0Ω

Cause Shorted circuit in harness #1 and #2

Normal in above check Voltage: less than 0.25 V

Faulty lift arm angle sensor Open circuit in harness #1

Voltage: less than 0.25 V

Open circuit in harness #3

Normal in above check 0Ω

Faulty lift arm angle sensor Shorted circuit in harness #1 and #2

Refrigerant Pressure Measure resistance Sensor Circuit High Input between refrigerant pressure sensor end #1 and #2. Normal in above check Refrigerant Pressure Measure voltage between Voltage: less than Sensor Circuit Low Input refrigerant pressure sensor 0.25 V harness end #1 and body. Measure voltage between Voltage: less than refrigerant pressure sensor 0.25 V harness end #1 and #3. Normal in above check

Connector (Harness end)  Lift Arm Angle Sensor Connector  Refrigerant Pressure Sensor Connector

T6LE-05-05-010

T5-5-74

Faulty refrigerant pressure sensor Open circuit in harness #1

Open circuit in harness #3

Faulty refrigerant pressure sensor

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 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 Evaluation Primary Pilot Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit High Input code Measure voltage between B Voltage: or more and body. 4.75 V Primary Pilot Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit Low Input code Measure voltage between A Voltage: less than and body. 0.25 V Measure voltage between A Voltage: less than and C (GND). 0.25 V Normal in above check

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

TDAA-05-06-003

T5-5-75

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111206 Preparation  Check the wiring connections first.  Connect the test harness (ST 6701) and dummy sensor equivalent to #4436271.  Before inspection, set the key switch to the ON position. Fault Code 111206-3

111206-4

Trouble Pressure Sensor (Fan Circuit Pressure) Circuit High Input Pressure Sensor (Fan Circuit Pressure) Circuit Low Input

Inspection Method Retry by using MPDr.

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

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

TDAA-05-06-003

T5-5-76

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111208 Preparation  Check the wiring connections first.  Connect the test harness (ST 6701) and dummy sensor equivalent to #4436271.  Before inspection, set the key switch to the ON position. Fault Code 111208-3

111208-4

Trouble Inspection Method Evaluation Emergency Steering Retry by using MPDr. Un-displayed fault Pump Delivery Pressure code Sensor Circuit High Input Measure voltage between B Voltage: or more and body. 4.75 V Emergency Steering Retry by using MPDr. Un-displayed fault Pump Delivery Pressure code Sensor Circuit Low Input Measure voltage between A Voltage: less than and body. 0.25 V Measure voltage between A Voltage: less than and C (GND). 0.25 V Normal in above check.

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

TDAA-05-06-003

T5-5-77

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111311 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 111311-3

111311-4

Trouble Service Brake Primary Pressure Sensor Circuit High Input Service Brake Primary Pressure Sensor Circuit Low Input

Inspection Method Retry by using MPDr.

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

TDAA-05-06-003

T5-5-78

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111406 Preparation  Check the wiring connections first. Fault Code 111406-2

111406-3

111406-4

Trouble Inspection Method Muffler Filter Measure resistance Regeneration Control between solenoid valve #1 Solenoid Valve Abnormal and #2. FB Measure voltage between solenoid valve harness end #1 and body. Monitor Muf/Fltr Regeneration Load P/S FB. Muffler Filter Regeneration Control Solenoid Valve FB High Current

Measure resistance between solenoid valve #1 and #2 -

Muffler Filter Regeneration Control Solenoid Valve FB Low Current

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Muf/Fltr Regeneration Load P/S FB.

Connector (Harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-5-79

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

Cause Faulty solenoid valve

0 mA

Open circuit in harness #2

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

Shorted circuit in harness #1 and #2 Faulty solenoid valve

0 mA

Open circuit in harness #2

Open circuit in harness #1

Shorted circuit in harness #1 and #2 Faulty solenoid valve

Open circuit in harness #1

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111411 Preparation  Check the wiring connections first. Fault Code 111411-2

111411-3

111411-4

Trouble Fan Reverse Rotation Control Solenoid Valve Abnormal FB

Fan Reverse Rotation Control Solenoid Valve FB High Current

Fan Reverse Rotation Control Solenoid Valve FB Low Current

Inspection Method Evaluation Measure resistance 0/∞Ω between solenoid valve #1 (Normal value: and #2. 22±0.4 Ω) Measure voltage between 0 V solenoid valve harness end #1 and body. Monitor Oil Pressure Driving 0 mA Fan Reverse P/S FB Normal in above check Measure resistance 0Ω between solenoid valve #1 (Normal value: and #2. 22±0.4 Ω) Normal in above check Measure resistance ∞Ω between solenoid valve #1 (Normal value: and #2. 22±0.4 Ω) Measure voltage between 0 V solenoid valve harness end #1 and body. Monitor Oil Pressure Driving 0 mA Fan Reverse P/S FB

Connector (Harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-5-80

Cause Faulty solenoid valve

Open circuit in harness #1

Open circuit in harness #2 Shorted circuit in harness #1 and #2 Faulty solenoid valve

Shorted circuit in harness #1 and #2 Faulty solenoid valve

Open circuit in harness #1

Open circuit in harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111412 Preparation  Check the wiring connections first. Fault Code 111412-2

111412-3

111412-4

Trouble Inspection Method Evaluation Fan Speed Control Measure resistance 0/∞Ω Solenoid Valve Abnormal between solenoid valve #1 (Normal value: FB and #2. 22.3±0.4 Ω) Measure voltage between 0 V solenoid valve harness end #1 and body. Monitor Oil Pressure Driving 0 mA Fan Control P/S FB Normal in above check Fan Speed Control Measure resistance 0Ω Solenoid Valve FB High between solenoid valve #1 (Normal value: Current and #2. 22.3±0.4 Ω) Normal in above check Fan Speed Control Measure resistance ∞Ω Solenoid Valve FB Low between solenoid valve #1 (Normal value: Current and #2. 22.3±0.4 Ω) Measure voltage between 0 V solenoid valve harness end #1 and body. Monitor Oil Pressure Driving 0 mA Fan Control P/S FB

Connector (Harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-5-81

Cause Faulty solenoid valve

Open circuit in harness #1

Open circuit in harness #2 Shorted circuit in harness #1 and #2 Faulty solenoid valve

Shorted circuit in harness #1 and #2 Faulty solenoid valve

Open circuit in harness #1

Open circuit in harness #2

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

111422-3

111422-4

Trouble Ride Control Solenoid Valve Abnormal FB

Ride Control Solenoid Valve FB High Current

Ride Control Solenoid Valve FB Low Current

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Ride Control P/S FB Measure resistance between solenoid valve #1 and #2. -

Evaluation 0/∞Ω (Normal voltage: 23.2±0.4 Ω) 0V

Cause Faulty solenoid valve

0 mA Normal in above check 0Ω (Normal voltage: 23.2±0.4 Ω) Normal in above check ∞Ω (Normal voltage: 23.2±0.4 Ω) 0V

Open circuit in harness #2 Shorted circuit in harness #1 and #2 Faulty solenoid valve

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Ride Control P/S FB 0 mA

Connector (Harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-5-82

Open circuit in harness #1

Shorted circuit in harness #1 and #2 Faulty solenoid valve

Open circuit in harness #1

Open circuit in harness #2

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

111908-4

Trouble 1st Speed Limit Switch Circuit High Input

1st Speed Limit Switch Circuit Low Input

Inspection Method Measure resistance between 1st speed limit switch end #1 and #2. -

Evaluation 0Ω

Normal in above check Measure voltage between 1st Less than 0.25 V speed limit switch harness end #1 and body. Measure voltage between 1st Less than 0.25 V speed limit switch harness end #1 and #3. Normal in above check

Connector (Harness end)  1st Speed Limit Switch Connector

TNDF-05-05-007

T5-5-83

Cause Shorted circuit in harness #1 and #2 Faulty 1st speed limit switch Open circuit in harness #1

Open circuit in harness #3

Faulty 1st speed limit switch

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111909 Preparation  Check the wiring connections first. Fault Code 111909-3

111909-4

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 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 harness #1

Normal in above check Refer to the table.

Open circuit in harness #2 Faulty sensor

Normal in above check

Shorted circuit in harness #1

Specification of HST Oil Temperature Sensor

Connector (Harness end)

HST Oil Temperature °C (°F) -30 (-22) -20 (-4) -10 (14) 0 (32) 10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140) 70 (158) 80 (176) 90 (194) 100 (212) 110 (230) 120 (248)

 HST Oil Temperature Sensor Connector

Resistance (kΩ) (24.5) 15.04+1.29-1.20 (9.16) (5.74) (3.70) 2.45+0.14-0.13 (1.66) (1.15) (0.811) (0.584) (0.428) 0.318±0.008 (0.240) (0.1836) 0.1417±0.0018 (0.1108)

TNED-05-05-021

T5-5-84

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 120003, 120004, 120014 Fault Code 120003-2

Trouble Emergency Steering Operation Alarm

Inspection Method Check the secondary steering operation check switch (OPT).

Evaluation Correct Incorrect

120004-2

Emergency Steering Operating Pressure Error

Disconnect a connector from the steering pressure switch (OPT). Retry by using MPDr. Diagnose on fault codes of HST controller.

Displayed fault code

120014-2

Overrun Alarm

T5-5-85

Un-displayed fault code -

Cause Faulty harness Faulty secondary steering operation check switch (OPT) Faulty MC or shorted circuit in harness. Faulty steering pressure switch (OPT) -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-86

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller Fault Codes 111027, 111028 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 T5-5-54 to 56.) Fault Code 111027-2

111028-2

Trouble Inspection Method MC Communication Continuity check (open circuit) Error Discontinuity check (shorted circuit) ECM Continuity check (open circuit) Communication Error Discontinuity check (shorted circuit)

T5-5-87

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller Fault Code 111332 Preparation  Disconnect the connector from the HST controller.  Check the wiring connections first. Fault Code 111332-5

Trouble Enable Signal Disconnection Error

Inspection Method Evaluation Measure voltage between 0 V HST controller harness end #13 and body. Normal in above check

Connector (Harness end)  HST Controller Connector

#13

T4FC-05-05-001

T5-5-88

Cause Open circuit in harness Faulty HST controller

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller Fault Codes 111330, 111331, 111333 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

111331-3

111331-4

111333-3

111333-4

Trouble Inspection Method Evaluation Pressure Sensor (Front Retry by using MPDr. Un-displayed fault Attachment Pressure) code Circuit High Input Measure voltage between 4.75 V or more B and body. Measure voltage between Less than 0.25 V A and C (GND). Un-displayed fault Pressure Sensor (Front Retry by using MPDr. code Attachment Pressure) Circuit Low Input Measure voltage between Less than 0.25 V A and body. Normal in above check HST Circuit Pressure Retry by using MPDr. Un-displayed fault 1 Sensor Circuit High code Input Measure voltage between 4.75 V or more B and body. Measure voltage between Less than 0.25 V A and C (GND). HST Circuit Pressure Retry by using MPDr. Un-displayed fault 1 Sensor Circuit Low code Input Measure voltage between Less than 0.25 V A and body. Normal in above check HST Circuit Pressure Retry by using MPDr. Un-displayed fault 2 Sensor Circuit High code Input Measure voltage between 4.75 V or more B and body. Measure voltage between Less than 0.25 V A and C (GND). HST Circuit Pressure Retry by using MPDr. Un-displayed fault 2 Sensor Circuit Low code Input Measure voltage between Less than 0.25 V A and body. Normal in above check C

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

TDAA-05-06-003

T5-5-89

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller Fault Code 111334 Preparation  Check the wiring connections first. Fault Code 111334-3

111334-4

Trouble Brake Angle Sensor Circuit High Input

Brake Angle Sensor Circuit Low Input

Inspection Method Evaluation Measure resistance 0Ω between brake angle sensor end #B and #A. Measure voltage between Less than 0.25 V brake angle sensor harness end #B and #C. Normal in above check Measure voltage between Less than 0.25 V brake angle sensor harness end #B and body. Normal in above check

Cause Shorted circuit in harness #B and #A Open circuit in harness #C

Faulty brake angle sensor Open circuit in harness #B

Faulty brake angle sensor

Connector (Harness end)  HST Controller Connector

 Brake Angle Sensor Connector

#20

TNDF-05-05-008 #36

 Brake Angle Sensor Connector (Harness end) Connection List Brake Angle Sensor End Terminal No. #A #B #C

HST Controller End Terminal No. #20 #38 #36

Remark Output GND Power Source (5 V)

T5-5-90

#38

T4FC-05-05-001

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller Fault Codes 111430, 111431, 111432 Preparation  Check the wiring connections first. Fault Code 111430-2

111431-2

111432-2

Trouble Motor 1 Displacement Angle Control Solenoid Valve Abnormal FB

Motor 2 Displacement Angle Control Solenoid Valve Abnormal FB

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Motor1 Swash Angle Control Signal FB. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Motor2 Swash Angle Control Signal FB. -

Clutch Pressure Control Measure resistance Solenoid Valve Abnormal between solenoid valve #1 FB and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Clutch Pressure Control Signal FB. -

Connector (Harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-5-91

Evaluation 0/∞Ω

Cause Faulty solenoid valve

Open circuit in harness #1

0 mA

Open circuit in harness #2

Normal in above check 0/∞Ω

Shorted circuit in harness #1 and #2 Faulty solenoid valve

Open circuit in harness #1

0 mA

Open circuit in harness #2

Normal in above check 0/∞Ω

Shorted circuit in harness #1 and #2 Faulty solenoid valve

Open circuit in harness #1

0 mA

Open circuit in harness #2

Normal in above check

Shorted circuit in harness #1 and #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller Fault Code 111433 Preparation  Check the wiring connections first. Fault Code 111433-2

Trouble Pump Displacement Angle Control Solenoid Valve Abnormal FB

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Pump Swash Angle Control Signal FB. -

Connector (Harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-5-92

Evaluation 0/∞Ω

Cause Faulty solenoid valve

Open circuit in harness #1

0 mA

Open circuit in harness #2

Normal in above check

Shorted circuit in harness #1 and #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller 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 HST controller (#5).

Connector (Harness end)  Back Buzzer Relay Connector

T183-05-04-003

HST Controller Connector #5

T4FC-05-05-001

T5-5-93

Evaluation 0V

Cause Faulty fuse #18

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

Correct operation 0V

Open circuit in harness between back buzzer relay and HST controller (#5).

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

111451-2

Trouble Forward Side Solenoid Valve Output Error

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

Connector (Harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-5-94

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

Cause Faulty solenoid valve

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

Open circuit in harness #2

Normal in above check

Open circuit in harness #2

Open circuit in harness #1

Faulty solenoid valve

Open circuit in harness #1

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller Fault Codes 111620, 111621 Preparation  Check the wiring connections first. Fault Code 111620-2

111621-2

Trouble Inspection Method Evaluation Vehicle Speed 1 Sensor Disconnect a connector Fault code 111620(Rotation Direction) Error from the machine speed 1 2 is not displayed. sensor. Retry by using MPDr. Measure voltage between Less than 0.25 V machine speed 1 sensor harness end #1 and body. Check shorted circuit in 0Ω harness between machine speed 1 sensor harness end #1 and #4. Normal in above check Vehicle Speed 1 Sensor Disconnect a connector Fault code 111621(Rotation Speed) Error from the machine speed 1 2 is not displayed. sensor. Retry by using MPDr. Measure voltage between Less than 0.25 V machine speed 1 sensor harness end #1 and body. 0Ω Check shorted circuit in harness between machine speed 1 sensor harness end #1 and #3. Normal in above check

Cause Faulty machine speed 1 sensor Open circuit in harness #1

Shorted circuit in harness #1 and #4

Faulty HST controller Faulty machine speed 1 sensor Open circuit in harness #1

Shorted circuit in harness #1 and #3

Faulty HST controller

Connector (Harness end)  HST Controller Connector

 Machine Speed 1 Sensor Connector

#12

TNDF-05-05-009 #43 #44

 Machine Speed 1 Sensor Connector (Harness end) Connection List Terminal No. HST Controller End Remark Terminal No. #1 Fuse #6 in fuse box A #2 #43 GND #3 #44 Rotation Speed #4 #12 Rotation Direction

T5-5-95

T4FC-05-05-001

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

Trouble Vehicle Speed 2 Sensor Error

Inspection Method Evaluation Disconnect a connector Fault code 111622from the machine speed 2 2 is not displayed. sensor. Retry by using MPDr. Check shorted circuit in 0Ω harness between machine speed 2 sensor harness end #1 and #2. Normal in above check

Cause Faulty machine speed 2 sensor Shorted circuit in harness #1 and #2

Faulty HST controller

Connector (Harness end)  HST Controller Connector

 Machine Speed 2 Sensor Connector

#17 #18

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

 Machine Speed 2 Sensor Connector (Harness end) Connection List Terminal No. #1 #2

HST Controller End Terminal No. #18 #17

Remark Rotation Speed GND

T5-5-96

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller 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 body. Check shorted circuit in 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 harness #1

0Ω

Shorted circuit in harness #2 and #4

Normal in above check

Faulty HST controller

Connector (Harness end)  HST Controller Connector

 Forward/Reverse Lever Connector

#10 #37

TNDF-05-05-011 #48

 Forward/Reverse Lever Connector (Harness end) Connection List Terminal No. HST Controller End Remark Terminal No. #1 Fuse #10 in fuse box B #2 #48 Reverse #3 #10 Neutral #4 #37 Forward

T5-5-97

T4FC-05-05-001

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A HST Controller Fault Code 111905 Preparation  Check the wiring connections first. Fault Code 111905-2

Trouble Abnormal Forward/ Reverse Switch

Inspection Method Evaluation Disconnect a connector Fault code 111905from the forward/reverse 2 is not displayed. switch (OPT). Retry by using MPDr. Measure voltage between Less than 0.25 V forward/reverse switch (OPT) harness end #2 and body. 0Ω Check shorted circuit in harness between forward/ reverse switch (OPT) harness end #1 and #3. Normal in above check

Cause Faulty forward/reverse switch (OPT)

Open circuit in harness #2

Shorted circuit in harness #1 and #3

Faulty HST controller

Connector (Harness end)  HST Controller Connector

 Forward/Reverse Switch (OPT)

#34

TNDF-05-05-009 #45

 Forward/Reverse Lever Connector (Harness end) Connection List Terminal No. HST Controller End Remark Terminal No. #1 #45 Forward #2 Fuse #6 in fuse box A #3 #34 Reverse #4 Neutral

T5-5-98

T4FC-05-05-001

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

Trouble Abnormal REG input H level

Inspection Method Measure voltage between column display controller harness end #2-B28 and body. Measure voltage at alternator terminal L. -

Connector (Harness end)  Column Display Controller 2-B Connector

TNDB-05-05-013

T5-5-99

Evaluation 13 to 33.5 V

Cause Faulty column display controller

13 to 33.5 V

Open circuit in harness Faulty alternator

Normal in above check

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

115011-4

Trouble Open circuit in fuel sensor

Shorted circuit in fuel sensor

Fuel Gauge

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

Cause Faulty sensor

Open circuit in harness #1

Normal in above check Refer to the table.

Open circuit in harness #2 Faulty sensor

Measure resistance between sensor #1 and #2. Normal in above check No. A B C

Evaluation Refer to the table.

Fuel Level (%) 100 (FULL) 50 0 (EMPTY)

C TNED-05-05-008

Connector (Harness end)  Fuel Sensor

TNED-05-05-022

T5-5-100

Shorted circuit in harness #1 and #2

Fuel Sensor (Ω) 100-4 33±5 90+100

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display 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 Evaluation Pressure Sensor (Parking Retry by using MPDr. Un-displayed fault Brake) Circuit High Input code Measure voltage between B 4.75 V or more and body. Pressure Sensor (Parking Retry by using MPDr. Un-displayed fault Brake) Circuit Low Input code Measure voltage between A Less than 0.25 V and body. Measure voltage between A Less than 0.25 V and C (GND). Normal in above check C

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

TDAA-05-06-003

T5-5-101

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display Controller (Information) Fault Codes 120500 to 120505 Fault Code 120500-2

Trouble Overheat Alarm

120501-2

Engine Trouble Alarm

120502-2

Engine Oil Pressure Alarm

120503-2

Air Cleaner Restriction Alarm

120504-2

Hydraulic Oil Level Alarm

120505-2

Brake Pressure Alarm

Inspection Method Disconnect a connector from the overheat switch. Retry by using MPDr.

Evaluation Displayed fault code

Un-displayed fault code Diagnose on fault codes of ECM. Diagnose on fault codes of ECM. Disconnect a connector Displayed fault code from air filter restriction switch. Retry by using MPDr. Un-displayed fault code Displayed fault code Disconnect a connector from hydraulic oil level switch. Short the body harness end connector. Un-displayed fault code Diagnose on fault codes of MC.

Connector (Harness end)  Column Display Controller 1-A Connector

TNDF-05-05-005

 Column Display Controller 1-B Connector

TNDF-05-05-006

T5-5-102

Cause Faulty column display controller or shorted circuit in harness Faulty overheat switch Faulty column display controller or shorted circuit in harness. Faulty air filter restriction switch. Faulty column display controller or shorted circuit in harness. Faulty hydraulic oil level switch. -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display Controller Fault Codes 120506, 120507, 120510 to 120513, 120515, 120517, 120518 Fault Code 120506-2 120507-2 120510-2 120511-2 120512-2 120513-2 120515-2 120517-2

120518-2

Trouble Inspection Method Steering Oil Pressure Alarm Diagnose on fault codes of MC. Transmission Warning Diagnose on fault codes of Alarm HST controller. HST Oil Temperature Alarm Diagnose on fault codes of MC. Fuel Filter Restriction Diagnose on fault codes of Alarm ECM. Emergency Steering Alarm Diagnose on fault codes (Lighting) of MC. Muffler Filter Alarm Diagnose on fault codes of ECM. Engine Alarm Diagnose on fault codes of ECM. Water Separator Alarm Disconnect a connector from the water separator alarm switch. Retry by using MPDr. Emergency Steering Alarm Diagnose on fault codes (Blinking) of MC.

Connector (Harness end)  Column Display Controller 1-A Connector

TNDF-05-05-005

 Column Display Controller 1-B Connector

TNDF-05-05-006

T5-5-103

Evaluation -

Cause -

Displayed fault code

Faulty column display controller or shorted circuit in harness Faulty water separator alarm switch -

Un-displayed fault code -

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

T5-5-104

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

Open circuit in harness #2.

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.

Faulty sensor. Shorted circuit in harness #1 and #2. Shorted circuit in harness #1 and #2.

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

Normal in above check. 0 Ω (Normal value: 100 to 115 kΩ) Normal in above check.

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Codes 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 refrigerant pressure high and low.

E91

CAN communication error

E92

CAN bus off error

Inspection Method Measure voltage between air vent damper servo motor harness end 7C and 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 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.

Normal in above check. 0V

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

Faulty air mix damper servo motor. Faulty controller or open circuit in harness between controller and High and low pressure switch. Faulty High and low pressure switch. Faulty controller. Faulty CAN1 harness.

Check continuity in CAN1 harness.

Faulty controller. Faulty CAN1 harness.

T5-5-105

Normal Abnormal

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-106

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. y Diagnosis Procedure x The diagnosis procedures for the displayed fault codes are explained in this group. x Perform diagnosis by using MPDr. or the service menu of monitor first. x In case any fault code has not been displayed by diagnosis, perform inspection according to the procedures when diagnosing. x When the fault code is displayed, refer to the troubleshooting A group and diagnose. x 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: Harness end connector viewed from the open end side by the all connectors image shown in this section.

T6L4-05-03-001 1-

Harness End Connector

Harness

T5-6-1

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Contents of Diagnosis

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

How to Read Table Procedure (A) (F)

Inspection Method (B) (G)

Condition

Evaluation

Cause

(D) (I)

(E) (J)

y A, F: Inspection order y B, G: Inspection method for trouble cause y C, H: Conditions for inspection y D, I: Evaluation specification of check results y 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)

Accelerator Pedal (Accelerator Pedal Sensor)

Item Function

Controls engine, pump, and valve Instructs target engine speed operation. according to accelerator pedal depressing amount. Symptoms Depending on trouble situations, MC holds engine speed in 1300 in control control system malfunction may min-1. system when differ. (The following symptoms trouble occurs in machine operation indicates that MC logic circuit has failed.) Symptoms The engine speed is fixed to 1300 The engine speed is fixed to 1300 in machine min-1. min-1. operation As pump displacement is held at when trouble minimum, all actuator speeds are occurs slow. Evaluation by 111000, 111001, 111002, 111003 111103 Fault Code Evaluation by MC: Demand Engine Speed Monitoring ECM: Actual Engine Speed Evaluation by using Test Harness Note -

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

T2-2

T5-6-3

Brake Pedal (Brake Angle Sensor)

Detects brake pedal stroke.

Same as shown below

The maximum speed and maximum traction force are limited.

111334, 111722 HST Controller: Brake Angle Sensor -

When the brake angle sensor calibration is not performed, inching is activated, but the feeling when applying the brake may be bad. T2-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Power Mode Switch Item Function Turns power mode ON/OFF. Symptoms Same as shown below in control system when trouble occurs Symptoms Power mode (ON/OFF) can not in machine change. operation The power mode indicator on when trouble monitor is not shifted. occurs Evaluation by Fault Code Evaluation by MC: Power Mode Switch Monitoring Evaluation by using Test Harness Note Descriptions 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 1st Speed Limit Switch Item Function

Selects the maximum speed at the first speed within the specified range. Same as shown below

Symptoms in control system when trouble occurs Symptoms When the 1st speed limit switch is operated with the shift switch in machine set in 1st, the maximum speed operation when trouble at the first speed is fixed to the minimum value. occurs Evaluation by 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)

Creeper Switch

Shifts standard/ slow speed mode of speed limit control. Same as shown below

When the creeper switch is turned ON with the shift switch set in 1st, the slow speed mode is not selected. MC: Creeper Switch -

T2-2

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 HST controller holds the travel in in control neutral. system when trouble occurs Symptoms Even if forward/reverse lever is operated, the machine does not in machine travel forward/reverse. operation when trouble The FNR indication on monitor is not shifted. occurs Evaluation by 111904 Fault Code Evaluation by HST Controller: Forward/Reverse Monitoring Lever (N)/(F)/(R) Evaluation by using Test Harness Note -

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

T2-2, T2-5

Forward/Reverse Selector Switch Forward/Reverse Switch

Shifts forward/reverse lever and forward/reverse switch operations. HST controller makes forward/ reverse lever operation effective.

HST controller makes forward/ reverse lever operation effective.

Functions of forward/reverse lever become effective.

111905

HST Controller: Forward/Reverse Selector Switch -

HST Controller: Option Forward/ Reverse Switch (N)/(F)/(R) -

The operation is effective with forward/reverse lever and forward/reverse switch set in the neutral position. T2-2, T2-5

When forward/reverse lever is operated, forward/reverse switch operation becomes ineffective. (Forward/reverse lever priority) T2-2, T2-5

T5-6-6

Shifts forward/reverse control solenoid valve in HST pump.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Shift Switch Item Function

Selects speed shift.

Symptoms Same as shown below in control system when trouble occurs Symptoms Even if shift switch is operated, in machine speed shift is not shifted. The speed shift is held in second operation when trouble speed. 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 Switch

Control Lever Lock Switch

Shifts parking brake solenoid valve. Same as shown below

Shifts control lever lock solenoid valve. Same as shown below

Even if parking brake switch is turned ON/OFF, the parking brake is not released/ applied. (While the engine runs)

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. -

HST Controller: Shift Switch 1/2/3/4 -

Column Display Controller: Parking Brake Signal Output -

When the clutch calibration is not performed, clutch control is impossible. T2-2, T2-5

Even if parking brake is turned OFF, the parking brake is applied with the engine stopped. T2-2, T2-5

T5-6-7

T2-4

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 is always OFF. Even if ride control in machine switch is turned ON, the ride operation when trouble control is not activated. Shorted circuit: Ride control occurs 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)

Fan Reverse Rotation Switch (Option)

Secondary Steering Operation Check Switch (Option)

Shifts fan reverse rotation control Checks operation of secondary solenoid valve of fan valve. steering pump. Same as shown below

Same as shown below

Even if fan reverse rotation switch Even if secondary steering is turned ON, the cooling fan operation check switch is set does not rotate in reverse. to ON side, secondary steering The fan reverse rotation indicator pump is not operated. is not ON. (The indicator does not blink when shifting.) -

MC: Secondary Steering Operation Check Switch -

T2-2, 2-4

T2-2

T5-6-8

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Back Buzzer Switch (Option) Item Function

Turns back buzzer ON/OFF.

Symptoms Same as shown below in control system when trouble occurs Symptoms Even if back buzzer switch is in machine turned ON, back buzzer does not sound while driving in reverse operation when trouble direction. occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-2, T2-4 of Control (Refer to F&S S/M)

Lift Arm Auto Leveler (Raise) Switch

Lift Arm Auto Leveler (Lower) Switch

Sets lift arm auto leveler height kickout control (OPT). Same as shown below

Sets lift arm auto leveler lower kickout control (OPT). Same as shown below

The lift arm auto leveler height kickout control (OPT) is not activated.

The lift arm auto leveler lower kickout control (OPT) is not activated.

T2-2, T2-4

T5-6-9

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Exhaust Filter Regeneration Switch Item Function

Shifts exhaust filter regeneration control solenoid valve and performs manual regeneration of the exhaust filter. Same as shown below

Symptoms in control system when trouble occurs Even if exhaust filter regeneration Symptoms switch is set to manual in machine regeneration position, manual operation when trouble regeneration of exhaust filter is not performed. occurs Evaluation by Fault Code Evaluation by ECM: Muf/Fltr Switch Monitoring Evaluation by using Test Harness Note When exhaust filter manual regeneration is required Descriptions T2-2 of Control (Refer to F&S S/M)

T5-6-10

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts HST Oil Temperature Sensor Item Function

Monitors hydraulic oil temperature. Symptoms MC recognizes that HST oil in control temperature is 120 °C when system when open circuit occurs. (HST oil trouble occurs temperature: 120 °C is not displayed on monitoring.) Symptoms When HST oil temperature is 0 °C or less when starting engine, in machine auto-warming up control is not operation when trouble operated. occurs Evaluation by 111901 Fault Code Evaluation by MC: HST Oil Temperature Monitoring Evaluation by using Test Harness Note Descriptions T2-2 of Control (Refer to F&S S/M)

T5-6-11

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts HST Circuit Pressure 1 Sensor

HST Circuit Pressure 2 Sensor

Pressure Sensor (Brake Primary Pressure)

Detects HST circuit pressure (forward side). When output is 0 V or 5 V, the following symptoms occur.

Detects HST circuit pressure (reverse side). When output is 0 V or 5 V, the following symptoms occur.

Detects brake pressure.

Symptoms in control system when trouble occurs Symptoms The maximum speed and in machine maximum traction force are limited. operation when trouble occurs Evaluation by 111331 Fault Code Evaluation by HST Controller: HST Circuit Monitoring Pressure 1 Evaluation by using Test Harness Note Possible to judge if sensor or harness is faulty by switching pressure sensor with other delivery pressure sensor. Descriptions T2-2 of Control (Refer to F&S S/M)

When output is 0 V or 5 V, the following symptoms occur.

The maximum speed and maximum traction force are limited.

The low brake oil pressure indicator is always ON.

111333

111311

HST Controller: HST Circuit Pressure 2 -

MC: Service Brake Primary Pressure -

Possible to judge if sensor or harness is faulty by switching pressure sensor with other delivery pressure sensor. T2-2

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2, T2-4

T5-6-12

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pressure Sensor (Primary Pilot Pressure) Item Function Detects primary pilot pressure. Symptoms When output is 0 V or 5 V, the in control following symptoms occur. system when trouble occurs Symptoms Even if control lever lock solenoid in machine valve is operated with control operation lever lock switch set in the OFF when trouble (Lock) position, control lever lock indicator is not ON. occurs Evaluation by 111217 Fault Code Evaluation by MC: Pilot Primary Pressure Monitoring Evaluation by using Test Harness Note Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. Descriptions T2-2, T2-4 of Control (Refer to F&S S/M)

T5-6-13

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pressure Sensor (Front Attachment Pressure) Item Function

Detects pump delivery pressure (main, steering). When output is 0 V or 5 V, the following symptoms occur.

Symptoms in control system when trouble occurs Symptoms The matching control is not in machine activated. operation when trouble occurs Evaluation by 111330 Fault Code Evaluation by HST Controller: Front Attachment Monitoring Pressure Evaluation by using Test Harness Note Possible to judge if sensor or harness is faulty by switching pressure sensor with other delivery pressure sensor. Descriptions T2-2 of Control (Refer to F&S S/M)

Pressure Sensor (Fan Circuit Pressure)

Pressure Sensor (Refrigerant Pressure)

Detects hydraulic fan circuit pressure. When output is 0 V or 5 V, the following symptoms occur.

Detects air conditioner refrigerant pressure. When output is 0 V or 5 V, the following symptoms occur.

Even if fan reverse rotation switch The fan speed is fixed to the is operated, fan rotation direction maximum. can not change. The fan reverse rotation control is not activated. 111206

111207

MC: Hydraulic Fan Circuit Pressure MC: Air Conditioner Refrigerant Pressure -

Possible to judge if sensor or harness is faulty by switching pressure sensor with other delivery pressure sensor. T2-2

T5-6-14

T2-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Lift Arm Angle Sensor (Option) Item Function

Detects operating angle of the lift arm. When output is 0 V or 5 V, the following symptoms occur.

Symptoms in control system when trouble occurs Symptoms The lift arm auto leveler lower in machine kickout control is not activated. The lift arm auto leveler height operation when trouble kickout control is not activated. occurs Evaluation by 111205 Fault Code Evaluation by MC: Lift Arm Angle Sensor Monitoring Evaluation by using Test Harness Note When the lift arm angle calibration is not performed, lift arm auto leveler lower/height kickout control are not activated. Descriptions T2-2 of Control (Refer to F&S S/M)

T5-6-15

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Exhaust Filter Differential Pressure Sensor Item Function

Symptoms in control system when trouble occurs

Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Refer to F&S S/M)

DOC Exhaust Temperature Sensor CSF Exhaust Temperature Sensor (DOC) (CSF)

Measures differential pressure before and after the filter and detects PM trapping amount. ECM judges that differential pressure is 0 kPa.

Detects exhaust temperature before diesel oxidation catalyst.

Detects exhaust temperature before the filter.

ECM judges that exhaust temperature is 0 °C.

ECM: 81

ECM: 10024

ECM: 173

ECM: Muf/Fltr EGP Differential Pressure -

ECM: Muf/Fltr Catalyst Inlet EGT

ECM: Muf/Fltr Inlet EGT

T2-3

DOC exhaust temperature sensor is used as exhaust filter regeneration judging temperature. ECM judges that exhaust temperature is 0 °C. Engine output power decreases. Engine output power decreases. Engine output power decreases. Regeneration of the exhaust filter Regeneration of the exhaust filter Regeneration of the exhaust filter is not performed. is not performed. is not performed.

T5-6-16

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Machine Speed 1 Sensor

Machine Speed 2 Sensor

Item Function

Detects input shaft speed and Detects transmission output rotation direction of HST motor 2. shaft speed. Symptoms When output is 0 V or 5 V, the When abnormality on machine in control following symptoms occur. speed 1 sensor and machine system when speed 2 sensor is detected, the trouble occurs following symptoms occur. The speed meter continues to Symptoms Even if the machine can travel display 0 km/h. in machine normally, the HST warning indicator is turned on. The overrun prevention control is operation when trouble HST controller calculates machine not activated. speed according to output The ride control (OPT) is not occurs signals from machine speed 2 activated. sensor. Evaluation by 111620, 111621 111622 Fault Code Evaluation by HST Controller: Machine Speed 1 HST Controller: Machine Speed 2 Monitoring Pulse Pulse Evaluation by using Test Harness Note Descriptions T2-2 T2-2 of Control (Refer to F&S S/M)

T5-6-17

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

Applies and releases parking brake by using pilot pressure oil. Same as shown below

Symptoms in control system when trouble occurs Symptoms When closed: The parking brake in machine is not released. (Pilot pressure oil is not supplied to parking brake.) operation when trouble When open: The parking brake is applied. (Pilot pressure oil is occurs supplied to parking brake.) Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-2, 2-4 of Control (Refer to F&S S/M)

Pilot Shut-Off Solenoid Valve

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. -

T2-5

T5-6-18

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Fan Speed Control Solenoid Valve Fan Reverse Rotation Control Solenoid Valve (Option) Item Function

Controls fan rotation speed.

Symptoms Same as shown below in control system when trouble occurs Symptoms High current: The fan speed is fixed to the minimum. in machine Low current: The fan speed is operation when trouble fixed to the maximum. occurs Evaluation by 111412 Fault Code Evaluation by MC: Hyd Fan Speed Control P/S Monitoring Output, Hyd Fan Speed Control P/S Output FB Evaluation by using Test Harness Note Descriptions T2-2, 2-4 of Control (Refer to F&S S/M)

Shifts fan reverse rotation spool of fan valve. Same as shown below

Exhaust Filter Regeneration Control Solenoid Valve Shifts exhaust filter regeneration/ quick coupler spool in control valve. Same as shown below

High current: The fan always rotates in reverse. Low current: The fan does not rotate in reverse.

Regeneration may not be performed during manual or auto regeneration of the exhaust filter.

111411

111406

MC: Hyd Fan Reverses Rotation P/S Output, Hyd Fan Reverses Rotation P/S Output FB -

MC: Muf/Fltr Regeneration P/S Output, Muf/Fltr Regeneration Load P/S Output FB Install light harness (ST 7226). Check output signals from MC and harness condition. T2-2, 2-4

T2-2, 2-4

T5-6-19

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Ride Control Solenoid Valve (Option) Item Function 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 effective. occurs Evaluation by 111422 Fault Code Evaluation by MC: Ride Control P/S Output, Ride Monitoring Control P/S Output FB Evaluation Install light harness (ST 7226). by using Test Check output signals from MC Harness and harness condition. Note Descriptions T2-2, 2-4 of Control (Refer to F&S S/M)

T5-6-20

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pump Displacement Angle Control Solenoid Valve Item Function

Supplies control pressure to the displacement angle control cylinder of HST pump. Same as shown below

Symptoms in control system when trouble occurs Symptoms High current: HST pump displacement angle becomes in machine maximum. The engine stalls at operation when trouble high loaded. Low current: As HST pump occurs displacement angle becomes minimum, the machine can not travel. Evaluation by 111433 Fault Code Evaluation by HST Controller: Pump Swash Monitoring Angle Control Signal, Pump Swash Angle Control Signal FB Evaluation by using Test Harness Note Descriptions T2-2 of Control (Refer to F&S S/M)

Forward Side Solenoid Valve

Reverse Side Solenoid Valve

Shifts HST pump displacement angle to the forward side.

Shifts HST pump displacement angle to the reverse side.

Same as shown below

The machine can not travel forward. The maximum speed and maximum traction force are limited while traveling in reverse.

The machine can not travel in reverse. The maximum speed and maximum traction force are limited while traveling forward.

HST Controller: Forward Solenoid HST Controller: Reverse Solenoid Valve Valve -

T2-2

T5-6-21

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Clutch Pressure Control Solenoid Motor 1 Displacement Angle Valve Control Solenoid Valve Item Function

Supplies control pressure to the clutch of transmission. Same as shown below

Symptoms in control system when trouble occurs Symptoms The maximum speed and in machine maximum traction force are limited. operation when trouble occurs Evaluation by 111432 Fault Code Evaluation by HST Controller: Clutch Pressure Monitoring Control Signal, Clutch Pressure Control Signal FB Evaluation by using Test Harness Note Descriptions T2-2 of Control (Refer to F&S S/M)

Motor 2 Displacement Angle Control Solenoid Valve

Controls displacement angle of HST motor 1. Same as shown below

Controls displacement angle of HST motor 2. Same as shown below

The maximum speed and maximum traction force are limited.

HST Controller: Motor 1 Swash Angle Control Signal, Motor 1 Swash Angle Control Signal FB -

HST Controller: Motor 2 Swash Angle Control Signal, Motor 2 Swash Angle Control Signal FB -

T2-2

T5-6-22

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 If stuck in fully closed position, Symptoms hose of front attachment may be in machine damaged. operation when trouble If stuck in fully open position, power is weak during digging occurs operation. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Refer to F&S S/M)

Overload Relief Valve

Flow Rate Control Valve (Bucket Circuit)

Prevents actuator circuit pressure Restricts bucket circuit and generated by external force from keeps lift arm raise speed during exceeding the set pressure with a combined operation of lift arm front attachment control lever set and bucket. in neutral. Same as shown below 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.

If check valve is stuck in fully closed position, bucket is not rolled back during combined operation. If check valve is stuck in fully open position, lift arm raise speed becomes slow. -

T2-4

T5-6-23

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Steering Relief Valve (Priority Valve) Item Function

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 If stuck in fully closed position, Symptoms steering hose may be damaged. in machine 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 of Control (Refer to F&S S/M)

Ride Control Spool (Ride Control Valve) (Option)

Fan Reversing Spool (Fan Valve) (Option)

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

Is shifted by pilot pressure from fan reverse rotation control solenoid valve in fan valve. Changes the fan rotation direction (in normal / reverse).

If stuck in neutral position, the ride control is not activated. If stuck in ride control operating position, digging operation is not smooth.

Same as shown below

If stuck in normal direction position, the fan always rotates in normal direction. If stuck in reverse direction position, the fan always rotates in reverse direction. Overheating occurs easily. -

T2-4

T5-6-24

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Back Buzzer Relay Item Function

Sounds the buzzer while driving in reverse.

Symptoms Same as shown below in control system when trouble occurs Even if the forward/reverse lever Symptoms is set to the (R) position, the in machine buzzer does not sound. operation when trouble occurs

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Refer to F&S S/M)

111457

Bucket Regenerative Valve (Parallel Link Front Attachment)

Bucket Regenerative Selector Valve (Parallel Link Front Attachment) Returns returning oil from rod Is shifted by bucket dump pilot side of bucket cylinder and pressure. increases bucket dump operating Supplies returning oil from rod speed. side of bucket cylinder to bucket regenerative valve. Same as shown below Same as shown below

If logic valve is kept closed, bucket tilt operating speed becomes slow. If logic valve is kept open, bucket dump operating speed becomes slow. If pilot check valve is kept closed, bucket dump operating speed becomes slow. If pilot check valve is kept open, bucket tilt operating speed becomes slow. -

If kept closed, bucket dump operating speed becomes slow. If kept open, bucket tilt operating speed becomes slow.

HST Controller: Back Buzzer Relay -

T2-5

T2-4

T5-6-25

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-26

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Correlation between Trouble Symptoms and Part Failures This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed. The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom. The marks z/{ in this table indicate the influence to trouble symptom. z: Related, required to check {: Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.

T5-6-27

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting Trouble Symptom E-1 Starter does not rotate. Parts Main Controller (MC) { Engine Control Module (ECM) Hydrostatic Transmission (HST) Controller Information Controller Monitor Column Display Controller MPDr. z Key Switch Accelerator Pedal Sensor Forward/Reverse Lever z (Neutral) Forward/Reverse Selector Switch { Forward/Reverse Switch { (Neutral) z Battery z Battery Relay Fuse Box A Fuse Box B z (#8, #13) z Neutral Relay z Starter Cut Relay z Starter Relay 1 { ECM Main Relay Fuel Pump Relay z Starter Engine Unit Coolant Temperature Sensor Glow Plug Relay Glow Plug Pressure Sensor (Front Attachment Pressure) Remark

E-2 E-3 Even if starter rotates, engine Engine starts with forward/ does not start. reverse lever set in the positions except N. { z

{

{ { (Neutral) { { (Neutral)

{ (#8)

z (#10) z

{ { {

Neutral Engine Start Circuit (T2-5)

z: Check required {: Related

T5-6-28

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom E-4 E-5 Even if power mode switch is Even if key switch is turned operated, power mode is not OFF, engine does not stop. shifted.

{ Main Controller (MC) Engine Control Module (ECM) Hydrostatic Transmission (HST) Controller Information Controller { Monitor Column Display Controller { MPDr. Key Switch Accelerator Pedal Sensor z Power Mode Switch z Traction Control Switch Parking Brake Switch Forward/Reverse Lever Forward/Reverse Selector Switch Forward/Reverse Switch Exhaust Filter Switch Battery Battery Relay Fuse Box A Fuse Box B Key Switch ON Cut Relay (Option) ACC Cut Relay (Option) Auto Idling Stop Relay Starter Relay 1 ECM Main Relay Fuel Pump Relay Starter Engine Unit Coolant Temperature Sensor Pressure Sensor (Front Attachment Pressure) HST Oil Temperature Sensor Pressure Sensor (Parking Brake) Remark

{ z

E-6 Auto idling stop is not activated. { {

{ { z

{

{ (Setup) { { { { (Neutral) { { (Neutral) { { { { (#1) { (#8, 15) z z z

{

{ {

z: Check required {: Related

T5-6-29

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting Trouble Symptom A-1 Actuator of only front attachment does not work. Parts Main Controller (MC) Battery Fuse Box B Pilot Shut-Off Relay Control Lever Lock Switch Power Mode Switch

{ (#16) z z

Traction Control Switch Pilot Pump Brake Charge Valve Priority Valve (Brake) Pilot Relief Valve (Brake) Manifold Valve Pilot Reducing Valve (Manifold Valve) Control Lever Lock Solenoid Valve (Manifold Valve) Pilot Valve Pressure Sensor (Primary Pilot Pressure) Slow Return Valve Spool (Control Valve) Main Relief Valve (Control Valve) Cylinder Main Pump

{ { { z { {

{

Steering Pump Pressure Sensor (Front Attachment Pressure) Priority Valve Pilot Filter Pump Displacement Angle Control Solenoid Valve (HST Pump) Remark

z: Check required {: Related

T5-6-30

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom A-2 A-3 Actuator of front attachment Auto or manual regeneration does not stop even if a of exhaust filter cannot be control lever is set to neutral. performed. (It fails.)

Main Controller (MC) Engine Control Module (ECM) Hydrostatic Transmission (HST) Controller Information Controller Monitor Key Switch Accelerator Pedal Sensor Forward/Reverse Lever Forward/Reverse Selector Switch Forward/Reverse Switch Pilot Shut-Off Relay Control Lever Lock Switch Exhaust Filter Regeneration Switch Battery Exhaust Filter Differential Pressure Sensor Engine Unit Crank Revolution Sensor Cam Angle Sensor Coolant Temperature Sensor Exhaust Temperature Sensor Main Pump Pilot Pump Pressure Sensor (Front Attachment Pressure) Manifold Valve Control Lever Lock Solenoid Valve (Manifold Valve) Pressure Sensor (Primary Pilot Pressure) z Pilot Valve z Control Valve Slow Return Valve { (Lift Arm) Spool (Control Valve) Exhaust Filter Regeneration Control Solenoid Valve Pilot Filter Pilot Relief Valve (Brake Charge Valve) HST Oil Temperature Sensor Pressure Sensor (Parking Brake) Pump Displacement Angle Control Solenoid Valve (HST Pump) Remark

{ {

{ { { { (Neutral) { (Neutral) z z

{

{ { { {

{

z z { { {

{ {

z: Check required {: Related

T5-6-31

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom A-4 Fan speed does not change. Parts Main Controller (MC) Engine Control Module (ECM) Hydrostatic Transmission (HST) Controller Information Controller Monitor MPDr. Key Switch Accelerator Pedal Sensor Power Mode Switch Fan Reverse Rotation Switch Battery Fuse Box A Fuse Box B Fan Valve Fan Speed Control Solenoid Valve Fan Reverse Rotation Control Solenoid Valve (Option) Fan Control Valve Fan Motor Fan Pump Engine Unit Crank Revolution Sensor Cam Angle Sensor Coolant Temperature Sensor Boost Temperature Sensor Fan Circuit Pressure HST Oil Temperature Sensor Refrigerant Pressure Sensor Pressure Sensor (Parking Brake) Remark

{

A-5 Fan does not rotate in reverse when pushing fan reverse rotation switch (option). { {

{ { z

{ {

{

z z z z

z { {

{ { { { {

{

Fan Speed Control

{ Fan Reverse Rotation Control (Option)

z: Check required {: Related

T5-6-32

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-33

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting Trouble Symptom F-1 F-2 All front attachment actuator Some cylinders are not power are weak. operated or speed are slow. Parts Main Controller (MC) Battery Fuse Box B Pilot Shut-Off Relay Control Lever Lock Switch Power Mode Switch Pilot Pump Priority Valve (Brake Charge Valve) Pilot Relief Valve (Brake Charge Valve) Pilot Reducing Valve (Manifold Valve) Control Lever Lock Solenoid Valve (Manifold Valve) Pilot Valve Pressure Sensor (Primary Pilot Pressure) Bucket Flow Rate Control Valve (Control 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) Pilot Filter Remark

{

{ { { {

z {

{ z

z { z z

{ { { {

z: Check required {: Related

T5-6-34

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom F-3 Front attachment drifts remarkably. Parts Main Controller (MC) Information Controller Monitor Lift Arm Angle Sensor (Option) Pilot Pump Brake Charge Valve Manifold Valve Pilot Valve Slow Return Valve Spool (Control Valve)

z z

F-4 Shock is large when stopping lift arm raise / lower operation.

{ z (Lift Arm) z

Overload Relief Valve (Control z Valve) Load Check Valve (Control Valve) z z Cylinder Main Pump Remark with the engine stopped

z: Check required {: Related

T5-6-35

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom F-5 F-6 Bucket auto leveler control is Lift arm float control is not not activated. (Detent is not activated. (Detent is not held.) held.)

Main Controller (MC) Information Controller

MPDr. Monitor Battery Battery Relay Fuse Box B Lift Arm Angle Sensor (Option)

{ (#16)

Bucket Leveler Relay Kickout Relay

Proximity Switch Pilot Pump Brake Charge Valve Manifold Valve Pilot Valve Spool (Control Valve) Cylinder Main Pump Remark

z (Bucket)

z (Bucket) { (Bucket)

{ (#16)

z (Lift Arm) { (Lift Arm)

z: Check required {: Related

T5-6-36

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom F-7 F-8 Lift arm auto leveler height Lift arm auto leveler lower kickout control (option) is not kickout control (option) is not activated. activated.

Main Controller (MC) Information Controller

{

MPDr.

z (Lift Arm Angle Sensor Learning)

{ (#16) {

z (Lift Arm) { (Lift Arm)

Monitor Battery Battery Relay Fuse Box B 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

z: Check required {: Related

T5-6-37

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom F-9 Ride control (optinal) is not activated. Parts { Main Controller (MC) Hydrostatic Transmission (HST) Controller Information Controller MPDr. z (Setting: ON) Fuse Box B { Lift Arm Angle Sensor z Machine Speed 1 Sensor Machine Speed 2 Sensor HST Circuit Pressure 1 Sensor Power Mode Switch Traction Control Switch Forward/Reverse Lever Forward/Reverse Switch Shift Switch z Ride Control Switch (Option) Pilot Pump { Pressure Sensor (Primary Pilot Pressure) { Ride Control Solenoid Valve (Option) z Spool (Ride Control Valve) (Option) Cylinder { (Lift Arm) Accumulator (Ride Control Valve) { (Option) Main Pump { Pressure Sensor (Front Attachment Pressure) HST Pump Pump Displacement Angle Control Solenoid Valve HST Motor 1 Motor 1 Displacement Angle Control Solenoid Valve Remark

z: Check required {: Related

T5-6-38

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom F-10 Bucket tilt operating speed is slow. (Parallel Link Front Attachment)

Pilot Pump Bucket Regenerative Valve Bucket Regenerative Selector Valve Pilot Valve Spool (Control Valve) Main Relief Valve (Front Attachment) Overload Relief Valve (Control Valve) Cylinder Main Pump Remark

F-11 Bucket dump operating speed is slow. (Parallel Link Front Attachment)

{ z {

{ z z

{ { {

{

{ {

z: Check required {: Related

T5-6-39

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting Trouble Symptom S-1 Steering operation is weak.

S-2 Steering operation is slow.

Parts Steering Valve Overload Relief Valve (Steering) Steering Cylinder (Left, Right) Steering Accumulator Steering Pump Pressure Sensor (Front Attachment Pressure) Priority Valve (Main) Steering Relief Valve (Priority Valve) Pump Displacement Angle Control Solenoid Valve (HST Pump) Remark

{

S-3 Shock of steering operation is large.

z {

{ {

{

{ z

z z

{

z: Check required {: Related

T5-6-40

z z

{

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom S-4 Secondary steering (option) is not operated. (Automatic operation check when the engine starts)

Main Controller (MC) Hydrostatic Transmission (HST) Controller Information Controller Monitor MPDr. Battery Fuse Box B Secondary Steering Relay Machine Speed 2 Sensor Pilot Pump Brake Charge Valve Manifold Valve Steering Pressure Switch (Option) Secondary Steering Pump Delivery Pressure Sensor (Option) Steering Cylinder (Left, Right) Steering Accumulator Steering Pump Secondary Steering Motor Secondary Steering Pump Remark

z (Setting: ON) { (#20) z {

z {

{ {

z: Check required {: Related

T5-6-41

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting

Parts

Trouble Symptom T-1 Even if forward/reverse lever is operated, machine does not travel forward/reverse.

Main Controller (MC) Hydrostatic Transmission (HST) { Controller Information Controller { Monitor Battery Fuse Box A Fuse Box B { (#10) Accelerator Pedal Sensor Forward/Reverse Lever z (Forward / Reverse) Forward/Reverse Switch { (Forward / Reverse) Forward/Reverse Selector Switch { { Shift Switch { Transmission Clutch Pressure Control Solenoid Valve z Machine Speed 1 Sensor z Machine Speed 2 Sensor z Forward Side Solenoid Valve (HST Pump) Reverse Side Solenoid Valve (HST z Pump) Motor Displacement Angle Control Solenoid Valve (HST Motor 1) { Propeller Shaft { Axle Pressure Sensor (Parking Brake) z Remark Forward/Reverse Selection Control

T-2 Even if forward/reverse lever is set to neutral position, machine travels.

T-3 Even if shift switch is operated, speed shift is not shifted.

{

{ { (#6)

{ (#10) z (Neutral) { (Neutral) { { {

z z z

z { z z z

z {

Forward/Reverse Selection Control

z: Check required {: Related

T5-6-42

Speed Shift Control

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom T-4 Speed limit control is not activated. Parts { Main Controller (MC) Hydrostatic Transmission (HST) Controller Information Controller { Monitor Battery Fuse Box A Fuse Box B Accelerator Pedal Sensor Forward/Reverse Lever Forward/Reverse Switch Forward/Reverse Selector Switch Shift Switch z 1st Speed Limit Switch z Creeper Switch { Transmission Clutch Pressure Control Solenoid z Valve { Machine Speed 1 Sensor { Machine Speed 2 Sensor Forward/Reverse Control Solenoid Valve (HST Pump) { Motor 1 Displacement Angle Control Solenoid Valve (HST Motor 1) Propeller Shaft Axle Pressure Sensor (Parking Brake) Remark Speed Limit Control

z: Check required {: Related

T5-6-43

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting Trouble Symptom B-1 B-2 B-3 Parking brake is not released. Parking brake is not applied. Service brake braking force (While the engine runs) becomes weak. Parts { Main Controller (MC) Information Controller { Column Display Controller Key Switch { (ON) Battery Fuse Box A z (#10) Fuse Box B { (#14) Parking Brake Switch z (Released) Parking Brake Relay 1 z (OFF) Parking Brake Relay 2 z (ON) Brake Pedal (Brake Angle Sensor) z Parking Brake z Brake Charge Valve Pilot Relief Valve (Brake Charge z Valve) Pressure Sensor (Brake Primary Pressure) Service Brake Accumulator { Manifold Valve Pilot Reducing Valve (Manifold z Valve) Pressure Sensor (Parking Brake) { z Parking Brake Solenoid Valve (Manifold Valve) { Parking Brake Accumulator Brake Valve Axle (Service Brake) { Pilot Pump { Pilot Filter Pump Displacement Angle Control Solenoid Valve (HST Pump) Remark The parking brake can not be released as the parking brake release pressure is not supplied with the engine stopped.

{ { (ON) z (#10) { (#14) z (Operated) z (ON) z (OFF) z z z z { { { z { z

z: Check required {: Related

T5-6-44

z z { { {

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-45

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting

Parts

Trouble Symptom O-1 Clearance light, tail light, and license plate light are not ON.

Main Controller (MC) Information Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Light Switch Dimmer Switch Head Light Relay (Left) Head Light Relay (Right) High Beam Relay Head Light Clearance Light Tail Light License Plate Light (Option) Remark

{ (Indicator)

O-2 Head light is not ON.

O-3 Head light is not shifted to high beam.

{ (Indicator) { (ON)

{ z (#2, #11, #12) z

z (#1, #5) { (#2) { z z z z

z z z

z: Check required {: Related

T5-6-46

z (#2, #19) { z

z z (High Beam)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom O-4 O-5 Hazard light is not operated. Turn signal light is not operated.

O-6 Horn does not sound.

Parts Main Controller (MC) Information Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Hazard Light Switch Turn Signal Lever Horn Switch Flasher Relay Turn Signal Light Relay (Left) Turn Signal Light Relay (Right) Horn Relay Turn Signal Light (Hazard Light) Horn Remark

{ (Indicator)

{ (Indicator) { (ON)

{ z (#6) z

{ z (#8) z (#6)

z (#5)

z z z z z

z z z

z z

z: Check required {: Related

T5-6-47

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom O-7 Reverse light is not ON. Reverse buzzer does not sound.

Main Controller (MC) Hydrostatic Transmission (HST) Controller Information Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Forward/Reverse Lever Forward/Reverse Selector Switch Forward/Reverse Switch Brake Light Switch (Brake Pedal) Light Switch Work Light Switch Reverse Buzzer Relay Brake Light Relay Work Light (Front) Relay Work Light (Rear) Relay Reverse Light (Option) Reverse Buzzer Brake Light Work Light Remark

O-8 Brake light is not ON.

O-9 Work light does not light.

{ (ON)

{ (Indicator) { (ON)

z (#7) { (#10) { (Reverse)

z (#8)

{

z (#4) z (#17)

{ (Reverse) z { z z z z z z z z z

z: Check required {: Related

T5-6-48

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom O-10 Wiper is not operated.

O-11 Washer is not operated.

O-12 Cab light is not ON.

Parts Main Controller (MC) Information Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Front Wiper/ Washer Switch Rear Wiper/ Washer Switch Cab Light Switch Rear Cab Light Switch Door Open/Close Switch (Cab) Front Wiper Relay 1 Front Wiper Relay 2 Rear Wiper Relay Front Washer Relay Rear Washer Relay Front Wiper Motor Rear Wiper Motor Front Washer Motor Rear Washer Motor Remark

z { (ON)

{ (ON) {

z (#3) z (#18) z z

z (#3)

z z z z z (Fast Speed) z z z z z z z

z: Check required {: Related

T5-6-49

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-50

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting E-1

Starter does not rotate.

Preparation x In case the radio with the key switch set in the ACC position and the horn with the key switch set in the OFF position are operated normally, the harness between battery and key switch terminal B is considered normal.

x Check that the forward/reverse lever is in the neutral position. x This trouble has nothing to do with the electronic control system such as MC. x Check the wiring connections first. Procedure Inspection Method 1 Measure battery voltage and electrolyte density.

8 9 10 11 12

Condition -

Replace the neutral relay with Set the key switch other general relay. to START after switching relays. Key switch: START Measure voltage between neutral relay harness end #1 and #3. Replace the starter cut relay Set the key switch with other general relay. to START after switching relays. Measure voltage between Key switch: START starter cut relay harness end #1 and #3. Measure voltage at starter Key switch: START relay 1 harness end terminal S. Check continuity between Key switch: ON starter cut relay harness end #2 and body. Measure voltage at battery Key switch: ON relay terminal A. Measure voltage at starter Key switch: START terminal S. Check continuity between Key switch: START key switch #1 and #6. Monitor Forward/Reverse Forward/reverse Lever (N). lever: N -

Evaluation Cause The measured values Faulty battery are not within the normal values (Normal value: Voltage: 24 V or more, Electrolyte density: 1.26 or more) Starter: Rotating Faulty neutral relay

Open circuit in harness between key switch and neutral relay

Starter: Rotating

Faulty starter cut relay

Open circuit in harness between neutral relay and starter cut relay Open circuit in harness between starter cut relay and starter relay 1 Open circuit in harness between starter cut relay and ECM

0Ω

Faulty battery relay

Faulty starter relay 1

∞Ω

Faulty key switch

OFF is displayed.

Faulty forward/reverse lever

The above checks resulted all normal.

Faulty starter

T5-6-51

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-2

Even if starter rotates, engine does not start.

Preparation x Check that #8 fuse in fuse box B. x Check the wiring connections first.

Procedure Inspection Method 1 Measure voltage between ECM main relay harness end #3 and body. 2 Measure voltage between ECM main relay harness end #1 and body. 3 Replace fuel pump relay with other general relay 4 -

x Check for the fuel filter clogging. x Check that the fuel pump is operated normally when turning the key switch ON.

Condition Key switch: ON

Evaluation 0V

Key switch: ON

The engine starts.

The above checks resulted all normal.

T5-6-52

Cause Open circuit in harness between ECM main relay and fuse #8 in fuse box B Open circuit in harness between ECM main relay and ECM terminal #114 Faulty fuel pump relay Faulty ECM or engine unit

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-3

Engine starts with forward/reverse lever set in the positions except N.

Preparation x Even if the key switch is set to the START position with the forward/reverse lever set in the positions except N (neutral), the starter does not rotate. x Check #10 fuse in fuse box B. x Refer to SYSTEM / Electrical System / Neutral Engine Start Circuit. x Refer to SYSTEM / Hydraulic System. x Check the wiring connections first. Procedure Inspection Method 1 Measure voltage at neutral relay harness end #1. 2

Condition Forward/reverse lever: F or R

Replace the neutral relay with Set the key switch other general relay. to START after switching relays. -

Evaluation 0V

Starter: Not rotating

Cause Open circuit in harness between forward/reverse lever and neutral relay Faulty neutral relay

The above checks resulted all normal.

Find out cause of trouble by tracing other trouble symptoms

T5-6-53

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-4

Even if power mode switch is operated, power mode is not shifted.

Preparation x Check the wiring connections first. Procedure Inspection Method 1 Monitor Power Mode Switch.

Condition Power mode switch: ON

Evaluation OFF is displayed.

Monitor traction control switch.

Traction control switch: ON

OFF is displayed.

The above checks resulted all normal.

T5-6-54

Cause Faulty power mode switch or open circuit in harness between power mode switch and MC Faulty traction control switch or open circuit in harness between traction control switch and MC Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-5

Even if key switch is turned OFF, engine does not stop.

Preparation x Remove fusible link (1) and stop the engine as emergency procedures first. x In case other trouble symptoms occur, perform troubleshooting of these troubles first. x If the fault code is not displayed, the key switch may be faulty. x Refer to SYSTEM / Electrical System. x Check the wiring connections first.

TNDF-05-01-001

T5-6-55

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-6

Auto idling stop is not activated.

Preparation x Check the auto idling stop setting with the monitor or MPDr. first. x Refer to SYSTEM / Control System and SYSTEM / Electrical System / Auto Idling Stop Control. x Check the wiring connections first. Procedure Inspection Method 1 Replace auto idling stop relay with other general relay. 2 Replace key switch ON cut relay with other general relay. 3 Replace ACC cut relay with other general relay. 4 Monitor Forward/Reverse Lever (N). 5 Monitor Parking Brake Pressure.

Monitor Pilot Primary Pressure.

Monitor Muf/Fltr Switch.

Monitor Accelerator pedal.

Condition Forward/reverse lever: N Parking brake switch: ON Engine: Running

Front control lever lock switch: UNLOCK position Exhaust filter regeneration switch: OFF Accelerator pedal: Not depressed -

Evaluation The symptom disappears. The symptom disappears. The symptom disappears. F or R is displayed.

Cause Faulty auto idling stop relay Faulty key switch ON cut relay Faulty ACC cut relay Faulty forward/reverse lever

The measured values Stuck spool in parking brake solenoid valve are not within the normal values. (Normal value: 3.0 ~ 4.4 MPa (435 ~ 638 PSI)) Pressure is not Faulty pilot shut-off circuit (A-1) detected. ON is displayed.

Faulty exhaust filter regeneration switch

0.5 V±0.1 V

Faulty accelerator pedal

The above checks resulted all normal.

Faulty MC

T5-6-56

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting A-1

Actuator of only front attachment does not work.

Preparation x If other function (steering) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal. If the pilot system is faulty, the cause of trouble may exist in the pilot shut-off circuit. x Check that #16 fuse in fuse box B is not abnormal. x Pilot valves, travel motors, and/or control valve spools are unlikely to be faulty at the same time. Procedure Inspection Method 1 Replace pilot shut-off relay with other general relay. 2 Monitor Pilot Primary Pressure. 3

Measure resistance between control lever lock solenoid valve #1 and #2. Check continuity between pilot shut-off relay harness end #4 and body.

x Refer to SYSTEM / Electrical System. x Check the wiring connections first.

Condition Evaluation Pilot shut-off lever: The symptom UNLOCK position disappears Control lever lock Pressure is not switch: UNLOCK detected position 0/∞ Ω

Connect control ∞Ω lever lock solenoid valve harness end terminal #2 to body. The above checks resulted all normal.

T5-6-57

Cause Faulty pilot shut-off relay Faulty control lever lock switch

Faulty control lever lock solenoid valve Open circuit in harness between control lever lock solenoid valve and pilot shut-off relay

Faulty pilot valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-2

Actuator of front attachment does not stop even if a control lever is set to neutral.

Preparation x Stuck spool in the pilot valve or stuck main spool in the control valve is suspected. x When the lift arm does not stop for a while, the orifice of slow return valve may be clogged. (Refer to F-4.) Procedure Inspection Method 1 Set the control lever lock switch to LOCK position. 2 Set the control lever lock switch to LOCK position.

Condition -

Evaluation Actuator stops.

Cause Faulty pilot valve (stuck spool)

Actuator does not stop.

Faulty control valve (stuck spool)

T5-6-58

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-3

Auto or manual regeneration of exhaust filter cannot be performed. (It fails.)

Preparation x Refer to SYSTEM / Control System / Exhaust Filter Manual/Auto Regeneration Control. x Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (N). 2 Monitor Parking Brake Pressure.

Condition Forward/reverse lever: N Parking brake switch: OFF Engine: Running

Monitor Pilot Primary Pressure

Monitor Muf/Fltr Switch.

Measure pressure at port A of exhaust filter regeneration control solenoid valve.

Front control lever lock switch: UNLOCK position Exhaust filter regeneration switch: OFF Exhaust filter: ON

Monitor Pump Delivery Pressure

Control lever in neutral

Evaluation F or R is displayed

Cause Faulty forward/reverse lever

The measured Stuck spool in parking brake values are not within solenoid valve the normal values (Normal value: 3.0 ~ 4.4 MPa (435 ~ 638 PSI)) Pressure is not Faulty pilot shut-off circuit (A-1) detected ON is displayed.

Faulty exhaust filter regeneration switch

The measured value Stuck spool in exhaust filter regeneration control solenoid is not within the valve normal values. (Normal value: approx. 3.7 MPa (537 PSI) The measured value Faulty control valve (stuck spool) is not within the normal values. (Normal value: 1.0 ~ 2.5 MPa (145 ~ 363 PSI)) The check mentioned Faulty MC above is normal

T5-6-59

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-4

Fan speed does not change.

Preparation x The sensors detect the conditions necessary to operate fan speed control. Therefore, if these sensors fails, fan speed control becomes ineffective. x Accelerator pedal sensor, coolant temperature sensor, boost temperature sensor, HST oil temperature sensor, and pressure sensor (refrigerant pressure) are also engaged in the fan speed control. However, if these sensors fail, other operating functions will be also affected. Procedure Inspection Method 1 Monitor Target Hydraulic Fan Speed.

Condition Engine: Running

Evaluation Fan speed does not change according to accelerator pedal depressing amount. Fan pump delivery pressure does not change according to accelerator pedal depressing amount. There is abnormality.

There is abnormality. Faulty fan control valve

The above checks resulted all normal.

Monitor Hydraulic Fan Circuit Engine: Running Pressure.

Disassemble and inspect the fan speed control solenoid valve. Disassemble and inspect the fan control valve. -

4 5

x Refer to SYSTEM / Control System / Fan Reverse Rotation Control.

T5-6-60

Cause Faulty ECM, or faulty MC

Faulty pilot pump

Faulty fan speed control solenoid valve

Faulty fan motor

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-5

Fan does not rotate in reverse when pushing fan reverse rotation switch (option).

Preparation x Refer to SYSTEM / Control System / Fan Reverse Rotation Control (OPT). x Check the wiring connections first. Procedure Inspection Method 1 Monitor Fan Reversing Switch.

Condition Parking brake is applied Fan reverse rotation switch: ON -

Measure resistance between fan reverse rotation control solenoid valve #1 and #2. Measure voltage between Key switch: ON fan reverse rotation control solenoid valve harness end #1 and body. -

Evaluation OFF is displayed.

Cause Faulty fan reverse rotation switch

0/∞ Ω (Normal value: Faulty fan reverse rotation 22 Ω) control solenoid valve 0V

Open circuit in harness between fan reverse rotation control solenoid valve and MC

The above checks resulted all normal.

Faulty MC

T5-6-61

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-62

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting F-1

All front attachment actuator power are weak.

Main Relief Valve Set Pressure Lift arm and bucket relief operation

Specification MPa (PSI) 20.6 +1.2−0.5 (2988 +174−72.5)

Remark

Preparation x If operating speeds are extremely slow, pump control may be faulty. Faulty pilot system may also cause this trouble. Procedure Inspection Method 1 Monitor Pump Delivery Pressure.

Condition Lift arm relief operation

Evaluation The measured values are not within the normal values. The above checks resulted all normal.

T5-6-63

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 speed are slow.

Overload Relief Specification Valve Set Pressure MPa (PSI) Lift Arm Raise 27.4+1.0−0 (3974 +145−0) Bucket 22.6+1.0−0 (3278 +145−0)

Remark

Preparation x When the pilot valve is operated normally, the pilot pump (primary pilot pressure) is considered to be normal. x When bucket operation speed is slow during combined operation of lift arm and bucket, the bucket flow rate control valve in control valve may be stuck (clogged). Procedure Inspection Method 1 Measure Pilot Secondary Pressure.

Condition Full operation of bucket roll back/ dump and lift arm raise/lower

Replace overload relief valves, of which the set pressure are same. -

Evaluation Cause The measured values Faulty pilot valve are not within the normal values. (Normal value: 3.0 ~ 4.4 MPa (435 ~ 638 PSI)) Symptom is reversed. Faulty overload relief valve

The above checks resulted all normal.

T5-6-64

Stuck control valve spool, or faulty cylinder (faulty seal kit)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-3

Front attachment drifts remarkably.

Procedure Inspection Method 1 Replace the control lever lock switch to LOCK position. 2 Replace the overload relief valves (lift arm raise, bucket). 3 Disassemble and inspect the cylinder. 4 -

Condition -

Evaluation The symptom disappears. The symptom disappears. There is abnormality. The above checks resulted all normal.

T5-6-65

Cause Faulty pilot valve Faulty overload relief valve Faulty cylinder (seal kit) Scored control valve spool, broken spring, or loose spool end

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-4

Shock is large when stopping lift arm raise / lower operation.

Preparation x Check that control levers are not abnormal first. x Refer to SYSTEM / Hydraulic System. Procedure Inspection Method 1 Disassemble and inspect the slow return valve. 2 -

Condition -

Evaluation Cause There is abnormality. Faulty slow return valve

The above checks resulted all normal.

T5-6-66

Stuck control valve spool, or faulty cylinder (faulty seal kit)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-5

Bucket auto leveler control is not activated. (Detent is not held.)

Preparation x Refer to SYSTEM / Control System / Bucket Auto Leveler Control. x Check fuse #16 in fuse box B. x Check the wiring connections first.

Procedure Inspection Method 1 Measure voltage between pilot valve bucket roll back side coil harness end #1 and body. 2 Check continuity between pilot valve bucket roll back side coil harness end #2 and body. 3 Measure voltage between bucket leveler relay harness end #2 and body. 4 -

Condition Key switch: ON

Evaluation 0V

Cause Open circuit in harness between fuse #16 in fuse box B 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

The above checks resulted all normal.

T5-6-67

Open circuit in harness between bucket proximity switch and bucket leveler relay Faulty bucket proximity switch

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-6

Lift arm float control is not activated. (Detent is not held.)

Preparation x Refer to SYSTEM / Control System / Lift Arm Float Control. x Check fuse #16 in fuse box B. x Check the wiring connections first. Procedure Inspection Method 1 Measure voltage between pilot valve lift arm lower side coil harness end #1 and body. 2 Check continuity between pilot valve lift arm lower side coil harness end #2 and body. 3 -

Condition Key switch: ON

Evaluation 0V

Lift arm lower, detent control lever operation -

0Ω

The above checks resulted all normal.

T5-6-68

Cause Open circuit in harness between fuse #16 in fuse box B and pilot valve lift arm lower side coil Faulty ground in pilot valve lift arm lower side coil Faulty pilot valve lift arm lower side coil

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-7

Lift arm auto leveler height kickout control (option) is not activated.

Preparation x Refer to SYSTEM / Control System / Lift Arm Auto Leveler Height Kickout Control. x In case fault code 111720-2 is displayed, perform the lift arm angle sensor learning. (Refer to T4-6.) Procedure Inspection Method 1 Measure voltage between pilot valve lift arm raise side coil harness end #1 and body. 2 Check continuity between pilot valve lift arm raise side coil harness end #2 and body. 3 Monitor Lift Arm Auto Leveler Switch (raise). 4

Condition Key switch: ON

Lift arm raise, detent control lever operation Lift arm auto leveler switch (raise): ON Monitor lift arm Angle Sensor. Lift arm raise/ lower operation -

x Check fuse #16 in fuse box B. x Check the wiring connections first.

Evaluation 0V

0Ω

Cause Open circuit in harness between fuse #16 in fuse box B and pilot valve lift arm raise side coil Faulty ground in pilot valve lift arm raise side coil

OFF is displayed.

Faulty lift arm auto leveler switch (raise)

0 V, or Sensor value: Fixed

Faulty lift arm angle sensor or open circuit in harness between MC and sensor Faulty pilot valve lift arm raise side coil

The above checks resulted all normal.

T5-6-69

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-8

Lift arm auto leveler lower kickout control (option) is not activated.

Preparation x Refer to SYSTEM / Control System / Lift Arm Auto Leveler Lower Kickout Control. x In case fault code 111720-2 is displayed, perform the lift arm angle sensor learning. (Refer to T4-6.) Procedure Inspection Method 1 Measure voltage between pilot valve lift arm lower side coil harness end #1 and body. 2 Check continuity between pilot valve lift arm lower side coil harness end #2 and body. 3 Monitor Lift Arm Auto Leveler Switch (lower). 4

Condition Key switch: ON

Lift arm lower, detent control lever operation Lift arm auto leveler switch (lower): ON Monitor lift arm Angle Sensor. Lift arm raise/ lower operation -

x Check fuse #16 in fuse box B. x Check the wiring connections first.

Evaluation 0V

0Ω

Cause Open circuit in harness between fuse #16 in fuse box B and pilot valve lift arm lower side coil Faulty ground in pilot valve lift arm lower side coil

OFF is displayed.

Faulty lift arm auto leveler switch (lower)

0 V, or Sensor value: Fixed

Faulty lift arm angle sensor or open circuit in harness between MC and sensor Faulty pilot valve lift arm lower side coil

The above checks resulted all normal.

T5-6-70

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-9

Ride control (option) is not activated.

Preparation x Check the ride control setting with the MPDr. first. The activating conditions for ride control are different according to the settings. x Refer to SYSTEM / Control System / Ride Control. Procedure Inspection Method 1 Monitor Ride Control Switch.

x When other actuator (front attachment) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal. x Check the wiring connections first.

Condition Ride control switch: ON

Measure resistance between ride control solenoid valve #1 and #2. -

Evaluation OFF is displayed.

Cause Faulty ride control switch or open circuit in harness between ride control switch and MC 0/∞ Ω (Normal value: Faulty ride control solenoid 22±0.4 Ω) valve The above checks resulted all normal.

Connector (Harness end) x Solenoid Valve Connector

TNED-05-05-020

T5-6-71

Stuck ride control valve spool or faulty accumulator

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-10 Bucket tilt operating speed is slow. (Parallel Link Front Attachment) Preparation x Refer to SYSTEM/Hydraulic System/Bucket Tilt Circuit (Parallel Link Front Attachment). Procedure Inspection Method 1 Disassemble and inspect the bucket regenerative valve. 2 -

Condition -

Evaluation There is abnormality.

Cause Faulty bucket regenerative valve

Normal in above check

Find out cause of trouble by tracing other trouble symptoms.

T5-6-72

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-11 Bucket dump operating speed is slow. (Only Parallel Link Front Attachment) Preparation x Refer to SYSTEM/Hydraulic System/Bucket Dump Circuit (Parallel Link Front Attachment). Procedure Inspection Method 1 Measure secondary pilot pressure.

3 4

Disassemble and inspect the bucket regenerative selector valve. Disassemble and inspect the bucket regenerative valve. -

Condition Evaluation Cause Operate bucket The value is not within Faulty pilot valve dump. the normal value. (Normal value: 3.0 to 4.4 MPa) There is abnormality. Faulty bucket regenerative selector valve -

There is abnormality.

Faulty bucket regenerative valve

Normal in above check

Find out cause of trouble by tracing other trouble symptoms.

T5-6-73

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-74

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting S-1

Steering operation is weak.

Main Relief Valve Set Pressure Steering relief operation

Specification MPa (PSI) 19.6 +1.9−0 (2843 +276−0)

Remark

Preparation x If operating speeds are extremely slow, pump control may be faulty. Procedure Inspection Method 1 Monitor Pump Delivery Pressure.

Condition Steering relief operation

Evaluation The measured values are not within the normal values. The above checks resulted all normal.

T5-6-75

Cause Faulty steering relief valve (readjust) Find out cause of trouble by tracing other trouble symptoms.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-2

Steering operation is slow.

Specification (seconds) Steering cylinder 3.4±0.4 operation time

Remark Accelerator pedal: Fully depressed Power mode switch: OFF The bucket should be empty

Preparation x If speed of front attachment is also slow, the main system may be faulty (A-2). x Check that the steering wheel is not abnormal first. x Refer to SYSTEM / Hydraulic System. Procedure Inspection Method 1 Measure Steering Relief Pressure.

Condition -

Disassemble and inspect the priority valve. -

Evaluation The measured values are not within the normal values. (Normal value: 19.6 ~ 21.5 MPa (2843 ~ 3118 PSI)) There is abnormality. The above checks resulted all normal.

T5-6-76

Cause Faulty main relief valve (steering)

Faulty priority valve Stuck steering valve spool or faulty steering cylinder (faulty seal kit)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-3

Shock of steering operation is large.

Preparation x Check that the steering wheel is not abnormal first. x The steering valve may be faulty. x Refer to SYSTEM / Hydraulic System.

Procedure Inspection Method 1 Check gas pressure in the accumulator. 2 Disassemble and inspect the steering valve. 3 -

x Set machine to carry position before checking gas pressure in the accumulator. Stop the engine, operate the steering wheel, and release remaining pressure.

Condition -

Evaluation Cause There is abnormality. Gas leakage of accumulator

There is abnormality. Faulty steering valve (stuck spool, clogged orifice) The above checks Faulty steering cylinder (faulty resulted all normal. seal kit)

T5-6-77

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-4

Secondary steering (option) is not operated. (Automatic operation check when the engine starts)

Preparation x Check the secondary steering control setting with the MPDr. first. x Refer to SYSTEM / Control System / Secondary Steering Control (Option). x Check fuse #20 in fuse box B. x Check the wiring connections first. Procedure Inspection Method 1 Monitor Secondary Steering Pump Delivery Pressure.

x The secondary steering check switch may be faulty when secondary steering operation cannot be checked manually.

Condition Engine starts.

Set the key switch Replace secondary steering relay with other general relay. to START after switching relays. -

Evaluation The measured values are not within the normal values (Normal value: 4.8 MPa (696 PSI)) The symptom disappears. The above checks resulted all normal.

T5-6-78

Cause Faulty secondary steering pump unit

Faulty secondary steering relay

Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting T-1

Even if forward/reverse lever is operated, Vehicle does not travel forward/reverse.

Preparation x Check that the parking brake is not abnormal. x Faulty transmission and/or axle (front and/or rear) may be the cause of this trouble. Check if a noise is emitted from each section.

x When the HST warning indicator is turned on, something related with the HST control may be faulty. x Refer to SYSTEM / Control System / Forward/Reverse Selection Control. x Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (F) and (R)

Condition Forward/reverse lever: F, R

Measure resistance between forward/reverse control solenoid valve #1 and #2. Measure resistance between pump displacement angle control solenoid valve #1 and #2. -

Evaluation N is displayed

Cause Faulty forward/reverse lever, or open circuit in harness between forward/reverse lever and HST controller 0/∞ Ω (Normal value: Faulty forward/reverse control 22±0.4 Ω) solenoid valve

0/∞ Ω (Normal value: Faulty pump displacement 22±0.4 Ω) angle control solenoid valve

The above checks resulted all normal.

Connector (Harness end) x Solenoid Valve Connector

TNED-05-05-020

T5-6-79

HST controller

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-2

Even if forward/reverse lever is set to neutral position, Vehicle travels.

Preparation x Refer to SYSTEM / Control System / Neutral Control. x Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (N). 2 Measure resistance between forward/reverse control solenoid valve #1 and #2. 3 -

x Check that fuse #10 in fuse box B is not abnormal.

Condition Forward/reverse lever: N -

Evaluation F or R is displayed

The above checks resulted all normal.

Cause Faulty forward/reverse lever.

0/∞ Ω (Normal value: Faulty forward/reverse control 22±0.4 Ω) solenoid valve

T5-6-80

Faulty HST controller

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-3

Even if shift switch is operated, speed shift is not shifted.

Preparation x Refer to SYSTEM / Control System / Speed Shift Control. x Check the wiring connections first.

x When the shift switch is faulty, the speed shift is held in second speed. x Faulty transmission may be the cause of this trouble. Check if a noise is emitted from each section.

Procedure Inspection Method 1 Monitor Shift Switch and Operate Shift Switch.

Condition Shift switch: 1/2/3/4 position

Monitor Vehicle Speed (For Speedometer).

While traveling

Measure resistance between clutch pressure control solenoid valve #1 and #2. Measure resistance between motor 1 displacement angle control solenoid valve #1 and #2. Measure resistance between motor 2 displacement angle control solenoid valve #1 and #2. -

Evaluation Cause The position of shift Faulty shift switch or open switch is not identical circuit in harness between shift to the display of switch and HST controller monitoring. 0 km/h is displayed. Faulty vehicle speed 2 sensor or open circuit in harness between vehicle speed 2 sensor and HST controller 0/Ω (Normal value: Faulty clutch pressure control 22±0.4 Ω) solenoid valve

0/∞ Ω (Normal value: Faulty motor 1 displacement 22±0.4 Ω) angle control solenoid valve

0/∞ Ω (Normal value: Faulty motor 2 displacement 22±0.4 Ω) angle control solenoid valve

The above checks resulted all normal.

Connector (Harness end) x Solenoid Valve Connector

TNED-05-05-020

T5-6-81

Faulty HST controller

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-4

Speed limit control is not activated.

Preparation x Check that the speed shift is in 1st (forward/reverse). x Refer to SYSTEM / Control System / Speed Limit Control. x Check the wiring connections first. Procedure Inspection Method Condition 1 Operate the 1st speed limit switch and monitor. 2

Operate the Creeper Switch and monitor.

Slow speed mode (option) Creeper switch: ON -

Evaluation 0 is displayed on the monitor or the value is not changed. OFF is displayed.

The above checks resulted all normal.

T5-6-82

Cause Faulty 1st speed limit switch or open circuit in harness between 1st speed limit switch and MC Faulty creeper switch or open circuit in harness between creeper switch and MC Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting B-1

Parking brake is not released. (While the engine runs)

Preparation x When other actuator (front attachment) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal. x Refer to SYSTEM / Electrical System. x Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Parking brake signal. Parking brake switch: ON (Release) Engine: Running 2 Monitor Parking Brake Parking brake Pressure. switch: ON (Release) Engine: Running

Monitor Service Brake Primary Pressure.

Replace parking brake relay 1 Parking brake with other general relay. switch: ON (Release) Engine: Running Replace parking brake relay 2 Parking brake with other general relay. switch: ON (Release) Engine: Running -

Parking brake switch: OFF (Apply) Engine: Running

Evaluation OFF is displayed.

Cause Faulty column display controller

The measured values are not within the normal values. (Normal value: 3.0 ~ 4.4 MPa (435 ~ 638 PSI)) The measured values are not within the normal values. (Normal value: 3.0 ~ 4.4 MPa (435 ~ 638 PSI)) The symptom disappears.

Stuck spool in parking brake solenoid valve

Faulty parking brake accumulator

Faulty parking brake relay 1

The symptom disappears.

Faulty parking brake relay 2

The above checks resulted all normal.

Faulty MC

T5-6-83

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-2

Parking brake is not applied.

Wear amount of Specification parking brake mm (in) Brake Disc 2.5 (0.098) Brake Friction Pad 1.6 (0.063)

Allowable Limit mm (in) 2.2 (0.087) 1.4 (0.055)

Preparation x Check the wiring connections first. Procedure Inspection Method 1 Monitor Parking Brake Pressure. 2 Check the wear amount of parking brake. 3 -

Condition Key switch: ON

Evaluation Pressure is detected.

≤ Allowable limit

The above checks resulted all normal.

T5-6-84

Cause Stuck spool in parking brake solenoid valve Faulty brake disc and faulty brake friction pad Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-3

Service brake braking force becomes weak.

Wear amount of service brake Brake Disc Brake Ring

Specification mm (in) 9.2 (0.362) 8.0 (0.315)

Allowable Limit mm (in) 7.9 (0.311) 7.5 (0.295)

Preparation x When other actuator (front attachment) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal. x Check the wiring connections first. Procedure Inspection Method 1 Monitor Service Brake Primary Pressure.

Condition -

Measure service brake pressure.

Refer to T4-5.

Check the wear amount of service brake.

Refer to T4-4.

Evaluation The measured values are not within the normal values (Normal value: 3.0 ~ 4.4 MPa (435 ~ 638 PSI)) The measured values are not within the normal values (Normal value: 3.0 ~ 5.0 MPa (435 ~ 725 PSI)) -

T5-6-85

Cause Faulty brake charge valve

Faulty brake valve

The wear amount of brake disc is beyond the allowable limit of use.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-86

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting O-1 Clearance light, tail light, and license plate light are not ON. Preparation x Failure of the clearance light indicator lighting will be also affected. x Refer to SYSTEM / Electrical System. x Check the wiring connections first.

x Check that the clearance light, tail light, and license plate light are not broken first. x Check fuse #2 in fuse box B when the clearance lights at both sides, tail light, and license plate light are not ON at the same time. x Check fuse #11 or #12 in fuse box B when only the light at one side is not ON. Procedure Inspection Method 1 Monitor Light Switch.

Condition Light switch: Clearance light position or Head light position -

Evaluation OFF is displayed.

The above checks resulted all normal.

T5-6-87

Cause Faulty light switch Open circuit in harness between light switch and fuses #2 and #12 in fuse box B Faulty fuses #2, #11, and #12 in fuse box B

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-2 Head light is not ON. Preparation x Check that the head lights are not broken first. x The light switch may be faulty (O-1) or the dimmer switch may be faulty when the head lights at both sides are not ON at the same time. x Check fuses #1 and #5 in fuse box A when only the light at one side is not ON.

x Check that the light switch is the head light position. x Refer to SYSTEM / Electrical System. x Check the wiring connections first.

Procedure Inspection Method 1 Set the dimmer switch to the low beam position. 2

Condition Evaluation Key switch: ON The head lights (left/ Light switch: Head right) are not ON light position Replace head light relay (left/ Key switch: ON The head lights (left/ right) with other general Dimmer switch: right) are ON relay. Low beam position Measure voltage between Key switch: ON 0V head light relay (left/right) Dimmer switch: harness end #1 and body. Low beam position Measure voltage between head light relay (left) harness end #3 and body. Measure voltage between head light (left) harness end #512 and body. Measure voltage between head light relay (right) harness end #3 and body. Measure voltage between head light (right) harness end #513 and body.

Connector (Harness end) x Head Light Relay (Left/ Right)

Key switch: ON 0V Dimmer switch: Low beam position Key switch: ON 0V Dimmer switch: Low beam position Key switch: ON 0V Dimmer switch: Low beam position Key switch: ON 0V Dimmer switch: Low beam position

x Head Light (Left/Right) #512 #513

T183-05-04-003

TNED-05-06-003

T5-6-88

Cause Faulty dimmer switch, or open circuit in harness between dimmer switch and light switch Faulty head light relay (left/ right) Open circuit in harness between head light relay (left/right) and light switch, or faulty dimmer switch Open circuit in harness between head light relay (left) and #5 fuse in fuse box A, or faulty #5 fuse Open circuit in harness between head light (left) and head light relay (left) Open circuit in harness between head light relay (right) and fuse #1 in fuse box A, or faulty fuse #1 Open circuit in harness between head light (right) and head light relay (right)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-3 Head light is not shifted to high beam. Preparation x Check fuse #19 in fuse box B when the high beams at both sides are not ON. x Check that the light switch is the head light position.

x Failure of the high beam indicator lighting will be also affected. x Refer to SYSTEM / Electrical System. x Check the wiring connections first.

Procedure Inspection Method 1 Set the dimmer switch to the high beam position. 2

Condition Key switch: ON Light switch: Head light position Replace high beam relay with Key switch: ON other general relay. Dimmer switch: High beam position Measure voltage between Key switch: ON high beam relay harness end Dimmer switch: High beam #1 and body. position Key switch: ON Measure voltage between high beam relay harness end Dimmer switch: #3 and body. High beam position Measure voltage between Key switch: ON head light (left) harness end Dimmer switch: #511A and body. High beam position Measure voltage between Key switch: ON head light (right) harness end Dimmer switch: #511B and body. High beam position -

Connector (Harness end) x High Beam Relay

Evaluation Cause High beam is not ON. Faulty dimmer switch, or open circuit in harness between dimmer switch and light switch High beam is ON. Faulty high beam relay

Open circuit in harness between high beam relay and dimmer switch

Open circuit in harness between high beam relay and #19 fuse in fuse box B, or faulty fuse #19

Open circuit in harness between head light (left) and high beam relay

Faulty head light (right), or open circuit in harness between head light (right) and high beam relay

The above checks resulted all normal.

Faulty head light (right/left) or faulty ground

x Head Light (Left/Right) #511B #511A

T183-05-04-003

TNED-05-06-003

T5-6-89

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-4 Hazard light is not operated. Preparation x Check that the turn signal lights (hazard lights) are not broken first. x Check fuse #6 in fuse box B when all turn signal lights do not blink at the same time. Faulty flasher relay may also cause this trouble. Procedure Inspection Method 1 Turn the hazard light switch ON.

Condition Key switch: OFF

Hazard light switch: ON Hazard light switch: ON

Measure voltage at terminal L in flasher relay. Replace turn signal light relay (left) with turn signal light relay (right). Measure voltage between turn signal light relay (left/ right) harness end #1 and body. Measure voltage between turn signal light relay (left/ right) harness end #3 and body. Measure voltage between hazard lights (right front/ right rear) harness end #501A/#501B and body. Measure voltage between hazard lights (left front/ left rear) harness end #502A/#502B and body. -

Connector (Harness end) x Turn Signal Light Relay (Left/Right)

x Failure of blinking of the turn signal light indicators at both sides will be also affected. x Refer to SYSTEM / Electrical System. x Check the wiring connections first.

Evaluation Hazard light is not operated.

Cause Faulty hazard light switch, open circuit in harness between hazard light switch and fuse #6 in fuse box B 0V Faulty flasher relay or faulty ground Symptom is reversed. Faulty turn signal light relays (left/right)

Hazard light switch: ON

The above checks resulted all normal.

x Hazard Light (Front) #501A

Open circuit in harness between turn signal light relay (left/right) and hazard light switch, or faulty diode P(k) Open circuit in harness between turn signal light relay (left/right) and flasher relay Open circuit in harness between hazard lights (right front/ right rear) and turn signal light relay (right) Open circuit in harness between hazard lights (left front/ left rear) and turn signal light relay (left) Faulty fuse #6 in fuse box B

x Hazard Light (Rear)

x Flasher Relay

#501B #502B

#502A L

T183-05-04-003

TNED-05-06-002

T5-6-90

TNED-05-06-003

TNED-05-06-001

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-5 Turn signal light is not operated. Preparation x Check fuse #8 in fuse box A when all turn signal lights do not blink. x Refer to SYSTEM / Electrical System. x Check the wiring connections first. Procedure Inspection Method 1 Operate the turn signal lever to the right and left.

Condition Key switch: ON

Evaluation All turn signal lights do not blink.

Measure voltage between turn signal light relay (left) harness end #1 and body.

Key switch: ON Turn signal lever: Left position

Measure voltage between turn signal light relay (right) harness end #1 and body.

Key switch: ON Turn signal lever: Right position

Connector (Harness end) x Turn Signal Light Relay (Left/Right)

T183-05-04-003

T5-6-91

Cause Faulty turn signal lever, or open circuit in harness between turn signal lever and fuse #8 in fuse box A Open circuit in harness between turn signal light relay (left) and turn signal lever, or faulty diode P Open circuit in harness between turn signal light relay (right) and turn signal lever, or faulty diode k

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-6 Horn does not sound. Preparation x Check that the horn is not broken first. x Check fuse #5 in fuse box B when the horn does not sound by pushing two horn switches. x Refer to SYSTEM / Electrical System. x Check the wiring connections first. Procedure Inspection Method 1 Replace horn relay with other general relay. 2 Measure voltage between horn relay harness end #1 and body. 3 -

Condition Horn switch: ON

Evaluation Horn sounds.

Cause Faulty horn relay

Horn switch: ON

The above checks resulted all normal.

Open circuit in harness between horn relay and fuse #5 in fuse box B, or faulty fuse #5 Faulty horn switch or open circuit in harness between horn switch and horn relay

Connector (Harness end) x Horn Relay

T183-05-04-003

T5-6-92

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-7 Reverse light is not ON. Reverse buzzer does not sound. Preparation x Check that the forward/reverse lever is in the R position. x Refer to SYSTEM / Electrical System. x Check the wiring connections first.

x Check that the reverse light and reverse buzzer are not broken first. x Check fuse #7 in fuse box A when the reverse lights at both sides and reverse buzzer are not operated at the same time. Faulty forward/reverse lever (T-1) may also cause this trouble. Procedure Inspection Method 1 Replace reverse buzzer relay with other general relay.

Condition Key switch: ON

Measure voltage between reverse lights (left/right) harness end #505D/#506C and body. Measure voltage between reverse buzzer harness end #2 and body. Measure voltage between reverse buzzer relay harness end #1 and body. Measure voltage between reverse buzzer relay harness end #3 and body. -

Connector (Harness end) x Reverse Buzzer Relay

Cause Faulty reverse buzzer relay

Key switch: ON

Evaluation Reverse light is ON and reverse buzzer sounds. 0V

Key switch: ON

The above checks resulted all normal.

Open circuit in harness between reverse buzzer and reverse buzzer relay Open circuit in harness between reverse buzzer relay and fuse #10 in fuse box B, or faulty fuse #10 Open circuit in harness between reverse buzzer relay and fuse #7 in fuse box A, or faulty fuse #7 Faulty reverse lights (left/right) or faulty ground

x Reverse Buzzer

Open circuit in harness between reverse lights (left/right) and reverse buzzer relay

x Reverse Light (Left/ Right) #505D #506C

T183-05-04-003

TNED-05-06-006

T5-6-93

TNED-05-06-003

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-8 Brake light is not ON. Preparation x Check that the brake lights are not broken first. x Check #8 fuse in fuse box A when the brake lights at both sides are not ON. x Refer to SYSTEM / Electrical System. x Check the wiring connections first. Procedure Inspection Method Condition Evaluation 1 Replace brake light relay with Brake light switch: The symptom other general relay. ON (Brake pedal is disappears. operated) 2 Measure voltage between Brake light switch: 0 V brake light relay harness end ON (Brake pedal is #1 and body. operated) 3 The above checks resulted all normal.

Connector (Harness end) x Brake Light Relay

T183-05-04-003

T5-6-94

Cause Faulty brake light relay

Open circuit in harness between brake light relay and fuse #8 in fuse box A, or faulty fuse #8 Faulty brake light switch, or open circuit in harness between brake light switch and brake light relay

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-9 Work light does not light. Preparation x Check that the work lights are not broken first. x 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. x Check fuse #4 in fuse box A and fuse #17 in fuse box B when only the light at one side is not ON.

x Failure of blinking of the work light indicator will be also affected. x Refer to SYSTEM / Electrical System. x Check the wiring connections first.

Procedure Inspection Method Condition 1 Set work light switch to ON 1/ Key switch: ON ON 2. Light switch:

Evaluation Work light is not ON.

Work light is ON.

Replace work light relays Key switch: ON (front/rear) with other general Work light switch: relay. ON 2 position Measure voltage between Key switch: ON work light relay (front/rear) Work light switch: harness end #1 and body. ON 2 position Measure voltage between Key switch: ON work light relay (front) Work light switch: ON 2 position harness end #3 and body. Measure voltage between Key switch: ON work light (front) harness end Work light switch: connector and body. ON 2 position Measure voltage between Key switch: ON work light relay (rear) harness Work light switch: end #3 and body. ON 2 position Measure voltage between work light (rear) harness end (connector RG) and body. -

Key switch: ON Work light switch: ON 2 position -

The above checks resulted all normal.

Connector (Harness end) x Work Light Relay

T183-05-04-003

T5-6-95

Cause Faulty work light switch or open circuit in harness between work light switch and light switch Faulty work light relay (front/ rear) Open circuit in harness between work light relay (front/rear) and work light switch Open circuit in harness between work light relay (front) and fuse #4 in fuse box A, or faulty fuse #4 Open circuit in harness between work light (front) and work light relay (front) Open circuit in harness between work light relay (rear) and fuse #17 in fuse box B, or faulty fuse #17 Open circuit in harness between work light (rear) and work light relay (rear) Faulty work light relay (front/ rear) or faulty ground

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-10 Wiper is not operated. Preparation x In case the front washer is also not operated, check fuse #3 in fuse box A. In case the rear washer is also not operated, check fuse #18 in fuse box B. x Refer to SYSTEM / Electrical System. x Check the wiring connections first.

x The wiper is driven by electric power routed via the relay circuit. The relay circuit of front wiper is controlled by the column display controller. x 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. y Front Wiper Procedure Inspection Method 1 Monitor Front Wiper Relay 1 Output.

Monitor Front Wiper Relay 2 Output.

Monitor Front Wiper Switch.

Replace front wiper relay 1/2 with other general relay.

Condition Key switch: ON Front wiper/ washer switch: LOW Key switch: ON Front wiper/ washer switch: HI Key switch: ON Front wiper/ washer switch: LOW/HI

Key switch: ON Front wiper/ washer switch: LOW/H1 -

Evaluation OFF is displayed.

Cause Faulty column display controller

OFF is displayed.

Faulty column display controller

Faulty front wiper/ washer The position of front wiper/ washer switch, or open circuit in harness switch is not identical between front wiper/ washer to the display of switch and column display monitoring. controller, or open circuit in harness between front wiper relay 1/2 and column display controller Wiper is operated. Faulty front wiper relay 1/2

The above checks resulted all normal.

T5-6-96

Faulty front wiper motor

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B y Rear Wiper Preparation x The rear wiper/ washer switch may be faulty when the rear wiper is not operated. Procedure Inspection Method Condition 1 Set rear wiper/ washer switch Key switch: ON to LOW.

Evaluation Rear wiper is not operated.

Replace rear wiper relay with other general relay.

Rear wiper is operated.

Check continuity between rear wiper relay harness end #2 and body.

Measure voltage between rear wiper relay harness end #1 and body.

Key switch: ON Rear wiper/ washer switch: LOW Key switch: ON Rear wiper/ washer switch: LOW Key switch: ON Rear wiper/ washer switch: LOW -

Cause Faulty rear wiper/ washer switch, or open circuit in harness between rear wiper/ washer switch and rear wiper relay Faulty rear wiper relay

0Ω

Open circuit in harness between rear wiper relay and rear wiper/ washer switch

Open circuit in harness between rear wiper relay and #18 fuse in fuse box B, or faulty #18 fuse

The above checks resulted all normal.

Faulty rear wiper motor

Connector (Harness end) x Rear Wiper Relay

T183-05-04-003

T5-6-97

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-11 Washer is not operated. Preparation x Refer to SYSTEM / Electrical System. x Check the wiring connections first. y Front Washer Procedure Inspection Method Condition 1 Replace the front washer Front wiper/ relay with other general relay. washer switch: ON position 2 Check continuity between Front wiper/ front washer relay harness washer switch: ON end #2 and body. position 3 Measure voltage between Key switch: ON front washer relay harness end #1 and body. 4 Monitor Front Washer Switch. Front wiper/ washer switch: Washer ON

Measure voltage between front washer motor harness end #2 and body. -

Connector (Harness end) x Front Washer Relay

T183-05-04-003

Evaluation Front washer is operated.

Cause Faulty front washer relay

0Ω

Open circuit in harness between front washer relay and front wiper/ washer switch Open circuit in harness between front washer relay and fuse #3 in fuse box A, or faulty fuse #3 Faulty front wiper/ washer switch, or open circuit in harness between front wiper/ washer switch and column display controller Open circuit in harness between front washer relay and front washer motor Faulty front washer motor

OFF is displayed.

Front wiper/ 0V washer switch: ON position The above checks resulted all normal.

x Front Washer Motor

TNED-05-06-006

T5-6-98

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B y Rear Washer Preparation x The rear wiper/ washer switch may be faulty when the rear washer is not operated. Procedure Inspection Method Condition 1 Replace the rear washer relay Key switch: ON with other general relay. Rear wiper/ washer switch: Washer ON 2 Check continuity between Key switch: ON rear washer relay harness end Rear wiper/ #2 and body. washer switch: Washer ON 3 Measure voltage between Key switch: ON rear washer relay harness end Rear wiper/ washer switch: #1 and body. Washer ON 4 Measure voltage between Key switch: ON rear washer motor harness Rear wiper/ end #2 and body. washer switch: Washer ON 5 -

Connector (Harness end) x Rear Washer Relay

T183-05-04-003

Evaluation Rear washer is operated.

Cause Faulty rear washer relay

∞Ω

Open circuit in harness between rear washer relay and rear wiper/ washer switch

Open circuit in harness between rear washer relay and fuse #18 in fuse box B

Open circuit in harness between rear washer relay and rear wiper motor

The above checks resulted all normal.

Faulty rear wiper motor or faulty fuse #3 in fuse box A

x Rear Washer Motor

TNED-05-06-006

T5-6-99

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-12 Cab light is not ON. Preparation x Check fuse #3 in fuse box B when the cab light and rear cab light are not ON at the same time. x Refer to SYSTEM / Electrical System. x Check the wiring connections first. Procedure Inspection Method 1 Set cab light switch to ON position.

Condition -

Evaluation Cab light is not ON.

Door open/close switch: ON -

Cab light is not ON.

Set cab light switch to Door Interlocking Position. Set rear cab light switch to ON position.

Rear cab light is not ON.

T5-6-100

Cause Faulty cab light, open circuit in harness between cab light and fuse #3 in fuse box B Faulty door open/close switch Faulty rear cab light, open circuit in harness between rear cab light and fuse #3 in fuse box B

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Exchange Inspection 3

Exchange inspection method is a troubleshooting method to find the trouble location by exchanging the suspected part / component with another part / component having identical characteristics.

Many sensors and solenoid valves used on this machine are identical. Therefore, by using this switch-check method, faulty part /component, and/or harness can be easily found. Example: HST Circuit Pressure 1 Sensor Circuit High Input (HST Controller Fault Code 111331-3)

Check Method: 1. Connect the HST circuit pressure 1 sensor and HST circuit pressure 2 sensor to the opposite connector each other. 2. Retry troubleshooting.

TNDF-05-01-005 12-

Result: In case HST Circuit Pressure 2 Sensor Circuit High Input (HST Controller Fault Code 111333-3) is displayed, the HST circuit pressure 1 sensor is considered to be faulty. In case HST Circuit Pressure 1 Sensor Circuit High Input (HST Controller Fault Code 111331-3) is displayed, the HST circuit pressure 1 sensor harness is considered to be faulty.

T5-6-101

HST Circuit Pressure 1 Sensor HST Circuit Pressure 2 Sensor

HST Pump

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Applicability of Switch-Check Method Fault Code Trouble Remedy 111330-3 Pressure Sensor (Front Attachment Pressure) Circuit High Input Applicable (Harness / Sensor) 111330-4 Pressure Sensor (Front Attachment Pressure) Circuit Low Input 111331-3 HST Circuit Pressure 1 Sensor Circuit High Input 111331-4 HST Circuit Pressure 1 Sensor Circuit Low Input 111333-3 HST Circuit Pressure 2 Sensor Circuit High Input 111333-4 HST Circuit Pressure 2 Sensor Circuit Low Input 111206-3 Pressure Sensor (Fan Circuit Pressure) Circuit High Input 111206-4 Pressure Sensor (Fan Circuit Pressure) Circuit Low Input 111311-3 Service Brake Primary Pressure Sensor Circuit High Input 111311-4 Service Brake Primary Pressure Sensor Circuit Low Input 111208-3 Emergency Steering Pump Delivery Pressure Sensor Circuit High Input 111208-4 Emergency Steering Pump Delivery Pressure Sensor Circuit Low Input 111217-3 Primary Pilot Pressure Sensor Circuit High Input Applicable (Harness / Sensor) 111217-4 Primary Pilot Pressure Sensor Circuit Low Input 111313-3 Parking Brake Pressure Sensor Circuit High Input 111313-4 Parking Brake Pressure Sensor Circuit Low Input

T5-6-102

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Air Bleeding Procedures for Brake (Axle) IMPORTANT: If air is mixed in the brake system, the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. In addition, bleed air from the brake system until hydraulic oil (about 0.5 L (0.5 quart)) is drawn from each wheel (4 places) after bubbling stops.

1 1

NOTE: Perform this work on all wheels (4 places) by two

T4GB-05-04-004

or more persons. Air bleed plug (1) is located around the center on front and rear axles. 1. Set the parking brake switch of front console to the ON position, start the engine, and increases service brake oil pressure.

2. Attach clear vinyl tube (2) onto one end of air bleed plug (1). Insert other of clear vinyl tube (2) into clear container (3) filled with hydraulic oil.

2 1

3. Depress brake pedal (4) several times. Then, depress and hold brake pedal (4) to the stroke end. 3

4. Loosen air bleed plug (1) under condition in step 3 and drain hydraulic oil and air for several seconds. 5. Tighten air bleed plug (1). 6. Drain hydraulic oil after bubbling stops in step 3 to step 5 repeatedly.

T4GB-05-04-005

NOTE: When bubbling does not stop after hydraulic oil

(about 0.5 L (0.5 quart)) is drawn, repeat until bubbling stops in step 3 to step 5. 7. Bleed air at other 3 places in the same way as step 3 to step 5.

IMPORTANT: After air bleeding work is completed at 4 places, bleed air at 4 places again. Bleed air in the same way as step 3 to step 5 twice and check that no air remains inside.

T5-6-103

T4GB-05-04-006

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-104

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. x Observe the rules and regulations associated to this wheel loader, and travel carefully. x Recommended tire pressures and traveling speeds may vary depending on the type of tires used and the road conditions. Consult your nearest Kawasaki dealer. x Check the tire pressure before self-traveling when the tires are cool. x 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. x Keep the bucket empty when traveling. x Do not drive the machine with the tires containing calcium chloride or dry ballast, which accelerate heating.

T5-6-105

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Precautions for Towing Never attempt to tow the machine if CAUTION: 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. y If the engine is operable: Keep the engine running so that the steering and brake system are operable. Release the parking brake. y If the engine is inoperable: - Removal of the propeller shaft x When the parking brake cannot be released, manually release the parking brake. (Refer to the "Releasing Parking Brake" on T5-6-106.) Then, Remove the front and rear propeller shafts. At this time, wedge wheel stoppers to all tires to prevent the machine from moving. x 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.

Steering cylinder

Hose

- Hydraulic Circuit Bypass The machine can be towed by bypassing the hydraulic circuit without removing the propeller shaft when towing for short distance at vehicle speed less than 3 km/h (1.86 mph).

NOTE: Take care not to spill oil when disconnecting the hoses.

M4GB-06-007

T5-6-106

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Hydraulic Circuit Bypass The machine can be towed by loosening shuttle valve (1) of the HST pump in an emergency. When towing the machine at CAUTION: high speed, components may be damaged by

insufficient lubrication due to heat generated from the components. Use this towing method only in an emergency when towing for short distance at vehicle speed less than 3 km/h (1.86 mph).

NOTE: Before towing the machine in an emergency, be sure to forcibly release the parking brake. Refer to T5-6106.

IMPORTANT: Set the machine in position for inspection and maintenance before starting work. 1. Turn the key OFF and stop the engine. 2. Loosen shuttle valve (1) until it contacts to stopper (2). 3. The bypass function will be enabled. 4. After finishing the machine towing, tighten shuttle valve (1) to the original position. : 8 mm (0.31 in) : 50 N·m (49 kgf·m, 37 lbf·ft)

TNDF-03-01-013

T5-6-107

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Releasing Parking Brake

CAUTION:

y Once the parking brake is released, the machine becomes impossible to stop with the brake system, possibly resulting in personal injury or death. y Before releasing the parking brake or connecting the brake system, be sure to lock tires with wheel stoppers.

CAUTION:

y As soon as towing operation is complete, connect the parking brake. y Use towing only when moving the machine to a place where the machine is inspected and/ or serviced. Avoid towing to move the machine over a long distance.

Releasing the parking brake is made manually only when the parking brake switch becomes inoperable due to any abnormality or failure in the brake system such as a pump.

T5-6-108

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parking Brake Manual Release Procedures

CAUTION: 2

y Once the parking brake is released, the machine becomes impossible to stop with the brake system.

y Wedge wheel stoppers to all tires to prevent the machine from moving.

1. Remove plug (1) from brake cap (8). 6, 7

2. Remove nut (3) while preventing oil from spilling out by using waste cloth.

M4FC-06-001

3. Loosen nut (2). 1 8

4. Remove connector (4). Install connector (4) to the hole of plug (1). Install tube (5) to connector (4) and secure them with nuts (2, 3).

5. Remove orifice (9) from brake cap (8). 6, 7

6. Remove release bolt (6) and flat washer (7).

M4FC-06-002

7. Insert release bolt (6) and flat washer (7) into the hole of orifice (9). Tighten release bolt (6). 8. When release bolt (6) touches brake cap (8), further tighten release bolt (6) for 2 turns (apporx. 2~3 mm (0.08~0.12 in). The parking brake will be released. 9

: 17, 22, 27 mm (0.67, 0.87, 1.06 in) : 8 mm (0.31 in)

M4FC-06-003

6, 7

M4FC-06-004

T5-6-109

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-110

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Troubleshooting C (Monitor Diagnosis) Procedure This procedure is used when there are malfunctions on components regarding column display, such as gauges or indicators. 1 2

 Diagnosis Procedure  The diagnosis procedures for components regarding column display, 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: Harness end connector viewed from the open end side by the all connectors image shown in this section.

T6L4-05-03-001 1-

Harness End Connector

Harness

Column Monitor (Gauges and Indicators) 40

7 8

9 10

37 12 36 35

14 15

33 16

32 31 30

12345-

29 28 27 26

25 24 23 22 21 20 19 18 17

T5-7-1

MNDB-01-034

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)

 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

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 exhaust filter indicator. 4 Check the brake oil low pressure indicator. 5 Check the hydraulic oil level indicator. 6 Check the steering oil pressure indicator. 7 -

Condition Engine: Running

Evaluation Indicator: ON

Engine: Running Engine: Running

Indicator: ON Indicator: ON

Engine: Running

Indicator: ON

Cause Faulty engine lubrication oil pressure system Engine overheating Excessively clogged exhaust filter Faulty brake hydraulic circuit

Engine: Running

Indicator: ON

Insufficient hydraulic oil

Engine: Running

Indicator: ON

Normal in above check

Faulty steering hydraulic circuit Faulty column display controller

The buzzer does not sound even when the engine oil pressure indicator, overheat indicator, exhaust filter indicator, brake oil low pressure indicator, hydraulic oil level indicator, or steering oil pressure 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 column display controller harness end #28 and the body. -

Evaluation Less than 900min-1 Indicator: OFF

Normal in above check

Connector (Harness end)  Column Display Controller 2-B Connector

TNDB-05-05-013

T5-7-3

Cause Normal Perform the troubleshooting for the lighting indicator. Faulty alternator Faulty column display controller Open circuit in harness between alternator and column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Coolant Temperature Gauge  The coolant temperature is sent from ECM to the column display 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 terminal to the body. 2 Check continuity between ECM harness end terminal #25 and the body.

Condition Key Switch: ON

Evaluation The gauge pointer reaches the (H) side.

Cause Faulty coolant temperature sensor

Connect ∞Ω Open circuit in harness between ECM and the coolant temperature coolant temperature sensor harness end sensor terminal to the body. Normal in above check Faulty column display controller

The coolant temperature gauge pointer swings over scale. Procedure Inspection Method 1 Disconnect the coolant temperature sensor terminal. 2 Check continuity between ECM harness end terminal #25 and the body.

Condition Key Switch: ON

Evaluation The gauge pointer returns to zero. 0Ω

Cause Faulty coolant temperature sensor Shorted circuit in harness between ECM and coolant temperature sensor

Key Switch: ON Disconnect the coolant temperature sensor terminal. Normal in above check Faulty column display 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

Connector (Harness end)  ECM-1 Connector

TDAB-05-06-020

T5-7-4

Cause Faulty coolant temperature sensor

Faulty column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Fuel Gauge  Perform these steps when the fault codes of column display 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 harness between Key Switch: ON fuel level sensor harness end #1 and #2. 2 Check continuity between Connect fuel level column display controller harness sensor harness end end #35 and the body. terminal #1 to the 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 harness between column display controller and fuel level sensor Normal in above check Faulty column display controller

The fuel gauge pointer swings over scale. Procedure Inspection Method 1 Disconnect the fuel level sensor connector. 2 Check continuity between column display controller harness end #35 and the body. 3

Condition Key Switch: ON Key Switch: ON Disconnect the fuel level sensor connector. -

Shorted circuit in harness between column display controller and fuel level sensor Normal in above check Faulty column display controller

The fuel gauge pointer keeps moving unstably. Procedure Inspection Method 1 Visually inspect the fuel gauge.

Condition Short-circuit in harness between fuel level sensor harness end #1 and #2. -

Connector (Harness end)  Column Display 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 column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of HST Oil Temperature Gauge  The HST oil temperature is sent from MC to the column display controller by using CAN communication.  Perform these steps when the fault codes of MC and CAN are not displayed.  Check the wiring connections first. The HST oil temperature gauge pointer does not move at all. Procedure Inspection Method 1 Connect the HST oil temperature sensor harness end terminal to the body. 2 Check continuity between MC harness end terminal E16 and the body.

Condition Key Switch: ON

Evaluation The gauge pointer reaches the (H) side.

Cause Faulty HST oil temperature sensor

Connect the HST ∞Ω Open circuit in harness oil temperature between MC and HST oil sensor harness end temperature sensor terminal to the body. Normal in above check Faulty column display 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 MC harness end terminal E16 and the body. 3

Condition Key Switch: ON

Evaluation The gauge pointer returns to zero. 0Ω

Cause Faulty HST oil temperature sensor Shorted circuit in harness between MC and HST oil temperature sensor

Evaluation The gauge pointer reaches the (H) side and is stabilized.

Cause Faulty HST oil temperature sensor

Key Switch: ON Disconnect the HST oil temperature sensor terminal. Normal in above check Faulty column display controller

The HST oil temperature gauge pointer keeps moving unstably. Procedure Inspection Method 1 Visually inspect the HST oil temperature gauge.

Condition Connect the HST oil temperature sensor harness end terminal to the body. Key Switch: ON -

Connector (Harness end)  MC-E Connector

TNDB-05-05-006

T5-7-6

Normal in above check Faulty column display controller

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 column display controller by using CAN communication and is proceeded in the logic circuit of column display 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

Cause If the data of monitoring function can be displayed on MPDr., CAN communication between column display controller and other controllers is faulty. If the data cannot be displayed on MPDr., the sensor system detecting the related signal is faulty. (Some trouble must occur with the machine. Refer to Troubleshooting A and take the remedy.)

Traction Control Indicator ECO Indicator Ride Control Indicator (OPT)

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 column Hour Meter display controller and other controllers is faulty. Odometer If the data cannot be displayed on MPDr., the sensor PM Accumulating Amount system detecting the related signal is faulty. Engine Speed Displayed only when (Some trouble must occur with the machine. Refer starting on service mode to Troubleshooting A and take the remedy.) Engine Coolant Displayed only when 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 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 2 Hour Meter (Pilot 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 Exhaust Filter 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 B) 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 column Key Switch: ON ∞ Ω display controller harness end #2 and the body. 2 Normal in above check

Connector (Harness end)  Column Display Controller 1-A Connector

TNDF-05-05-005

T5-7-10

Cause Open circuit in harness between column display controller and key switch Faulty column display 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.

2 3

Inspection Method Shift the hazard light switch.

Condition Evaluation Hazard Light Switch: Turn Signal Light: ON Lighting, Blinking Turn Signal Light Indicator: Lighting, Blinking Replace right turn signal light relay Hazard Light Switch: The symptom is with left turn signal light relay. ON switched. Normal in above check

Cause Faulty turn signal lever

Faulty turn signal light relay Open circuit in 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 Replace 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 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 harness between turn signal light relay and column display controller may be faulty or the column display controller may be faulty.  If the turn signal light indicator at one side is not lighting or blinking, refer to troubleshooting that the 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 #2 (fuse box B) and the light switch. Even when the dimmer switch is set to the High beam position, the high beam indicator does not light.

Inspection Method Condition Measure voltage at column display Light Switch: H controller terminal #13. Dimmer Switch: Hi

Evaluation 0V

Cause Open circuit in harness between high beam relay and column display controller Normal in above check Faulty column display controller

Even when the dimmer switch is not in the High beam position, the high beam indicator lights.

1 2

Inspection Method Measure voltage at column display controller terminal #13. -

Condition Light Switch: H Dimmer Switch: Hi -

Connector (Harness end)  Column Display Controller 2-A Connector

TNDF-05-05-005

T5-7-13

Evaluation 0V

Cause Faulty column display controller Normal in above check Shorted circuit in harness between high beam relay and column display 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 #4 (fuse box A) 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

Inspection Method Condition Measure voltage at column display Work Light Switch: controller terminal #12. Front work light position

Evaluation 0V

Cause Open circuit in harness between work light (front) relay and column display controller Normal in above check Faulty column display controller

Work Light: OFF

Inspection Method Measure voltage between work light (front) relay harness end connector terminal #3 and the body. Replace work light (front) relay with work light (rear) relay.

Condition Key Switch: ON

Evaluation 0V

Cause Open circuit in harness between work light (front) relay and battery relay

Work Light Switch: Front work light position Work Light Switch: Front work light position Work Light Switch: Front work light position

Indicator: ON

Faulty work light (front) relay

∞Ω

Faulty work light switch

Check continuity between terminals #1 and #2 of work light switch end connector. Measure voltage between work light (front) relay harness end connector terminal #1 and the body. Measure voltage at column display Work Light Switch: controller terminal #12. Front work light position -

T5-7-14

Open circuit in harness between work light (front) relay and work light switch 0V Open circuit in harness between work light (front) relay and column display controller Normal in above check Faulty column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Even when the work light switch is in the OFF position, the work light indicator lights.

2 3 4

Inspection Method Check the work light.

Condition Work Light Switch: OFF

Evaluation Work Light: OFF

Replace work light (front) relay with work light (rear) relay. Disconnect connectors of work light switch. -

Work Light Switch: OFF -

Indicator: OFF

Cause Shorted circuit in harness between work light (front) relay and column display controller Faulty work light (front) relay Faulty work light switch

Normal in above check Shorted circuit in harness between work light (front) relay and work light switch

Connector (Harness end)  Column Display Controller 2-A Connector

 Work Light Switch

 Work Light Relay

TNDF-05-05-005 T4FJ-05-07-002 T183-05-04-003

T5-7-15

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 column display 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 column display controller may be faulty.

T5-7-16

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Preheat Indicator  The glow plug is controlled by ECM. (Refer to SYSTEM / ECM System.)  Check the wiring connections first. The preheat indicator lights even when the glow plug is not operated.

1 2

Inspection Method Disconnect ECM-2 connector from ECM. Check continuity between ECM-2 connector harness end connector terminal #145 and the body. -

Condition Key Switch: ON

Evaluation Cause Preheat Indicator: OFF Faulty ECM

Key Switch: ON

0Ω

Shorted circuit in harness between ECM and column display controller Normal in above check Faulty column display controller

The preheat indicator does not light even when the glow plug is operated.

Inspection Method Disconnect ECM-2 connector from ECM. Connect ECM-2 connector harness end connector terminal #145 to the body. Connect column display 1-B connector terminal #21 to the body. -

Condition Key Switch: ON

Evaluation Preheat Indicator: ON

Key Switch: ON

Preheat Indicator: ON

Cause Faulty ECM

Open circuit in harness between ECM and column display controller Normal in above check Faulty column display controller

Connector (Harness end)  Column Display Controller 1-B Connector

 ECM-2 Connector

TNDF-05-05-006 TDAB-05-06-021

T5-7-17

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of HST Oil Temperature Indicator  The HST oil temperature is sent from MC to the column display controller by using CAN communication.  Perform these steps when the fault codes of MC and CAN are not displayed.  Check the wiring connections first. The indicator does not light even when the engine overheats.

Inspection Method Condition Connect the HST oil temperature Key Switch: ON sensor harness end terminal to the body. Connect MC terminal E16 to the Key Switch: ON body. -

Evaluation Indicator: ON

Cause Faulty HST oil temperature sensor

Indicator: ON

Open circuit in harness between MC and HST oil temperature sensor Normal in above check Faulty column display controller

The indicator lights even when HST oil temperature is low.

Inspection Method Disconnect the terminal of HST oil temperature sensor. Disconnect MC-E connector.

Condition Key Switch: ON Engine: Stopped Key Switch: ON

Connector (Harness end)  MC-E Connector

TNDB-05-05-006

T5-7-18

Evaluation Indicator: OFF

Cause Faulty HST oil temperature sensor Indicator: OFF Shorted circuit in harness between MC and HST oil temperature sensor Normal in above check Faulty column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of HST Warning Indicator  Check the wiring connections first. Even when the HST controller circuit is abnormal, the indicator does not light.

Inspection Method Measure voltage at terminal #13 of column display controller 1-A connector.

Condition Key Switch: ON

Evaluation 0V

Cause Open circuit in harness between HST controller and column display controller Normal in above check Faulty column display controller

Even when the HST controller circuit is not abnormal, the indicator lights.

Inspection Method Condition Check continuity between harness Key Switch: ON end terminal #13 of column display controller 1-A connector and the body. -

Connector (Harness end)  Column Display Controller 1-A Connector

TNDF-05-05-005

T5-7-19

Evaluation 0Ω

Cause Shorted circuit in harness between HST controller and column display controller Normal in above check Faulty column display 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 Condition 1 Connect terminal #7 of column Key Switch: ON display controller 1-A connector to the body. 2 -

Evaluation Indicator: ON

Cause Open circuit in harness between ECM and column display controller Normal in above check Faulty column display controller

Even when the engine runs, the indicator is not turned off. Procedure Inspection Method 1 Disconnect ECM-2 connector. 2

Disconnect column display controller 1-A connector.

Condition Evaluation Cause Key Switch: ON Indicator: OFF Faulty ECM Engine: Stopped Key Switch: ON Indicator: OFF Shorted circuit in harness Connect only to between ECM and column terminal #2. display controller Normal in above check Faulty column display controller

Connector (Harness end)  Column Display Controller 1-A Connector

TNDF-05-05-005

T5-7-20

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Overheat Indicator  Check the wiring connections first. Even when the engine overheats, the indicator does not light. Procedure Inspection Method Condition 1 Connect the overheat switch Key Switch: ON harness end connector to the body. 2 After connecting the overheat Key Switch: ON switch harness end connector to the body, check continuity between monitor controller harness end terminal #17 and the body. 3 -

Evaluation Indicator: ON

Cause Faulty overheat switch

∞Ω

Open circuit in harness between monitor controller and overheat switch

Normal in above check Faulty column display controller

Even when coolant temperature is low, the indicator lights. Procedure Inspection Method 1 Disconnect the overheat switch connector. 2 Disconnect the monitor controller connector.

Condition Key Switch: ON

Evaluation Indicator: OFF

Key Switch: ON Indicator: OFF Connect only to terminal #2.

Cause Faulty overheat switch

Shorted circuit in harness between monitor controller and overheat switch Normal in above check Faulty column display controller

Connector (Harness end)  Column Display Controller 1-A Connector

TNDF-05-05-005

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 ECM-2 connector harness end connector terminal #130 to the body. 2 Connect column display 1-B connector terminal #22 to the body. 3 -

Condition Key Switch: ON

Evaluation Indicator: ON

Key Switch: ON

Indicator: ON

Cause Faulty ECM

Open circuit in harness between ECM and column display controller Normal in above check Faulty column display controller

Even when the engine is not abnormal, the indicator lights. Procedure Inspection Method 1 Disconnect the ECM-2 connector. 2 Disconnect column display controller 1-B connector. 3

Condition Key Switch: ON Key Switch: ON Connect only to terminal #2. -

Connector (Harness end)  ECM-2 Connector

TDAB-05-06-021

 Column Display Controller 1-B Connector

TNDF-05-05-006

T5-7-22

Evaluation Indicator: OFF Indicator: OFF

Cause Faulty ECM Shorted circuit in harness between ECM and column display controller Normal in above check Faulty column display controller

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 column display controller may be faulty. Items when the service indicator lights  Faulty power generation of the alternator  Lighting the air filter restriction indicator  Lighting the engine warning indicator  Lighting the HST warning indicator  High temperature of HST oil (Within a short time)  Lighting the fuel filter restriction indicator  Lighting the water separator indicator (option) (Only machine with the optional parts equipped)  Secondary steering operation (option) (Only machine with the optional parts equipped)  Lighting the exhaust filter indicator

T5-7-23

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Parking Brake Indicator  Perform these steps when the fault codes of column display controller are 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 column display controller 2-B connector and the body. -

Evaluation Indicator: OFF

Cause Faulty parking brake pressure sensor 0Ω Shorted circuit in harness between parking brake pressure sensor and column display controller Normal in above check Faulty column display controller

Even when the parking brake switch is in the ON position, the indicator does not light.

Inspection Method Condition Check continuity between terminal Key Switch: ON #25 of column display controller Parking Brake 2-B connector and the body. Switch: ON

Connector (Harness end)  Column Display Controller 2-B Connector

TNDB-05-05-013

T5-7-24

Evaluation ∞Ω

Cause Open circuit in harness between parking brake pressure sensor and column display controller Normal in above check Faulty column display 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 harness between light switch and clearance light or column display controller may be shorted.  Check the wiring connections first. The indicator does not light.

1 2

Inspection Method Check if the clearance light lights. Measure voltage at terminal #25 of column display controller 1-B connector. -

Condition Light Switch: S or H position Key Switch: ON

Connector (Harness end)  Column Display Controller 1-B Connector

TNDF-05-05-006

T5-7-25

Evaluation Light is ON. 0V

Cause Faulty light switch

Open circuit in harness between light switch and column display controller Normal in above check Faulty column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Secondary Steering Indicator (OPT)  Check that fuse #20 (fuse box B) is normal.  Refer to Troubleshooting B as for the secondary steering troubleshooting.  When there is no trouble, the column display controller may be faulty.

T5-7-26

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Low Steering Oil Pressure Indicator (OPT)  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 column display controller may be faulty.

T5-7-27

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Alternator Indicator  Perform these steps when the fault codes of column display controller are not displayed.  Check the wiring connections first. Even when the engine runs, the alternator indicator is not turned off. Procedure Inspection Method 1 Measure voltage at alternator terminal L. 2 Measure voltage between terminal #28 of column display controller 2-B connector and the body. 3 -

Condition Evaluation Cause Engine: Running Less than 13 V or 33.5 V Faulty alternator or more Engine: Running Less than 13 V Faulty harness between alternator and column display controller Normal in above check Faulty column display controller

Even when charging is low, the alternator indicator does not light. Procedure Inspection Method 1 Check if the engine has started. 2 3

Condition Key Switch: ST

Evaluation Cause The engine does not To Troubleshooting B start. Measure voltage at alternator Engine: Running Less than 13 V or 33.5 V Faulty alternator terminal L. or more Measure voltage between terminal Engine: Running From 13 V to less than Faulty harness between #28 of column display controller 33.5 V alternator and column 2-B connector and the body. display controller Normal in above check Faulty column display controller

Connector (Harness end)  Column Display Controller 2-B Connector

TNDB-05-05-013

T5-7-28

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Air Filter Restriction Indicator  Check the wiring connections first. Even when the air filter is clogged, the indicator does not light. Procedure Inspection Method 1 Connect the air filter restriction switch harness end connector to the body. 2 After connecting the air filter restriction switch harness end connector to the body, check continuity between terminal #18 of column display controller 1-A connector and the body. 3 -

Condition Key Switch: ON

Evaluation Indicator: ON

Cause Faulty air filter restriction switch

Key Switch: ON

∞Ω

Open circuit in harness between column display controller and air filter restriction switch

Normal in above check Faulty column display controller

Even when the air filter is not clogged, the indicator lights. Procedure Inspection Method 1 Disconnect the air filter restriction switch connector. 2 Disconnect column display controller 1-A connector.

Condition Key Switch: ON

Key Switch: ON Connect only to terminal #2.

Connector (Harness end)  Column Display Controller 1-A Connector

TNDF-05-05-005

T5-7-29

Evaluation Indicator: OFF

Cause Faulty air filter restriction switch Indicator: OFF Shorted circuit in harness between column display controller and air filter restriction switch Normal in above check Faulty column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Fuel Filter Restriction Indicator  Perform these steps when the fault codes of ECM are not displayed.  Check the wiring connections first. Even when the fuel filter is clogged, the indicator does not light.

Inspection Method Condition Connect terminal #15 of column Key Switch: ON display controller 1-A connector to the body. -

Evaluation Indicator: ON

Cause Open circuit in harness between ECM and column display controller Normal in above check Faulty column display controller

Even when the fuel filter is not clogged, the indicator lights.

Inspection Method Disconnect ECM-2 connector.

Condition Key Switch: ON

Connector (Harness end)  Column Display Controller 1-A Connector

TNDF-05-05-005

T5-7-30

Evaluation Indicator: OFF

Cause Shorted circuit in harness between ECM and column display controller Normal in above check Faulty column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Low Brake Oil Pressure Indicator  Perform these steps when the fault codes of MC are not displayed.  Check the wiring connections first. Even when brake pressure is insufficient, the indicator does not light.

Inspection Method Condition Connect terminal #32 of column Key Switch: ON display controller 1-B connector to the body. -

Evaluation Indicator: ON

Cause Open circuit in harness between MC and column display controller Normal in above check Faulty column display controller

Even when brake pressure is not abnormal, the indicator lights.

Inspection Method Disconnect column display controller 1-B connector.

Condition Key Switch: ON

Connector (Harness end)  Column Display Controller 1-B Connector

TNDF-05-05-006

T5-7-31

Evaluation Indicator: OFF

Cause Shorted circuit in harness between MC and column display controller Normal in above check Faulty column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Hydraulic Oil Level Indicator  Check the wiring connections first. Even when hydraulic oil is low, the indicator does not light.

Inspection Method Connect harness end connector terminal #1 of hydraulic oil level switch to the body. After connecting terminal #1 of the hydraulic oil level switch harness end connector to the body, check continuity between terminal #17 of column display controller 1-A connector and the body. -

Condition Key Switch: ON

Evaluation Indicator: ON

Cause Faulty hydraulic oil level switch

Key Switch: ON

∞Ω

Open circuit in harness between column display controller and hydraulic oil level switch

Normal in above check Faulty column display controller

Even when hydraulic oil is enough, the indicator lights.

1 2

Inspection Method Disconnect the hydraulic oil level switch connector. Disconnect column display controller 1-A connector.

Condition Key Switch: ON

Key Switch: ON Connect only to terminal #2.

Connector (Harness end)  Column Display Controller 1-A Connector

TNDF-05-05-005

 Hydraulic Oil Level Switch

TCJB-05-06-004

T5-7-32

Evaluation Indicator: OFF

Cause Faulty hydraulic oil level switch Indicator: OFF Shorted circuit in harness between column display controller and hydraulic oil level switch Normal in above check Faulty column display controller

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Exhaust Filter Indicator Malfunction of Exhaust Filter Regeneration Inhibit Indicator Malfunction of Water Separator Indicator (OPT) Malfunction of Exhaust Filter Regeneration Inhibit Indicator Malfunction of Control Lever Lock Indicator Malfunction of Power Mode Indicator Malfunction of Fan Reverse Rotation Indicator (OPT) 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 column display 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 column display controller may be faulty.

T5-7-33

SECTION 5 TROUBLESHOOTING Group 7 Troubleshooting C Malfunction of Seat Belt Indicator The indicator does not light.

Inspection Method Measure voltage between terminal #28 of column display controller 2-B connector and the body. -

Condition Key Switch: ON Engine: Stopped -

Evaluation Voltage: 24V

Cause Shorted circuit in harness between column display controller and alternator Normal in above check Faulty column display controller

The indicator does not go out.

Inspection Method Condition Measure voltage between terminal Engine: Running #28 of column display controller 2-B connector and the body. -

Connector (Harness end)  Column Display Controller 2-B Connector

TNDB-05-05-013

T5-7-34

Evaluation Voltage: 0V

Cause Open circuit in harness between column display controller and alternator Normal in above check Faulty column display 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

TDAA-05-07-001

15 12345-

Air Vent Damper Servo Motor Defroster Vent Rear Vent Front Vent Evaporator

6789-

Fresh / Re-circulated Air Damper Servo Motor Re-circulated Air Sensor Fresh Air Induction Port Re-circulated Air Filter

10- Re-circulated Air Induction Port 11- Blower Motor 12- Power Transistor 13- Frost Sensor

T5-8-1

11 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

12 TNDF-05-07-002

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

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner

18 17 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 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

T5-8-4

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.

T5-8-5

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

T5-8-6

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

T5-8-7

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

T5-8-8

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 (coolant) or lowconcentration LLC, the heater core will receive a bad influence and it may lead water leaks and shorten the service life of machine. Replace coolant and manage LLC concentration according to the Operator's Manual.

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

123-

4. When some fault codes exist and whenever pushing Up or Down button of temperature control switch (3), other fault codes are displayed. 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.

T5-8-9

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 provided. temperature sensor. Check the harness. Shorted circuit in Voltage: less than Operation is controlled under outdoor ambient 0.096 V such circumstance as no outdoor Replace the outdoor ambient temperature sensor ambient temperature sensor is temperature provided. sensor. Shorted circuit in solar Voltage: more than Operation is controlled under Check the harness. radiation sensor 5.04 V such circumstance as no solar Replace the solar radiation sensor is provided. radiation sensor. Open circuit in frost Voltage: more than The compressor clutch is Check the harness. sensor 4.79 V disengaged. (The compressor Replace the frost stops.) sensor. Shorted circuit in frost Voltage: less than The compressor clutch is Check the harness. sensor 0.096 V disengaged. (The compressor Replace the frost stops.) sensor. Abnormal air vent Shorted circuit: Air vent damper servo motor Check the harness. damper servo motor Voltage: 0 V becomes inoperable. Replace the air Open circuit: Voltage: vent damper servo more than 5 V motor. Abnormal air mix Shorted circuit: Air mix damper servo motor Check the harness. damper servo motor Voltage: less than 0.2 V servo motor becomes inoperable. Replace the air Open circuit: Voltage: vent damper servo more than 4.8 V motor. Abnormal high/low Voltage: 0 V The compressor clutch is Check the harness. refrigerant pressure disengaged. (The compressor Replace the high/ stops.) low pressure switch. CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1 error between monitor harness. controller and air Replace air conditioner controller conditioner controller. CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1 controller harness. Faulty CAN1 harness Replace air conditioner controller.

T5-8-10

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. -

T5-8-11

Evaluation Cause ∞ Ω (Normal value: Faulty sensor. 300 to 430 kΩ) 0V Open circuit in harness #1.

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

Open circuit in harness #2.

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.

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) Measurement of voltage 0V 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.

T5-8-12

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)

T5-8-13

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

T5-8-14

Filter cleaning Filter cleaning Remove obstacles Replacement of blower To A Evaporator surface cleaning Check battery charging system Repair Replace Replace Replace Replace Replace Repair Replace the controller Make sure to ground Wirings inspection Replace motor Replace blower motor Refer to wiring diagram and check Wirings inspection

SECTION 5 TROUBLESHOOTING Group 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

T5-8-15

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 A/M link

Close window and door Readjust fresh / re-circulated air selection damper Setting link again

T5-8-16

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner (Blank)

T5-8-17

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

T5-8-18

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor

Reinsert (floating distance from evaporator is 3 mm (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

T5-8-19

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

T5-8-20

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 (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

T5-8-22

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner (Blank)

T5-8-23

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

T5-8-24

Filter cleaning Filter cleaning Remove obstacles Replacement of blower To A Evaporator surface cleaning Check battery charging system Repair Replace Replace Replace blower motor Refer to wiring diagram and check Wirings inspection Replace Replace Replace Repair Replace the controller Make sure to ground Wirings inspection Replace motor

Setting link again Air Bleeding Circuit Repair or replace. Charge engine coolant to proper level Replace heater core

SECTION 5 TROUBLESHOOTING Group 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

T5-8-25

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

T5-8-26

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Others  Faulty air vent switch Fault code is not 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 not 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 not 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

T5-8-27

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 armature due to resonance. Loose belt. Loose screws. Noisy compressor. Vibration due to V belt looseness. Loose screws.

Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud. No functional problem exists. Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard. Replace. Repair or replace clutch. Re-tighten screws. Repair or replace. Re-adjust belt. Re-tighten screws.

 Others Water leak. Water splash.

Abnormal smell.

Broken heater core. Broken hose. Clogged case drain port and/or drain hose. Absorbed cigarette and dust smell on evaporator fins.

T5-8-28

Replace. Clean. Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L mode for more than 10 minutes, flush smell out by condensed water.

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner (Blank)

T5-8-29

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. Key Switch: ON 3 Measurement of voltage 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

T5-8-30

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

Faulty compressor clutch. Procedures as steps 1 to 3 above are normal.

Open circuit in harness between compressor relay and compressor clutch.

 Compressor Clutch

Connector (Harness end)  Compressor Relay

TDAB-05-07-019

T5-8-31

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: 0 ~ 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

T5-8-32

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

T5-8-33

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

T5-8-34

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.

 Compressor oil refill container Oil type ND-OIL8

Quantity 40 cm3 (2.4 in3)

fNOTE: Compressor oil quantity: 160 cm (9.8 in ) 3

TDAA-05-07-015

New Compressor

Replacing Compressor

T5-8-35

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

T5-8-36

SECTION 5 TROUBLESHOOTING Group 8 Air Conditioner Procedures for charging air conditioner with refrigerant 1

IMPORTANT: Do not mistake the charge hose connections. 1. Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Connect high-pressure side charge hose (3) and low-pressure side charge hose (6) on manifold gauge (1) to the high-pressure side charge valve (“D” marked) and to the 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

T5-8-37

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.

4. With high pressure valve (2) and low pressure valve (7) on manifold gauge (1) closed, connect charge hose (5) to refrigerant container (8).

W115-02-10-005

 Refrigerant Specification R134a

Volume (g) 200 250 300

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

5 9

W115-02-10-007

T5-8-38

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

T5-8-39

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: 900 ± 50 g (1.98 ± 0.1 lb)

10. If refrigerant container (8) becomes empty during the charging work, replace refrigerant container (8) with a new refrigerant container as follows:  Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1).  Replace the empty container with new refrigerant container (8).  Tighten, then slightly loosen refrigerant container (8) joint.  Slightly open low pressure valve (7) on manifold gauge (1).  When refrigerant container (8) joint starts to leak, immediately tighten refrigerant container (8) joint and close low-pressure valve (7) on manifold gauge (1). 11. After charging, close low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8), and stop the engine.

T5-8-40

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.

T5-8-41

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. Refrigerant will produce poisonous dCAUTION: material if exposed to heat of 1000 °C (1832°F) or more. Never bring refrigerant close to a fire. 1. Check the air conditioner for gas leaks using a leak tester.  Perform checking under well-ventilated conditions.  Thoroughly wipe off dust from the charge hose connections of the compressor.  Pay special attention to check the line connections.  If any gas leaks are found, retighten the line connections. 2. Performance Check. Carry out performance check of the air conditioner after checking each air conditioner component.

W115-02-10-013

 Check each component for abnormalities.  Carry out ON-OFF check of the compressor clutch.  Check compressor fan belt tension.  Check the coolant level in the radiator.  Operate the air conditioner and check the performance.

W115-02-10-014

T5-8-42

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.

fNOTE: When the machine is in normal and the air

conditioner is operated with the following conditions, air vent temperature decrease approx. 20°C (68°F) or less. (it may be different under special environment.)

Operating Conditions of the Air Conditioner  Engine Speed: Fast Idle  Cab Window: Fully closed  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh / re-circulated air selection: Re-circulated Air  Season: Summer

T5-8-43

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

T5-8-44

INDEX 111000 to 111002...................................................................T5-5-57 111003........................................................................................T5-5-58 111006, 111007 .......................................................................T5-5-61 111008........................................................................................T5-5-69 111014........................................................................................T5-5-69 111025........................................................................................T5-5-69 111027, 111028 .......................................................................T5-5-86 111030........................................................................................T5-5-61 111103........................................................................................T5-5-73 111205........................................................................................T5-5-74 111206........................................................................................T5-5-76 111207........................................................................................T5-5-74 111208........................................................................................T5-5-77 111217........................................................................................T5-5-75 111311........................................................................................T5-5-78 111330, 111331 .......................................................................T5-5-89 111332........................................................................................T5-5-88 111333........................................................................................T5-5-89 111334........................................................................................T5-5-90 111406........................................................................................T5-5-79 111411........................................................................................T5-5-80 111412........................................................................................T5-5-81 111422........................................................................................T5-5-82 111430, 111431, 111432 ......................................................T5-5-91 111433........................................................................................T5-5-92 111450, 111451 .......................................................................T5-5-94 111457........................................................................................T5-5-93 111620, 111621 .......................................................................T5-5-95 111622........................................................................................T5-5-96 111904........................................................................................T5-5-97 111905........................................................................................T5-5-98 111908........................................................................................T5-5-83 111909........................................................................................T5-5-84 115001........................................................................................T5-5-99 115011..................................................................................... T5-5-100 115015..................................................................................... T5-5-101 120003, 120004 .......................................................................T5-5-85 120014........................................................................................T5-5-85 120500 to 120505................................................................ T5-5-102 120506, 120507 .................................................................... T5-5-103 120510 to 120513................................................................ T5-5-103 120515..................................................................................... T5-5-103 120517, 120518 .................................................................... T5-5-103 24-Volt Circuit ..........................................................................T5-1-18 4-Gear Pump Unit...................................................................T5-4-16 5-Volt Circuit.............................................................................T5-1-24 A Accumulator Gas Pressure ..................................................T4-5-34 Adjustment ................................................................................. T4-6-1 Air Bleeding Procedures for Brake (Axle) .................... T5-6-103 Air Conditioner Controller Fault Code List ... T5-5-28,T5-8-10 Air Conditioner Controller Fault Codes E11 to E22 ........................................................ T5-5-104, T5-8-11 E43 to E92 ........................................................ T5-5-105, T5-8-12 Air Conditioner, Component Layout ................................. T5-8-2

Air Conditioner, Outline ......................................................... T5-8-1 Air Filter Restriction Indicator, Malfunction ..................T5-7-29 All Actuator System Troubleshooting ............T5-6-30, T5-6-57 Alternator Check .....................................................................T5-1-15 Alternator Indicator, Malfunction .....................................T5-7-28 B Battery Voltage Check ..........................................................T5-1-14 Bell Crank Stopper Clearance............................................... T4-4-8 Brake Charge Valve ................................................................T5-4-18 Brake Circuit Pressure ............................................................. T4-5-1 Brake Pedal Angle Learning................................................T4-6-10 Brake System Troubleshooting.........................T5-6-44, T5-6-83 Brake Warning Pressure (Pressure-Decreasing) ...........T4-5-28 Brake Warning Pressure (Pressure-Increasing).............T4-5-30 Brake Wear Amount, Service ................................................ T4-4-6 Bucket Levelness ....................................................................T4-4-13 Bucket Stopper Clearance ..................................................... T4-4-8 C CAN1 Harness Check .............................................................T5-5-62 CAN2 Harness Check ............................................................T5-5-70 CAN3 (Engine) Harness Check ...........................................T5-5-66 Charge Air Conditioner with Refrigerant .......................T5-8-36 Check by False Signal ............................................................T5-1-25 Clearance Light Indicator, Malfunction ..........................T5-7-25 Clutch Learning ......................................................................... T4-6-6 Column Display Controller (Information) Fault Codes 120500 to 120505 .......................................................... T5-5-102 Column Display Controller Fault Codes 115001 ..................................................................................T5-5-99 115011 ............................................................................... T5-5-100 115015 ............................................................................... T5-5-101 120506, 120507 .............................................................. T5-5-103 120515 ............................................................................... T5-5-103 120510 to 120513 .......................................................... T5-5-103 120517, 120518 .............................................................. T5-5-103 Column Display Controller Fault Code List ...................T5-5-26 Column Monitor (Gauges and Indicators) ....................... T5-7-1 Combined Delivery Pressure of Main Pump and Steering Pump ..................................................................... T4-5-5 Communication System......................................................... T5-3-7 Communication Terminal Fault Code List .....................T5-5-30 Compressor Oil, Refill ............................................................T5-8-35 Continuity Check ....................................................................T5-1-16 Control Lever Lock Indicator, Malfunction ....................T5-7-33 Control Lever Operating Force ..........................................T4-4-14 Control Lever Stroke ..............................................................T4-4-16 Control Valve ............................................................................T5-4-17 Coolant Temperature .............................................................. T5-2-4 Coolant Temperature Gauge ................................................ T5-2-7 Coolant Temperature Gauge, Malfunction ..................... T5-7-4 Cooling, Faulty .........................................................................T5-8-14 Correlation between Trouble Symptoms and Part Failures .........................................................................T5-6-27 Current Measurement ..........................................................T5-1-18 Cylinder Drift Check ..............................................................T4-4-12 62Z7/67Z7/67TM7 Trbl

INDEX D Daily Report Data ..................................................................... T5-3-2 Diagnosing Procedure, Introduction................................. T5-1-1 Diagnosis Procedure ............................................................... T5-1-2 E e-Service, Outline ..................................................................... T5-3-1 ECM Fault Code List ...............................................................T5-5-32 Electric System Inspection .................................................... T5-1-5 Electrical System (Cab) ........................................................... T5-4-7 Electrical System (Overview) ................................................ T5-4-6 Engine.........................................................................................T5-4-13 Engine Oil Pressure Indicator, Malfunction ...................T5-7-20 Engine Speed ...............................................................T4-3-1, T5-2-4 Engine System Troubleshooting ......................T5-6-28, T5-6-51 Engine Test .................................................................................. T4-3-1 Engine Warning Indicator, Malfunction .........................T5-7-22 Exchange Inspection .......................................................... T5-6-101 Exhaust Filter............................................................................T5-4-15 Exhaust Filter, Maintenance.................................................. T4-6-5 Exhaust Filter Indicator, Malfunction ..............................T5-7-33 Exhaust Filter Regeneration Inhibit Indicator, Malfunction.........................................................................T5-7-33 Exhaust Filter Serial No. Rewrite.......................................... T4-6-4 F False Signal ...............................................................................T5-1-25 Fan Reverse Rotation Indicator (OPT), Malfunction...T5-7-33 Fan Valve ....................................................................................T5-4-19 Fan Valve (with Fan Reverse Rotation) (Option) ..........T5-4-19 Fault Code ................................................................................... T5-2-5 Fault Code List Air Conditioner Controller ............................T5-5-28, T5-8-10 Column Display Controller ............................................T5-5-26 Communication Terminal ..............................................T5-5-30 ECM ........................................................................................T5-5-32 HST Controller ....................................................................T5-5-19 Information Controller ....................................................T5-5-25 MC ............................................................................................ T5-5-9 MPDr. ....................................................................................... T5-5-3 Fault Code Reference Table, MPDr...................................... T5-5-3 Faulty Cooling..........................................................................T5-8-14 Faulty Heating .........................................................................T5-8-24 Frequency Distribution Data ................................................ T5-3-4 Front Attachment System Troubleshooting ...............................................T5-6-34, T5-6-63 Front Console............................................................................. T5-4-8 Fuel Consumption.................................................................... T5-2-5 Fuel Filter Restriction Indicator, Malfunction ...............T5-7-30 Fuel Gauge .................................................................................. T5-2-8 Fuel Gauge, Malfunction ....................................................... T5-7-5 Functions of Main Parts, Air Conditioner ......................... T5-8-4 Fuse Box A .................................................................................T5-1-11 Fuse Box B .................................................................................T5-1-12 Fuse Inspection .......................................................................T5-1-10 Fusible Link Inspection.........................................................T5-1-13

G Gas Pressure Adjustment, Accumulator Ride Control Accumulator (Option) ...........................T4-5-40 Service Brake Accumulator ...........................................T4-5-40 Steering Accumulator .....................................................T4-5-40 H Hazard Light Indicator, Malfunction ................................T5-7-12 Heating, Faulty ........................................................................T5-8-24 High Beam Indicator, Malfunction ...................................T5-7-13 Hose Tightening Torque.......................................................T5-8-44 HST Charging Pump Delivery Pressure............................. T4-5-7 HST Controller Fault Code 111027, 111028 .................................................................T5-5-86 111330, 111331 .................................................................T5-5-89 111332 ..................................................................................T5-5-88 111333 ..................................................................................T5-5-89 111334 ..................................................................................T5-5-90 111430, 111431, 111432 ................................................T5-5-91 111433 ..................................................................................T5-5-92 111450, 111451 .................................................................T5-5-94 111457 ..................................................................................T5-5-93 111620, 111621 .................................................................T5-5-95 111622 ..................................................................................T5-5-96 111904 ..................................................................................T5-5-97 111905 ..................................................................................T5-5-98 HST Controller Fault Code List ...........................................T5-5-19 HST Motor .................................................................................T5-4-17 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 ................................................ T4-5-6 HST Pump Relief Pressure....................................................T4-5-14 HST Warning Indicator, Malfunction ...............................T5-7-19 Hydraulic Circuit Bypass.................................................... T5-6-107 Hydraulic Cylinder Cycle Time ...........................................T4-4-10 Hydraulic Oil Level Indicator, Malfunction ....................T5-7-32 I Information Controller Fault Code List ...........................T5-5-25 Instructions for Disconnecting Connectors .................... T5-1-8 L Lever Stopper Clearance........................................................ T4-4-8 Lift Arm Angle Sensor Learning ........................................T4-6-14 Light Bulb Check System, Malfunction...........................T5-7-10 List of Daily Report Data ........................................................ T5-3-2 List of Frequency Distribution Data ................................... T5-3-4 List of Operation Data............................................................. T5-3-2 List of Service Menu Display................................................. T5-2-6 List of Total Operating Hours ............................................... T5-3-5 Loading Circuit Main Relief Set Pressure .......................T4-5-10 Loading Overload Relief Valve Set Pressure .................T4-5-18 Low Brake Oil Pressure Indicator, Malfunction ............T5-7-31 Low Steering Oil Pressure Indicator (OPT), Malfunction.........................................................................T5-7-27 62Z7/67Z7/67TM7 Trbl

INDEX Lubricant Consumption ......................................................... T4-3-3 M MC Fault Code 111000 to 111002 .............................................................T5-5-57 111003 ..................................................................................T5-5-58 111006, 111007 .................................................................T5-5-61 111008 ..................................................................................T5-5-69 111014 ..................................................................................T5-5-69 111025 ..................................................................................T5-5-69 111030 ..................................................................................T5-5-61 111103 ..................................................................................T5-5-73 111205 ..................................................................................T5-5-74 111206 ..................................................................................T5-5-76 111207 ..................................................................................T5-5-74 111208 ..................................................................................T5-5-77 111217 ..................................................................................T5-5-75 111311 ..................................................................................T5-5-78 111406 ..................................................................................T5-5-79 111411 ..................................................................................T5-5-80 111412 ..................................................................................T5-5-81 111422 ..................................................................................T5-5-82 111908 ..................................................................................T5-5-83 111909 ..................................................................................T5-5-84 120003, 120004 .................................................................T5-5-85 120014 ..................................................................................T5-5-85 MC Fault Code List ................................................................... T5-5-9 MPDr. Fault Code Reference Table...................................... T5-5-3 Machine Performance Test.................................................... T4-4-1 Main Component Layout (Hydraulic System) ................ T5-4-3 Main Component Layout (Overview)................................ T5-4-1 Main Component Layout (Travel System) ....................... T5-4-5 Main Pump and Steering Pump, Combined Delivery Pressure .................................................................................. T4-5-5 Main Relief Valve Pressure Adjustment Procedure.....T4-5-12 Maintenance Light, Malfunction ......................................T5-7-16 Maintenance of Exhaust Filter ............................................. T4-6-5 Malfunction of Air Filter Restriction Indicator.......................................T5-7-29 Alternator Indicator..........................................................T5-7-28 Clearance Light Indicator ...............................................T5-7-25 Control Lever Lock Indicator .........................................T5-7-33 Coolant Temperature Gauge .......................................... T5-7-4 Engine Oil Pressure Indicator........................................T5-7-20 Engine Warning Indicator ..............................................T5-7-22 Exhaust Filter Indicator ...................................................T5-7-33 Exhaust Filter Regeneration Inhibit Indicator .........T5-7-33 Fan Reverse Rotation Indicator (OPT)........................T5-7-33 Fuel Filter Restriction Indicator ....................................T5-7-30 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 Hydraulic Oil Level Indicator .........................................T5-7-32

Malfunction of Left And Right Turn Signal Light Indicators.............T5-7-11 Light Bulb Check System................................................T5-7-10 Low Brake Oil Pressure Indicator .................................T5-7-31 Low Steering Oil Pressure Indicator (OPT) ...............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 Power Mode Indicator .....................................................T5-7-33 Preheat Indicator...............................................................T5-7-17 Seat Belt Indicator ............................................................T5-7-34 Secondary Steering Indicator (OPT) ..........................T5-7-26 Service Indicator ...............................................................T5-7-23 Water Separator Indicator (OPT) .................................T5-7-33 Work Light Indicator ........................................................T5-7-14 Manifold Valve .........................................................................T5-4-18 Measuring Method of No-Load-Max Differential Pressure ........................................................... T4-6-1 Monitor, Outline........................................................................ T5-2-1 Monitor Buzzer, Malfunction ................................................ T5-7-3 Monitor Display......................................................................... T5-2-2 Monitor Display, Malfunction .............................................. T5-7-8 Monitor Panel ........................................................... T5-2-1, T5-4-12 Multiple Control Valve ..........................................................T5-4-17 N No-Load-Max Differential Pressure, Measuring Method ................................................................................................... T4-6-1 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 ........................T5-6-46, T5-6-87 Overheat Indicator, Malfunction.......................................T5-7-21 Overload Relief Valve Pressure Adjustment Procedure .................................................................................................T4-5-21 P Parking Brake, Releasing ................................................... T5-6-108 Parking Brake Function Check ............................................. T4-4-7 Parking Brake Indicator, Malfunction ..............................T5-7-24 Parking Brake Manual Release Procedures ................ T5-6-109 Parking Brake Pressure .........................................................T4-5-24 Pipe Tightening Torque ........................................................T5-8-44 Power Mode Indicator, Malfunction ................................T5-7-33 Precautions for Inspection and Maintenance ................ T5-1-6 Precautions for Self-Traveling ......................................... T5-6-105 Precautions for Towing ...................................................... T5-6-106 Preheat Indicator, Malfunction ..........................................T5-7-17 Preparation for Performance Tests ..................................... T4-1-2 Primary Pilot Pressure (Including Brake Circuit) ............ T4-5-1 Primary Pilot Pressure Adjustment Procedure ............... T4-5-3

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INDEX R Rear Console ............................................................................T5-4-11 Refill Compressor Oil .............................................................T5-8-35 Refrigerant, Charge Air Conditioner ................................T5-8-36 Relationship between Machine Trouble Symptoms and Related Parts ................................................................ T5-6-3 Releasing Parking Brake .................................................... T5-6-108 Rewrite of Exhaust Filter Serial No. .................................... T4-6-4 Ride Control Accumulator (Option) Gas Pressure Adjustment .........................................................................T4-5-40 Ride Control Circuit (Option) ..............................................T4-5-41 Ride Control Valve (Option) ................................................T5-4-20 Right Console............................................................................. T5-4-9 S Seat Belt Indicator, Malfunction ........................................T5-7-34 Secondary Pilot Pressure ....................................................... T4-5-4 Secondary Steering Block (Option)..................................T5-4-21 Secondary Steering Indicator (OPT), Malfunction......T5-7-26 Secondary Steering Pump (Option) ................................T5-4-21 Sensor Activating Range ....................................................... T4-2-8 Service Brake Accumulator Gas Pressure Adjustment .................................................................................................T4-5-40 Service Brake Accumulator Pressure ...............................T4-5-26 Service Brake Circuit ..............................................................T4-5-36 Service Brake Function Check.............................................. T4-4-4 Service Brake Pressure (Front and Rear) .........................T4-5-22 Service Brake Wear Amount ................................................. T4-4-6 Service Indicator, Malfunction ...........................................T5-7-23 Service Menu ............................................................................. T5-2-3 Service Menu Display, List ..................................................... T5-2-6 Snapshot Data ........................................................................... T5-3-6 Solenoid Valve (In Front Chassis) ......................................T5-4-22 Standard ...................................................................................... T4-2-1 Steering Accumulator Gas Pressure Adjustment ........T4-5-40 Steering Circuit........................................................................T4-5-38 Steering Circuit Main Relief Set Pressure .......................T4-5-16 Steering Overload Relief Valve Set Pressure .................T4-5-18 Steering Pump and Main Pump, Combined Delivery Pressure .................................................................................. T4-5-5 Steering System Troubleshooting ...................T5-6-40, T5-6-75

Troubleshooting B Procedure (by Troubleshooting Symptom) .............................................................................. T5-6-1 Troubleshooting C Procedure (Monitor Diagnosis) ..... T5-7-1 Turn Signal Light Indicators, Malfunction .....................T5-7-11 V Voltage Measurement ..........................................................T5-1-18 W Water Separator Indicator (OPT), Malfunction ............T5-7-33 Work Light Indicator, Malfunction ...................................T5-7-14 Work after Replacing Components..................................T5-8-34 Z Zero-Point Calibration (Correction) ................................... T4-6-3

T Temperature Gauge ................................................................ T5-2-7 Test Harness..............................................................................T5-1-26 Total Operating Hours ............................................................ T5-3-5 Towing, Precautions ........................................................... T5-6-106 Transmission ............................................................................T5-4-17 Transmission Charge Pump Delivery Pressure .............. T4-5-8 Transmission Clutch Pressure ............................................T4-5-32 Transmission Learning............................................................ T4-6-6 Transporting Wheel Loader (Urgent Situation) ........ T5-6-105 Travel Speed ............................................................................... T4-4-1 Travel System Troubleshooting ........................T5-6-42, T5-6-79 Troubleshooting, Air Conditioner....................................... T5-8-9 Troubleshooting A Procedure (by Fault Codes) ............ T5-5-1

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