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80Z6

93209-00740

SHOP MANUAL Operational Performance Test Troubleshooting

Printed in Japan (K) （トルコ輸出一般用）

93209-00740

April 2016

SHOP MANUAL WHEEL LOADER

80Z6 Operational Performance Test Troubleshooting

93209-00740

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

Group 5 Component Test Group 6 Adjustments

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

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

(Blank)

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

Additional References Please refer to the other materials (operation and maintenance manual, parts catalog, engine technical material, Kawasaki shop materials, etc.) in addition to this manual.

Manual Composition Our shop manuals consist of the Technical Manual, the Workshop Manual and the Engine Manual.

 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.

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

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

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

 Workshop Manual: W 1-3-2-5 W Workshop Manual (Disassembly & Reassembly) 1 Section Number 3 Group Number 2 Sub Group Number 5 Consecutive Page Number for Each Group

IN-01

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.

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

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

dCAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death. IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

fNOTE: Indicates supplementary technical information.

Units Used 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. Quantity Length Volume Weight Force Torque Pressure Power Temperature Velocity Flow rate

To Convert From mm mm L L m3 kg N N N·m MPa MPa kW kW °C km/h min-1 L/min mL/rev

Example: 24.5 MPa (250 kgf/cm2, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes. Into in ft US gal US qt yd3 lb kgf lbf kgf·m kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

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

IN-02

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 0.10197 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

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

Name

Explanation

Shop Manual Torque Converter Transmission Main Controller

ECM

Engine Control Module

DCU

Dozing Control Unit

VGS VGT

Variable Geometry System controller Variable Geometry Turbo

CAN

Controller Area Network

A/C HVAC OP, OPT MPDr.

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

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

ATT

Attachment

Optional component. MPDr. is software that troubleshooting, monitoring, and adjustment. Front attachment, such as bucket

SY-1

Symbol and Abbreviation (Blank)

SY-2

SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices.

SA-688

Understand Signal Words  On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.  DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.  WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.  CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.  DANGER or WARNING safety signs signs are located near specific hazards. General precautions are listed on CAUTION safety signs.  Some safety signs do not use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.  CAUTION also calls attention to safety messages in this manual.  To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. 

f NOTE indicates an additional explanation for an element of information.

SA-1

SA-1223

SAFETY Follow Safety Instructions  Carefully read and follow all safety signs on the machine and all safety messages in this manual.  Safety signs should be installed, maintained and replaced when necessary.  If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).  Learn how to operate the machine and its controls correctly and safely.  Allow only trained, qualified, authorized personnel to operate the machine.  Keep your machine in proper working condition.  Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.  Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void KCM Warranty Policy.  Never attempt to modify or disassemble the inlet/exhaust parts and the muffler filter. Avoid giving shocks on the muffler filter by striking elements with other objects or dropping the elements. Failure to do so may affect the exhaust gas purifying device, possibly damaging it or lowering its performance.  Do not use attachments and/or optional parts or equipment not authorized by KCM. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void KCM Warranty Policy.  The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/ or your authorized dealer before operating or performing maintenance work on the machine.

SA-2

SA-003

SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly.  To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual.  Establish emergency procedure guidelines to cope with fires and accidents.  Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

Wear Protective Clothing  Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.  Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.  Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

SA-3

SA-438

SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

Inspect Machine  Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.  In the walk-around inspection, be sure to cover all points described in the “Inspect Machine Daily Before Starting” section in the operator’s manual.

SA-435

SA-4

SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.  Do not mess up around the operator's seat with parts, tools, soil, stones, obstacles that may fold up or turn over, cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the accelerator pedal, brake pedals, control lever lock switch or control levers, which may result in serious injury or death.  Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.  Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.  Keep all flammable objects and/or explosives away from the machine.  After using the ashtray, always cover it to extinguish the match and/or tobacco.  Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.  Use proper floor mat dedicated to the machine. If another floor mat is used, it may be displaced and contact with the accelerator or brake pedals during operation, resulting in serious injury or death.

SA-5

SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as handholds.  Never jump on or off the machine. Never mount or dismount a moving machine.  Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.  Never get on and off the machine with tools in your hands.

SA-439

Never Ride Attachment  Never allow anyone to ride attachment or the load. This is an extremely dangerous practice.

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

SA-6

SA-462

SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.  Before leaving the machine, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position. Turn the key switch OFF to stop the engine.  Before leaving the machine, close all windows, doors, and access covers and lock them up.

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

SA-7

SA-237

SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.  Use a signal person when moving, or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.  Ensure the cab door, windows, doors and covers are securely locked.  Check the mirrors and the monitor in the CAB for problems. If there is any problem, replace the problem part(s) or clean the mirror, camera and the monitor. Refer to Rear View Monitor section on the cleaning of the camera and the monitor.

SA-398

Handle Starting Aids Safely Starting fluid:  Starting fluid is highly flammable.  Keep all sparks and flame away when using it.  Keep starting fluid well away from batteries and cables.  Remove container from machine if engine does not need starting fluid.  To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.  Do not incinerate or puncture a starting fluid container. SA-293

SA-8

SAFETY Operate Only from Operator’s Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  NEVER start the engine while standing on the tire or on ground.  Do not start engine by shorting across starter terminals.  Before starting the engine, confirm that all control levers are in neutral.  Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-431

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

SA-9

SA-032

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

SA-10

SA-447

SAFETY Equipment of Head Guard, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) Any modification of the ROPS structure will modify its performances and its certification will be lost. ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

SA-521

Provide Signals for Jobs Involving Multiple Machines  For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

SA-481

SA-11

SAFETY Keep Riders Off Machine  Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner. SA-427

Drive Safely  Beware of the possibility of slipping and / or turning over the machine when driving on a slope.  When driving on level ground, hold the bucket at mark (A) 300 mm (12 in) above the ground as illustrated.  Avoid traveling over any obstacles.  Drive the machine slowly when driving on rough terrain.  Avoid quick direction changes. Failure to do so may cause the machine to turn over.  If the engine stops while driving, the steering function becomes inoperative. Immediately stop the machine by applying the brake to prevent personal accident. SA-448

SA-12

SAFETY Drive Machine Safely (Work Site)  Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. SA-449

 When driving up or down a slope, keep the bucket facing the direction of travel, approximately 200 to 300 mm (approximately 8 to 12 in) (A) above the ground.  If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.  Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-450

WRONG

SA-451

SA-13

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

SA-400

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

SA-14

SA-452

SAFETY Travel on Public Roads Safely  This machine is not allowed to drive on public roads with the bucket loaded.  Be sure to empty the bucket.  Hold the bucket at mark (A) 300 mm (12 in) above the road surface as illustrated.

SA-453

Avoid Injury from Rollaway Accidents  Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways:  Select level ground when possible to park machine.  Do not park the machine on a grade.  Lower the bucket to the ground.  Put the forward / reverse lever (switch) in neutral, and pull up the parking brake switch (lever) in the ON (parking brake) position.  Run the engine at low idle speed without load for 5 minutes to cool down the engine.  Stop the engine and remove the key from the key switch.  Turn the control lever lock switch to the lock ( ) position.  Block both tires and lower the bucket to the ground.  Position the machine to prevent rolling.  Park at a reasonable distance from other machines.

SA-457

SA-458

SA-15

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

SA-383

SA-312

SA-16

SAFETY Avoid Positioning Bucket or Attachment Over Anyone  Never allow the bucket or attachment to pass over coworkers and / or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket or attachment may cause serious personal accidents and / or damage to the machine.  Avoid carrying the bucket or attachment over the coworkers to ensure safe operation.

SA-518

Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE MACHINE IS PREDICTED, SECURELY HOLD THE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT  The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping:  Be extra careful before operating on a grade.  Prepare machine operating area flat.  Keep the bucket low to the ground and close to the machine.  Reduce operating speeds to avoid tipping or slipping.  Avoid changing direction when traveling on grades.  NEVER attempt to travel across a grade steeper than 5 degrees if crossing the grade is unavoidable.  Reduce swing speed as necessary when swinging loads.  Be careful when working on frozen ground.  Temperature increases will cause the ground to become soft and make ground travel unstable.

SA-17

SA-463

SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death.

SA-519

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

SA-396

Perform Truck Loading Safely  Do not operate the machine involuntarily. Unexpected machine movement may cause personal injury and / or death.  Do not lower the bucket with the lift arm control lever in the FLOAT position. The bucket may free fall, possibly causing personal injury and / or death.  Always select a level surface for truck loading. SA-397

SA-18

SAFETY Avoid Power Lines Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length. SA-455

Precautions for Operation  If the front attachment or any part of the machine comes in contact with an overhead obstacle, both the machine and the overhead obstacle may become damaged, and personal injury may result.  Take care to avoid coming in contact with overhead obstacles with the bucket or arm during operation.

Precautions for Lightning  The machine is vulnerable to lightning strikes.  In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.  After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

SA-19

SAFETY Object Handling CRANING OPERATION USING THE MACHINE IS NOT ALLOWED.  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example). They may come off, causing the load to fall.

SA-132

Protect Against Flying Debris  If flying debris hit eyes or any other part of the body, serious injury may result.  Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.  Keep bystanders away from the working area before striking any object.

SA-432

SA-20

SAFETY Park Machine Safely To avoid accidents:  Park the machine on a firm, level surface.  Lower bucket to the ground.  Put the forward / reverse lever (switch) in neutral, and turn the parking brake switch (lever) ON (parking brake) position.  Run the engine at low idle speed without load for 5 minutes.  Turn key switch to OFF to stop engine.  Remove the key from the key switch.  Turn the control lever lock switch to the lock ( ) position.  Close windows, roof vent, and cab door.  Lock all access doors and compartments.

SA-456

Store Attachments Safely  Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.  Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

SA-034

SA-21

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

SA-22

Less than 15 ° SA-454

SAFETY Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and / or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.  Always stop the engine before refueling the machine.  Fill the fuel tank outdoors.  All fuels, most lubricants, and some coolants are flammable.  Store flammable fluids well away from fire hazards.  Do not incinerate or puncture pressurized containers.  Do not store oily rags; they can ignite and burn spontaneously.  Securely tighten the fuel and oil filler caps.

SA-018

SA-019

SA-23

SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving.  Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Run the engine at low idle speed without load for 5 minutes.

SA-028

4. Turn the key switch to OFF to stop engine. 5. Relieve the pressure in the hydraulic system by moving the control levers several times. 6. Remove the key from the key switch. 7. Attach a “Do Not Operate” tag on the control lever. 8. Turn the control lever lock switch to the lock ( ) position. 9. Lock bar connects the front and rear frames. 10. Allow the engine to cool.  If a maintenance procedure must be performed with the engine running, do not leave machine unattended.  Never work under a machine raised by the lift arm.  Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual.  Keep all parts in good condition and properly installed.  Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.  When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.  Disconnect battery ground cable (-) before making adjustments to electrical systems or before performing welding on the machine.

SA-312

SA-134

SA-527

SA-24

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

SA-037

Warn Others of Service Work  Unexpected machine movement can cause serious injury.  Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.

SS2045102

Support Machine Properly  Never attempt to work on the machine without securing the machine first.  Always lower the attachment to the ground before you work on the machine.  If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. SA-527

SA-25

SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

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

SA-26

SA-249

SAFETY Prevent Parts from Flying  Travel reduction gears are under pressure.  As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.  GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

SA-344

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

SA-039

Hot fluids and surfaces:  Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well.  Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

SA-27

SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.  Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)  Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

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

SA-031

SA-292

SA-044

SA-28

SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.  Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.  Do not bend or strike high-pressure lines.  Never install bent or damaged lines, pipes, or hoses.  Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance. Check for Shorts:  Short circuits can cause fires.  Clean and tighten all electrical connections.  Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.  Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.  DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.  Never attempt to modify electric wirings.

SA-29

SA-019

SAFETY Clean up Flammables:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammables immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval.  Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents.  Do not store oily cloths as they are vulnerable to catching fire.  Keep flammables away from open flames.  Do not ignite or crush a pressurized or sealed container.  Wire screens may be provided on openings on the engine compartment covers to prevent flammables such as dead leaves from entering. However, flammables which have passed through the wire screen may cause fires. Check and clean the machine every day and immediately remove accumulated flammables. Check Key Switch:  If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at low idle. 2. Turn the key switch to the OFF position to confirm that the engine stops.  If any abnormalities are found, be sure to repair them before operating the machine. Check Heat Shields:  Damaged or missing heat shields may lead to fires.  Damaged or missing heat shields must be repaired or replaced before operating the machine.  If hydraulic hoses are broken while the engine cover is open, splattered oil on the high temperature parts such as mufflers may cause fire. Always close the engine cover while operating the machine.

SA-30

SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time.  Exit the machine.  In an emergency, if the cab door can not be opened,

break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation pages on the Emergency Evacuation Method.

SA-393

SS-1510

Beware of Exhaust Fumes  Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.  If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.  PM (Particle Matter) combustion may generate white smoke during muffler filter regeneration. Do not attempt to do muffler filter manual regeneration in a badly ventilated indoors.

SA-016

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

SA-31

SA-818

SAFETY Avoid Heating Near Pressurized Fluid Lines  Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.  Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.  Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

Avoid Applying Heat to Lines Containing Flammable Fluids

SA-030

 Do not weld or flame cut pipes or tubes that contain flammable fluids.  Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause explosion, possibly resulting in serious injury or death. Strictly comply with the following items:  Do not disassemble the unit.  Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing the unit, sealed gas must be released. Consult your nearest authorized dealer.

SA-32

SAFETY Remove Paint Before Welding or Heating  Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.  Avoid potentially toxic fumes and dust.  Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.  Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

SA-029

Beware of Asbestos and Silicon Dust and Other Contamination  Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. Inhalation of silicon dust and other contamination may cause sickness.  Depending on the work site conditions, the risk of inhaling asbestos fiber, silicon dust or other contamination may exist. Spray water to prevent asbestos fibers, silicon dust or other contamination from becoming airborne. Do not use compressed air.  When operating the machine in a work site where asbestos fibers, silicon dust or other contamination might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos, silicon dust or other contamination.  Keep bystanders out of the work site during operation.  Asbestos might be present in imitation parts. Use only genuine KCM/Hitachi Parts.

SA-33

SA-029

SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.  Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first.  Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.  Loose terminals may produce sparks. Securely tighten all terminals.  Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.

SA-032

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

Service Air Conditioning System Safely  If spilled onto skin, refrigerant may cause a cold contact burn.  Refer to the instructions described on the container for proper use when handling the refrigerant.  Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.  Never touch the refrigerant.

SA-405

SA-34

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

SA-309

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

SA-35

SA-226

SAFETY Notes for Muffler Filter Muffler Filter The muffler filter removes particle matters (PM) in the exhaust gas. The muffler filter traps PM, and it is automatically regenerated by burning PM when the set amount of PM is accumulated in the filter. Follow the instructions below to prevent the muffler filter from being damaged. Exhaust gas from the muffler filter, muffler dWARNING: and exhaust piping becomes hot during and right after engine running and filter regeneration (burning PM). Keep away from the direction of the exhaust piping and its vicinity during the filter regeneration. Be careful not to let your skin contact with any hot gas from the exhaust piping. It may cause severe burns.

Do not directly touch water coming out of the muffler filter. The water is mildly-acidic by oxidation catalyst mounted in the muffler filter. If filter water spills on your skin, immediately flush it out with clean water.

Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices. Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal.

SA-36

SAFETY Precaution for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed inside a rear tray which is situated at the back of the driver's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment. Any person affixed with a medical device such as the above should not use this machine, unless the medical device and the rear tray are at least 22 centimeters (8.662 inches) apart at all times. If such condition cannot be met, please contact our company's nearest dealer and have the person in charge stop the communication terminal equipment from functioning completely and confirm that it is not emitting electrical waves. Specific Absorption Rate ("SAR") (measured by 10 g per unit) of communication terminal equipment: Model A E-GSM900 0.573 W/Kg (914.8 MHz) DCS-1800 0.130 W/Kg (1710.2 MHz) WCDMA Band I 0.271 W/Kg (1950.0 MHz) WCDMA Band VIII -

Model B 0.12 W/Kg (897.6 MHz) 0.06 W/Kg (1748.0 MHz) 0.05 W/Kg (1950.0 MHz) 0.10 W/Kg (892.6 MHz)

fNOTE: Please contact to your authorized representative

if you want to know which terminal type A or B is installed.

* This data was measured by having each type of communication terminal equipment, such as the communication terminal equipment used with this machine, and a human body set apart by 3 cm (1.18 inches). * SAR is a measure of the amount of radio frequency energy absorbed by the body when using a wireless application such as a mobile phone. In Japan: * Under the Japanese Radio Act and other relevant Japanese regulations, the maximum SAR value is 2 W/kg (as of March 2010). In EU Member nation: * Under the "Council Recommendation 1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg (as of March 2010).

SA-37

MNEC-01-046

SAFETY  Never attempt to disassemble, repair, modify or displace the communication terminal, antennas or cables. Failure to do so may result in damage and/or fire to the base machine or to the communication terminal. (When required to remove or install the communication terminal, consult your nearest authorized dealer.)  Do not pinch or forcibly pull cables, cords or connectors. Failure to do so may cause short circuit or broken circuit that may result in damage and/or fire to the base machine or to the communication terminal.

SA-38

SAFETY Before Returning the Machine to the Customer  After maintenance or repair work is complete, confirm that:  The machine is functioning properly, especially the safety systems.  Worn or damaged parts have been repaired or replaced.

SA-435

SA-39

SAFETY (Blank)

SA-40

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 Main Pump P-Q Diagram................................................T4-2-10 Sensor Activating Range.................................................T4-2-12

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 and Bell Crank Stopper Clearance........................................................................... T4-4-8 Hydraulic Cylinder Cycle Time.......................................T4-4-10 Dig Function Drift Check.................................................T4-4-12 Bucket Levelness................................................................T4-4-13 Control Lever Operating Force......................................T4-4-14 Control Lever Stroke.........................................................T4-4-16

Group 5 Component Test

Primary Pilot Pressure (Including Brake Circuit)....... T4-5-1 Secondary Pilot Pressure................................................... T4-5-4 Main Pump Delivery Pressure......................................... T4-5-6 Main Relief Set Pressure.................................................... T4-5-8 Steering Relief Pressure...................................................T4-5-12 Overload Relief Valve Set Pressure..............................T4-5-14 Main Pump Flow Rate Measurement.........................T4-5-16 Service Brake Pressure (Front and Rear) ...................T4-5-24 Parking Brake Pressure.....................................................T4-5-26 Brake Accumulator Pressure .........................................T4-5-28 Brake Warning Pressure (Pressure-Decreasing)......T4-5-30 Brake Warning Pressure (Pressure-Increasing)........T4-5-32 Transmission Clutch Pressure........................................T4-5-34 Torque Converter Pressure (Inlet)................................T4-5-36

Group 6 Adjustment

Transmission Learning....................................................... T4-6-1 Lift Arm Angle Sensor Learning...................................... T4-6-5 Digging Position Adjustment.......................................... T4-6-7

80Z6 Trbl

(Blank)

80Z6 Trbl

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

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

Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values. 2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.

Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine. 2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.

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

T4-1-1

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

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

T4-1-2

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

Unit

Engine Speed Slow Idle Speed (without load) Fast Idle Speed (without load) Fast Idle Speed (with torque converter stalled) Fast Idle Speed (with torque converter stalled and relieved) Engine Speed Slow Idle Speed (without load) Fast Idle Speed (without load) Fast Idle Speed (with torque converter stalled) Fast Idle Speed (with torque converter stalled and relieved) Valve Clearance (In, Ex)

min-1

Lubricant Consumption (Rated output)

mL/h

The following switch positions shall be selected and the hydraulic oil temperature shall be maintained as indicated below as the preconditions of performance tests unless otherwise instructed in each performance test procedure:  Accelerator Pedal: Full Stroke  Power Mode Switch: ON  Hydraulic Oil Temperature: 50±5 °C (122±9 °F) Performance Standard 800±25 2280±30 1920±50 1660±50

min-1 800±25 2320±30 2110±50 1820±50 mm (in)

In: 0.254 (0.010) Ex: 0.508 (0.020) 50 or less

T4-2-1

Remarks

Reference Page T4-3-1

Power mode switch: OFF Value indicated on MPDr. Value indicated on MPDr. Second- speed forward, Value indicated on MPDr. Third- speed forward, Value indicated on MPDr. Power mode switch: ON T4-3-1 Value indicated on MPDr. Value indicated on MPDr. Second- speed forward, Value indicated on MPDr. Third- speed forward, Value indicated on MPDr. With the engine cold Refer to Engine Manual Hour meter: 2000 hours T4-3-4 or less

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Travel Speed First Speed (Forward/Reverse)

km/h (mph)

Second Speed (Forward/Reverse) Third Speed (Forward/Reverse) Fourth Speed (Forward) Fifth Speed (Forward) Travel Speed First Speed (Forward/Reverse)

km/h (mph)

Second Speed (Forward/Reverse) Third Speed (Forward/Reverse) Fourth Speed (Forward) Fifth Speed (Forward) Service Brake Function Check Service Brake Wear Amount CLUCH Disc (Out Put Side) CLUCH Disc (Piston In Put Side) Parking Brake Function Check Parking Brake Wear Amount Brake Disc Brake Pad Bucket Stopper Clearance Bell Crank Stopper Clearance Front Pin Wear Amount Front Bushing Wear Amount Clearance Between Front Pin and Bushing

m (ft)

Performance Standard

Remarks Power mode switch: OFF Value indicated on MPDr.

6.4±0.6/6.8±0.7 (4.0±0.3/4.2±0.4) 11.0±1.1/11.5±1.1 Value indicated on MPDr. (6.8±0.6/7.1±0.6) 16.4±1.6/25.0±2.5 Value indicated on MPDr. (10.0±0.9/15.5±1.5) 23.6±2.4 (14.7±1.4) Value indicated on MPDr. 37.1±3.6 (23.0±2.2) Power mode switch: ON 6.4±0.6/6.8±0.7 Value indicated on MPDr. (3.9±0.3/4.2±0.4) 11.6±1.2/12.2±1.2 Value indicated on MPDr. (7.2±0.7/7.6±0.7) 17.4±1.7/27.1±2.7 Value indicated on MPDr. (10.8±1.0/16.8±1.7) 25.9±2.6 (16.1±1.6) Value indicated on MPDr. 37.1±3.7 (23.1±2.3) 12 (39) or less Vehicle speed: 35±3 km/h (21.7±1.8 mph)

mm (in)

mm/5 min mm

mm mm mm mm mm

Reference Page T4-4-1

T4-4-1

T4-4-4 T4-4-6

0 2.2 (0.1) 6.0 (0.2) 0 2 (0.1) 0.3 (0.01)

T4-2-2

Allowable limit: 3.5 (0.14) T4-4-7 Allowable limit: 1.9 (0.07) Allowable limit: 4.5 (0.18) T4-4-8 T4-4-8 Allowable limit: -1.0 (-0.03) Allowable limit: -1.5 (-0.05) -

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

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

sec

Performance Standard

Remarks Power mode switch: OFF

Reference Page T4-4-10

Power mode switch: ON

T4-4-10

5.6±0.3 2.9±0.4 1.6±0.3 2.5±0.4 sec 5.0±0.3 2.9±0.4 1.5±0.3 2.5±0.4 mm (in)/15 min

T4-4-12 15 or less (0.6) 10 or less (0.4) 75 or less (3) 14 or less (0.6)

T4-2-3

T4-4-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Control Lever Operating Force Lift Arm Raise Lift Arm Raise (Detent) Lift Arm Raise (Detent Release) Lift Arm Lower Lift Arm Lower (Float) Lift Arm Lower (Float Release) Bucket Control Lever Tilt Bucket Control Lever Tilt (Detent) Bucket Control Lever Tilt (Detent Release) Bucket Control Lever Dump Steering Forward/Reverse Lever Accelerator Pedal Brake Pedal (Right) Inching Pedal (Left)

N (kgf )

Performance Standard

Remarks Two-lever

10 (1.0) or less 16 (1.6) or less 36 (3.6) or less 10 (1.0) or less 16 (1.6) or less 36 (3.6) or less 11 (1.1) or less 16 (1.6) or less 36 (3.6) or less 16 (1.6) or less 16 (1.6) or less 12+3-2 (1.2+0.3-0.2) 40±2 (4.0±0.2) 323±32 (32.9±3.3) 278±28 (28.3±2.9)

T4-2-4

Reference Page T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

N (kgf )

Performance Standard

Remarks MF (Joystick type) lever

20 (2.0) or less 40 (4.0) or less 50 (5.0) or less 20 (2.0) or less 40 (4.0) or less 50 (5.0) or less 20 (2.0) or less 40 (4.0) or less 50 (5.0) or less 30 (3.0) or less 16 (1.6) or less 12+3-2 (1.2+0.3-0.2) 40±2 (4.0±0.2) 323±32 (32.9±3.3) 278±28 (28.3±2.9)

fNOTE: MF: Multi-Function

T4-2-5

Reference Page T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

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

mm (in)

Performance Standard

Remarks Two-lever

Reference Page T4-4-16

MF (Joystick type) lever

T4-4-16

42±5 (1.7±0.2) 65±5 (2.6±0.2) 32±5 (1.3±0.2) 55±5 (2.2±0.2) 42±5 (1.7±0.2) 65±5 (2.6±0.2) 55±5 (2.2±0.2) 4.0 to 4.5 (0.2) 50±5 (2.0±0.2) 5 to 15 (0.2 to 0.6) 7 to 16 (0.3 to 0.6) mm (in) 58±10 (2.3±0.4) 79±10 (3.1±0.4) 58±10 (2.3±0.4) 79±10 (3.1±0.4) 58±10 (2.3±0.4) 79±10 (3.1±0.4) 79±10 (3.1±0.4) 4.0 to 4.5 (0.2) 50±5 (2.0±0.2) 5 to 15 (0.2±0.6) 4 to 13 (0.2±0.5)

fNOTE: MF: Multi-Function

T4-2-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Pedal Depressing Angle Accelerator Pedal Brake Pedal (Right) Inching Pedal (Left) Electrolyte Density (Specification at 20 °C) Tire Inflation Bias Tire Radial Tire

deg.

Performance Standard 18±1 17.2±1.5 15.1±1.5 1.26

kPa (kgf/cm2)

Remarks (without play)

Reference Page T4-4-16

Allowable limit: 1.16

375 (3.8) 300 (3.0)

T4-2-7

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Primary Pilot Pressure Secondary Pilot Pressure Main Pump Delivery Pressure

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

Main Relief Set Pressure Relief Operation of Lift Arm Relief Operation of Bucket Steering Relief Pressure Overload Relief Pressure

MPa (kgf/cm2)

Lift Arm Raise Bucket Main Pump Flow Rate Measurement Service Brake Pressure (Front/Rear) Parking Brake Pressure Brake Accumulator Pressure Service Brake Parking Brake Brake Warning Pressure (PressureDecreasing) Brake Warning Pressure (PressureIncreasing) Transmission Clutch Pressure Torque Converter Pressure Inlet Pressure Outlet Pressure

Performance Standard 4.8±0.3 (48±3) 3.7+0.5-0.3 (38+5-3) 2.0+1.0-0.5 (20+10-5)

L/min MPa (kgf/cm2) MPa (kgf/cm2)

In neutral, Value indicated on MPDr.

Reference Page T4-5-1 T4-5-4 T4-5-6 T4-5-8

27.4 (280 ) 27.4+1.9-0 (280+19-0) 27.4+1.9-0 (280+19-0) +1.9 -0

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

Remarks

+19 -0

34.3+1.0-0 (350+10-0) 30.4+1.0-0 (310+10-0) 6.6±0.6 (67±6) 10.8 to 17.0 (110 to 173)

MPa (kgf/cm2)

Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Reference values at 50 L/ min

Refer to T4-2-10, 11 at brake pedal (right)

T4-5-12 T4-5-14

T4-5-16 T4-5-24 T4-5-26 T4-5-28

MPa (kgf/cm2)

16±1.0 (163±10) 16±1.0 (163±10) 8±0.5 (82±5)

T4-5-30

MPa (kgf/cm2)

10±0.5 (102±5)

T4-5-32

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

1.6 to 1.8 (16 to 18)

T4-5-34 T4-5-36

0.9 to 1.2 (9 to 12) 0.45 to 0.7 (4.5 to 7.0)

T4-2-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard (Blank)

T4-2-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Main Pump P-Q Diagram  P-Q Control (Torque Control) (Reference: Measured at Test Stand)  Rated Pump Speed: 2200 min-1 (rpm)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F) NOTE: Refer to T4-5-16.

Points on P-Q Line Delivery Pressure MPa (kgf/cm2) A 4.9 (50) B 19.6 (200) C 24.5 (250) D 27.4 (280)

Flow Rate L/min 275±3 275±5 243±6 213±6

Q L/min

B C

MPa (kgf/cm2)

P T4GB-04-02-001

T4-2-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard  P-Q Control by Pump Control Pilot Pressure Signal (Reference: Measured at Test Stand)  Rated Pump Speed: 2200 min-1 (rpm)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F) NOTE: Refer to T4-5-18.

Points on P-Q Line Pump Control Pressure MPa (kgf/cm2) A 0.39+0.1 −0.2 (4+1 −2) B 1.25±0.05 (12.7±0.5) C 1.96+0.02 −0 (20+0.2 −0)

Flow Rate L/min 275±3 70±2 40±2

Q L/min

MPa (kgf/cm2)

Pi1-Pi2

T4GB-04-02-002

T4-2-11

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

Power Mode Switch Fast Idle Speed ON • Monitor each sensor by using MPDr. 2. Sensor Activating Range Item Pump Delivery Pressure Main Relief Pressure Parking Brake Pressure Service Brake Pressure

Operation Neutral Relieved Neutral Control Lever: Relieved Parking Brake Switch: ON Parking Brake Switch: OFF Brake Pedal: Neutral Brake Pedal: Fully Depressed

T4-2-12

Specification 1.5 to 3.0 MPa (15 to 30 kgf/cm2) 27.4 to 29.3 MPa (279 to 299 kgf/cm2) 1.5 to 3.0 MPa (15 to 30 kgf/cm2) 27.4 to 29.3 MPa (279 to 299 kgf/cm2) 0 to 0.1 MPa (0 to 1 kgf/cm2) 10.8 to 17.0 MPa (110 to 173 kgf/cm2) 0 to 0.05 MPa (0 to 0.5 kgf/cm2) 6.6±0.6 MPa (67±6 kgf/cm2)

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

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

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

Preparation: 1. Select the service menu of monitor (In case of MPDr., install MPDr. first). 2. Warm up the machine until coolant temperature reaches 50 °C (122 °F) or more, hydraulic oil temperature is 50±5 °C (122±9 °F), and transmission oil temperature is 85±5 °C (185±41 °F).

T4-3-1

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

Forward/Reverse Lever, Shift Switch N

Accelerator Pedal

Parking Brake Switch Power Mode Switch

No depression

ON/OFF

Second speed/third speed forward Second speed forward

Full stroke

ON/OFF

Full stroke

OFF

ON/OFF

Third speed forward

Full stroke

OFF

ON/OFF

Declutch Position Switch OFF

Brake Pedal

Fast Idle Speed (with no load)

OFF

Full stroke

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

OFF

Full stroke

OFF

Full stroke

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

Slow Idle Speed (with no load) Fast Idle Speed (with no load) Fast Idle Speed (with torque converter stalled) Fast Idle Speed (with torque converter stalled and relieved)

Slow Idle Speed (with no load)

Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

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.

fNOTE: When measuring, use a high-precision

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

Evaluation: Refer to Operational Performance Standard.

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 (torque converter to transmission). Preparation: 1. Adjust air pressure of the tires evenly in advance. (Refer to Operational Performance Standard.) 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.) 3. Empty the bucket and hold the lift arm with it floated 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 in) above the ground. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicators of the coolant temperature monitor and the torque converter oil temperature monitor should rise above the horizontal position.

a c

c T4GB-04-04-001

ab-

T4-4-1

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

cde-

Acceleration/Deceleration Zone End Start

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

Parking Brake Switch

Accelerator Pedal

Power Mode Switch

First Speed

OFF

Full Stroke

ON/OFF

Second Speed

OFF

Full Stroke

ON/OFF

Third Speed

OFF

Full Stroke

ON/OFF

Fourth Speed

OFF

Full Stroke

ON/OFF

Fifth Speed

OFF

Full Stroke

ON/OFF

3. Set the forward/reverse lever to the F (forward) position. Start traveling the machine in the acceleration zone with the accelerator pedal depressed to the stroke end. 4. Measure the travel speed (sec) of each travel mode. 5. Repeat the measurement three times and calculate the mean values. 6. Convert the measurement value to be expressed in km/h. Measurement value (seconds) = S (sec) Converted value (hourly speed) = A (km/h) A = (50×3600)/(S×1000) Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-4-2

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. (Refer to Operational Performance Standard.) 2. On a paved dry road, prepare a 150 m (492 ft) straight travel course (a 100 m (328 ft) of acceleration zone and a 50 m (164 ft) of test track) and set the brake starting point. 3. Empty the bucket and hold the lift arm with it floated 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 in) above the ground. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicators of the coolant temperature monitor and the torque converter oil temperature monitor should rise above the horizontal position.

a c ab-

T4-4-4

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

d cd-

T4GB-04-04-002

Stopping Point Brake Starting Point

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

Parking Brake Switch

Accelerator Pedal

Power Mode Switch

Declutch Position Switch

Fifth Speed

OFF

Full Stroke

OFF

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

T4-4-5

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

1, 2

Summary: 1. Check the wear amount of the brake disc at the service brake of the axle by using thickness gauge (3) (ST 8077). Preparation: 1. Clean around inspection plug (1) of the axle (2 places at both sides). Remove inspection plugs (1) and O-rings (2). 2. After the measurement, install inspection plugs (1) and new O-rings (2). m : 50 N·m (5 kgf·m)

TNEJ-04-04-002

Measurement:

1. Operate the service brake by stepping on the brake pedal. 2. Insert thickness gauge (3) into the inspection port. Measure dimension (A) between clutch discs (4) at the output side. Evaluation: 1. When dimension (A) between clutch discs (4) at the output side is 3.5 mm (0.14 in) or less, clutch disc (5) inside the piston side is worn in excess of the maximum allowable limit of use.

TNEJ-04-04-003

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 assembled, refer to Operational Performance Standard in T4-2.

5 1234-

T4-4-6

Inspection Plug O-Ring Thickness Gauge (ST 8077) Clutch Disc (Output Side)

TNEJ-03-09-004 Clutch Disc (Piston Input Side)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Parking Brake Function Check Summary: 1. Measure the parking brake function on a specified slope. 2. The braking capability of the brake is an item of safety control. Be sure to conduct the performance test. Preparation: 1. Measure on a pavement surface with a gradient of 20 % (11.31°). 2. Empty the bucket and hold the bucket with it 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 50±5 °C (122±9 °F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicators of the coolant temperature monitor and the torque converter oil temperature monitor should rise above the horizontal position.

a b T4GB-04-04-003 a-

Measurement: 1. Climb the slope and set the parking brake switch to the ON position. 2. Stop the engine. 3. After the body has stopped, put a mark (white line) on the tire and the road surface respectively. 4. After five minutes have passed, measure the amount of movement between white lines of tire and road surface. 5. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard.

T4-4-7

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

20 %(11.31°)

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

Measurement:

 Bucket Dump Stopper (a) 1. Raise the lift arm to the highest lifting position and stop the engine. 2. Dump the bucket slowly 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 bell crank stopper (b) and the cross tube. 3. At the same time, measure the contact condition of bucket dump stopper (a) (left and right).  Bucket Tilt Stopper (c) 1. Raise the lift arm until lift arm cylinder stroke (E) becomes the length of the specified.

T4GB-04-04-008

2. Set the engine at idling speed and make tilting operation until the bucket calmly contacts bucket tilt stopper (c).

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

Bucket Dump Stopper

Bell Crank Stopper

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

T4GB-04-04-010 c-

T4-4-8

Bucket Tilt Stopper

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

2. Bucket Tilt Stopper

 Cylinder Strokes A and B

 Cylinder Strokes D and E

Model

Bucket Cylinder Lift Arm Cylinder

80Z6

A (mm) (in)

B (mm) (in)

362±1.5 (14.2±0.06)

1120±2 (44±0.08)

Model

80Z6

Model

C (deg.)

80Z6

50±2

Clearance between Bell Crank Stopper and Cross Tube (mm) (in)

80Z6

360 (14.2)

Model

F (deg.)

80Z6

Model

G (mm) (in)

80Z6

450 (17.7)

Model

2.0 (0.08)

 Clearance between Bucket Dump Stopper and Lift Arm Model

690 (27.2)

 Clearance between Bucket Dump Stopper and Lift Arm

Standard 0 Limit

E (mm) (in)

 Height from Ground to Bucket Lowest Portion (G)

 Clearance between Bell Crank Stopper and Cross Tube

80Z6

D (mm) (in)

 Bucket Tilt Angle (F)

 Bucket Dump Angle C

Model

Bucket Cylinder Lift Arm Cylinder

80Z6

Clearance at Unsymmetrical Contact (mm) (in)

Longitudinal and Lateral Clearance of a Stopper (mm) (in)

Standard

Limit

0.5 (0.02)

1.0 (0.04)

Clearance at Unsymmetrical Contact (mm)

(in)

Longitudinal and Lateral Clearance of a Stopper (mm) (in)

Standard

Limit

0.5 (0.02)

1.0 (0.04)

Clearance at Unsymmetrical Contact

c a

Longitudinal and Lateral Clearance of a Stopper Clearance at Unsymmetrical Contact

c a

b T4GB-04-04-009

b ab-

Longitudinal and Lateral Clearance of a Stopper

Left Right

Clearance Limit

c a

b T4GB-04-04-009

ab-

Left Right

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

Clearance Limit

T4-4-9

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

Lift Arm Cylinder: (Raising)

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

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

(Lowering)

 Measurement of Lift Arm Cylinder (Raising) Fully tilt the bucket and lower the lift arm.  Measurement of Lift Arm Cylinder (Lowering) Lower the lift arm until the bucket bottom surface touches the ground horizontally.  Measurement of Bucket Cylinder Lift the lift arm to the highest position.  Measurement of Steering Cylinder Empty the bucket and take the driving position. 2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T487-04-03-005

Bucket Cylinder:

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

T487-04-03-006

Driving Position

a M4GB-04-001 a-

T4-4-10

0.4 to 0.5 m (1 ft 4in to 1 ft 8 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: fast idle speed)

ON/OFF

Lift Arm (Lowering)

Neutral (engine: slow idle speed)

ON/OFF

Bucket

Full stroke (engine: fast idle speed)

ON/OFF

Steering

Full stroke (engine: fast idle speed)

OFF

ON/OFF

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

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

T4-4-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Dig Function 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 5580 kg (12400 lb).

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

T4GB-04-04-014

b=A-B 3. Repeat the measurement three times and calculate the mean values.

Bucket Cylinder

Dig Function Drift Amount

Lift Arm Cylinder

Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

B A TNEJ-04-04-001 c-

T4-4-12

Mark

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 dCAUTION: 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: Refer to Operational Performance Standard.

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 the lever stroke along the control lever operation from the grip center of each control lever. Measure at 150 mm (6 in) from the pedal support of each pedal. Preparation: 1. Empty the bucket and hold the litt arm with it floated 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 in) above the ground. 2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

a M4GB-04-001 a-

T4-4-14

0.4 to 0.5 m (1 ft 4 in to 1 ft 8 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. Accelerator Pedal

Parking Brake Switch

Forward/ Reverse Lever

Neutral (engine: slow idle speed)

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

TNED-04-04-001

3. Attach a spring balance scale (tension type) onto each of the lift arm, bucket, and forward/reverse lever. Measure the maximum operating force by operating them to the stroke end. 4. In case of the pedals, attach a spring balance scale (compression type) or a load cell onto them. Measure the operating force when they are stepped slightly. 5. In case of the steering wheel, attach a spring balance scale (tension type) onto knob (1). Measure the maximum operating force when it is moved. 6. Repeat the measurement three times and calculate the mean values.

3 12-

Evaluation: Refer to Operational Performance Standard.

T4-4-15

Knob Accelerator Pedal

2 3-

Brake Pedal

MNEC-01-036

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Stroke Summary: 1. Measure a play and operating condition of each control lever, pedal, and steering wheel, and measure the stroke. 2. Measure at the grip tip of each control lever. Measure at the pedal top of each pedal. 3. In case lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes. Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Measure as follows.  Measurement of Control Lever  Lower the bucket bottom onto the ground.  Stop the engine.  Measure each lever stroke from neutral to the stroke end of each control lever of lift arm, bucket, and forward/reverse at the grip top center.  Measurement of Pedal  Lower the bucket bottom onto the ground.  Stop the engine.  Measure the stroke from neutral to the stroke end of the pedal at the pedal top.  Measurement of Steering Wheel  Start the engine. (Slow idle)  Float the bucket slightly above the ground.  Measure the number of times of rotation required for movement of the steering wheel from the right to the left stroke end and from the left to the right stroke end. 2. Measure the chord length from neutral to the stroke end. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard.

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, dCAUTION: the brake function is reduced and serious hazard

may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. (Refer to Troubleshooting B.) IMPORTANT: Primary pilot pressure circuit delivers pressure oil from pilot pump (1) to the brake circuit when pressure in service brake accumulator (4) decreases, and accumulates pressure in service brake accumulator (4). Therefore, the brake circuit pressure (15.5 MPa, 158 kgf/cm2 or higher) is higher than the pilot circuit pressure. Use a pressure gauge capable of measuring 15.5 MPa (158 kgf/cm2) or higher. Preparation:

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

TNED-04-05-001

3. Disconnect hose (3) from the pilot filter (2) inlet or outlet port. Install the adapter (13/16-16UNF), a nipple, a pressure gauge, and a coupling between pilot filter (2) and hose (3). j : 22 mm, 24 mm, 27 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T1F3-04-05-001

T4-5-1

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

Power Mode Parking Switch Brake Switch

Forward/ Reverse Lever

Full stroke

2. Read pressures on the pressure gauge with no load. 3. Repeat the measurement three times and calculate the mean values.

fNOTE: When pressure in the service brake accumulator

decreases during measurement of primary pilot pressure, the measured value increases to 15.5 MPa (158 kgf/cm2) for several seconds.

Evaluation: Refer to Operational Performance Standard.

T4-5-2

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

Adjustment: 1. Remove plug (1) from the relief valve. A

j : 36 mm

2. Remove shim (2) from the relief valve. 3. Install the estimated number of shims (2).

fNOTE: Total thickness of shim (2) should be 1.5 mm or less. 4. Install shim (2) to the relief valve. Tighten plug (1). m : 98.0±9.8 (10±1.0 kgf·m) 5. After adjustment, check the set pressure.

fNOTE: Standard Change in Pressure (Reference) Shim (2) Thickness mm

Change in Pressure kPa

(kgf/cm2)

0.2

61.8

(0.63)

0.5

154.5

(1.57) TNED-03-07-008

Section A-A

TNED-03-07-018

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 a tee and a pressure gauge. j : 17 mm, 19 mm, 22 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement:

1. Select the following conditions: Accelerator Pedal

Power Mode Parking Switch Brake Switch

Forward/ Reverse Lever

Full stroke

2. Measure pilot pressure by using a pressure gauge with the lift arm and bucket control levers operated to full stroke. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-5-4

TNEJ-04-05-001

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

T4-5-5

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

ST 6941

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug (G1/4) from delivery pressure check port (1) on the main pump. Install the adapter (ST 6069), the hose (ST 6943), and the pressure gauge (ST 6941). l : 6 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

1 ST 6069

Measurement:

T4GB-04-05-008

1. Select the following conditions: Accelerator Pedal Full stroke

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

ST 6943

2. Measure pressure with the control levers in neutral without load. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-5-6

Pump 1 Delivery Pressure Check Port

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

T4-5-7

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Set Pressure Summary: 1. Measure the main relief valve set pressure at the delivery port in main pump.

ST 6941

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 delivery pressure check port (1) on the main pump. Install the adapter (ST 6069), the hose (ST 6943), and the pressure gauge (ST 6941). 1

l : 6 mm

ST 6069

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

ST 6943 T4GB-04-05-008

T4-5-8

Pump 1 Delivery Pressure Check Port

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: Refer to Operational Performance Standard.

T4-5-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Valve Pressure Adjustment Procedure 1. While holding lock nut (1), remove nut (3). j : 17 mm 2. While holding screw (2), loosen lock nut (1). j : 17 mm 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). m : 19.5 N·m (2 kgf/cm2)

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

2 T4GB-04-05-010

6. Check the relief set pressures.

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (2) 1/4 Turns Change in MPa 2.79 Pressure (kgf/cm2) (28.5)

1/2

3/4

5.59 (57)

8.36 (85.2)

11.2 (114)

b T105-06-05-002

T4-5-10

Pressure Increase

Pressure Decrease

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

T4-5-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Steering Relief Pressure Summary: 1. Measure the steering relief valve set pressure at the main pump delivery port and check performance of the steering relief valve.

ST 6941

l : 6 mm

ST 6069

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

T4GB-04-05-008

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

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

ST 6943

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: Refer to Operational Performance Standard.

T4-5-12

Pump 1 Delivery Pressure Check Port

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Steering Relief Valve (4) Pressure Adjustment Procedure

1. While holding lock nut (1), remove nut (3). j : 24 mm 2. While holding screw (2), loosen lock nut (1). j : 24 mm 3. Turn adjusting screw (2) in order to adjust the relief pressure to the specification. 4. While holding screw (2), tighten lock nut (1). j : 37 N·m (3.8 kgf·m)

T4GB-04-05-012

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

j : 37 N·m (3.8 kgf·m)

6. Check the relief set pressures.

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (2) 1/4 Turns Change in MPa 3.8 Pressure (kgf/cm2) (39)

1/2

3/4

7.5 (77)

11.3 (115)

15.0 (153) 2 T4GB-04-05-013

b T105-06-05-002

T4-5-13

Pressure Increase

Pressure Decrease

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

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Select the following conditions: Accelerator Pedal Full stroke

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

2. 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. ST 6941

3. If the overload relief valve performance must be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range. 1

Preparation:

ST 6069

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

ST 6943 T4GB-04-05-008

3. Remove the plug (G1/4) from delivery pressure check port (1) on the main pump. Install the adapter (ST 6069), the hose (ST 6943), and the pressure gauge (ST 6941).

l : 6 mm

T4-5-14

Pump 1 Delivery Pressure Check Port

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Evaluation: Performance of the overload relief valves are normal if the measured main relief pressures are within the specified value range. Refer to Operational Performance Standard.

Overload Relief Valve Pressure Adjustment Procedure

fNOTE: In principle, adjust the overload relief valve

TNED-04-05-003

pressure on a test stand.

Loosen lock nut (1) and adjust pressure by using adjusting screw (2).

Lock Nut

Adjusting Screw

1. Loosen lock nut (1). j : 22 mm 2. Turn adjusting screw (2) in order to adjust the pressure. l : 6 mm

3. Tighten lock nut (1). j : 22 mm 4. After adjustment, check the set pressure.

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (2) 1/4 Turns Change in MPa 5.2 Pressure 2 (kgf/cm ) (54)

1/2

3/4

10.6

15.9

21.1

(108)

(162)

(216)

W107-02-05-129 a-

T4-5-15

Pressure Increase

Pressure Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Pump Flow Rate Measurement  P-Q Control (Torque Control) Summary: Main pump performance is checked by measuring the pump flow rate by using a hydraulic tester installed at the main pump delivery port to be measured. Use MPDr. and a pressure gauge at the same time. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5 % than the accurately measured value. In order to measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank.

6. Remove the vacuum pump. Loosen plug (12) on top of the pump casing. Bleed air from the casing until oil only comes out. j : 41 mm 7. Fully open the loading valve of hydraulic tester (5). 8. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. Connect MPDr. and select the monitoring function.

Preparation:

Measurement:

1. Stop the engine. Push the air bleed valve on top the hydraulic oil tank and bleed air. Connect a vacuum pump to the oil filler port.

1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). 2. Measure the maximum flow rate.

fNOTE: Operate the vacuum pump while connecting the pump flow rate test line. 2. Disconnect delivery hose (7) from the main pump. Connect test hose (3) to the main pump delivery port.

3. Select the following conditions: Accelerator Pedal Full stroke

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

j : 41 mm 3. Install test hose (3) to hydraulic tester (5) by using adapter (4). Install adapter (6) and delivery hose (7) to hydraulic tester (5). j : 41 mm 4. Install a pressure gauge to the main pump to be measured. (Refer to Main Relief Set Pressure.)

4. Slowly restrict the loading valve of hydraulic tester (5) while relieving pressure in the bucket tilt circuit. Measure the flow rates and engine speeds at each pressure point specified in the P-Q curve. (Refer to T4-2-10.) 5. Repeat the measurement three times and calculate the mean values.

l : 6 mm 5. Disconnect the hose (14) from regulator port ST (13). Install the plug (G1/4) to the removed hose (14) and the regulator port ST (13). j : 17 mm

T4-5-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Evaluation: 1. Convert the measured flow rates to those at the specified engine speed by using the following formula: Qc = Ns×Q/Ne Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Engine Speed: 2200 min-1 Ne : Measured Engine Speed: Values indicated on MPDr. 2. Standard Flow Rate Refer to Operational Performance Standard.

TNED-04-05-005

TNED-04-05-004

14 34-

Test Hose (1-7/16-12UN) Adapter 1-7/16-12UN×G1-1/2

56-

Hydraulic Tester (ST 6299) Adapter 1-7/16-12UN×G1-1/2

7- Delivery Hose 12- Plug

T4-5-17

13- Port ST 14- Hose

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test  Pilot Characteristics Summary: Main pump performance is checked by measuring the pump flow rate by using hydraulic tester (5) installed at the main pump delivery port to be measured. Use MPDr. and pressure gauge (18) at the same time. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5 % than the accurately measured value. In order to measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank. Preparation: 1. While referring to steps 1 to step 3 on T4-5-16, install hydraulic tester (5) to the main pump to be measured. 2. Disconnect the hose from regulator port Pi1 (21). Install the plug (G1/4) to the removed hose. j : 19 mm 3. Connect regulator port Pi2 (8) and port VQ (2) to the hydraulic oil tank. j : 19 mm 4. Install adapters (15) (3 used) to pressure reducing valve (16). Remove plug (23) from manifold valve (1). Install adapter (13) and hose (14). Connect hose (14) to port P1 of pressure reducing valve (16). l : 8 mm j : 19 mm 5. Install tee (17) to port P2 of pressure reducing valve (16). Connect pressure gauge (18) and hose (9) to tee (17). Connect hose (9) to the regulator (c). j : 19 mm 6. Connect hose (19) and tee (20) to port T of pressure reducing valve (16). Disconnect hose (10) from return pipe (22). Install tee (20) to return pipe (22). Connect hoses (10, 19) to tee (20). j : 22 mm, 27 mm

T4-5-18

7. Remove the vacuum pump. Loosen plug (12) on top of the pump casing. Bleed air from the casing until oil only comes out. j : 41 mm 8. Fully open the loading valve of hydraulic tester (5). 9. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 3

TNED-04-05-005

21 8 12

TNED-04-05-007

Pressure Reducing Valve Port Position

16 10

19 15 T P2

TNED-04-05-006

To Manifold Valve

To Regulator Port Pi1 (21)

123456-

Manifold Valve Port VQ Test Hose (1-7/16-12UN) Adapter 1-7/16-12UN×G1-1/2 Hydraulic Tester (ST 6299) Adapter 1-7/16-12UN×G1-1/2

789101213-

Delivery Hose Port Pi2 Hose G1/4 Hose G1/2 Plug (Regulator) Adapter G3/8

14- Hose G3/8 15- Adapter G3/8 16- Pressure Reducing Valve (4325439) 17- Tee G3/8×G1/4×G1/4 18- Pressure Gauge (ST 6931)

T4-5-19

1920212223-

Hose G3/8 Tee G3/8×G1/2×G1/2 Port Pi1 Return Pipe Plug G3/8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). 2. Measure pump flow rate in response to the external command pilot pressure. 3. Select the following conditions: Accelerator Pedal Full stroke

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

4. Adjust the pressure reducing valve set pressure to each pressure point specified along the main pump P-Q curve. (Pilot Characteristics) (Refer to T4-2-11.) Measure the flow rates and engine speeds at the pressure points specified in the P-Q curve. 5. Repeat the measurement three times and calculate the mean values. Evaluation: 1. Convert the measured flow rates to those at the specified engine speed by using the following formula: Qc = Ns×Q/Ne Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Engine Speed: 2200 min-1 Ne : Measured Engine Speed: Values indicated on MPDr. 2. Standard Flow Rate Refer to Operational Performance Standard.

T4-5-20

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 3

TNED-04-05-005

21 8 12

TNED-04-05-007

Pressure Reducing Valve Port Position

16 10

19 15 T P2

TNED-04-05-006

To Manifold Valve

To Regulator Port Pi1 (21)

123456-

Manifold Valve Port VQ Test Hose (1-7/16-12UN) Adapter 1-7/16-12UN×G1-1/2 Hydraulic Tester (ST 6299) Adapter 1-7/16-12UN×G1-1/2

789101213-

Delivery Hose Port Pi2 Hose G1/4 Hose G1/2 Plug (Regulator) Adapter G3/8

14- Hose G3/8 15- Adapter G3/8 16- Pressure Reducing Valve (4325439) 17- Tee G3/8×G1/4×G1/4 18- Pressure Gauge (ST 6931)

T4-5-21

1920212223-

Hose G3/8 Tee G3/8×G1/2×G1/2 Port Pi1 Return Pipe Plug G3/8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Regulator Adjustment

1 2

7 8

10 TNED-03-01-025

12-

Lock Nut (For Minimum Flow Rate) Adjusting Screw (For Minimum Flow Rate)

34-

Lock Nut (For Maximum Flow Rate) Adjusting Screw (For Maximum Flow Rate)

567-

Adjustment Item 1. Maximum Flow Rate Q

Lock Nut (For Pilot Pressure Characteristic) Adjusting Screw (For Pilot Pressure Characteristic) Lock Nut (For P-Q Control)

Adjusting Screw (For P-Q Control) 9- Lock Nut (For P-Q Control) 10- Adjusting Screw (For P-Q Control)

Adjustment Procedure

Remarks

Loosen lock nut (3) and turn adjusting screw (4). Rotating adjusting screw (4) 1/4 a turn clockwise decreases the flow rate by 12.58 cm3/rev. j : 22 mm m : 20 N·m (2 kgf·m)

Do not turn it more than 2 turns. Do not increase the maximum flow rate. In other words, do not turn the adjusting screw counterclockwise. Securely tighten lock nut (3) after adjustment.

P TDAA-04-05-004

T4-5-22

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment Item 2. Pilot Pressure Characteristics Q

Adjustment Procedure

Remarks

Loosen lock nut (1) and turn adjusting screw (2). Rotating adjusting screw (2) 1/4 turn clockwise decreases the flow rate by 9.22 cm3/rev. j : 17 mm m : 20 N·m (2 kgf·m)

Do not turn adjusting screw (2) more than one turn. Securely tighten lock nut (1) after adjustment.

TNED-04-5-008

3. P-Q Control (Torque Adjustment) Loosen lock nut (7) and turn adjusting Do not turn it more than 1 turn. screw (8). Rotate the adjusting screws watching Rotating the adjusting screw 1/4 a turn the engine performance. clockwise increases the flow rate by Securely tighten lock nut (7) after 15.5 cm3/rev. adjustment. j : 30 mm m : 30 N·m (3 kgf·m) Pd

Q TDAA-04-05-006

4. P-Q Control (Torque Adjustment) Loosen lock nut (9) and turn adjusting Do not turn it more than 1 turn. screw (10). Rotate the adjusting screws watching Rotating the adjusting screw 1/4 a turn the engine performance. clockwise increases the flow rate by 4.2 Securely tighten lock nut (9) after cm3/rev. adjustment. Pd j : 13 mm m : 10 N·m (1 kgf·m)

TDAA-04-05-007

T4-5-23

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Service Brake Pressure (Front and Rear) If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard

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

Summary: 1. Measure the pressure at the outlet port of brake valve (5) when brake pedal (2) is depressed. Preparation: Set blocks (1) onto the front and rear dCAUTION: tires in order not to move the machine. Keep away from the machine. 1. Stop the engine.

T4GB-04-05-017

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

3. Depress brake pedal (2) at least 50 strokes in order to decrease the accumulated pressure left in the brake circuit. 4. Install a pressure gauge to the front and rear wheel brake circuits.  Front wheel brake circuit pressure: Disconnect hose (3) from brake valve (5). Install the tee (9/16-18UNF) and a pressure gauge between brake valve (5) and hose (3). j : 22 mm  Rear wheel brake circuit pressure: Disconnect hose (4) from brake valve (5). Install the tee (9/16-18UNF) and a pressure gauge between brake valve (5) and hose (4). j : 22 mm 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

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

3 TNEJ-04-05-002

T4-5-24

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. 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: Refer to Operational Performance Standard. 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.

T4-5-25

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Parking Brake Pressure Summary: 1. Measure the parking brake release pressure in the parking brake release circuit. Preparation: Set blocks (1) onto the front and rear dCAUTION: 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. Disconnect brake hose (2) from the parking brake side. Install a pressure gauge to the removed hose. j : 19 mm

T4GB-04-05-017

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

1 2

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

M4GB-06-004

T4-5-26

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

Full stroke

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: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-5-27

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Brake Accumulator Pressure If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard

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

Summary: 1. Measure the accumulated brake pressure at the accumulator 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 dCAUTION: tires in order not to move the machine. Keep away

T4GB-04-05-017

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 accumulator (5) of the brake circuit. 4. Disconnect hoses (3, 4) from brake charge valve (2). Install the tee (7/16-20UNF) and a pressure gauge between brake charge valve (2) and hoses (3, 4). 2

j : 19 mm 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

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

TNED-04-05-009 a-

T4-5-28

To Brake Valve

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. Measure the maximum pressure when depressing the brake pedal slowly several times. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-5-29

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Brake Warning Pressure (PressureDecreasing) If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard

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

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

T4GB-04-05-017

from the machine. 1. Stop the engine.

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

j : 19 mm 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

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

TNED-04-05-009 a-

T4-5-30

To Brake Valve

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: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-5-31

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Brake Warning Pressure (PressureIncreasing) If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard

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

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

T4GB-04-05-017

from the machine. 1. Stop the engine.

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

j : 19 mm 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

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

TNED-04-05-009 a-

T4-5-32

To Brake Valve

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: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-5-33

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Transmission Clutch Pressure Summary: 1. Measure each operating pressure of the transmission clutch at each check port of the transmission control valve. Preparation: 1. Stop the engine. 2. Remove the plug from the check port. Install a hose, an adapter, and a pressure gauge. l : 5 mm m : 6 N·m (0.6 kgf/cm2)

fNOTE: Although the pressure can be measured by using one pressure gauge, all pressures can be measured by using six pressure gauges at the same time. 3. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

4. Maintain the torque converter oil temperature at 80 to 95 °C (176 to 203 °F). Measurement: Set blocks (1) onto the front and rear dCAUTION: tires in order not to move the machine. Keep away from the machine. 1. Select the following conditions:

Accelerator Pedal Full stroke

Brake Pedal Full stroke

Power Mode Switch ON

T4GB-04-05-017

Declutch Position Switch OFF

2. Operate the forward/reverse lever and the shift switch. Measure each clutch pressure. (As for the combination of clutch pack, refer to the following page.) 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard.

T4-5-34

Parking Brake Switch OFF

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test

T4GB-04-05-021

123-

Second Speed Low-Speed Forward Third Speed

456-

High-Speed Forward Reverse First Speed

Transmission Clutch Pack Combination Selected Speed Shift First Speed Forward (F1) Second Speed Forward (F2) Third Speed Forward (F3) Fourth Speed Forward (F4) Fifth Speed Forward (F5) First Speed Reverse (R1) Second Speed Reverse (R2) Third Speed Reverse (R3)

Directional Control Clutch Pack Low-Speed High-Speed Forward (2) Forward (4) 

Reverse (5)

Speed Control Clutch Pack First Speed (6) Second Speed (1) 



Third Speed (3)

 



 



fNOTE: The operating pressure is applied to the clutch

with the mark  when setting the forward/reverse lever and the shift switch to each selected speed shift.

T4-5-35

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Torque Converter Pressure (Inlet) Summary: 1. Measure the inlet pressure of torque converter pressure at the check port of torque converter housing. Preparation: 1. Stop the engine. 2. Remove plug (3) from the check port of transmission control valve (2). Install a hose, an adapter, and a pressure gauge to the open part. l : 5 mm m : 6 N·m (0.6 kgf/cm2) 3. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 4. Maintain the torque converter oil temperature at 80 to 95 °C (176 to 203 °F). Measurement: Set blocks (1) onto the front and rear dCAUTION: tires in order not to move the machine. Keep away from the machine. 1. Select the following conditions:

Accelerator Pedal Full stroke

Brake Pedal Full stroke

Power Mode Switch ON

T4GB-04-05-017

Declutch Position Switch OFF

2. Set the forward/reverse lever to F (Forward) and the shift switch to 5 (Fifth Speed). Measure the pressure. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard.

T4-5-36

Parking Brake Switch OFF

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 3

T4GB-04-05-021 23-

Transmission Control Valve Plug

T4-5-37

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

T4-5-38

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Transmission Learning IMPORTANT: When transmission or transmission control valve has been repaired/replaced, and TCU has been replaced, perform transmission 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 transmission oil temperature (2) appears. (Refer to T5-2.) 4. Stall the transmission with the following machine conditions. Condition:  Declutch Position Switch: OFF  Travel Mode: Manual Mode  Shift Switch: 5th  Parking Brake Switch: OFF  Brake Pedal: Depressed (Fully)  Accelerator Pedal: Depressed (Fully)  Forward/Reverse Lever: Forward Position

Detail A

TNDB-01-02-029

5. Depress the accelerator pedal and raise transmission oil temperature (2) up to 110 ºC (230 ºF). 6. When transmission oil temperature (2) is 110 ºC (230 ºF), stop transmission stalling with the following machine conditions. Deactivation Condition:  Accelerator Pedal: Not Depressed  Forward/Reverse Lever: Neutral Position  Parking Brake Switch: ON  Brake Pedal: Not Depressed

TNDB-01-02-005

TNDB-04-06-011

T4-6-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment MPDr. Operation: IMPORTANT: Do not operate control levers and other switches when learning is performed.

1. Start MPDr. Select Functions, Machine Body, Main Setting, Constant Change, Calibration Value Setting, and Transmission Calibration in sequence. Then, the Transmission Calibration screen appears. (Figure A) 2

2. When transmission oil temperature (3) is 110 ºC, select Start (1) from the pull-down menu on the Transmission Calibration screen and click Set (2). 3. The message on the inquity is displayed on the Transmission Calibration screen on MPDr.. Click Yes (4) (Figure B).

TNDB-04-06-013

4. The learning starts and Progress (C1 to C6) of learning is displayed on the monitor. (Figure C)

TNDB-04-06-011

3 B

TNDB-04-06-014

4 C

T4-6-2

TNDB-04-06-004

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment 5. When the learning is completed, the Learning End screen appears on the monitor. (Figure D)

6. The message "Writing process in controller is complete" is displayed on the Transmission Calibration screen on MPDr. Click OK (5). (Figure 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 Transmission Calibration screen on MPDr. Perform the learning again. (Figure F)

T4GB-04-06-006

TNDB-04-06-015

TNDB-04-06-016

T4-6-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment (Blank)

T4-6-4

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

IMPORTANT: When lift arm angle sensor has been replaced, perform lift arm angle sensor learning. Preparation: 1. Connect MPDr. (Refer to Transmission Learning.) 2. Start the engine. 3. Set front control lever lock switch (1) to UNLOCK Position (3). 4. Raise lift arms to the highest level by lift arm raise operation. 5. Set front control lever lock switch (1) to LOCK Position (2).

MNEC-01-041

6. Set the key switch to the OFF position. 1

3 MNEC-01-015 2-

T4-6-5

LOCK

UNLOCK

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

IMPORTANT: When lift arm angle sensor has been replaced, perform lift arm angle sensor learning. 1. Set the key switch to the ON position. 2. Start MPDr. Select 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. (Figure A)

3. Select Start (1) from the pull-down menu on the Arm Angle Sensor Calibration screen and click Set (2). TNDB-04-06-017

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. 4. When the learning is completed correctly, the buzzer sounds. The message "Writing process in controller is complete" is displayed on the Arm Angle Sensor Calibration screen on MPDr. Click OK (3). (Figure B)

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

fNOTE: In case the learning is stopped on the way, the

message on the error is displayed on the Angle Sensor Calibration screen on MPDr. Perform the learning again. (Figure C) 3

TNDB-04-06-018

TNDB-04-06-019

T4-6-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Digging Position Adjustment 1

IMPORTANT: When lift arm angle sensor has been replaced, perform the digging position adjustment after performing the lift arm angle sensor learning. (only the machine with the ride control system attached) In case of the machine without the ride control system, perform the digging position adjustment after performing the lift arm angle sensor learning. Preparation: 1. Connect MPDr. (Refer to Transmission Learning.)

MNEC-01-041

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

4. Lower the lift arms and set the bucket on the ground horizontally. 5. Set front control lever lock switch (1) to LOCK Position (2). 6. Set the key switch to the OFF Position.

3 MNEC-01-015 2-

T4-6-7

LOCK

UNLOCK

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

1. Set the key switch to the ON position. 2. Start MPDr. Select Functions, Machine Body, Main Setting, Constant Change, Calibration Value Setting, and Digging Position Calibration in sequence. Then, the Digging Position Calibration screen appears. (Figure A) 3. Select Start (1) from the pull-down menu on the Digging Position Calibration screen and click Set (2).

4. When the learning is completed correctly, the message "Writing process in controller is complete" is displayed on the screen on MPDr. Click ON (3). (Figure B) 5. Set the key switch to the OFF position and finish the learning.

TNDB-04-06-020 B

fNOTE: Digging position adjustment can be set at the position lower than horizontal lift arm position.

T4-6-8

TNDB-04-06-021

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

Group 2 Monitor

Outline..................................................................................... T5-2-1 Operating Procedures of Service Menu....................... T5-2-3 Coolant Temperature Gauge and Transmission 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 Snapshot Data....................................................................... T5-3-6 Communication System.................................................... T5-3-7

Group 4 Component Layout

Main Component (Overview).......................................... T5-4-1 Main Component................................................................. T5-4-2 Main Component (Travel System)................................. T5-4-3 Electrical System (Overview)........................................... T5-4-5 Electrical System (Cab)....................................................... T5-4-6 Engine and Fan Pump......................................................T5-4-14 Pump Device.......................................................................T5-4-15 Control Valve.......................................................................T5-4-15 Fan Valve (Option).............................................................T5-4-16 Drive Unit..............................................................................T5-4-17 Front Axle..............................................................................T5-4-17 Manifold Valve.....................................................................T5-4-18 Parking Brake Solenoid Valve Block............................T5-4-18 Brake Charge Valve............................................................T5-4-18 Steering Valve, Secondary Steering Valve (Option)................................................................T5-4-19 Secondary Steering Pump (Option)............................T5-4-19 Ride Control Valve (Option)............................................T5-4-20

Group 5 Troubleshooting A

Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure.............................. T5-5-1 MC Fault Code List............................................................... T5-5-3 Column Display Controller Fault Code List...............T5-5-15 Air Conditioner Controller Fault Code List................T5-5-18 ECM FAULT CODE CONTRAST LIST...............................T5-5-19 TCU Fault Code List...........................................................T5-5-35 MC Fault Codes 111000 to 111002..............................T5-5-55 MC Fault Code 111003.....................................................T5-5-56 MC Fault Codes 111006, 111007, 111011.................T5-5-59 CAN1 Harness Check........................................................T5-5-60 MC Fault Codes 111014, 111025..................................T5-5-64 MC Fault Code 111100.....................................................T5-5-65 MC Fault Code 111103, 111106, 111107...................T5-5-66 MC Fault Codes 111205...................................................T5-5-67 MC Fault Codes 111200, 111203..................................T5-5-68 MC Fault Codes 111217, 111312..................................T5-5-69 MC Fault Codes 111204, 111206..................................T5-5-70 MC Fault Code 111208.....................................................T5-5-71 MC Fault Codes 111311, 111313..................................T5-5-72 MC Fault Code 111411.....................................................T5-5-73 MC Fault Code 111412.....................................................T5-5-74 MC Fault Code 111413.....................................................T5-5-75 MC Fault Code 111422.....................................................T5-5-76 MC Fault Code 111901.....................................................T5-5-77 MC Fault Codes 120003, 120004..................................T5-5-78 MC Fault Codes 120014...................................................T5-5-79 Column Display Controller Fault Code 115001.......T5-5-81 Column Display Controller Fault Code 115011.......T5-5-82 Column Display Controller (Information) Fault Codes 120500 to120503, 120505................T5-5-83 Column Display Controller Fault Codes 120506, 120507, 120510 to 120512, 120515, 120516, 120518............................................T5-5-84

Group 6 Troubleshooting B

Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure.................................... T5-6-1 Relationship between Machine Trouble Symptoms and Related Parts............................................................ T5-6-3 Correlation between Trouble Symptoms and Part Failures.............................................................................T5-6-24 Engine System Troubleshooting..................................T5-6-47 All Actuator System Troubleshooting.........................T5-6-53 Front Attachment System Troubleshooting.............T5-6-59 80Z6 Trbl

Steering System Troubleshooting...............................T5-6-69 Travel System Troubleshooting....................................T5-6-73 Brake System Troubleshooting.....................................T5-6-83 Other System Troubleshooting.....................................T5-6-87 Exchange Inspection..................................................... T5-6-101 Air Bleeding Procedures for Brake (Axle)................ T5-6-103

Group 7 Air Conditioner

Outline..................................................................................... T5-7-1 Functions of Main Parts..................................................... T5-7-6 Troubleshooting.................................................................T5-7-11 Air Conditioner Controller Fault Code List................T5-7-12 Air Conditioner Controller Fault Codes E11 to E22........................................................................T5-7-13 Air Conditioner Controller Fault Codes E43 to E92........................................................................T5-7-14 Work after Replacing Components.............................T5-7-36 Refill Compressor Oil........................................................T5-7-37 Charge Air Conditioner with Refrigerant..................T5-7-38 Hose and Pipe Tightening Torque................................T5-7-46

80Z6 Trbl

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

 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). IMPORTANT: The information controller receives and retains a record of the electrical signal system malfunction of each controller in the form of fault codes by using the CAN communication. In addition, the self-diagnosing function records the electrical signal system malfunction in the form of fault codes Example: Fault Code 111000-2: Abnormal EEPROM  Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Refer to troubleshooting B for diagnosis by using trouble symptom. Refer to these procedures when no fault codes are displayed after diagnosing the machine by using MPDr. (or the service menu of monitor).

 Component Layout

Example: Even if accelerator pedal is operated, engine speed does not change.  Air Conditioner This group contains system of the air conditioner, troubleshooting, and procedures for charging air conditioner with refrigerant.

T5-1-1

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

T107-07-01-001

T4GB-05-01-002

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

T5-1-2

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

machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Stop the engine before disconnecting wire harnesses or hydraulic lines. Perform diagnosis by connecting MPDr. to the machine or by using the service menu of monitor. In case any fault code has been displayed by diagnosis by using MPDr. (the service menu of monitor), check the cause of the trouble by referring to Troubleshooting A in this section. In case any fault code has been displayed by diagnosis by using MPDr. (the service menu of monitor), write the fault code. Delete the fault code once and retry self-diagnosis again. If the fault code is displayed again, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code (displayed by the service menu of monitor) will be deleted. Therefore, in case the problems which are not easily re-predicable are encountered, check the fault code by using MPDr.. In case the fault code is not displayed, check operating condition of each component by referring to Troubleshooting B in this section and by using the monitoring function of 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 wire harness from the negative terminal side in battery first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses and fusible links and, in some cases, cause fire due to short circuiting. In addition, even when the key switch is turned OFF, the controller may be operated for a specified time. Therefore, disconnect the wire 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 Code Color

W R White Red Lg Or Orange Light green

L Blue Br Brown

G Green p Pink

Y Yellow Gr Gray

B Black V Violet

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

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

TDAA-05-08-002

1 2 3

4 TDAA-05-08-003 12-

Correct Rusting

34-

Bent Coming Off

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

TDAA-05-08-004

T5-1-7

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

T107-04-05-002

 Raise Lock, Pull, and Separate Type

T107-04-05-003

T4GB-05-06-003

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

T107-04-05-004

T5-1-8

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure  Remove the Bolt, Pull, and Separate Type l : 4 mm

TNEE-05-01-001

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

T4GB-05-06-001

T4GB-05-06-002

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

T4GB-05-06-007

T5-1-9

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

fNOTE: 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.)

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

M178-07-034 d-

Terminals connected to the power source

Terminals connected to loads (accessories)

a, b a

c ab-

Fuse Box A Fuse Box B

10 9 8 7 6

20 19 18 17 16

5 4 3 2 1

15 14 13 12 11

MNEC-01-047 c-

Relay Box

M178-07-034

T5-1-10

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Box A (a) Fuse No. Capacity Connected to 1 5A Back Buzzer Relay, Backup Buzzer 2 5A Brake Light Relay, Brake Light (RH), Brake Light (LH), Brake Light Switch, Turn Signal Lever, Turn Signal Light Relay (RH) (Power), Turn Signal Light Relay (LH) (Power) 3 10A Head Light Relay, Head Light (LH), Head Light (RH) 4 10A Light Switch, Dimmer Switch, Work Light Switch 5 (15A) Auxiliary 1 6 10A Horn Relay, Horn, Horn Switch 7 10A Flasher Relay, Hazard Light Switch, Turn Signal Light Relay (RH), Turn Signal Light Relay (LH), Turn Signal Light (Hazard Light) (RH), Turn Signal Light (Hazard Light) (LH) 8 10A Load Dump 2 Relay, Load Dump 1 Relay, MC (Power), GSM (Option) (Power), GPS (Option) (Power), Column Display Controller (Backup Power), Information Controller (Power) 9 10A TCU (Power) 10 30A ECM Main Relay, Fuel Pump Relay, Fuel Pump 11 10A Parking Brake Switch, Hazard Light Switch, Work Light Switch, Control Lever Lock Switch, Power Mode Switch, Fan Reverse Rotation Switch (Option), Ride Control Switch (Option), Secondary Steering Check Switch (Option), First Speed Fixed Switch, Tail Light (RH), Tail Light (LH), Clearance Light (RH), Clearance Light (LH) 12 (20A) Auxiliary 2 (Rear View Monitor, Rear Camera) 13 10A Battery Relay, ECM Main Relay (Power), Fuel Pump Relay (Power), ECM, Column Display Controller, Buzzer in Column Display Controller, Information Controller, Declutch Position Switch, Speed Shift Retard Mode Switch, MC, GSM (Option), GPS (Option), Back Buzzer Relay (Power), Air Conditioner Controller (Air Conditioner), Fresh/Re-Circulated Air Damper Servo Motor (Air Conditioner), Compressor Relay (Air Conditioner) (Power), Blower Motor Relay (Air Conditioner) (Power), Condenser Relay (Air Conditioner) 14 10A TCU (Power), Parking Brake Relay 1, Parking Brake Relay 2 (Power), Parking Brake Switch, DIAG, Hold Switch, DSS (Down Shift Switch), Forward/Reverse Lever, Shift Switch 15 10A MC (Solenoid Valve Power) 16 5A Coil (Bucket Tilt Side), Bucket Leveler Relay, Bucket Proximity Switch, Coil (Lift Arm Raise Side), Kickout Relay, Lift Arm Proximity Switch, Coil (Lift Arm Lower Side), Pilot Shut-Off Relay, Control Lever Lock Switch, Pilot Shut-Off Solenoid Valve, Quick Coupler Switch (Option) 17 20A Work Light (Rear) Relay, Rear Work Light (RH), Rear Work Light (LH) 18 5A Parking Brake Solenoid Valve, Parking Brake Relay 2 19 10A High-Beam Relay, Head Light/High-Beam (RH), Head Light/High-Beam (LH) 20 5A Secondary Steering Pump Relay (Option), Secondary Steering Motor (Option)

T5-1-11

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Box B (b) Fuse No. 1 2 3

13 14 15

Capacity Connected to 5A Radio (Backup Power) 10A Cigar Lighter 15A Wiper Motor (F), Wiper Relay (F) 2, Wiper Relay (F) 1, Washer Relay (F), Washer Motor (F), Wiper/ Washer Switch (F) 20A Work Light (Front) Relay, Front Work Light (Right) (Cab), Front Work Light (Left) (Cab) 10A Wiper Motor (R), Wiper Relay (R), Washer Relay (R), Washer Motor (R), Wiper/Washer Switch (R) 10A Compressor Relay (Air Conditioner), Compressor (Air Conditioner), 15A External Power (12 V) (Option) 20A Seat Heater (Option) 10A Beacon Light Switch (Option), Beacon Light (Option) 20A Blower Motor Relay (Air Conditioner), Blower Motor (Air Conditioner), Power Transistor 5A Cab Light, Radio 10A High/Low Pressure Switch (Air Conditioner), Condenser Relay (Air Conditioner), Condenser Relay (HI) (Air Conditioner), Electric Fan (Air Conditioner) (10A) Auxiliary 3 (10A) Auxiliary 4 -

16 17 18 19 20

4 5 6 7 8 9 10 11 12

T5-1-12

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fusible Link Inspection

Inspection 1. Visually inspect fusible links (2, 3). Replacement 1. Disconnect the negative cable from the battery. 2. Pull out fusible links (2, 3). Replace fusible links (2, 3). 3. Connect the negative cable to the battery. MNEC-01-503

T111-04-05-015 12-

T5-1-13

Battery Relay Fusible Link (140 A) (2 Used)

Fusible Link (65 A) (2 Used)

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 indicator (1) will disappear. If alternator indicator (1) is displayed while the engine is running, the alternator might be defective. How to Check Alternator 1. Set the key switch to the ON position. Confirm that alternator indicator (1) is displayed. 2. Measure voltage between 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. 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.

MNDB-01-008

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

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

 Single-line short-circuit check Disconnect both end connectors of the wire harness and check continuity between one end connector of the wire harness and the body:  0 Ω = Short-circuit is present.  ∞ Ω = No short-circuit is present. T107-07-05-003

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

A B C

a b c

T107-07-05-004

A B C

a b c

T107-07-05-005

T5-1-16

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure (Blank)

T5-1-17

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

Location to be Measured Between (2) and (1): Between (3) and (2): Between (3) and (1): Between (4) and Ground: Between (5) and Ground: Between (1) and Ground:

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

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

ON or START ON or START

Between (11) and Ground: Key Switch (M) Between (7) and Ground: Intake Air Heater Relay *2

ON ON ON ON

Between (9) and Ground: Alternator (B)/Generating Voltage 26 to 30 V Between (8) and Ground: Battery Relay (Switch) 26 to 30 V Between (17) and Ground: Fusible Link (140 A)/Generating Voltage 26 to 30 V Between (14) and Ground: Column Display Controller (#2-28) 13 to 30 V

ON ON ON

Between (9) and Ground: Alternator (B) Between (10) and Ground: Load Dump 1 Relay Between (6) and Ground: Battery Relay (Coil)

*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

20 to 25 V 20 to 25 V

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

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

h(8)

c k

3 2

2-17

m a 6

2-28

1-21

J2-50 J2-40 J2-42

E 7

E-

Ground

abc-

Battery Alternator Fusible Link A (65A)

def-

Battery Relay Intake Air Heater Load Dump 1 Relay

ghi-

T5-1-19

Key Switch Fuse Box A Column Display Controller

TNEJ-05-01-001

jECM k- Fusible Link (140 A) m- To Battery Relay

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Engine Accessory Circuit Stopped Stopped Stopped

Key Switch

Location to be Measured

Specification

ON ON ON

Between (12) and Ground: Key Switch (ACC) Between (13) and Ground: Radio Between (5) and Ground: Fusible Link A (65A)

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

T5-1-20

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

E 5 c

n(1)

TNEJ-05-01-002 E-

Ground

ac-

Battery Fusible Link A (65A)

dg-

Battery Relay Key Switch

hp-

T5-1-21

Fuse Box B Radio

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

Key Switch

Location to be Measured

Specification

START START START START START START START START START START START

Between (6) and Ground: Battery Relay (Coil) Between (8) and Ground: Battery Relay (Switch) Between (14) and Ground: Starter (#30) Between (15) and Ground: Starter (#50) Between (16) and Ground: Starter Relay 1 (B) Between (17) and Ground: Key Switch (ST) Between (18) and Ground: Neutral Relay Between (19) and Ground: Fuse Box A (#10) Between (20) and Ground: ECM(J3-4) Between (21) and Ground: ECM Main Relay (Switch) Between (22) and Ground: ECM Main Relay (Coil)

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

ON ON ON ON ON

Between (11) and Ground: Key Switch Between (23) and Ground: Fuse Box A (#14) Between (24) and Ground: TCU(#67) Between (25) and Ground: Neutral Relay (Coil) Between (18) and Ground: Neutral Relay (Switch)

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

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

T5-1-22

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

8 4 E

d t

h(14)

24 g

11 17

t r 18

19 h(10) b

20 j

21 s

15 22 16 c

E TNEJ-05-01-003 E-

Ground

bcd-

Starter Starter Relay 1 Battery Relay

g hj-

Key Switch Fuse Box A ECM

rst-

T5-1-23

Neutral Relay ECM Main Relay Forward/Reverse Lever

TCU

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

Two Polarities 1

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

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

T107-07-05-007

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

Two Polarities 1

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

T107-07-05-008

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

Three Polarities 1

T107-07-05-009

T5-1-24

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

Turn the key switch OFF. Disconnect the sensor connector. Turn the key switch ON. Connect terminal #1 (power source) of the body harness end connector to terminal #2 (signal). (Power voltage is used as a false signal.) Check this state by using the monitor function of MPDr. When the maximum value is displayed, MC and the circuit up to the body harness end connector are normal. If "ON" is displayed, the pressure switch circuits are normal. IMPORTANT: Do not connect terminal #1 or #2 to terminal #3 or to the body (ground) when checking a three-polarity connector.

T107-07-05-010

Three Polarities

NOTE: Some kinds of sensors can be monitored by the service menu of the monitor.

T107-07-05-011

T5-1-25

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Test Harness

Parts Number 4283594 (ST 7126)

Install a test harness between connectors. Check the circuit condition depending on whether the test harness lamp lights or extinguishes during operation.  Parts Number 4283594 (ST 7126) Use in order to check a single-line (discontinuity and/or voltage). T107-07-05-012

 During Operation: Light is ON. Parts Number (ST 7226)

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

3 1

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

150

4 50 50

1 T107-07-06-015

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

TDAA-05-06-003

T5-1-26

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

fNOTE: The connecting procedures of test harness of

pump delivery pressure sensor (1) are explained. 1. Disconnect a connector of pump delivery pressure sensor (1).

TNED-05-01-003

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

39 38

37 12 36 35

14 15

33 32

12345678910111213-

Left Turn Signal Light Indicator High Beam Indicator Work Light Indicator Right Turn Signal Light Indicator (Unused) (Unused) Service Indicator Maintenance Indicator Parking Brake Indicator Clearance Light Indicator Control Lever Lock Indicator (Unused) Brake Oil Low Pressure Indicator

16 31 30

29 28 27 26

25 24 23 22 21 20 19 18 17

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- (Unused) 23- Monitor Display Selection Switch (Up) 24- Preheat Indicator

25- Monitor Display Selection Switch (Down) 26- Forward/Reverse Selector Switch Indicator (Option) 27- Monitor Display 28- Fan Reverse Rotation Indicator (Option) 29- Engine Warning Indicator 30- Overheat Indicator 31- Coolant Temperature Gauge 32- Engine Oil Low Pressure Indicator 33- Air Filter Restriction Indicator 34- (Unused) 35- (Unused)

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

T5-2-1

MNDB-01-034

36- (Unused) 37- Hydraulic Oil Temperature Indicator 38- Transmission Warning Indicator 39- Transmission Oil Temperature Indicator 40- Transmission Oil Temperature Gauge

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitor Display

1- Monitor Display 2- Monitor Display Mode Switch 3- Monitor Display Selection Switch (Up) 4- Monitor Display Selection Switch (Down) 5- Speedometer 6- Machin Information Display 7- Hold Indicator 8- Forward/Reverse and Shift Position Indicator

9- Ride Control Indicator 10- ECO Indicator

MNDB-01-008

Vehicle Information Display (6) 12- Engine Speed Display 13- Coolant Temperature Display 14- Transmission Oil Temperature Display 15- Hydraulic Oil Temperature Display 16- Fuel Consumption Display 17- (Unused) 18- Hour Meter Display 19- Average Fuel Consumption Display

MNDB-01-033

20- Odometer Display 21- Fault Code Display

22- (Unused)

18 17 16

T5-2-2

MNDB-01-033

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

f NOTE: Refer to the separated volume, 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 Vehicle Information Display Screen (1) with the key switch set in the ON position or the engine running. By this operation, Service Menu is added to Vehicle Information Display Screen (1). 2. When setting the key switch to the OFF position, the normal menu appears. Engine Speed

MNDB-01-008

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

Current Engine Coolant Temperature (6) is displayed. (Figure B) When pushing monitor display selection switch (3) once on this screen, Transmission Oil Temperature is displayed. Transmission Oil Temperature Current Transmission Oil Temperature (7) is displayed. (Figure C) When pushing monitor display selection switch (3) once on this screen, Hydraulic Oil Temperature is displayed.

Hydraulic Oil Temperature Current Hydraulic Oil Temperature (8) is displayed. (Figure D) When pushing monitor display selection switch (3) once on this screen, Fault Code is displayed.

6 C

7 D

T5-2-4

TNDB-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, '-----' (bar) is displayed.

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

MNDB-01-008

f NOTE: The fault code of air conditioner controller is

displayed on the LCD panel of air conditioner controller. (Refer to T5-7.)

4 6

Fuel Consumption/Average Fuel Consumption 1. Current Fuel Consumption (7) is displayed. (Figure F) 2. When pushing monitor display selection switch (2) once on this screen, Average Fuel Consumption (8) up to the present is displayed. (Figure G)

TNDB-05-02-006

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

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

TNDB-05-02-007

8 G

TNDB-05-02-008

TNDB-05-02-009

T5-2-5

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Service Menu Display Display Order Item 1 Clock (time, 24-hour) * 2 Hour Meter * 3 Odometer * 4 INFO (Information) * 5 Engine Speed 6 Coolant Temperature 7 Transmission Oil Temperature 8 Hydraulic Oil Temperature 9 Fault Code 10 Fuel Consumption 11 Average Fuel Consumption

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

Data Input signal from ECM Input signal from ECM Input signal from TCU 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 Transmission Oil Temperature Gauge Coolant Temperature Gauge E D

No. A B C D E

Coolant Temperature (ºC) 25 40 95 105 (120)

No. A B C D E

Coolant Temperature (ºC) 25 50 80 120 (125)

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.

Transmission Oil Temperature Gauge E D

TNDB-05-02-010

f NOTE: When the transmission oil temperature reaches the (D) zone, 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 monitor controller. The recorded data is downloaded to the personal computer and is uploaded to the center server via LAN, so that the data can be used as “e-Service”. The machine equipped with the communication terminal (option) sends the data to the center server by using the communication terminal. (As for the communication system, refer to T5-3-7.)

T5-3-1

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Operation Data List of Daily Report Data Item Date Time Fuel Level

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 monitor controller.) Fuel Usage Amount The value of fuel used during a day. (Value is calculated and recorded by accumulated fuel usage amount from ECM.) Machine Hour Meter Hour meter cumulative hours. (Hours are recorded by hour meter from monitor controller.) Machine Travel Distance Travel distance during a day. Engine Power Mode OFF Total hours of power mode (OFF) with engine running during a day. (Hours are Operating Hours recorded by power mode switch information from MC.) Hours Power Mode ON Hours Total hours of power mode (ON) with engine running during a day. (Hours are recorded by power mode switch information from MC.) Travel AUTO 1 Mode Total operating hours of travel mode (AUTO 1 mode) during a day. (Hours are Operating Traveling Hours recorded by travel mode switch information from MC.) Hours AUTO 2 Mode Total operating hours of travel mode (AUTO 2 mode) during a day. (Hours are Traveling Hours recorded by travel mode switch information from MC.) Manual Mode Total operating hours of travel mode (Manual mode) during a day. (Hours are Traveling Hours recorded by travel mode switch information from MC.)

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 Pump Load Radiator Coolant Temperature (79 °C or less) Radiator Coolant Temperature (80 to 93 °C) Radiator Coolant Temperature (94 to 104 °C) Radiator Coolant Temperature (105 °C or more) Hydraulic Oil Temperature (49 °C or less) Hydraulic Oil Temperature (50 to 89 °C) Hydraulic Oil Temperature (90 to 99 °C) Hydraulic Oil Temperature (100 °C or more) Torque Converter Oil Temperature (49 °C or less) Torque Converter Oil Temperature (50 to 89 °C) Torque Converter Oil Temperature (90 to 109 °C) Torque Converter Oil Temperature (110 °C or more)

Details Frequency distribution of main pump delivery pressure Total hours when coolant temperature is less than 80 °C during a day. Total hours when coolant temperature is 80 °C or more and less than 94 °C during a day. Total hours when coolant temperature is 94 °C or more and less than 105 °C during a day. Total hours when coolant temperature is 105 °C or more during a day. Total hours when hydraulic oil temperature is less than 50 °C during a day. Total hours when hydraulic oil temperature is 50 °C or more and less than 90 °C during a day. Total hours when hydraulic oil temperature is 90 °C or more and less than 100 °C during a day. Total hours when hydraulic oil temperature is 100 °C or more during a day. Total hours when torque converter oil temperature is less than 50 °C during a day. Total hours when torque converter oil temperature is 50 °C or more and less than 90 °C during a day. Total hours when torque converter oil temperature is 90 °C or more and less than 110 °C during a day. Total hours when torque converter oil temperature is 110 °C or more during a day.

T5-3-4

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Total Operating Hours Item Details Hour Meter End Hour meter’s value accumulated in machine’s monitor Travel Distance Odometer’s value accumulated in machine’s monitor Engine Power Mode OFF Total engine operating hours selecting power mode (OFF) Operating Hours Hours Power Mode ON Hours Total engine operating hours selecting power mode (ON) Travel AUTO 1 Mode Total operating hours of travel mode (AUTO 1 mode) Operating Traveling Hours Hour AUTO 2 Mode Total operating hours of travel mode (AUTO 2 mode) Traveling Hours Manual Mode Total operating hours of travel mode (Manual mode) Traveling Hours MC Communication Error Time Total hours of MC communication error ECM Communication Time Out Time Total hours of ECM communication time out

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:  Communication Terminal: Receives the data from monitor controller and GPS antenna, and sends the data to the communication antenna.  GPS Antenna: Receives location information of the machine.  Communication Antenna: Communicates the data.

T5-3-7

SECTION 5 TROUBLESHOOTING Group 3 e-Service (Blank)

T5-3-8

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

6 5

8 9 4 3

2 10 1

13 14

123-

Bucket Bell Crank (Lever) Bucket Cylinder

56-

TNEJ-01-02-001

Front Combination Light (Headlight, Turn Signal Light, Clearance Light, Hazard Light) (2 Used) Front Work Light (2 Used) Cab

789-

Rain Cap/Pre-Cleaner (Option) Rear Work Light (2 Used) Rear Combination Light (Turn Signal Light, Hazard Light, Tail Light, Brake Light) (2 Used) 10- Battery (2 Used)

T5-4-1

11121314-

Steering Cylinder (2 Used) Lift Arm Cylinder (2 Used) Lift Arm Bucket Link

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Main Component

8 9 10

123456-

Radiator Assembly (Refer to T5-4-4.) Muffler Air Cleaner Hydraulic Oil Tank Pilot Valve Parking Brake Solenoid Valve Block (Refer to T5-4-18.)

Manifold Valve (Refer to T54-18.) 8- Brake Charge Valve (Refer to T5-4-18.) 9- Brake Valve 10- Steering Valve 11- Control Valve (Refer to T5-415.)

12- Ride Control Valve (Option) (Refer to T5-4-20.) 13- Ride Control Accumulator (Option) 14- Steering Pilot Valve 15- Pilot Filter 16- Service Brake Accumulator (2 Used)

T5-4-2

TNEJ-01-02-002

17- Engine and Fan Pump (Refer to T5-4-14.) 18- Fuel Tank 19- Fan Motor

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

9 8 7

123-

Front Axle (Refer to T5-4-17.) Steering Accumulator (2 Used) Pump Device (Refer to T5-415.)

456-

Drive Unit (Refer to T5-4-17.) Rear Axle Torque Converter Cooler Check Valve

789-

T5-4-3

TNEJ-01-02-003

Rear Propeller Shaft Front Propeller Shaft Steering Cylinder (2 Used)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Radiator Assembly 4

1 a TNEJ-01-02-004 a-

Front Side of Machine

12-

Coolant Reservoir Oil Cooler

34-

Inter Cooler Torque Converter Cooler

T5-4-4

Radiator

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

8 9

12-

Engine and Fan Pump (Refer to T5-4-14.) Electrical System (Around Hydraulic Oil Tank) (Refer to T5-4-12.)

3456-

TNEJ-01-02-005

Electrical System (Cab) (Refer to T5-4-6.) Horn (2 Used) Lift Arm Proximity Switch Bucket Proximity Switch

T5-4-5

Electrical System (Components Related with Relays) (Refer to T5-4-11.)

Electrical System (Around Fuel Tank and Radiator Assembly) (Refer to T5-4-13.) 9- Battery (2 Used) 10- Back Buzzer (Option)

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

12 4

6 10

TNED-01-02-029

TNEJ-01-02-013

12345-

Radio Upper Switch Panel (Option) Speaker Rear Wiper Motor Components Related with Right Console (Refer to T5-4-8.)

78-

Components Related with Controllers and Relays (Refer to T5-4-7.) Accelerator Pedal Sensor (Accelerator Pedal) Brake Light Switch

9101112-

T5-4-6

Brake Pedal Brake Pedal (Option) Front Wiper Motor Components Related with Monitor and Switches (Refer to T5-4-9.)

13- GPS Antenna (Option) 14- Communication Antenna (Option)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Controller and Relays View A

TNDB-01-02-032

30 TNDB-01-02-029

29 28

5 12 11 10 9

17 16 15 14 13

22 21 20 19 18 27 26 25 24 23

6 34 33

2 TNEJ-01-02-006

1 4

123456-

TCU Flasher Relay Air Conditioner Controller MC (Main Controller) ECM Main Relay Air Conditioner Condenser Relay 8- Fuel Pump Relay (AR1) 9- Head Light Relay (Right) (AR2) 10- High-Beam Relay (AR3) 11- Bucket Leveler Relay (AR4) 12- Kickout Relay (AR5)

TNDB-01-02-030

13- Work Light (Front) Relay (AR6) 14- Work Light (Rear) Relay (AR7) 15- Right Turn Signal Light Relay (AR8) 16- Horn Relay (AR9) 17- Secondary Steering Relay (AR10) (Option) 18- Parking Brake Relay 1 (BR1) 19- Parking Brake Relay 2 (BR2) 20- Pilot Shut-Off Relay (BR3) 21- Brake Light Relay (BR4) 22- Load Dump Relay 1 (BR5)

23- Neutral Relay (BR6) 24- Left Turn Signal Light Relay (BR7) 25- Front Washer Relay (BR8) 26- Rear Wiper Relay (BR9) 27- Rear Washer Relay (BR10) 28- Fuse Box B 29- Fuse Box A 30- MPDr. Connector 32- Relay Box A (RBA) 33- Relay Box B (RBB)

T5-4-7

34- Air Conditioner Condenser (High Pressure) Relay 35- Front Wiper (1) Relay (WR1) 36- Front Wiper (2) Relay (WR2) 37- GSM 38- Back Buzzer Relay 39- Load Dump Relay 2 40- ICF (Information Controller)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Right Console Detail #2(1), #3 (2) 21

Fingertip Control Lever Type

*3(2)

*3(2) 6 7 8

10 11

*2(1)

*1(3)

13 14 15 TNEJ-01-02-014

Detail #24

Multi-Function Joystick Lever Type 23

TNEJ-01-02-016

6 7 8

24 10 11

12 25 26

1235678-

*Bucket Control Lever *Lift Arm Control Lever *Attachment Control Lever (Option) Control Lever Lock Switch Auxiliary Auxiliary Power Mode Switch

13 14 15 TNEJ-01-02-017

TNEJ-01-02-015

10- Fan Reverse Rotation Switch (Option) 11- Back Buzzer Switch (Option) 12- Hydraulic Coupler Switch (Option) 13- Secondary Steering Operation Check Switch (Option)

14- Lift Arm Auto Leveler (Raise) Switch (Option) 15- Lift Arm Auto Leveler (Lower) Switch (Option) 16- First Speed Fixed Switch 17- Ride Control Switch (Option) 20- Hold Switch 21- DSS (Down Shift Switch)

fNOTE: * The layout of each control lever may depend on the machine specification.

T5-4-8

2223242526-

Horn Switch Quick Power Switch Multi-Function Joystick Lever Hold Switch Horn Switch

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Monitor and Switches

TNED-01-02-029

3 4

10 11 12

MNDB-01-002

1234-

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

56-

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

Turn Signal Lever/Light Switch/Dimmer Switch 8- Key Switch 9- Travel Mode Switch 10- (Unused)

T5-4-9

MNDB-01-003

11- Declutch Position Switch 12- Automatic Speed Shift Retard Switch 13- Cigar Lighter

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Monitor Panel

39 38

37 12 36 35

14 15

33 32

12345678910111213-

Left Turn Signal Light Indicator High-Beam Indicator Work Light Indicator Right Turn Signal Light Indicator (Unused) (Unused) Service Indicator Maintenance Indicator Parking Brake Indicator Clearance Light Indicator Control Lever Lock Indicator (Unused) Brake Oil Low Pressure Indicator

16 31 30

29 28 27 26

25 24 23 22 21 20 19 18 17

14- (Unused) 15- Secondary Steering Indicator (Option) 16- Low Steering Oil Pressure Indicator (Option) 17- Seat Belt Indicator 18- Alternator Indicator 19- Fuel Gauge 20- Power Mode Indicator 21- Monitor Display Selection Switch 22- (Unused) 23- Monitor Display Selection Switch (Up) 24- Preheat Indicator

T5-4-10

MNDB-01-034

36- (Unused) 37- Hydraulic Oil Temperature Indicator 38- Transmission Warning Indicator 39- Transmission Oil Temperature Indicator 40- Transmission Oil Temperature Gauge

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

TNEE-01-02-006

Front Side of Machine

123-

Battery Relay Fusible Link (140 A) (2 Used) Fusible Link (65 A) (2 Used)

45-

Starter Relay 1 Intake Air Heater Relay

T5-4-11

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

2 1

Front Side of Machine

123-

Hydraulic Oil Tank Air Filter Restriction Switch Air Cleaner

456-

Fuel Pre-Filter (Option) Washer Fluid Tank Fuel Pump

T5-4-12

Hydraulic Oil Temperature Sensor

TNEJ-01-02-007

Secondary Steering Pump (Option) (Refer to T5-4-19.)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Electrical System (Around Fuel Tank and Radiator Assembly)  With Fan Valve (Option) Attached

 Without Fan Valve

5 5

6 4

12-

Fuel Level Sensor Fuel Tank

TNEJ-01-02-008

Fan Pump Delivery Pressure Sensor

45-

T5-4-13

Fan Speed Control Solenoid Valve Fan Motor

TNEJ-01-02-009

Fan Valve (Option) (Refer to T5-4-16.)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Engine and Fan Pump 2

15 6

7 9

View A

T4GD-01-02-009 1234-

Common Rail Pressure Sensor Boost Pressure/Boost Temperature Sensor Coolant Temperature Sensor Injector

56789-

Crankcase Pressure Sensor Engine Oil Pressure Switch Cam Angle Sensor ECM Crank Speed Sensor

1011121314-

T5-4-14

Engine Oil Filter Alternator Starter Motor Supply Pump Fan Pump

15- Fuel Main Filter

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Pump Device 1

T4GB-01-02-009

Control Valve

11 10 7 8

9 T4GB-01-02-027

12345-

Main Pump Regulator Priority Valve Pump Delivery Pressure Sensor Pilot Pump

678-

Main Relief Valve (Steering) Overload Relief Valve (Lift Arm: Bottom Side) Overload Relief Valve (Bucket: Bottom Side)

Overload Relief Valve (Bucket: Rod Side) 10- Make-Up Valve (Lift Arm: Rod Side)

T5-4-15

11- Main Relief Valve (Front Attachment)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Fan Valve (Option)

5 4

TNEE-01-02-031

Fan Speed Control Solenoid Valve

Fan Reverse Rotation Control Solenoid Valve

34-

T5-4-16

Fan Control Valve Fan Reverse Rotation Spool

Fan Pump Delivery Pressure Sensor

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Drive Unit View A

6 2 5 4

3 14

T4GB-01-02-026

Front Axle 15

TNEJ-01-02-010

12345-

Breather Transmission Control Valve Transmission Oil Filter Torque Converter Output Speed Sensor Transmission Intermediate Shaft Sensor

67-

Torque Converter Input Speed Sensor Proportional Solenoid Valve Y1 (For Fast-Speed Forward Clutch) Proportional Solenoid Valve Y2 (For Reverse Clutch)

Proportional Solenoid Valve Y3 (For 1st Speed Clutch) 10- Proportional Solenoid Valve Y4 (For 3rd Speed Clutch) 11- Proportional Solenoid Valve Y5 (For Slow-Speed Forward Clutch)

T5-4-17

12- Proportional Solenoid Valve Y6 (For 2nd Speed Clutch) 14- Parking Brake 15- Pressure Sensor (Brake Secondary Pressure)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Manifold Valve

Brake Charge Valve 3

1 TNED-01-02-021 TNED-01-02-013

Parking Brake Solenoid Valve Block

TNEE-01-02-013

123-

Pilot Accumulator (Steering) Torque Control Solenoid Valve Control Lever Lock Solenoid Valve

45-

Pressure Sensor (Primary Pilot Pressure) Pilot Accumulator (Front Attachment)

67-

T5-4-18

Pressure Sensor (Brake Primary Pressure) Parking Brake Solenoid Valve

89-

Pressure Sensor (Parking Brake) Parking Brake Accumulator

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Steering Valve, Secondary Steering Valve (Option) 2

6 5

4 TNEE-01-02-014

Secondary Steering Pump (Option) 9

TNED-01-02-019

123-

Overload Relief Valve Steering Valve Overload Relief Valve

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

6789-

T5-4-19

Steering Pressure Switch (Option) Electric Motor Gear Pump Relief Valve

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Ride Control Valve (Option) 2

TNDB-01-02-040

(Pilot Hose Mounting Part) 5 c

TNEJ-01-02-012

Front Side of Machine

Front Frame

Rear Frame

12-

Overload Relief Valve Ride Control Valve

34-

Ride Control Solenoid Valve Ride Control Accumulator

Pressure Sensor (Lift Arm Raise) (Option)

T5-4-20

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.

fNOTE: All connector images in this section are viewed from the open end side of wire harness end.

1 2

T6L4-05-03-001

Wire Harness End Connector

Wire Harness

T5-5-1

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Contents of Diagnosis

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

How to Read Table Fault Code

Trouble

(A)

(B)

    

A: B: C, D, E,

Inspection Method (C) (F)

Evaluation

Cause

(D) (G)

(E) (H)

Fault code Trouble details 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

T5-5-61

111001-2

Abnormal RAM

T5-5-9

T5-5-61

111002-2

Abnormal A/D Converter

T5-5-9

T5-5-61

111003-3

Abnormal Sensor Voltage

T5-5-9

T5-5-62

111006-2

(MC) EC Communication Error

T5-5-10

T5-5-65

111007-2

(MC) IC Communication Error 1

T5-5-10

T5-5-65

111011-2

(MC) Transmission Controller Communication Error

T5-5-10

T5-5-65

111014-2

(MC) Air Conditioner Controller Communication Error

T5-5-10

T5-5-70

111025-2

(MC) Column Monitor Communication Error

T5-5-10

T5-5-70

111100-2

Abnormal Engine Speed

T5-5-11

T5-5-71

111103-3

Accelerator Pedal Circuit High Input

T5-5-11

T5-5-72

111103-4

Accelerator Pedal Circuit Low Input

T5-5-11

T5-5-72

111106-3

Abnormal Accelerator Pedal 2 Circuit High Input

T5-5-11

T5-5-72

111106-4

Abnormal Accelerator Pedal 2 Circuit Low Input

T5-5-11

T5-5-72

111107-2

Accelerator Pedal Sensor Correlation Diagnosis

T5-5-11

T5-5-72

111200-3

Lift Arm Raise Pilot Pressure Sensor Circuit High Input

T5-5-13

T5-5-74

111200-4

Lift Arm Raise Pilot Pressure Sensor Circuit Low Input

T5-5-13

T5-5-74

111204-3

Pump Delivery Pressure Sensor Circuit High Input

T5-5-12

T5-5-76

111204-4

Pump Delivery Pressure Sensor Circuit Low Input

T5-5-12

T5-5-76

111205-3

Lift Arm Angle Sensor Circuit High Input

T5-5-19

T5-5-73

111205-4

Lift Arm Angle Sensor Circuit Low Input

T5-5-19

T5-5-73

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

111206-3

Hyd. Fan Circut Pressure Sensor Circuit High Input

T5-5-12

T5-5-76

111206-4

Hyd. Fan Circut Pressure Sensor Circuit Low Input

T5-5-12

T5-5-76

T5-5-12

T5-5-77

T5-5-12

T5-5-77

111208-3 111208-4

Emergency Steering Check Pressure Sensor Circuit High Input Emergency Steering Check Pressure Sensor Circuit Low Input

111217-3

Pilot Pressure Sensor Circuit High Input

T5-5-14

T5-5-75

111217-4

Pilot Pressure Sensor Circuit Low Input

T5-5-14

T5-5-75

111311-3

Service Brake Primary Pressure Sensor Circuit High Input MC

T5-5-14

T5-5-78

111311-4

Service Brake Primary Pressure Sensor Circuit Low Input

T5-5-14

T5-5-78

T5-5-15

T5-5-75

T5-5-15

T5-5-75

111312-3 111312-4

Service Brake Secondary Pressure Sensor Circuit High Input Service Brake Secondary Pressure Sensor Circuit Low Input

111313-3

Parking Brake Pressure Sensor Circuit High Input

T5-5-15

T5-5-78

111313-4

Parking Brake Pressure Sensor Circuit Low Input

T5-5-15

T5-5-78

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

111411-2

Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB

T5-5-16

T5-5-79

111411-3

Hydraulic Fan Reverse Rotation P/S Valve FB High Current

T5-5-16

T5-5-79

111411-4

Fan Reverse Rotation P/S Valve FB Low Current

T5-5-16

T5-5-79

111412-2

Hyd. Fan P/S Valve Abnormal FB

T5-5-17

T5-5-80

111412-3

Hyd. Fan P/S Valve FB High Current

T5-5-17

T5-5-80

111412-4

Hyd. Fan P/S Valve FB Low Current

T5-5-17

T5-5-80

111413-2

Pump Swash Angle P/S Valve Abnormal FB

T5-5-17

T5-5-81

111413-3

Pump Swash Angle P/S Valve FB High Current

T5-5-17

T5-5-81

111413-4

Pump Swash Angle P/S Valve FB Low Current

T5-5-17

T5-5-81

111422-2

Ride Control (Bottom) P/S Valve Abnormal FB

T5-5-17

T5-5-82

111422-3

Ride Control (Bottom) P/S Valve FB High Current

T5-5-17

T5-5-82

111422-4

Ride control Solenoid Valve FB Low Current

T5-5-17

T5-5-82

111720-2

Lift arm angle sensor is Uncalibrated

T5-5-18

111721-2

Digging position is Uncalibrated.

T5-5-18

111901-3

Hyd. Oil Temp Sensor Circuit High Input

T5-5-19

T5-5-83

111901-4

Hyd. Oil Temp Sensor Circuit Low Input

T5-5-19

T5-5-83

T5-5-5

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

MPDr. Message

Category

114100-2

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

114104-2

Communication Terminal: Remote Loop Back Error 1

114105-2

Communication Terminal: Remote Loop Back Error 2

114106-2

Communication Terminal: Transmission/Receiving Data Unmatched

T5-5-6

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

Reference 1

Reference 2

T5-5-24

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

T5-5-21

T5-5-87

115003-2

Abnormal EEPROM

Column Display

T5-5-21

115011-3

Open circuit in fuel level sensor

Column Display

T5-5-21

T5-5-88

115011-4

Shorted circuit in fuel level sensor

Column Display

T5-5-21

T5-5-88

115018-2

24 V Output Error

Column Display

T5-5-21

120003-2

Emergency Steering Operation Alarm

T5-5-20

T5-5-84

120004-2

Emergency Steering Operating Pressure Error

T5-5-20

T5-5-84

120014-2

Overrun Alarm

T5-5-20

T5-5-85

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

T5-5-22

T5-5-89

120501-2

Engine Warning Alarm

Column Display

T5-5-22

T5-5-89

120502-2

Engine Oil Pressure Alarm

Column Display

T5-5-22

T5-5-89

120503-2

Air Cleaner Restriction Alarm

Column Display

T5-5-22

T5-5-89

120505-2

Brake Pressure Alarm

Column Display

T5-5-22

T5-5-89

120506-2

Steering Oil Pressure Alarm

Column Display

T5-5-22

T5-5-90

120507-2

Transmission Error Alarm

Column Display

T5-5-22

T5-5-90

120510-2

Transmission Oil Temperature

Column Display

T5-5-23

T5-5-90

120511-2

Fuel Filter Restriction Alarm

Column Display

T5-5-23

T5-5-90

120512-2

Emergency Steering Alarm (Lighting)

Column Display

T5-5-23

T5-5-90

120515-2

Engine Alarm

Column Display

T5-5-23

T5-5-90

120516-2

Hydraulic Oil Temperature Alarm

Column Display

T5-5-23

T5-5-90

120518-2

Emergency Steering Alarm (Blinking)

Column Display

T5-5-22

T5-5-90

fNOTE:  Refer to page T5-5-25 for the ECM fault code list.  Refer to page T5-5-41 for the TCU fault code list.  Refer to Group 7 Air Conditioner for the air conditioner controller 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

Faulty MC Faulty MC Faulty MC

111003-3

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

Faulty MC Faulty sensor Faulty harness

Symptoms in Machine Operation When Trouble Occurs. -

Remedy

Replace MC. Replace MC. Replace MC.

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

T5-5-9

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN Data Reception Failure Fault Code Trouble 111006-2 111007-2

111011-2

111014-2

111025-2

(MC) EC Communication Error (MC) IC Communication Error 1

(MC) Transmission Controller Communication Error (MC) Air Conditioner Controller Communication Error

(MC) Column Monitor Communication Error

Cause

Symptoms in Machine Operation When Trouble Occurs. Faulty harness Even if accelerator pedal is operated, engine speed does not change. Faulty information The information for e-Service cannot controller be collected. Faulty CAN1 harness Faulty TCU Faulty harness Faulty air conditioner controller Faulty CAN1 harness Faulty column display controller Faulty CAN1 harness

Remedy

Check the wire harness. Check the CAN1 harness. Replace information controller. The automatic speed shift cannot be Check the wire performed. harness. Replace TCU The air conditioner is not effective. Check the CAN1 harness. Replace the air conditioner controller. The alarms and meters on column Check the CAN1 display cannot be displayed correctly. harness. Replace column display controller.

T5-5-10

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Engine Failure Fault Code

111100-2

Abnormal Engine Speed

111103-3

Accelerator Pedal Circuit High Input

Symptoms in Machine Operation When Trouble Occurs. Engine speed: 4000 The machine operation min-1 or more. speed is slow. (During Or engine speed speed sensing, the torque is (ECM): 500 min-1 or decreased.) less. And engine speed (TCU): 500 min-1 or more. Voltage: more than The engine speed is fixed to 4.74 V 1000 min-1.

111103-4

Accelerator Pedal Circuit Low Input

Voltage: less than 0.25 V

The engine speed is fixed to 1000 min-1.

111106-3

Abnormal Accelerator Pedal 2 Circuit High Input Abnormal Accelerator Pedal 2 Circuit Low Input Accelerator Pedal Sensor Correlation Diagnosis

Voltage: more than 4.74 V

The engine speed is fixed to 1000 min-1.

Voltage: less than 0.25 V

The engine speed is fixed to 1000 min-1.

111106-4

111107-2

Trouble

Cause

Voltage difference The engine speed is fixed to between accelerator 1000 min-1. pedal sensor end #1 and #2 is 0.5 V or more.

T5-5-11

Remedy

Check the wire harness. Check the crank speed sensor. Replace the cam angle sensor.

Check the wire harness. Replace the accelerator pedal. Check the wire harness. Replace the accelerator pedal. Check the wire harness. Replace the accelerator pedal. Check the wire harness. Replace the accelerator pedal. Check the wire harness. Replace the accelerator pedal.

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

111204-4

111206-3

111206-4

111208-3

111208-4

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs. Voltage: 4.75 V Traction force is lack during or more digging operation.

Pump Delivery Pressure Sensor Circuit High Input Pump Delivery Voltage: less Pressure Sensor than 0.25 V Circuit Low Input Hyd. Fan Circut Voltage: 4.75 V Pressure Sensor or more Circuit High Input Hyd. Fan Circut Voltage: less Pressure Sensor than 0.25 V Circuit Low Input Emergency Steering Voltage: 4.75 V Check Pressure or more Sensor Circuit High Input

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

Remedy

Check the wire harness. Replace the pump delivery pressure sensor. Traction force is lack during Check the wire harness. digging operation. Replace the pump delivery pressure sensor. Fan rotation direction (in normal / Check the wire harness. reverse) cannot change manually Replace the fan pump and automatically. delivery pressure sensor. Fan rotation direction (in normal / Check the wire harness. reverse) cannot change manually Replace the fan pump and automatically. delivery pressure sensor. The initial automatic check for Check the wire harness. secondary steering operation Replace the secondary cannot be performed. (When the steering pump delivery engine starts) pressure sensor. Secondary steering indicator of monitor blinks. The initial automatic check for Check the wire harness. secondary steering operation Replace the secondary cannot be performed. (When the steering pump delivery engine starts) pressure sensor. Secondary steering indicator of monitor blinks.

T5-5-12

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pilot Failure Fault Code 111200-3

111200-4

Trouble Lift Arm Raise Pilot Pressure Sensor Circuit High Input Lift Arm Raise Pilot Pressure Sensor Circuit Low Input

Cause

Symptoms in Machine Operation When Trouble Occurs. Voltage: 4.75 V Ride control is not activated. or more Voltage: less than 0.25 V

Ride control is not activated.

T5-5-13

Remedy Check the wire harness. Replace the pressure sensor (lift arm raise). Check the wire harness. Replace the pressure sensor (lift arm raise).

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code

Trouble

111217-3

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

111217-4

111311-3

111311-4

Service Brake Primary Pressure Sensor Circuit Low Input

Cause

Symptoms in Machine Operation When Trouble Occurs. Voltage: 4.75 V Front attachment control lever or more lock indicator of monitor is always OFF. Voltage: less Front attachment control lever than 0.25 V lock indicator of monitor is always OFF. Voltage: 4.75 V The low brake oil pressure or more indicator is always ON. Although the service brake is applied, the brake oil pressure gauge points at the minimum value, zero. Voltage: less The low brake oil pressure than 0.25 V indicator is always ON. Although the service brake is applied, the brake oil pressure gauge points at the minimum value, zero.

T5-5-14

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

Check the wire harness. Replace the pressure sensor (brake primary pressure).

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

111312-4

111313-3

111313-4

Trouble

Cause

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

T5-5-15

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

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

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble 111411-2

Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB

111411-3

Hydraulic Fan Reverse Rotation P/S Valve FB High Current Fan Reverse Rotation P/S Valve FB Low Current

111411-4

Cause

Symptoms in Machine Operation Remedy When Trouble Occurs. Solenoid valve The fan reverse rotation control Check the wire output: 140 mA becomes ineffective. harness. or more, feedback Fan rotation direction (in normal / current: More reverse) cannot change manually and than 920 mA or automatically. less than 70 mA; both are detected. Current: more Fan rotation direction is fixed in Check the wire than 920 mA reverse. harness. Current: less than Fan rotation direction (in normal / Check the wire 70 mA reverse) cannot change manually and harness. automatically.

T5-5-16

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code

Trouble

111412-2

Hyd. Fan P/S Valve Abnormal FB

111412-3 111412-4 111413-2

111413-3

111413-4 111422-2

111422-3

111422-4

Cause

Symptoms in Machine Operation When Trouble Occurs. The fan speed is fixed to the maximum.

Remedy

Solenoid valve Check the wire output: 140 mA harness. or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Hyd. Fan P/S Valve FB Current: more The fan speed is fixed to the Check the wire High Current than 920 mA minimum. harness. Hyd. Fan P/S Valve FB Current: less than The fan speed is fixed to the Check the wire Low Current 70 mA maximum. harness. Pump Swash Angle P/S Solenoid valve Machine overall operation is slow. Check the wire Valve Abnormal FB output: 140 mA harness. or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Pump Swash Angle P/S Current: more The engine stalls is remarkable at high Check the wire Valve FB High Current than 920 mA loaded. In addition, the engine lugharness. down is remarkable. Pump Swash Angle P/S Current: less than Machine overall operation is slow. Check the wire Valve FB Low Current 70 mA harness. Ride Control (Bottom) Solenoid valve The ride control becomes ineffective. Check the wire P/S Valve Abnormal FB output: 140 mA harness. or more, feedback current: More than 920 mA or less than 70 mA; both are detected. Ride Control (Bottom) Current: more The ride control is always activated. Check the wire P/S Valve FB High than 920 mA harness. Current Ride control Solenoid Current: less than The ride control is always activated. Check the wire Valve FB Low Current 70 mA harness.

T5-5-17

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Learning Failure Fault Code 111720-2

111721-2

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs. Lift arm angle sensor is The lift arm angle Dual lift arm auto leveler cannot be Uncalibrated. sensor calibration set. is not performed. Or, it fails. Digging position is The digging Dual lift arm auto leveler cannot be Uncalibrated. position set. (The machine with ride control calibration is not attached.) performed. Or, it fails.

T5-5-18

Remedy Perform lift arm angle sensor calibration. Perform digging Position calibration.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Other Failures Fault Code

Trouble

Cause

111901-3

Hyd. Oil Temp Sensor Circuit High Input

111901-4

Hyd. Oil Temp Sensor Circuit Low Input

111205-3

Lift Arm Angle Sensor Circuit High Input

Symptoms in Machine Operation When Trouble Occurs. Voltage: more When hydraulic oil temperature is than 4.35 V less than 0 °C, the auto-warming up control is not effective. The fan speed is always fixed to the maximum. The fan reverse rotation control is not activated. Voltage: less than When hydraulic oil temperature is 0.1 V less than 0 °C, the auto-warming up control is not effective. The fan speed is always fixed to the maximum. The fan reverse rotation control is not activated. Voltage: 4.75 V or Dual lift arm auto leveler operation is more not effective.

111205-4

Lift Arm Angle Sensor Circuit Low Input

Voltage: less than Dual lift arm auto leveler operation is 0.25 V not effective.

T5-5-19

Remedy Check the wire harness.

Check the wire harness.

Check the wire harness. Replace the lift arm angle sensor. Check the wire harness. Replace the lift arm angle sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code

Trouble

Cause

Symptoms in Machine Operation Remedy When Trouble Occurs. The alarm is displayed on the monitor. (It is displayed during operation.)

120003-2

Emergency Steering Activated

120004-2

Emergency Steering Activated Pressure Alarm

120014-2

Overrun Alarm

Secondary Steering Pump is activated. Secondary The alarm is displayed on the monitor. Check the wire steering pump harness. delivery pressure Replace the does not increase secondary steering up to the pump delivery specified value. pressure sensor. (When the engine starts) The vehicle speed The buzzer sounds. Check the wire is beyond the harness. upper limit. Replace the vehicle speed sensor.

T5-5-20

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

115001-2

115003-2 115011-3

115011-4

115018-2

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs. Abnormal REG Input Alternator generating The alternator Check the wire H level voltage: 33.5 V or more indicator is ON. harness. Check the battery. Check the alternator. Abnormal EEPROM Faulty column display Replace the column controller. display controller. Fuel Level sensor 131±5 Ω or less The fuel gauge Check the wire Circuit High Input continues for 5 (pointer) points to E. harness. seconds. Replace the fuel level sensor. Fuel Level Sensor 4±2 Ω or less The fuel gauge Check the wire Circuit Low Input continues for 5 (pointer) points to E. harness. seconds. Replace the fuel level sensor. Abnormal 24 V Output Faulty column display Check the wire controller. harness. Replace the column display controller.

T5-5-21

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 120500-2

Trouble Overheat Alarm

120501-2 120502-2

Engine Error Engine Oil Pressure Alarm Air Cleaner Restriction Alarm Brake Pressure Alarm

120503-2 120505-2

120506-2 120507-2

Steering Oil Pressure Alarm T/M Malfunction

Cause Remedy Coolant temperature is high while Check the wire harness. the engine runs. Replace the overheat switch. Faulty engine system Refer to ECM fault code list. Engine oil pressure decreases. Check the wire harness. Replace the engine oil pressure switch. Clogged air cleaner. Check the wire harness. Replace the air cleaner restriction switch. Brake oil pressure decreases. Check the wire harness. Replace the pressure sensor (brake primary pressure). Faulty steering pressure switch Check the wire harness. (Option) Replace the steering pressure switch. Faulty transmission system Refer to TCU fault code list.

T5-5-22

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 120510-2

120511-2 120512-2

120515-2 120516-2 120518-2

Trouble Transmission Oil Temperature

Cause Transmission oil temperature is high while the engine runs.

Remedy Check the wire harness. Replace the torque converter oil temperature sensor. Fuel Filter Supply pump inlet pressure Check the wire harness. Restriction Alarm decreases. Replace the fuel filter. Emergency Steering Faulty secondary steering system Check the wire harness. Alarm (Lighting) (OPT) Replace the secondary steering pump delivery pressure sensor. Engine Alarm Faulty engine system Refer to Engine Troubleshooting Manual. Hydraulic Oil Hydraulic Oil Temperature is high Check the wire harness. Temperature Alarm while the engine runs. Replace the hydraulic oil temperature. Emergency Steering Faulty secondary steering pump Check the wire harness. Alarm (Blinking) (OPT) Replace the secondary steering operation check switch (OPT).

T5-5-23

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Communication Terminal Fault Code List Fault Code Trouble or MPDr. Message 114100-2 Communication Terminal: Abnormal EEPROM

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.

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 Abnormality is detected on Loop Back Error 1 communication test with the satellite and base station. Communication Terminal: Remote Abnormality is detected on Loop Back Error 2 communication test with the satellite and base station. Communication Terminal: Transmission/receiving data with Transmission/Receiving Data the satellite is unmatched. Unmatched

114104-2

114105-2

114106-2

Air Conditioner Controller Fault Code List

fNOTE: Refer to Group 7 Air Conditioner.

T5-5-24

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 ECM FAULT CODE CONTRAST LIST Fault Code (MP.Dr.) 84-2

84-10

91-0

91-1

91-3

91-4

91-19

93-2

Trouble (Cause)

Fault Code (INSITE) 241

Wheel-Based Vehicle Speed-Data Erratic, Intermittent, or Incorrect. The ECM lost the vehicle speed signal. Wheel-Based Vehicle Speed Sensor 242 Circuit tampering has been detectedAbnormal Rate of Change. Signal indicates an intermittent connection or VSS tampering. Accelerator Pedal or Lever Position 148 Sensor 1-Data Valid but Above Normal Operational Range-Most Severe Level. A frequency of more than 1500 Hz has been detected at the frequency throttle input to the ECM. Accelerator Pedal or Lever Position 1 147 Sensor Circuit Frequency-Data Valid but Below Normal Operational RangeMost Severe Level. A frequency of less than 100 Hz has been detected at the frequency throttle input to the ECM. Accelerator Pedal or Lever Position 131 Sensor 1 Circuit-Voltage Above Normal, or Shorted to High Source. High voltage detected at accelerator pedal position circuit. Accelerator Pedal or Lever Position 132 Sensor 1 Circuit-Voltage Below Normal, or Shorted to Low Source. Low voltage detected at accelerator pedal position signal circuit. SAE J1939 Multiplexed Accelerator 287 Pedal or Lever Sensor System-Received Network Data In Error. The OEM vehicle electronic control unit (VECU) detected a fault with its accelerator pedal. Auxiliary Alternate Torque Validation 528 Switch-Data Erratic, Intermittent, or Incorrect.

T5-5-25

Lighting Indicator Service Indicator

Service Indicator

Engine Warning Indicator

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 97-3

97-4

97-15

100-1

100-2

100-3

100-4

Trouble (Cause) Water in Fuel Indicator Sensor CircuitVoltage Above Normal, or Shorted to High Source. High voltage detected at the water in fuel circuit. Water in Fuel Indicator Sensor CircuitVoltage Below Normal, or Shorted to Low Source. Low voltage detected at the water in fuel circuit. Water in Fuel Indicator-Data Valid but Above Normal Operational Range-Least Severe Level. Water has been detected in the fuel filter. Engine Oil Rifle Pressure-Data Valid but Below Normal Operational RangeMost Severe Level. Oil pressure signal indicates oil pressure below the engine protection critical limit. Engine Oil Rifle Pressure-Data Erratic, Intermittent, or Incorrect. An error in the engine oil pressure switch signal was detected by the ECM. Engine Oil Rifle Pressure 1 Sensor Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage detected at the engine oil pressure circuit. Engine Oil Rifle Pressure 1 Sensor Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage detected at engine oil pressure circuit.

Fault Code (INSITE) 428

Lighting Indicator

429

Service Indicator

418

Service Indicator (Blinking)

415

Engine Warning Indicator

435

Service Indicator

135

Service Indicator

141

Service Indicator

T5-5-26

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 100-18

102-2

102-3

102-4

102-16

103-10

103-16

103-18

Trouble (Cause) Engine Oil Rifle Pressure-Data Valid but Below Normal Operational RangeModerately Severe Level. Intake Manifold 1 Pressure-Data Erratic, Intermittent, or Incorrect. The ECM has detected an intake manifold pressure signal that is too high or low for current engine operating conditions. Intake Manifold 1 Pressure Sensor Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage detected at the intake manifold pressure circuit. Intake Manifold 1 Pressure Sensor Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage or open circuit detected at the intake manifold pressure circuit. Intake Manifold 1 Pressure-Data Valid but Above Normal Operational Range-Moderately Severe Level. Intake manifold pressure has exceeded the maximum limit for the given engine rating. Turbocharger 1 Speed-Abnormal Rate of Change. The turbocharger speed sensor has detected an erroneous speed value. Turbocharger 1 Speed-Data Valid but Above Normal Operational Range-Moderately Severe Level. High turbocharger speed has been detected. Turbocharger 1 Speed-Data Valid but Below Normal Operational Range-Moderately Severe Level. Low turbocharger speed detected by the ECM.

Fault Code (INSITE) 143

Lighting Indicator

2973

Service Indicator

122

Service Indicator

123

Service Indicator

124

Service Indicator

2345

Service Indicator

595

Service Indicator

687

Service Indicator

T5-5-27

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 105-0

105-3

105-4

105-16

108-3

108-4

110-0

Trouble (Cause) Intake Manifold 1 Temperature-Data Valid but Above Normal Operational Range-Most Severe Level. Intake manifold air temperature signal indicates intake manifold air temperature above engine protection critical limit. Intake Manifold 1 Temperature Sensor Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage detected at intake manifold air temperature circuit. Intake Manifold 1 Temperature Sensor Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage detected at intake manifold air temperature circuit. Intake Manifold 1 Temperature-Data Valid but Above Normal Operational Range-Moderately Severe Level. Intake manifold air temperature signal indicates intake manifold air temperature is above the engine protection warning limit. Barometric Pressure Sensor CircuitVoltage Above Normal, or Shorted to High Source. High signal voltage detected at barometric pressure circuit. Barometric Pressure Sensor CircuitVoltage Below Normal, or Shorted to Low Source. Low signal voltage detected at barometric pressure circuit. Engine Coolant Temperature-Data Valid but Above Normal Operational RangeMost Severe Level. Engine coolant temperature signal indicates engine coolant temperature above engine protection critical limit.

Fault Code (INSITE) 155

Lighting Indicator

153

Service Indicator

154

Service Indicator

488

Service Indicator

221

Service Indicator

222

Service Indicator

151

Engine Warning Indicator

T5-5-28

Engine Warning Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 110-2

110-3

110-4

110-16

111-1

111-3

111-4

Trouble (Cause) Engine Coolant Temperature-Data Erratic, Intermittent, or Incorrect. The engine coolant temperature reading is not changing with engine operating conditions. Engine Coolant Temperature 1 Sensor Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage or open circuit detected at engine coolant temperature circuit. Engine Coolant Temperature 1 Sensor Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage detected at engine coolant temperature circuit. Engine Coolant Temperature-Data Valid but Above Normal Operational Range-Moderately Severe Level. Engine coolant temperature signal indicates engine coolant temperature is above engine protection warning limit. Coolant Level-Data Valid but Below Normal Operational Range-Most Severe Level. Low engine coolant level detected. Coolant Level Sensor 1 Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage detected at engine coolant level circuit. Coolant Level Sensor 1 Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage detected at engine coolant level circuit.

Fault Code (INSITE) 334

Lighting Indicator

144

Service Indicator

145

Service Indicator

146

Service Indicator

235

Engine Warning Indicator

195

Service Indicator

196

Service Indicator

T5-5-29

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 111-18

157-0

157-1

157-2

157-3

157-4

157-16

Trouble (Cause) Coolant Level-Data Valid but Below Normal Operational Range-Moderately Severe Level. Low coolant level has been detected. Injector Metering Rail 1 Pressure-Data Valid but Above Normal Operational Range-Most Severe Level. Injector Metering Rail 1 Pressure-Data Valid but Below Normal Operational Range-Most Severe Level. The ECM has detected that fuel pressure is lower than commanded pressure. Injector Metering Rail 1 Pressure-Data Erratic, Intermittent, or Incorrect. The ECM has detected that the fuel pressure signal is not changing. Injector Metering Rail 1 Pressure Sensor Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage detected at the rail fuel pressure sensor circuit. Injector Metering Rail 1 Pressure Sensor Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage detected at the rail fuel pressure sensor circuit. Injector Metering Rail 1 Pressure-Data Valid but Above Normal Operational Range-Moderately Severe Level. The ECM has detected that fuel pressure is higher than commanded pressure.

Fault Code (INSITE) 197

Lighting Indicator

449

Engine Warning Indicator

2249

Service Indicator

554

Service Indicator

451

Service Indicator

452

Service Indicator

553

Service Indicator

T5-5-30

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 157-18

168-16

168-18

190-0

190-2

251-2

Trouble (Cause)

Fault Code (INSITE) 559

Injector Metering Rail 1 Pressure-Data Valid but Below Normal Operational Range-Moderately Severe Level. The ECM has detected that fuel pressure is lower than commanded pressure. Battery 1 Voltage-Data Valid but Above 442 Normal Operational Range-Moderately Severe Level. ECM supply voltage is above the maximum system voltage level. Battery 1 Voltage-Data Valid but Below 441 Normal Operational Range-Moderately Severe Level. ECM supply voltage is below the minimum system voltage level. Engine Crankshaft Speed/Position-Data 234 Valid but Above Normal Operational Range-Most Severe Level. Engine speed signal indicates engine speed above engine protection limit. Engine Crankshaft Speed/Position-Data 689 Erratic, Intermittent, or Incorrect. Loss of signal from crankshaft sensor. Engine Crankshaft Speed/Position2321 Data Erratic, Intermittent, or Incorrect. Crankshaft engine speed sensor intermittent synchronization. Real Time Clock Power Interrupt-Data 319 Erratic, Intermittent, or Incorrect. Real Time Clock lost power.

T5-5-31

Lighting Indicator Service Indicator

Service Indicator

Engine Warning Indicator

Service Indicator

Service Indicator (Blinking)

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 441-3

441-4

441-14 558-2

558-13

611-2

611-31

612-2

Trouble (Cause) Auxiliary Temperature Sensor Input 1 Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage or open circuit detected at the OEM auxiliary temperature circuit. Auxiliary Temperature Sensor Input 1 Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage detected at the OEM auxiliary temperature circuit. Auxiliary Temperature Sensor Input 1-Special Instructions. Accelerator Pedal or Lever Idle Validation Switch-Data Erratic, Intermittent, or Incorrect. Voltage detected simultaneously on both idle validation and off-idle validation switches. Accelerator Pedal or Lever Idle Validation Circuit-Out of Calibration. Voltage at idle validation on-idle and off-idle circuit does not match accelerator pedal position. Auxiliary Intermediate (PTO) Speed Switch Validation-Data Erratic, Intermittent, or Incorrect. Electronic Control Module data lostCondition Exists. Severe loss of data from the ECM. Engine Magnetic Crankshaft Speed/ Position lost both of two signals-Data Erratic, Intermittent, or Incorrect. The ECM has detected that the primary engine speed sensor and the backup engine speed sensor signals are reversed.

Fault Code (INSITE) 293

Lighting Indicator

294

Service Indicator

292

Engine Warning Indicator

431

Service Indicator

432

Engine Warning Indicator

523

Service Indicator

757

Service Indicator

115

Engine Warning Indicator

T5-5-32

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 625-2

627-2

627-12

629-12

630-13

633-31

Trouble (Cause)

Fault Code (INSITE) 1633

OEM Datalink Cannot Transmit-Data Erratic, Intermittent, or Incorrect. Communications within the OEM datalink network is intermittent. Power Supply Lost With Ignition On1117 Data Erratic, Intermittent, or Incorrect. Supply voltage to the ECM fell below 6.2 volts momentarily, or the ECM was not allowed to power down correctly (retain battery voltage for 30 seconds after key OFF). Injector Power Supply-Bad Intelligent 351 Device or Component. The ECM measured injector boost voltage is low. Engine Control Module Critical Internal 111 Failure-Bad Intelligent Device or Component. Error internal to the ECM related to memory hardware failures or internal ECM voltage supply circuits. Engine Control Module Warning 343 internal hardware failure-Bad Intelligent Device or Component. Internal ECM failure. Electronic Calibration Code 342 Incompatibilty-Out of Calibration. An incompatible calibration has been detected in the ECM. Electronic Fuel Injection Control Valve 2311 Circuit-Condition Exists. Fuel pump actuator circuit resistance too high or too low.

T5-5-33

Lighting Indicator Service Indicator

None

Service Indicator

Engine Warning Indicator

Service Indicator

Engine Warning Indicator

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 639-9

639-13

640-14 644-2

647-3

647-4

Trouble (Cause)

Fault Code (INSITE) 285

SAE J1939 Multiplexing PGN Timeout Error-Abnormal Update Rate. The ECM expected information from a multiplexed device but did not receive it soon enough or did not receive it at all. SAE J1939 Multiplexing Configuration 286 Error-Out of Calibration. The ECM expected information from a multiplexed device but only received a portion of the necessary information. Auxiliary Commanded Dual Output 599 Shutdown-Special Instructions. External Speed Command Input 237 (Multiple Unit Synchronization)-Data Erratic, Intermittent, or Incorrect. Communication between multiple engines may be intermittent. Fan Control Circuit-Voltage Above 2377 Normal, or Shorted to High Source. Open circuit or high voltage detected at the fan control circuit. Fan Control Circuit-Voltage Below 245 Normal, or Shorted to Low Source. Low signal voltage detected at the fan control circuit when commanded on.

T5-5-34

Lighting Indicator Service Indicator

Service Indicator

Engine Warning Indicator Service Indicator

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 651-5

652-5

653-5

654-5

655-5

Trouble (Cause) Injector Solenoid Driver Cylinder 1 Circuit-Current Below Normal, or Open Circuit. High resistance detected on injector Number 1 circuit or no current detected at Number 1 Injector driver or return pin when the voltage supply at the harness is on. Injector Solenoid Driver Cylinder 2 Circuit-Current Below Normal, or Open Circuit. High resistance detected on injector Number 2 circuit or no current detected at Number 2 injector driver or return pin when the voltage supply at the harness is on. Injector Solenoid Driver Cylinder 3 Circuit-Current Below Normal, or Open Circuit. High resistance detected on injector Number 3 circuit or no current detected at Number 3 injector driver or return pin when the voltage supply at the harness is on. Injector Solenoid Driver Cylinder 4 Circuit-Current Below Normal, or Open Circuit. High resistance detected on injector Number 4 circuit or no current detected at Number 4 injector driver or return pin when the voltage supply at the harness is on. Injector Solenoid Driver Cylinder 5 Circuit-Current Below Normal, or Open Circuit. High resistance detected on injector Number 5 circuit or no current detected at Number 5 injector driver or return pin when the voltage supply at the harness is on.

Fault Code (INSITE) 322

Lighting Indicator

331

Service Indicator

324

Service Indicator

332

Service Indicator

323

Service Indicator

T5-5-35

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 656-5

677-3

677-4

697-3

697-4

702-3

703-3

723-2

Trouble (Cause)

Fault Code (INSITE) 325

Injector Solenoid Driver Cylinder 6 Circuit-Current Below Normal, or Open Circuit. High resistance detected on injector Number 6 circuit or no current detected at Number 6 injector driver or return pin when the voltage supply at the harness is on. Starter Relay Driver Circuit-Voltage 584 Above Normal, or Shorted to High Source. Open circuit or high voltage detected at starter lockout circuit. Starter Relay Driver Circuit-Voltage 585 Below Normal, or Shorted to Low Source. Low voltage detected at starter lockout circuit. Auxiliary PWM Driver 1 Circuit-Voltage 2557 Above Normal, or Shorted to High Source. High signal voltage detected at the analog torque circuit. Auxiliary PWM Driver 1 Circuit-Voltage 2558 Below Normal, or Shorted to Low Source. Low signal voltage detected at the analog torque circuit. Auxiliary Input/Output 2 Circuit527 Voltage Above Normal, or Shorted to High Source. High signal voltage or open circuit has been detected at the auxiliary input/output 2 circuit. Auxiliary Input/Output 3 Circuit-Voltage 529 Above Normal, or Shorted to High Source. Low signal voltage has been detected at the auxiliary input/output 2 circuit. Engine Camshaft Speed / Position 778 Sensor-Data Erratic, Intermittent, or Incorrect. The ECM has detected an error in the camshaft position sensor signal.

T5-5-36

Lighting Indicator Service Indicator

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 723-2

723-7

723-11 729-3

729-4

974-3

974-4

974-19

Trouble (Cause)

Fault Code (INSITE) 2322

Engine Camshaft Speed / Position Sensor-Data Erratic, Intermittent, or Incorrect. Camshaft engine speed sensor intermittent synchronization. Engine Speed / Position Camshaft and 731 Crankshaft Misalignment-Mechanical System Not Responding Properly or Out of Adjustment. Mechanical misalignment between the crankshaft and camshaft engine speed sensors. Auxiliary Equipment Sensor Input 779 3-Root Cause Not Known. Intake Air Heater 1 Circuit-Voltage 2555 Above Normal, or Shorted to High Source. High voltage detected at the intake air heater signal circuit. Intake Air Heater 1 Circuit-Voltage 2556 Below Normal, or Shorted to Low Source. Low voltage detected at the intake air heater signal circuit. Remote Accelerator Pedal or Lever 133 Position Sensor 1 Circuit-Voltage Above Normal, or Shorted to High Source. High voltage detected at remote accelerator pedal position circuit. Remote Accelerator Pedal or Lever 134 Position Sensor 1 Circuit-Voltage Below Normal, or Shorted to Low Source. Low voltage detected at remote accelerator pedal position signal circuit. SAE J1939 Multiplexing Remote 288 Accelerator Pedal or Lever Position Sensor Circuit-Received Network Data In Error. The OEM vehicle electronic control unit (VECU) detected a fault with the remote accelerator.

T5-5-37

Lighting Indicator None

Service Indicator

Service Indicator Service Indicator

Service Indicator

Engine Warning Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 1075-3

1075-4

1172-3

1172-4

1347-3

1347-4

1347-7

Trouble (Cause)

Fault Code (INSITE) 2265

Electric Lift Pump for Engine Fuel Supply Circuit-Voltage Above Normal, or Shorted to High Source. High voltage or open detected at the fuel lift pump signal circuit. Electric Lift Pump for Engine Fuel 2266 Supply Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage detected at the fuel lift pump circuit. Turbocharger 1 Compressor Inlet 691 Temperature Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage detected at turbocharger compressor inlet air temperature circuit. Turbocharger 1 Compressor Inlet 692 Temperature Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage detected at turbocharger compressor inlet air tempera Fuel Pump Pressurizing Assembly 272 1 Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage or open circuit detected at the fuel pump actuator circuit. Fuel Pump Pressurizing Assembly 271 1 Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage detected at the fuel pump actuator circuit. Fuel Pump Pressurizing Assembly 281 1-Mechanical System Not Responding Properly or Out of Adjustment.

T5-5-38

Lighting Indicator Service Indicator

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 1377-2 1388-3

1388-4

1388-14 2789-15

2789-15

3509-3

3509-4

3510-3

Trouble (Cause)

Fault Code (INSITE) 497

Multiple Unit Synchronization SwitchData Erratic, Intermittent, or Incorrect. Auxiliary Pressure Sensor Input 1 297 Circuit-Voltage Above Normal, or Shorted to High Source. High signal voltage detected at the OEM pressure circuit. Auxiliary Pressure Sensor Input 1 298 Circuit-Voltage Below Normal, or Shorted to Low Source. Low signal voltage or open circuit detected at the OEM pressure circuit. Auxiliary Pressure Sensor Input 296 1-Special Instructions. Turbocharger Turbine Inlet Temperature 2346 (Calculated)-Data Valid but Above Normal Operational Range-Least Severe Level. Turbocharger turbine inlet temperature has exceeded the engine protection limit. Turbocharger Compressor Outlet 2347 Temperature (Calculated)-Data Valid but Above Normal Operational Range-Least Severe Level. Sensor Supply 1 Circuit-Voltage Above 386 Normal, or Shorted to High Source. High voltage detected at sensor supply number 1 circuit. Sensor Supply 1 Circuit-Voltage Below 352 Normal, or Shorted to Low Source. Low voltage detected at sensor supply number 1 circuit. Sensor Supply 2 Circuit-Voltage Above 227 Normal, or Shorted to High Source. High voltage detected at sensor supply number 2 circuit.

T5-5-39

Lighting Indicator Service Indicator Service Indicator

Service Indicator

Engine Warning Indicator None

None

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code (MP.Dr.) 3510-4

3512-3

3512-4

3611-4

Trouble (Cause)

Fault Code (INSITE) 187

Sensor Supply 2 Circuit-Voltage Below Normal, or Shorted to Low Source. Low voltage detected at the sensor supply number 2 circuit. Sensor Supply 4 Circuit-Voltage Above 2185 Normal, or Shorted to High Source. High voltage detected at +5 volt sensor supply circuit to the accelerator pedal position sensor. Sensor Supply 4 Circuit-Voltage Below 2186 Normal, or Shorted to Low Source. Low voltage detected at +5 volt sensor supply circuit to the accelerator pedal position sensor. Sensor Supply 3 Circuit-Voltage Below 238 Normal, or Shorted to Low Source. Low voltage detected on the +5 volt sensor supply circuit to the engine speed sensor.

T5-5-40

Lighting Indicator Service Indicator

Service Indicator

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A TCU Fault Code List Fault Code 5000-12

5010-12

5040-12

5110-3

5110-4

Trouble Signal Error in Shift Switch

Cause Behavior of TCU Broken wire harness between Fixed to neutral. shift switch and TCU. Shorted circuit in power circuit or grounding to the body because of faulty wire harness. Faulty forward/reverse switch. Signal Error Broken wire harness between Fixed to neutral. in Forward/ forward/reverse lever and Reverse Lever TCU. Shorted circuit in power circuit or grounding to the body because of faulty wire harness. Faulty forward/reverse lever. Signal Error Broken wire harness between Fixed to neutral. in Forward/ forward/reverse switch and Reverse Switch TCU. Shorted circuit in power circuit or grounding to the body because of faulty wire harness. Faulty forward/reverse switch. Transmission Shorted circuit in power Oil Temperature circuit because of faulty wire Sensor High harness. Voltage No connection to TCU harness. Faulty temperature sensor. Shorted circuit in power circuit by the connector pin or broken connector pin. Transmission Grounding to body because Oil Temperature of faulty wire harness. Sensor Low Faulty temperature sensor. Voltage Grounding to body by the connector pin.

T5-5-41

Repair Procedure Check the wire harness between TCU and shift switch. Check the combination signal at each speed shift in the shift switch. Check the wire harness between TCU and forward/ reverse lever. Check the combination signal of each position at F-N-R speed shift in the forward/ reverse lever. Check the wire harness between TCU and forward/ reverse switch. Check the combination signal of each position at F-N-R speed shift in the forward/ reverse switch. Check the wire harness between TCU and sensor. Check the connectors. Check the sensor.

Check the wire harness between TCU and sensor. Check the connectors. Check the sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5140-3

5140-4

5120-3

5120-4

Trouble Torque Converter Input Speed Sensor High Voltage Feedback. voltage to TCU: 7.00 V or more.

Cause Shorted circuit in power circuit because of faulty wire harness. No connection to TCU wire harness. Faulty rotation sensor. Shorted circuit in power circuit by the connector pin or faulty connection of connector pin. Torque Grounding to body because Converter Input of faulty wire harness. Speed Sensor Faulty rotation sensor. Low Voltage Feedback. voltage to TCU: 0.45 V or less. Torque Shorted circuit in power Converter Oil circuit because of faulty wire Temperature harness. Sensor High No connection to TCU wire Voltage harness. Faulty temperature sensor. Shorted circuit in power circuit by the connector pin or broken connector pin. Torque Grounding to body because Converter Oil of faulty wire harness. Temperature Faulty temperature sensor. Sensor Low Grounding to body by the Voltage connector pin.

Connect the clutch Check the wire harness according to the backup between TCU and sensor. program. Check the connectors. Shock when shifting Check the rotation sensor. travel speed may (1050 Ω at 20 °C (68 °F)) become strong. -

Check the wire harness between TCU and sensor. Check the connectors. Check the sensor.

T5-5-42

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5140-12

5150-3

5150-4

Trouble Cause Torque Faulty contact because of Converter Input faulty wire harness or faulty Speed Sensor connector. Signal Error Faulty rotation sensor. Feedback. voltage to TCU: Uncertain value. Torque Shorted circuit in power Converter circuit because of faulty wire Output Speed harness. Sensor High No connection to TCU wire Voltage harness. Feedback. Faulty rotation sensor. voltage to TCU: Shorted circuit in power 7.00 V or more. circuit by the connector pin or faulty connection of connector pin.

Torque Converter Output Speed Sensor Low Voltage Feedback. voltage to TCU: 0.45 V or less.

Grounding to body because of faulty wire harness. Faulty rotation sensor.

Behavior of TCU Repair Procedure Connect the clutch Check the wire harness according to the backup between TCU and sensor. program. Check the connectors. Shock when shifting Check the rotation sensor. travel speed may (1050 Ω at 20 °C (68 °F)) become strong. Connect the clutch Check the wire harness according to the backup between TCU and sensor. program. Check the connectors. Shock when shifting Check the rotation sensor. travel speed may (1050 Ω at 20 °C (68 °F)) become strong. If the vehicle speed sensor is abnormal, return the forward/ reverse lever to neutral and operate it again. Then, machine can travel only at first or second speed. Connect the clutch Check the wire harness according to the backup between TCU and sensor. program. Check the connectors. Shock when shifting Check the rotation sensor. travel speed may (1050 Ω at 20 °C (68 °F)) become strong. If the vehicle speed sensor is abnormal, return the forward/ reverse lever to neutral and operate it again. Then, machine can travel only at first or second speed.

T5-5-43

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5150-12

5160-3

5160-4

5160-12

Trouble Cause Behavior of TCU Repair Procedure Torque Faulty shorted circuit because Connect the clutch Check the wire harness Converter of faulty wire harness or according to the backup between TCU and sensor. Output Speed faulty connector. program. Check the connectors. Sensor Signal Faulty rotation sensor. Shock when shifting Check the rotation sensor. Error. travel speed may (1050 Ω at 20 °C (68 °F)) Feedback become strong. voltage to TCU: If the vehicle speed Uncertain value. sensor is abnormal, return the forward/ reverse lever to neutral and operate it again. Then, machine can travel only at first or second speed. Transmission Shorted circuit in power Connect the clutch Check the wire harness Intermediate circuit because of faulty wire according to the backup between TCU and sensor. Shaft Speed harness. program. Check the connectors. Sensor High No connection to TCU wire Shock when shifting Check the rotation sensor. Voltage harness. travel speed may (1050 Ω at 20 °C (68 °F)) Feedback. Faulty rotation sensor. become strong. voltage to TCU: Shorted circuit in power 7.00 V or more. circuit by the connector pin or faulty connection of connector pin. Transmission Grounding to body because Connect the clutch Check the wire harness Intermediate of faulty wire harness. according to the backup between TCU and sensor. Shaft Speed Faulty rotation sensor. program. Check the connectors. Sensor Low Shock when shifting Check the rotation sensor. Voltage travel speed may (1050 Ω at 20 °C (68 °F)) Feedback. become strong. voltage to TCU: 0.45 V or less. Transmission Faulty shorted circuit because Connect the clutch Check the wire harness Intermediate of faulty wire harness or according to the backup between TCU and sensor. Shaft Speed faulty connector. program. Check the connectors. Sensor Signal Faulty rotation sensor. Shock when shifting Check the rotation sensor. Error travel speed may (1050 Ω at 20 °C (68 °F)) Feedback. become strong. voltage to TCU: Uncertain value.

T5-5-44

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5170-3

Trouble Vehicle Speed Sensor High Voltage Feedback. voltage to TCU: 12.5 V or more.

5170-4

Vehicle Speed Sensor Low Voltage Feedback. voltage to TCU: 1.00 V or less.

5170-12

5180-2

Behavior of TCU Vehicle speed cannot be detected. Automatic speed shift is not performed. (Speed shift is fixed to first speed or second speed during automatic speed shift.)

Repair Procedure Check the wire harness between TCU and sensor. Check the connectors. Check the rotation sensor. (1050 Ω at 20 °C (68 °F))

Vehicle speed cannot be detected. Automatic speed shift is not performed. (Speed shift is fixed to first speed or second speed during automatic speed shift.) Vehicle Speed Faulty shorted circuit because Vehicle speed cannot Sensor Signal of faulty wire harness or be detected. Automatic Error faulty connector. speed shift is not Feedback. Faulty vehicle speed sensor. performed. (Speed shift voltage to TCU: Sensor gap dimension error. is fixed to first speed or Uncertain value. second speed during automatic speed shift.) Vehicle Speed Faulty vehicle speed sensor. Vehicle speed cannot Sensor Pulse Sensor gap dimension error. be detected. Automatic Output Error speed shift is not performed. (Speed shift is fixed to first speed or second speed during automatic speed shift.)

Check the wire harness between TCU and sensor. Check the connectors. Check the vehicle speed sensor. (1050 Ω at 20 °C (68 °F))

T5-5-45

Check the wire harness between TCU and sensor. Check the connectors. Check the vehicle speed sensor. (1050 Ω at 20 °C (68 °F)) Check the sensor gap. Check the vehicle speed sensor. (1050 Ω at 20 °C (68 °F)) Check the sensor gap. Check the wire harness between TCU and sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5480-3

Trouble Abnormal First Speed Clutch Proportional Solenoid Valve High Voltage

5480-4

Abnormal First Speed Clutch Proportional Solenoid Valve Low Voltage

5480-5

Open Circuit in First Speed Clutch Proportional Solenoid Valve

Cause Shorted circuit in power circuit because of faulty wire harness or faulty connector. Faulty proportional solenoid valve.

Behavior of TCU Turn TCU to neutral. After returning the forward/reverse lever to neutral, operate it again. Then, machine can travel only at first or second speed. If other proportional solenoid valve is abnormal, TCU is fixed to neutral.

Repair Procedure Check the wire harness between TCU and transmission control valve. Check the connector between TCU and transmission control valve. Check resistance in the proportional solenoid valve. (19 Ω at 20 °C (68 °F)) Check the internal wire harness in transmission control valve. Grounding to body because Turn TCU to neutral. Check the wire harness of faulty wire harness or After returning the between TCU and faulty connector. forward/reverse lever transmission control valve. Faulty shorted circuit to other to neutral, operate it Check the connector between proportional solenoid valve again. Then, machine TCU and transmission control output circuit in TCU because can travel only at first or valve. of faulty wire harness or second speed. Check resistance in the faulty connector. If other proportional proportional solenoid valve. Faulty proportional solenoid solenoid valve is (19 Ω at 20 °C (68 °F)) valve. abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve. Faulty contact of wire Turn TCU to neutral. Check the wire harness harness, connector, and TCU. After returning the between TCU and Faulty proportional solenoid forward/reverse lever transmission control valve. valve. to neutral, operate it Check the connector between again. Then, machine TCU and transmission control can travel only at first or valve. second speed. Check resistance in the If other proportional proportional solenoid valve. solenoid valve is (19 Ω at 20 °C (68 °F)) abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve.

T5-5-46

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5490-3

Trouble Abnormal Second Speed Clutch Proportional Solenoid Valve High Voltage

Cause Shorted circuit in power circuit because of faulty wire harness or faulty connector. Faulty proportional solenoid valve.

5490-4

Abnormal Second Speed Clutch Proportional Solenoid Valve Low Voltage

Grounding to body because of faulty wire harness or faulty connector. Shorted circuit to other proportional solenoid valve output circuit in TCU. Faulty proportional solenoid valve.

5490-5

Open Circuit in Second Speed Clutch Proportional Solenoid Valve

Faulty contact of wire harness, connector, and TCU. Faulty proportional solenoid valve.

Repair Procedure Check the wire harness between TCU and transmission control valve. Check the connector between TCU and transmission control valve. Check resistance in the proportional solenoid valve. (19 Ω at 20 °C (68 °F)) Check the internal wire harness in transmission control valve. Turn TCU to neutral. Check the wire harness After returning the between TCU and forward/reverse lever transmission control valve. to neutral, operate it Check the connector between again. Then, machine TCU and transmission control can travel only at first or valve. second speed. Check resistance in the If other proportional proportional solenoid valve. solenoid valve is (19 Ω at 20 °C (68 °F)) abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve. Turn TCU to neutral. Check the wire harness After returning the between TCU and forward/reverse lever transmission control valve. to neutral, operate it Check the connector between again. Then, machine TCU and transmission control can travel only at first or valve. second speed. Check resistance in the If other proportional proportional solenoid valve. solenoid valve is (19 Ω at 20 °C (68 °F)) abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve.

T5-5-47

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5500-3

5500-4

5500-5

Trouble Abnormal Third Speed Clutch Proportional Solenoid Valve High Voltage

Cause Shorted circuit in power circuit because of faulty wire harness or faulty connector. Faulty proportional solenoid valve.

Repair Procedure Check the wire harness between TCU and transmission control valve. Check the connector between TCU and transmission control valve. Check resistance in the proportional solenoid valve. (19 Ω at 20 °C (68 °F)) Check the internal wire harness in transmission control valve. Abnormal Third Grounding to body because Turn TCU to neutral. Check the wire harness Speed Clutch of faulty wire harness or After returning the between TCU and Proportional faulty connector. forward/reverse lever transmission control valve. Solenoid Valve Faulty shorted circuit to other to neutral, operate it Check the connector between Low Voltage proportional solenoid valve again. Then, machine TCU and transmission control output circuit in TCU because can travel only at first or valve. of faulty wire harness or second speed. Check resistance in the faulty connector. If other proportional proportional solenoid valve. Faulty proportional solenoid solenoid valve is (19 Ω at 20 °C (68 °F)) valve. abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve. Open Circuit Faulty contact of wire Turn TCU to neutral. Check the wire harness in Third harness, connector, and TCU. After returning the between TCU and Speed Clutch Faulty proportional solenoid forward/reverse lever transmission control valve. Proportional valve. to neutral, operate it Check the connector between Solenoid Valve again. Then, machine TCU and transmission control can travel only at first or valve. second speed. Check resistance in the If other proportional proportional solenoid valve. solenoid valve is (19 Ω at 20 °C (68 °F)) abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve.

T5-5-48

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5510-3

Trouble High-Speed Forward Clutch Proportional Solenoid Valve High Voltage

5510-4

High-Speed Forward Clutch Proportional Solenoid Valve Low Voltage

5510-5

Open Circuit in High-Speed Forward Clutch Proportional Solenoid Valve

Cause Shorted circuit in power circuit because of faulty wire harness or faulty connector. Faulty proportional solenoid valve.

T5-5-49

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5520-3

Trouble Low-Speed Forward Clutch Proportional Solenoid Valve High Voltage

5520-4

Low-Speed Forward Clutch Proportional Solenoid Valve Low Voltage

5520-5

Open Circuit in Low-Speed Forward Clutch Proportional Solenoid Valve

Cause Shorted circuit in power circuit because of faulty wire harness or faulty connector. Faulty proportional solenoid valve.

Repair Procedure Check the wire harness between TCU and transmission control valve. Check the connector between TCU and transmission control valve. Check resistance in the proportional solenoid valve. (19 Ω at 20 °C (68 °F)) Check the internal wire harness in transmission control valve. Grounding to body because Turn TCU to neutral. Check the wire harness of faulty wire harness or After returning the between TCU and faulty connector. forward/reverse lever transmission control valve. Shorted circuit to other to neutral, operate it Check the connector between proportional solenoid valve again. Then, machine TCU and transmission control output circuit in TCU because can travel only at first or valve. of faulty wire harness or second speed. Check resistance in the faulty connector. If other proportional proportional solenoid valve. Faulty proportional solenoid solenoid valve is (19 Ω at 20 °C (68 °F)) valve. abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve. Faulty contact of wire Turn TCU to neutral. Check the wire harness harness, connector, and TCU. After returning the between TCU and Faulty proportional solenoid forward/reverse lever transmission control valve. valve. to neutral, operate it Check the connector between again. Then, machine TCU and transmission control can travel only at first or valve. second speed. Check resistance in the If other proportional proportional solenoid valve. solenoid valve is (19 Ω at 20 °C (68 °F)) abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve.

T5-5-50

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5530-3

Trouble Abnormal Reverse Clutch Proportional Solenoid Valve High Voltage

5530-4

Abnormal Reverse Clutch Proportional Solenoid Valve Low Voltage

5530-5

Open Circuit in Reverse Clutch Proportional Solenoid Valve

Cause Shorted circuit in wire harness or connector and power circuit. Faulty proportional solenoid valve.

Repair Procedure Check the wire harness between TCU and transmission control valve. Check the connector between TCU and transmission control valve. Check resistance in the proportional solenoid valve. (19 Ω at 20 °C (68 °F)) Check the internal wire harness in transmission control valve. Grounding to body because Turn TCU to neutral. Check the wire harness of faulty wire harness or After returning the between TCU and faulty connector. forward/reverse lever transmission control valve. Shorted circuit to other to neutral, operate it Check the connector between proportional solenoid valve again. Then, machine TCU and transmission control output circuit in TCU because can travel only at first or valve. of faulty wire harness or second speed. Check resistance in the faulty connector. If other proportional proportional solenoid valve. Faulty proportional solenoid solenoid valve is (19 Ω at 20 °C (68 °F)) valve. abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve. Faulty contact of wire Turn TCU to neutral. Check the wire harness harness, connector, and TCU. After returning the between TCU and Faulty proportional solenoid forward/reverse lever transmission control valve. valve. to neutral, operate it Check the connector between again. Then, machine TCU and transmission control can travel only at first or valve. second speed. Check resistance in the If other proportional proportional solenoid valve. solenoid valve is (19 Ω at 20 °C (68 °F)) abnormal, TCU is fixed Check the internal wire to neutral. harness in transmission control valve.

T5-5-51

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5560-3

Trouble Abnormal Reverse Light Relay Exciting Circuit High Voltage

Cause Shorted circuit in power circuit because of faulty wire harness. Faulty reverse light relay. Shorted circuit in power circuit by the connector pin.

Behavior of TCU -

5560-4

Abnormal Reverse Light Relay Exciting Circuit Low Voltage

Grounding to body because of faulty wire harness. Faulty reverse light relay. Grounding to body by the connector pin.

5560-5

Faulty Open Circuit in Reverse Light Relay Exciting Circuit. TCU detects wrong voltage similar to voltage during faulty open circuit.

Faulty connection of wire harness and TCU. Faulty reverse light relay. Faulty contact of connector and TCU.

T5-5-52

Repair Procedure Check the wire harness between TCU and reverse light relay. Check the wire harness between reverse light relay and TCU. Check the wire harness in reverse light relay. Check the wire harness between TCU and reverse light relay. Check the wire harness between reverse light relay and TCU. Check the wire harness in reverse light relay. Check the wire harness between TCU and reverse light relay. Check the wire harness between reverse light relay and TCU. Check the wire harness in reverse light relay.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A fault Code 5570-3

Trouble TCU ADM3 circuit detects wrong voltage in power circuit like shorted circuit

5570-4

TCU ADM3 circuit detects wrong voltage like grounding to body TCU ADM3 Faulty contact between wire circuit detects harness or connector and TCU wrong voltage ADM3 circuit. like open circuit

5570-5

Cause Shorted circuit in wire harness to power circuit because of faulty wire harness. Shorted circuit in wire harness to power circuit because of connector pin. Grounding to body because of faulty wire harness. Grounding connector pin to body.

Behavior of TCU -

T5-5-53

Repair Procedure Check the wire harness between TCU ADM3 and power circuit. Check the connectors.

Check the wire harness to TCU ADM3 circuit. Check the connectors.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5620-4

Trouble Abnormal Output Signal Circuit of Transmission Failure Low Voltage

Cause Behavior of TCU Grounding to body because of faulty wire harness. Faulty column display controller. Grounding the connector pin to body.

5620-5

Open Circuit in Output Signal Circuit of Transmission Failure

Faulty connection of wire harness and TCU. Faulty column display controller. Faulty connection of connector and TCU.

5620-3

Abnormal Output Signal Circuit of Transmission Failure High Voltage

Shorted circuit in power circuit because of faulty wire harness. Faulty column display controller. Shorted circuit in power circuit by the connector pin.

T5-5-54

Repair Procedure Check the wire harness between TCU and column display controller. Check the connector between TCU and column display controller. Faulty column display controller. Check the wire harness between TCU and column display controller. Check the connector between TCU and column display controller. Faulty column display controller. Check the wire harness between TCU and column display controller. Check the connector between TCU and column display controller. Faulty column display controller.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5660-2

5665-2

5670-2

Trouble First Speed Clutch Slipping. When operating the first speed clutch, if the value calculated by the signal of transmission intermediate shaft speed sensor is different from the actual value of vehicle speed sensor, TCU determines that the clutch slipping occurs. Second Speed Clutch Slipping. When operating the second speed clutch, if the value calculated by the signal of transmission intermediate shaft speed sensor is different from the actual value of vehicle speed sensor, TCU determines that the clutch slipping occurs. Third Speed Clutch Slipping. When operating the third speed clutch, if the value calculated by the signal of transmission intermediate shaft speed sensor is different from the actual value of vehicle speed sensor, TCU determines that the clutch slipping occurs.

Cause First speed clutch pressure is low. Main clutch pressure is low. Faulty transmission intermediate shaft speed sensor. Faulty vehicle speed sensor. Faulty clutch.

Behavior of TCU Repair Procedure Turn TCU to neutral. Check the first speed clutch After returning the pressure. forward/reverse lever to Check the main clutch neutral, operate it again. pressure. Then, machine can Check the signal of travel at first or second transmission intermediate speed. shaft speed sensor. If other clutch is Check the signal of vehicle abnormal, TCU is fixed speed sensor. to neutral. Replace the clutch.

Second speed clutch pressure Turn TCU to neutral. Check the second speed is low. After returning the clutch pressure. Main clutch pressure is low. forward/reverse lever to Check the main clutch Faulty transmission neutral, operate it again. pressure. intermediate shaft speed Then, machine can Check the signal of sensor. travel at first or second transmission intermediate Faulty vehicle speed sensor. speed. shaft speed sensor. Faulty clutch. If other clutch is Check the signal of vehicle abnormal, TCU is fixed speed sensor. to neutral. Replace the clutch.

Third speed clutch pressure is low. Main clutch pressure is low. Faulty transmission intermediate shaft speed sensor. Faulty vehicle speed sensor. Faulty clutch.

Turn TCU to neutral. Check the third speed clutch After returning the pressure. forward/reverse lever to Check the main clutch neutral, operate it again. pressure. Then, machine can Check the signal of travel at first or second transmission intermediate speed. shaft speed sensor. If other clutch is Check the signal of vehicle abnormal, TCU is fixed speed sensor. to neutral. Replace the clutch.

T5-5-55

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5675-2

5680-2

5685-2

Trouble High-Speed Forward Clutch Slipping. When operating the high-speed forward clutch, if the value calculated by the signal of transmission intermediate shaft speed sensor is different from the actual value of torque converter output speed sensor, TCU determines that the clutch slipping occurs. Low-Speed Forward Clutch Slipping. When operating the low-speed forward clutch, if the value calculated by the signal of transmission intermediate shaft speed sensor is different from the actual value of torque converter output speed sensor, TCU determines that the clutch slipping occurs. Reverse Clutch Slipping. When operating the reverse clutch, if the value calculated by the signal of transmission intermediate shaft speed sensor is different from the actual value of torque converter output speed sensor, TCU determines that the clutch slipping occurs.

Cause High-speed forward clutch pressure is low. Main clutch pressure is low. Faulty transmission intermediate shaft speed sensor. Faulty torque converter output speed sensor. Faulty clutch.

Behavior of TCU Repair Procedure Turn TCU to neutral. Check the high-speed After returning the forward clutch pressure. forward/reverse lever to Check the main clutch neutral, operate it again. pressure. Then, machine can Check the signal of travel at first or second transmission intermediate speed. shaft speed sensor. If other clutch is Check the signal of torque abnormal, TCU is fixed converter output speed to neutral. sensor. Replace the clutch.

Low-speed forward clutch pressure is low. Main clutch pressure is low. Faulty transmission intermediate shaft speed sensor. Faulty torque converter output speed sensor. Faulty clutch.

Turn TCU to neutral. Check the low-speed forward After returning the clutch pressure. forward/reverse lever to Check the main clutch neutral, operate it again. pressure. Then, machine can Check the signal of travel at first or second transmission intermediate speed. shaft speed sensor. If other clutch is Check the signal of torque abnormal, TCU is fixed converter output speed to neutral. sensor. Replace the clutch.

Reverse clutch pressure is low. Main clutch pressure is low. Faulty transmission intermediate shaft speed sensor. Faulty torque converter output speed sensor. Faulty clutch.

Turn TCU to neutral. Check the reverse clutch After returning the pressure. forward/reverse lever to Check the main clutch neutral, operate it again. pressure. Then, machine can Check the signal of travel at first or second transmission intermediate speed. shaft speed sensor. If other clutch is Check the signal of torque abnormal, TCU is fixed converter output speed to neutral. sensor. Replace the clutch.

T5-5-56

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5700-0

5730-0

5745-15

5755-15

Trouble Cause Overheating Transmission Oil. TCU detects higher oil temperature than allowable value. Clogged Oil filter contamination. Transmission Oil Broken the wire harness Filter. and connector, or faulty TCU detects connection to power circuit pressure from the wire harness and difference connector. beyond Faulty transmission oil filter allowable restriction switch. range. Overrunning. TCU detects transmission output speed beyond the specified value. OverTransmission Input Torque. TCU detects transmission output torque beyond the specified value.

Behavior of TCU -

Repair Procedure Machine cooling. Check the transmission oil level. Check the sensor.

Check the transmission oil filter. Check the wire harness between TCU and transmission oil filter restriction switch. Check the transmission oil filter restriction switch. (resistance measurement) -

TCU may be fixed to neutral.

T5-5-57

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5760-0

5810-3

5810-4

Trouble Overheat at Torque Converter Outlet. TCU detects higher oil temperature than allowable value. Sensor Power Source High Voltage. 6 V or more at terminal #3 (for 5 V sensor) in TCU. Sensor Power Source Low Voltage. 4 V or less at terminal #3 (for 5 V sensor) in TCU.

Cause -

Behavior of TCU -

Repair Procedure Machine cooling. Check the transmission oil level. Check the sensor.

Check the wire harness and connector from terminal #3 in TCU. Check the power at terminal #3 in TCU. (5 V) Replace TCU.

T5-5-58

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5820-4

Trouble Power Source Voltage Decrease

Cause Measurement voltage at the power source is below 18 V.

Behavior of TCU Fixed to neutral.

5820-3

Power Source Voltage Increase

Measurement voltage at the power source is beyond 32.5 V.

Fixed to neutral.

5830-2

Proportional Shorted circuit in wire Fixed to neutral. Solenoid Valve harness or connector and Power Source power circuit. Error. Grounding the wire harness While power and connector to body. from CPU in No power from fuse #9 in fuse TCU is supplied box B. to terminals Faulty TCU. #12 and #13, measuring CPU detects low voltage, or while power from CPU in TCU is not supplied to terminals #12 and #13, measuring CPU detects voltage.

T5-5-59

Repair Procedure Check fuse #9 and fuse #14 in fuse box B. Check the wire harness and connector between fuse #9 and fuse #14 in fuse box B and TCU. Check fuse #9 and fuse #14 in fuse box B. Check the wire harness and connector between fuse #9 and fuse #14 in fuse box B and TCU. Check fuse #9 in fuse box B. Check the wire harness between control valve transmission control valve and TCU. Check the connector between control valve transmission control valve and TCU. Replace TCU.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 5890-2

5900-13

5910-13

5930-7

5930-13

Trouble Cause Abnormal Faulty TCU. EPROM TCU cannot make out the memory Broken Failure in data save. Program. Install new TCU or the used Transmission one for other machine. control is disabled. Application Error. Application is defective. Learning Failure One of the learning values in in Transmission transmission learning control Learning program is beyond normal Control range. Program No Correcting Failure in data save to the Data of memory. Transmission New TCU. Learning Control Program and Declutch Control Pressure

Behavior of TCU Fixed to neutral.

Repair Procedure Replace TCU.

Fixed to neutral.

Replace TCU.

Fixed to neutral.

Replace TCU.

Fixed to neutral.

Check the clutch.

Execute transmission learning control program. Re-install transmission learning control program.

T5-5-60

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.

T5-5-61

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

12 13 TNDJ-05-05-001

1234-

MC Pump Delivery Pressure Sensor Pressure Sensor (Primary Pilot Pressure) Pressure Sensor (Brake Primary Pressure)

567-

Pressure Sensor (Parking Brake) Pressure Sensor (Lift Arm Raise) (OP) Accelerator Pedal Sensor

Secondary Steering Pump Delivery Pressure Sensor (OP) 9- Steering Pressure Switch (OP) 10- Lift Arm Angle Sensor (OP) 11- Pressure Sensor (Brake Secondary Pressure)

T5-5-62

12- Fan Pump Delivery Pressure Sensor 13- Hydraulic Oil Temperature Sensor

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Harness end of connector viewed from the open end side)  Pressure Sensor (Lift Arm Raise) (Option)  Pressure Sensor (Brake Secondary Pressure)  Pressure Sensor (Primary Pilot Pressure)  Steering Pressure Switch (Option)

T6LE-05-05-011

 Pump Delivery Pressure Sensor  Fan Pump Delivery Pressure Sensor  Secondary Steering Pump Delivery Pressure Sensor (Option)  Lift Arm Angle Sensor (Option)  Pressure Sensor (Brake Primary Pressure)

T6LE-05-05-010

 Accelerator Pedal Sensor

TNDJ-05-05-011

T5-5-63

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-64

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111006, 111007, 111011 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 T5-5-60 to 62.) Fault Code 111006-2

111007-2

111011-2

Trouble (MC) EC Communication Error (MC) IC Communication Error 1 (MC) Transmission Controller Communication Error

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)

T5-5-65

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

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

Continuity (0 Ω) Correct

Discontinuity (∞ Ω) Discontinuity

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

ECM

TCU

#A28 #A29

#B46 #B47

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

#B46-#A1 #B46-#A2 #B47-#A1 #B47-#A2 -

T5-5-66

Column Display Controller #2-B30 #2-B29

A/C

#25 #26

Information Controller #C5 #C11

#25-#1 #25-#2 #26-#1 #26-#2 -

#C5-#C14 #C5-#C15 #C5-#C14 #C5-#C15 -

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

#8-#26 #9-#26 -

#8 #9

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Inspection

CAN Harness

ECM

TCU

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

#B46-#A3 #B46-#A4 #B47-#A3 #B47-#A4 #B46-#B39

#25-#23 #25-#68 #26-#23 #26-#68 #25-#45

Low side

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

Information Controller #C5-#C1 #C5-#C2 #C11-#C1 #C11-#C2 #C5-#C7

Column Display Controller #2-B30-#1-A1 #2-B29-#1-A1 #2-B30-#1-A2

#A29-#E10 #B47-#B39 #26-#45

#C11-#C7

#2-B29-#1-A2

#A28-#A29 #B46-#B47 #25-#26

#C5-#C11

#2-B29-#2-B30

T5-5-67

A/C #8-#17 #8-#17 #9-#17 #9-#17 -

#8-#9

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

 TCU Connector

TNDJ-05-05-010

 MC-D Connector

TNDJ-05-05-006

 EC-E Connector

TNDB-05-05-003

 Column Display Controller 1-A Connector

TNDJ-05-05-008 TNDJ-05-05-007

 ECM-B(J2) Connector

 Column Display Controller 1-B Connector

TNDB-05-05-007

 Column Display Controller 2-B Connector TNDJ-05-05-002

 ECM-A(J3) Connector TNDJ-05-05-009

 A/C3 Connector  Information Controller-C Connector

TNDJ-05-05-003

17 C1

26 C15 C11

T1V1-05-04-002

T5-5-68

TNCC-05-05-004

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-69

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111014, 111025 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 T5-5-60 to 62.) Fault Code 111014-2

111025-2

Trouble Inspection Method (MC) Air Conditioner Continuity check (open circuit) Controller Communication Discontinuity check (shorted Error circuit) (MC) Column Continuity check (open circuit) Monitor Communication Discontinuity check (shorted Error circuit)

T5-5-70

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111100 Preparation  Check the wiring connections first.  The actual engine speed which ECM sends by using the CAN bus line is abnormal. Diagnose ECM.  The engine speed which TCU sends by using the CAN bus line is abnormal. Diagnose TCU. Fault Code 111100-2

Trouble Abnormal Engine Speed

Cause Engine speed: 4000 min-1 or more. Or engine speed (ECM): 500 min-1 or less and engine speed (TCU): 500 min-1 or more.

T5-5-71

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111103, 111106, 111107 Preparation  Check the wiring connections first. Fault Code 111103-3

111103-4

111106-3

111106-4

111107-2

Trouble Inspection Method Accelerator Pedal Circuit Measure resistance High Input between accelerator pedal sensor end #1 and #3. Accelerator Pedal Circuit Measure voltage between Low Input accelerator pedal sensor harness end #3 and body. Measure voltage between accelerator pedal sensor harness end #3 and #4. -

Evaluation 0Ω

Cause Shorted circuit in wire harness #1 and #3.

Normal in above check. Voltage: less than 0.25 V

Open circuit accelerator pedal sensor. Open circuit in wire harness #1.

Voltage: less than 0.25 V

Open circuit in wire harness #4.

Normal in above check. Abnormal Accelerator Voltage: more than 4.74 V The engine speed Pedal 2 Circuit High is fixed to 1000 Input min-1. Abnormal Accelerator Voltage: less than 0.25 V The engine speed Pedal 2 Circuit Low Input is fixed to 1000 min-1. Accelerator pedal Sensor Voltage difference between The engine speed correlation diagnosis accelerator pedal sensor is fixed to 1000 end #1 and #2 is 0.5 V or min-1. more.

Connector (Wire Harness end)  Accelerator Pedal Sensor

TNDJ-05-05-011

T5-5-72

Faulty accelerator pedal. Check the wire harness. Replace the accelerator pedal. Check the wire harness. Replace the accelerator pedal. Check the wire harness. Replace the accelerator pedal.

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

111205-4

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. -

Connector (Wire harness end)  Lift Arm Angle Sensor (Option)

T6LE-05-05-010

T5-5-73

Evaluation 0Ω

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

Normal in above check. Voltage: less than 0.25 V

Open circuit lift arm angle sensor. Open circuit in wire harness #1.

Voltage: less than 0.25 V

Open circuit in wire harness #3.

Normal in above check.

Faulty lift arm angle sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111200, 111203 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 111200-3

111200-4

Trouble Lift Arm Raise Pilot Pressure Sensor Circuit High Input Lift Arm Raise Pilot Pressure Sensor Circuit Low Input

Inspection Method Retry by using MPDr.

Evaluation Un-displayed fault code Measure voltage between B Voltage: 4.75 V or and body. more 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 wire harness #1 and #2. Faulty sensor. Open circuit in wire harness #1. Open circuit in wire harness #3. Open circuit in wire harness #2.

TDAA-05-06-003

T5-5-74

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111217, 111312 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

111312-3

111312-4

Trouble Pilot Pressure Sensor Circuit High Input

Inspection Method Retry by using MPDr.

Evaluation Un-displayed fault code Measure voltage between B Voltage: 4.75 V or and body. more Pilot Pressure Sensor Retry by using MPDr. Un-displayed fault 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. Service Brake Secondary Retry by using MPDr. Un-displayed fault Pressure Sensor Circuit code High Input Measure voltage between B Voltage: 4.75 V or and body. more Service Brake Secondary Retry by using MPDr. Un-displayed fault Pressure Sensor Circuit code Low Input Measure voltage between A Voltage: less than and body. 0.25 V Measure voltage between A Voltage: less than and C (GND). 0.25 V Normal in above check. C

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

TDAA-05-06-003

T5-5-75

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111204, 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 111204-3

111204-4

111206-3

111206-4

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

TDAA-05-06-003

T5-5-76

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 Emergency Steering Check Pressure Sensor Circuit High Input Emergency Steering Check Pressure Sensor Circuit Low Input

Inspection Method Retry by using MPDr.

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

TDAA-05-06-003

T5-5-77

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111311, 111313 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 111311-3

111311-4

111313-3

111313-4

Trouble Service Brake Primary Pressure Sensor Circuit High Input

Inspection Method Retry by using MPDr.

Evaluation Un-displayed fault code Measure voltage between B Voltage: 4.75 V or and body. more Service Brake Primary Retry by using MPDr. Un-displayed fault Pressure Sensor Circuit code 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. Parking Brake Pressure Retry by using MPDr. Un-displayed fault Sensor Circuit High Input code Measure voltage between B Voltage: 4.75 V or and body. more Parking Brake 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. C

TDAA-05-06-003

T5-5-78

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 Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB

Hydraulic Fan Reverse Rotation P/S Valve FB High Current

Hydraulic Fan Reverse Rotation P/S Valve FB Low Current

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Oil Pressure Driving Fan Reverse P/S FB Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Oil Pressure Driving Fan Reverse P/S FB

Connector (Wire 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 wire harness #2. Shorted circuit in wire harness #1 and #2. Faulty solenoid valve.

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

0 mA

Open circuit in wire harness #1.

Shorted circuit in wire harness #1 and #2. Faulty solenoid valve.

Open circuit in wire harness #1. Open circuit in wire 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 Hyd. Fan P/S Valve Abnormal FB

Hyd. Fan P/S Valve FB High Current

Hyd. Fan P/S Valve FB Low Current

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Oil Pressure Driving Fan Control P/S FB Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Oil Pressure Driving Fan Control P/S FB

Connector (Wire harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-5-80

Evaluation 0/∞Ω (Normal value: 22.3±0.4 Ω) 0V

Cause Faulty solenoid valve.

0 mA

Open circuit in wire harness #2. Shorted circuit in wire harness #1 and #2. Faulty solenoid valve.

Normal in above check. 0Ω (Normal value: 22.3±0.4 Ω) Normal in above check. ∞Ω (Normal value: 22.3±0.4 Ω) 0V

0 mA

Open circuit in wire harness #1.

Shorted circuit in wire harness #1 and #2. Faulty solenoid valve.

Open circuit in wire harness #1. Open circuit in wire harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111413 Preparation  Check the wiring connections first. Fault Code 111413-2

111413-3

111413-4

Trouble Pump Swash Angle P/S Valve Abnormal FB

Pump Swash Angle P/S Valve FB High Current

Pump Swash Angle P/S Valve FB Low Current

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Pump Torque Control P/S Valve Output FB. Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Pump Torque Control P/S Valve Output FB.

Connector (Wire harness end)  Solenoid Valve Connector

T1V1-05-04-003

T5-5-81

Evaluation 0/∞Ω (Normal value: 10.3±0.515 Ω) 0V

Cause Faulty solenoid valve.

0 mA

Open circuit in wire harness #2.

Normal in above check. 0Ω (Normal value: 10.3±0.515 Ω) Normal in above check. ∞Ω (Normal value: 10.3±0.515 Ω) 0V

Shorted circuit in wire harness #1 and #2. Faulty solenoid valve.

0 mA

Open circuit in wire harness #2.

Open circuit in wire harness #1.

Shorted circuit in wire harness #1 and #2. Faulty solenoid valve.

Open circuit in wire harness #1.

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 (Bottom) P/S Valve Abnormal FB

Ride Control (Bottom) P/S Valve FB High Current

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Ride Control P/S FB

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 wire harness #2. Shorted circuit in wire harness #1 and #2. Faulty solenoid valve.

Measure resistance between solenoid valve #1 and #2. -

Ride Control (Bottom) Measure resistance P/S Valve FB Low Current between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Ride Control P/S FB

Connector (Wire harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-5-82

0 mA

Open circuit in wire harness #1.

Shorted circuit in wire harness #1 and #2. Faulty solenoid valve.

Open circuit in wire harness #1. Open circuit in wire harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111901 Preparation  Check the wiring connections first. Fault Code 111901-4

111901-3

Trouble Hyd. Oil Temp Sensor Circuit Low Input

Hyd. Oil Temp Sensor Circuit High Input

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

Evaluation Refer to the table.

Cause Faulty sensor.

Normal in above check. Refer to the table. 0V

Open circuit in wire harness #1. Open circuit in wire harness #2. Faulty sensor.

Normal in above check.

Shorted circuit in wire harness #1.

Specification of Hydraulic Oil Temperature Sensor

Connector (Wire harness end)

Hydraulic Oil Temperature (°C) -30 -20

Resistance (kΩ)

 Hydraulic Oil Temperature Sensor

-10 0 10 20

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

30 40 50 60 70 80 90 100 110 120

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

(24.5) 15.04+1.29-1.20

TNED-05-05-021

T5-5-83

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 120003, 120004 Fault Code 120003-2

Trouble Emergency Steering Activated

Inspection Method Check secondary steering check switch (Option).

120004-2

Emergency Steering Activated Pressure Alarm

Disconnect a connector Displayed fault code from the steering pressure switch. Retry by using Un-displayed fault MPDr. code

T5-5-84

Evaluation Correct Incorrect

Cause Faulty wire harness. Faulty secondary steering check switch. Faulty MC or shorted circuit in wire harness. Faulty steering pressure switch.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 120014 Fault Code 120014-2

Trouble Overrun Alarm

Inspection Method Diagnose on fault codes of TCU.

T5-5-85

Evaluation -

Cause -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-86

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 Measurement of voltage between column display controller harness end #2B28 and body Measurement of voltage at alternator terminal L -

Connector (Wire harness end)  Column Display Controller 2-B Connector

TNDJ-05-05-009

T5-5-87

Evaluation 13 to 33.5 V

Cause Faulty column display controller.

13 to 33.5 V

Open circuit in wire 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 Fuel Level Sensor Circuit High Input

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

Fuel Level Sensor Circuit Low Input

Evaluation Refer to the table.

Cause Faulty sensor.

Open circuit in wire harness #1.

Normal in above check. Refer to the table.

Open circuit in wire harness #2. Faulty sensor.

Measure resistance between sensor #1 and #2. Normal in above check.

Shorted circuit in wire harness #1 and #2.

Fuel Gauge

No. A

Fuel Level (%) 100 (FULL)

Fuel Sensor (Ω) 100-4

B C

50 0 (EMPTY)

33±5 90+100

TNED-05-05-008

Connector (Wire harness end)  Fuel Sensor

TNED-05-05-022

T5-5-88

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display Controller (Information) Fault Codes 120500 to120503, 120505 Fault Code 120500-2

Trouble Overheat Alarm

120501-2

Engine Error

120502-2

Engine Oil Pressure Alarm

120503-2

Air Cleaner Restriction Alarm

120505-2

Brake Pressure Alarm

Inspection Method Evaluation Diagnose on fault codes of ECM. 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 Diagnose on fault codes of MC. -

Connector (Wire harness end)  Column Display Controller 1-A Connector

TNDJ-05-05-008

 Column Display Controller 1-B Connector

TNDB-05-05-007

T5-5-89

Cause Faulty column display controller or shorted circuit in wire harness. Faulty air filter restriction switch. -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display Controller Fault Codes 120506, 120507, 120510 to 120512, 120515, 120516, 120518 Fault Code 120506-2 120507-2 120510-2 120511-2 120512-2 120515-2 120516-2 120518-2

Trouble Inspection Method Steering Oil Pressure Alarm Diagnose on fault codes of MC. T/M Malfunction Diagnose on fault codes of HST controller. Transmission Oil Diagnose on fault codes Temperature of MC. Fuel Filter Restriction Diagnose on fault codes of Alarm ECM. Emergency Steering Alarm Diagnose on fault codes (Lighting) of MC. Engine Alarm Diagnose on fault codes of ECM. Hydraulic Oil Temperature Diagnose on fault codes Alarm of MC. Emergency Steering Alarm Diagnose on fault codes (Blinking) of MC.

Connector (Wire harness end)  Column Display Controller 1-A Connector

TNDJ-05-05-008

 Column Display Controller 1-B Connector

TNDB-05-05-007

T5-5-90

Evaluation -

Cause -

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

fNOTE: All connector images in this section are viewed from the open end side of wire harness end.

T6L4-05-03-001 1-

Wire Harness End Connector

Wire Harness

T5-6-1

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Contents of Diagnosis

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

How to Read Table Procedure (A) (F)

Inspection Method (B) (G)

Condition

Evaluation

Cause

(D) (I)

(E) (J)

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

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

T5-6-2

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

Accelerator Pedal (Accelerator Pedal Sensor)

Controls engine, pump, and valve Instructs target engine speed operation. according to accelerator pedal depressing amount. Symptoms Depending on trouble situations, MC holds engine speed in 1000 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 1000 The engine speed is fixed to 1000 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 T2-2 T2-2 of Control (Operational Principle Section in F&S S/M)

T5-6-3

Travel Mode Selector Switch

Shifts the travel mode into AUTO 1, AUTO 2, and Manual modes. MC holds the travel mode in Manual mode.

Open circuit: Travel mode is always Manual mode. Shorted circuit: Travel mode is always AUTO 1/ AUTO 2 mode. MC: Travel Mode Selector Switch -

T2-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Power Mode Switch Item Function

Turns power mode ON/OFF.

Symptoms Same as shown below. in control system when trouble occurs Symptoms Power mode (ON/OFF) can not in machine change. operation The power mode indicator on when trouble monitor is not shifted. occurs Evaluation by Fault Code Evaluation by MC: Power Mode Switch Monitoring Evaluation by using Test Harness Note -

Descriptions T2-2 of Control (Operational Principle Section in F&S S/M)

Quick Power Switch

Declutch Position Switch

Turns power mode ON/OFF.

Activates or deactivates the declutch control. Declutch control is not activated.

Same as shown below.

Functions of power mode switch become effective.

Although declutch position switch is turned ON, the declutch indicator on monitor is not ON.

MC: Quick Power Switch

MC: Clutch Cut OFF Position Switch -

When quick power mode control Brake Pedal Depressing Amount: is effective. Two modes, Large and Small with (Quick power mode is not the declutch position switch set activated when travel is in neutral in the ON position or the travel load is light.) T2-2 T2-2

T5-6-4

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Fan Reverse Rotation Switch (Option)

Forward/Reverse Lever

Shifts fan reverse rotation control Shifts forward clutch solenoid solenoid valve of fan valve. valve, and reverse clutch solenoid valve of transmission. Same as shown below. TCU holds the travel in neutral.

Symptoms in control system when trouble occurs Symptoms Although fan reverse rotation in machine switch is turned ON, cooling fan operation does not rotate in reverse. when trouble The fan reverse rotation indicator occurs on monitor is not ON. (The indicator does not blink when shifting.) Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-2, 2-4 of Control (Operational Principle Section in F&S S/M)

Although forward/reverse lever is operated, machine does not travel forward/reverse. The FNR indication on monitor is not shifted.

TCU: 5010 TCU: Forward/Reverse Lever (N)/ (F)/(R) -

T2-2, T2-5

T5-6-5

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Forward/Reverse Selector Switch Forward/Reverse Switch (Option) (Option) Shifts forward/reverse lever and forward/reverse switch operations. TCU makes forward/reverse lever operation effective.

Symptoms in control system when trouble occurs Symptoms Functions of forward/reverse in machine lever become effective. operation when trouble occurs Evaluation by Fault Code Evaluation by TCU: Forward/Reverse Selector Monitoring Switch Evaluation by using Test Harness Note The operation is effective with forward/reverse lever and forward/reverse switch set in the neutral position. Descriptions T2-2, T2-5 of Control (Operational Principle Section in F&S S/M)

Shifts forward clutch solenoid valve, and reverse clutch solenoid valve of transmission. TCU makes forward/reverse lever operation effective.

Functions of forward/reverse lever become effective.

TCU: 5040 TCU: Option Forward/Reverse Switch (N)/(F)/(R) -

When forward/reverse lever is operated, forward/reverse selector switch operation becomes ineffective. (forward/ reverse lever priority) T2-2, T2-5

T5-6-6

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Shift Switch Item Function

Shifts solenoid valves of transmission control valve.

Symptoms When there are no output from in control shift switch, TCU holds the speed system when range in third speed with Manual trouble occurs mode, and TCU controls the speed range up to third speed with AUTO 1/AUTO 2 mode. Symptoms The speed shift is held in third in machine speed with travel mode set in operation Manual mode. when trouble The speed shift is automatically occurs changed to third speed as max. speed in AUTO 1/AUTO 2 mode. Evaluation by Fault Code Evaluation by TCU: Shift Switch Monitoring Evaluation by using Test Harness Note Descriptions T2-2, T2-5 of Control (Operational Principle Section in F&S S/M)

Downshift Switch (DSS)

Hold Switch

Shifts speed shift solenoid valves of transmission and shifts down the speed shift during automatic speed shift. Same as shown below.

Shifts speed shift solenoid valves of transmission and holds the speed shift during automatic speed shift. Same as shown below.

The speed shift is not shifted down although downshift switch (DSS) is turned ON during automatic speed shift. The shift indication on monitor is not shifted. -

The speed shift is not held although hold switch is turned ON during automatic speed shift. The hold indication on monitor is not displayed.

TCU: DSS Switch

TCU: Gear Hold Switch

T2-2

T5-6-7

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Ride Control Switch Item Function

Shifts ride control solenoid valve and activates or deactivates the ride control. Same as shown below.

Symptoms in control system when trouble occurs Symptoms Open circuit: Ride control switch in machine is always OFF. Although ride operation control switch is turned ON, the when trouble ride control is not activated. occurs Shorted circuit: Ride control switch is always ON. Evaluation by Fault Code Evaluation by MC: Ride Control Switch Monitoring Evaluation by using Test Harness Note Descriptions T2-2, T2-4 of Control (Operational Principle Section in F&S S/M)

T5-6-8

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

Front Control Lever Lock Switch

Pilot Shut-Off Solenoid Valve

Shifts parking brake solenoid valve. Same as shown below.

Shifts pilot shut-off solenoid valve. Same as shown below.

Opens and closes the front pilot circuit. Same as shown below.

When closed: The lift arm and bucket are not operated. (Pilot pressure oil is not supplied to pilot valve.) When open: Pilot pressure oil is always supplied to pilot valve.

Open circuit: Front control lever lock switch is always OFF. Pilot shut-off solenoid valve is not shifted. The lift arm and bucket are not operated although the control lever is operated with the front control lever lock switch set in UNLOCK position. Shorted circuit: Front control lever lock switch is always ON. MC: Pilot Primary Pressure

Symptoms in control system when trouble occurs Symptoms Although the parking brake in machine switch is turned ON/OFF, the operation parking brake is not released/ when trouble applied with the engine running. occurs

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

Descriptions of Control (Operational Principle Section in F&S S/M)

Column Display Controller: Parking Brake Signal Output -

Although the parking brake is turned OFF, the parking brake is applied with the engine stopped. T2-2, T2-5 T2-4

T2-5

T5-6-9

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor

Monitors hydraulic oil Monitors torque converter oil temperature. temperature. Symptoms MC recognizes that hydraulic MC recognizes that torque in control oil temperature is 120 °C when converter oil temperature is 120 system when open circuit occurs. (Hydraulic °C when open circuit occurs. trouble occurs oil temperature: 120 °C is not displayed on monitoring.) Symptoms When hydraulic oil temperature is The color of transmission oil in machine 0 °C or less when starting engine, temperature on monitor is red. operation auto-warming up control is not The indicator is displayed. when trouble operated. occurs Evaluation by 111901 111011 Fault Code Evaluation by MC: Hydraulic Oil Temperature TCU: Torque Converter Oil Monitoring Temperature Evaluation by using Test Harness Note Descriptions T2-2 T2-2 of Control (Operational Principle Section in F&S S/M)

T5-6-10

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pump Delivery Pressure Sensor

Fan Pump Delivery Pressure Sensor

Secondary Steering Pump Delivery Pressure Sensor (Option)

Detects pump delivery pressure.

Detects fan pump delivery pressure. When output is 0 V or 5 V, the following symptoms occur.

Detects secondary steering pump delivery pressure. When output is 0 V or 5 V, the following symptoms occur.

111204

111260

When the engine starts, the secondary steering pump is operated normally but Secondary Steering Alarm is indicated. When the engine stops, the secondary steering pump is not operated. 111208

MC: Pump Delivery Pressure -

MC: Hydraulic Fan Circuit Pressure MC: Emergency Steering Pump Delivery Pressure -

Possible to judge if sensor or wire harness is faulty by switching pressure sensor with other delivery pressure sensor. T2-2

Item Function

Symptoms When output is 0 V or 5 V, the in control following symptoms occur. system when trouble occurs Symptoms Matching control while digging is Although fan reverse rotation in machine not activated. switch (option) is operated, operation fan rotation direction can not when trouble change. occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

Descriptions of Control (Operational Principle Section in F&S S/M)

T5-6-11

Possible to judge if sensor or wire harness is faulty by switching pressure sensor with other delivery pressure sensor. T2-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Steering Pressure Switch (Option) Pressure Sensor (Parking Brake Pressure)

Pressure Sensor (Brake Primary Pressure)

Detects parking brake pressure. When output is 0 V or 5 V, the following symptoms occur.

Detects brake pressure. When output is 0 V or 5 V, the following symptoms occur.

Item Function Detects steering circuit pressure. Symptoms Same as shown below. in control system when trouble occurs Symptoms Secondary steering pump is in machine operated when the wire harness operation is disconnected while traveling. when trouble The low steering oil pressure occurs indicator is always ON. Shorted circuit: The initial automatic check for secondary steering operation cannot be performed. (When the engine starts) Secondary steering indicator of monitor blinks. Evaluation by 120004, 120506 Fault Code Evaluation by MC: Steering Pressure Switch Monitoring Evaluation by using Test Harness Note -

Descriptions T2-2 of Control (Operational Principle Section in F&S S/M)

Although the parking brake The low brake oil pressure is applied, the parking brake indicator is always ON. indicator is not ON. The machine does not accelerate. (with the parking brake dragging)

111313, 115015

111311

MC: Parking Brake Pressure

MC: Service Brake Primary Pressure -

Possible to judge if pressure Possible to judge if pressure sensor is faulty or port is clogged sensor is faulty or port is clogged by switching pressure sensor with by switching pressure sensor with other pressure sensor. other pressure sensor. T2-2, T2-4 T2-2, T2-4

T5-6-12

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Pressure Sensor (Brake Secondary Lift Arm Angle Sensor (Option) Pressure) Detects front brake pressure.

Symptoms When output is 0 V or 5 V, the in control following symptoms occur. system when trouble occurs Symptoms The speed shift does not in machine automatically downshift to first operation speed with the travel mode set in when trouble AUTO 1 mode. occurs The declutch control is not activated. Evaluation by 111312 Fault Code Evaluation by MC: Service Brake Secondary Monitoring Pressure (For Clutch Cut Off ) Evaluation by using Test Harness Note -

Descriptions T2-2 of Control (Operational Principle Section in F&S S/M)

Pressure Sensor (Lift Arm Raise) (Option)

Detects operating angle of the lift arm. When output is 0 V or 5 V, the following symptoms occur.

Detects lift arm raise pilot pressure. When output is 0 V or 5 V, the following symptoms occur.

The lift arm auto leveler lower kickout control is not activated. The lift arm auto leveler height kickout control is not activated.

The ride control is not activated.

111205

111200

MC: Lift Arm Angle Sensor

MC: Lift Arm Raise Pilot Pressure

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2, T2-4

T2-2

T5-6-13

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 Although front control lever lock in machine solenoid valve is operated with operation front control lever lock switch set when trouble in the ON (Lock) position, front occurs control lever lock indicator is not ON. 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 (Operational Principle Section in F&S S/M)

T5-6-14

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Torque Converter Input Speed Sensor

Torque Converter Output Speed Sensor

Transmission Intermediate Shaft Speed Sensor

Detects torque converter input shaft speed. When abnormality is detected, the following symptoms occur.

Detects torque converter output shaft speed. When abnormality is detected, the following symptoms occur.

Detects transmission intermediate shaft speed. When abnormality is detected, the following symptoms occur.

The speed change feeling becomes extremely bad during automatic speed shift. Engine speed may not increase up to fast idle speed. TCU: 5150

Nothing special.

Symptoms in control system when trouble occurs Symptoms The speed change feeling in machine becomes bad extremely during operation automatic speed shift. when trouble Engine speed may not increase occurs up to fast idle speed. Evaluation by TCU: 5140 Fault Code Evaluation by TCU: Actual Engine Speed Monitoring Evaluation by using Test Harness Note Possible to judge if speed sensor is faulty by switching pressure sensor with other speed sensor. Descriptions T2-2 of Control (Operational Principle Section in F&S S/M)

TCU: Torque Converter Output Speed -

Possible to judge if speed sensor is faulty by switching pressure sensor with other speed sensor. T2-2

T5-6-15

TCU: 5160, 5560, 5565, 5670, 5675, 5680, 5685 TCU: Transmission Output Speed -

Possible to judge if speed sensor is faulty by switching pressure sensor with other speed sensor. T2-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Vehicle Speed Sensor Item Function

Detects transmission output shaft speed. When abnormality is detected, the following symptoms occur.

Symptoms in control system when trouble occurs Symptoms The speed meter continues to in machine display 0 km/h. operation The overrun alarm control is not when trouble effective. occurs The ride control is not effective. Evaluation by TCU: 5170 Fault Code Evaluation by MC: Vehicle Speed Pulse Monitoring Evaluation by using Test Harness Note Possible to judge if speed sensor is faulty by switching pressure sensor with other speed sensor. Descriptions T2-2 of Control (Operational Principle Section in F&S S/M)

T5-6-16

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 wire harness condition. Note Descriptions T2-2, 2-4 of Control (Operational Principle Section in 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.

Torque Control Solenoid Valve

Supplies control pressure to main pump. Same as shown below.

Symptoms in control system when trouble occurs Symptoms When closed: The parking brake High current: Pump torque of in machine is not released. (Pilot pressure oil main pump is kept maximum. operation is not supplied to parking brake.) The engine stalls or engine when trouble When open: Parking brake is lug-down is remarkable at high occurs not activated while running the loaded. engine. (Pressure oil continues to Low current: Pump torque of be supplied to the parking brake.) main pump is kept minimum and machine movement becomes slow. Evaluation by 111413 Fault Code Evaluation by MC: Pump Swash Angle P/S Monitoring Output, Pump Swash Angle P/S Output FB Evaluation by using Test Harness Note Descriptions T2-2, 2-4 T2-2 of Control (Operational Principle Section in F&S S/M)

T5-6-18

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Fan Speed Control Solenoid Valve Fan Reverse Rotation Control Solenoid Valve (Option) Control fan speed.

Symptoms Same as shown below. in control system when trouble occurs Symptoms High current: The fan speed is in machine fixed to the minimum. operation Low current: The fan speed is when trouble fixed to the maximum. occurs Evaluation by 111412 Fault Code Evaluation by 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 (Operational Principle Section in F&S S/M)

Shifts fan reverse rotation spool of fan valve. Same as shown below.

High current: The fan always rotates in reverse. Low current: The fan does not rotate in reverse. 111411 MC: Hyd Fan Reverses Rotation P/S Output, Hyd Fan Reverses Rotation P/S Output FB -

T2-2, 2-4

T5-6-19

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Forward/ Reverse Clutch Solenoid Speed Shift Solenoid Valves (Y3, Valves (Y1, Y2, and Y5) Y4, and Y6) Shifts forward spool, and reverse spool of transmission control valve. Same as shown below.

Shifts spools in speed shift solenoid valves (Y3, Y4, and Y6) of transmission control valve. Same as shown below.

Symptoms in control system when trouble occurs Symptoms Refer to TCU Fault Code List (T5-5) Refer to TCU Fault Code List (T5-5) in machine operation when trouble occurs Evaluation by TCU: 5510, 5520, 5530, 5830 TCU: 5480, 5490, 5500, 5830 Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-2 T2-2 of Control (Operational Principle Section in F&S S/M)

T5-6-20

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Main Relief Valve (Front Attachment) Prevents pressure in main pump circuit from exceeding the set pressure when a control lever is operated. Same as shown below.

Symptoms in control system when trouble occurs Symptoms If stuck in fully closed position, in machine hose of front attachment may be operation damaged. when trouble If stuck in fully open position, occurs power is weak during digging operation. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Operational Principle Section in F&S S/M)

Overload Relief Valve

Prevents actuator circuit pressure generated by external force from exceeding the set pressure with a control lever set in neutral. Same as shown below.

If stuck in fully closed position, hose of front attachment may be damaged by external force. If stuck in fully open position, power is weak during digging operation. -

T2-4

T5-6-21

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pump Control Valve Item Function

Supplies pressure oil from the main pump to the regulator of pump device and increases/ decreases the pump delivery flow rate. Same as shown below.

Symptoms in control system when trouble occurs Symptoms Load is applied to the pump in machine as the pump delivery flow rate operation does not decrease with the front when trouble attachment control lever set in occurs neutral. As pump torque increases, acceleration is not smooth when staring the vehicle. Vehicle speed does not increase. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Operational Principle Section in F&S S/M)

T5-6-22

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Main Relief Valve (Steering) Item Function

Ride Control Spool (Ride Control Valve) (Option)

Fan Reversing Spool (Fan Valve) (Option)

Prevents pressure in main pump Is shifted by pilot pressure from circuit from exceeding the set ride control solenoid valve. pressure when a steering wheel is Connects the accumulator to operated. lift arm cylinder circuit and increases/decreases the lift arm cylinder bottom pressure. Same as shown below. 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).

Symptoms in control system when trouble occurs Symptoms If stuck in fully closed position, in machine steering hose may be damaged. operation If stuck in fully open position, when trouble turning force of steering wheel occurs increases and steering operation becomes difficult. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Operational Principle Section in F&S S/M)

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

T5-6-23

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Correlation between Trouble Symptoms and Part Failures This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed. The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom. The marks / in this table indicate the influence to trouble symptom. : Related, required to check : Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.

T5-6-24

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting Trouble Symptom E-1 Starter does not rotate. Parts MC ECM TCU Information Controller Monitor Column Display Controller MPDr. Key Switch Accelerator Pedal Sensor Forward/Reverse Lever Forward/Reverse Selector Switch (Option) Forward/Reverse Switch (Option) Battery Battery Relay Fuse Box A Fuse Box B Neutral Relay Load Dump 2 Relay Starter Relay 1 ECM Main Relay Fuel Pump Relay Starter Engine Unit Coolant Temperature Sensor Glow Plug Relay Glow Plug Pump Delivery Pressure Sensor Remark

: Check required



E-2 Even if starter rotates, engine does not start.

E-3 Engine starts with forward/ reverse lever set in the positions except N.

 





 (Neutral) 

 (Neutral) 

 (Neutral)

   (#13, #14)

 (#10)



 

 

 (#14)

 

 

: Related

T5-6-25

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom E-4 Power mode is not shifted when pushing power mode switch.

MC ECM TCU Information Controller Monitor Column Display Controller MPDr. Key Switch Accelerator Pedal Sensor Power Mode Switch Forward/Reverse Lever Forward/Reverse Selector Switch (Option) Forward/Reverse Switch (Option) Battery Battery Relay Fuse Box A Fuse Box B Neutral Relay Load Dump 2 Relay Starter Relay 1 ECM Main Relay Fuel Pump Relay Starter Engine Unit Coolant Temperature Sensor Glow Plug Relay Glow Plug Pump Delivery Pressure Sensor Remark

: Check required



E-5 Even if key switch is turned OFF, engine does not stop.  

    



 

: Related

T5-6-26

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting

Parts

Trouble Symptom A-1 Actuator of only front attachment do not work.

MC Battery Fuse Box A Pilot Shut-Off Relay Control Lever Lock Switch Power Mode Switch Pilot Pump Brake Charge Valve Priority Valve (Brake) Pilot Relief Valve (Brake) Manifold Valve Pilot Relief Valve Torque Control Solenoid Valve Pilot Shut-Off Solenoid Valve Pilot Valve Pressure Sensor (Primary Pilot Pressure) Pressure Sensor (Lift Arm Raise) (OP) Spool (Control Valve) Main Relief Valve (Front Attachment) Cylinder Main Pump Pump Delivery Pressure Sensor Priority Valve Pump Regulator Pilot Filter Remark

: Check required

A-2 Actuator speed of front attachment and steering are slow. 

 (#16)    

   

          



 

    

: Related

T5-6-27

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom A-3 Actuator of front attachment does not stop even if a control lever is set to neutral.

MC ECM TCU Information Controller Monitor Key Switch Accelerator Pedal Sensor Forward/Reverse Lever Forward/Reverse Selector Switch (Option) Forward/Reverse Switch (Option) Pilot Shut-Off Relay Control Lever Lock Switch Battery Engine Unit Crank Revolution Sensor Cam Angle Sensor Coolant Temperature Sensor Exhaust Temperature Sensor Main Pump Pilot Pump Pump Regulator Pump Delivery Pressure Sensor Manifold Valve Torque Control Solenoid Valve Pilot Shut-Off Solenoid Valve Pressure Sensor (Primary Pilot Pressure) Pilot Valve Control Valve Pilot Filter Pilot Relief Valve Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor Pressure Sensor (Parking Brake) Remark

: Check required



 

: Related

T5-6-28

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom A-5 Fan speed does not change. Parts MC ECM TCU Information Controller Monitor MPDr. Key Switch Accelerator Pedal Sensor Power Mode Switch Fan Reverse Rotation Switch (OP) Battery Fuse Box A Fuse Box B Fan Valve (OP) Fan Speed Control Solenoid Valve Fan Reverse Rotation Control Solenoid Valve (OP) Fan Control Valve (OP) Fan Motor Fan Pump Engine Unit Crank Revolution Sensor Cam Angle Sensor Coolant Temperature Sensor Boost Temperature Sensor Fan Pump Delivery Pressure Sensor Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor Pressure Sensor (Parking Brake) Remark

: Check required



A-6 Fan does not rotate in reverse when pushing fan reverse rotation switch (OP).  





 



   

  

  



  

: Related

T5-6-29

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-30

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting

Parts

Trouble Symptom F-1 All front attachment actuator power are weak.

F-2 Some cylinders are not operated or speed are slow.



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 Relief Valve (Manifold Valve) Torque Control Solenoid Valve (Manifold Valve) Pilot Shut-Off Solenoid Valve (Manifold Valve) Pilot Valve Pressure Sensor (Primary Pilot Pressure) Bucket Flow Rate Control Valve (Control Valve) Pressure Sensor (Lift Arm Raise) (OP) Spool (Control Valve) Main Relief Valve (Front Attachment) Pump Control Valve (Control Valve) Cylinder Main Pump Pump Delivery Pressure Sensor Priority Valve (Main) Pump Regulator Pilot Filter Remark

: Check required

 



  

 

  

  (Overload)

     

: Related

T5-6-31

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom F-3 Front attachment drifts remarkably. Parts MC Information Controller Monitor Lift Arm Angle Sensor (OP) Pilot Pump Brake Charge Valve Manifold Valve Pilot Valve Slow Return Valve Pressure Sensor (Lift Arm Raise) (OP) Spool (Control Valve) Load Check Valve (Control Valve) Cylinder Main Pump Remark

: Check required

F-4 Shock is large when stopping lift arm raise/lower operation or bucket dump/ tilt operation.



  (Lift Arm, Bucket) 

 



 with the engine stopped

: Related

T5-6-32

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.)

MC Information Controller Monitor Battery Battery Relay Fuse Box A Lift Arm Angle Sensor (OP) Bucket Proximity Switch Pilot Pump Brake Charge Valve Manifold Valve Pilot Valve Spool (Control Valve) Cylinder Main Pump Remark

: Check required

 

 (#16)

 (#16) 



 (Bucket)  (Bucket)

 (Lift Arm)  (Lift Arm)

: Related

T5-6-33

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom F-7 Lift arm auto leveler height kickout control (OP) is not activated.

MC TCU Information Controller MPDr.

F-8 Lift arm auto leveler lower kickout control (OP) is not activated.

F-9 Ride control is not activated (OP).



 (Lift Arm Angle Sensor Learning)  (#16) 

 (Setting: ON)

Fuse Box A Lift Arm Angle Sensor (OP) Vehicle Speed Sensor Ride Control Switch (OP) Pilot Pump Brake Charge Valve Pilot Shut-Off Solenoid Valve (Manifold Valve) Pilot Valve  (Lift Arm)  Lift Arm Raise Side Coil (Pilot Valve) Lift Arm Lower Side Coil (Pilot Valve) Pressure Sensor (Primary Pilot Pressure) Pressure Sensor (Lift Arm Raise) (OP) Ride Control Solenoid Valve (OP) Spool (Control Valve)  (Lift Arm) Spool (Ride Control Valve) (OP) Cylinder Accumulator (Ride Control) (OP) Main Pump Pump Delivery Pressure Sensor Remark

: Check required

  

 (Lift Arm)



   (Lift Arm)   (Lift Arm)  

: Related

T5-6-34

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 MC Priority Valve (Brake Charge Valve) Pilot Relief Valve (Brake Charge Valve) Pilot Relief Valve (Manifold Valve) Torque Control Solenoid Valve (Manifold Valve) Pressure Sensor (Primary Pilot Pressure) Steering Pilot Pump (Steering Wheel) Steering Valve (Spool) Overload Relief Valve (Steering Valve) Steering Pressure Switch Steering Cylinder (Left, Right) Steering Accumulator Main Pump Steering Relief Valve (Priority Valve) Pump Delivery Pressure Sensor Priority Valve (Main) Pump Regulator Pilot Pump Pilot Filter Remark

: Check required

S-3 Shock of steering operation is large.

    



 





   

 

 



 



: Related

T5-6-35

 

 

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom S-4 Secondary steering (option) is not operated. (Check automatic operation when the engine starts)

MC TCU Information Controller Monitor MPDr. Battery Fuse Box A Secondary Steering Relay (OP) Vehicle Speed Sensor Pilot Pump Brake Charge Valve Manifold Valve Steering Pressure Switch (OP) Secondary Steering Pump Delivery Pressure Sensor (OP) Steering Cylinder (Left, Right) Steering Accumulator Main Pump Secondary Steering Motor (OP) Secondary Steering Pump (OP) Remark

: Check required



 (Setting: ON)  (#20)  

 

 

: Related

T5-6-36

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting

Parts

Trouble Symptom T-1 Although forward/reverse lever is operated, machine does not travel forward/ reverse.

MC  TCU Information Controller  Monitor Battery Fuse Box A  (#14) Accelerator Pedal Sensor Brake Pedal (Right) Switch Brake Valve Forward/Reverse Lever  (Forward/Reverse)  Forward/Reverse Switch (Option)  Forward/Reverse Selector Switch (Option) Declutch Position Switch  Drive Unit  Transmission Control Valve Torque Converter Input Speed Sensor Torque Converter Output Speed Sensor Transmission Intermediate Shaft Speed Sensor Vehicle Speed Sensor  Slow-Speed Forward Clutch Solenoid Valve (Y5)  Fast-Speed Forward Clutch Solenoid Valve (Y1)  Reverse Clutch Solenoid Valve (Y2)  Propeller Shaft  Axle Pressure Sensor (Brake Secondary Pressure) Pressure Sensor (Parking Brake)  Remark

: Check required

T-2 Although forward/reverse lever is set to neutral position, machine travels.

T-3 Declutch is not operated.



 

 (#14)

 (Neutral) 

  (Forward)



 

    



 



Neutral Control

: Related

T5-6-37

Declutch Control

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom T-4 Travel mode can not be shifted.

 MC TCU Information Controller Monitor Battery Fuse Box A Brake Pedal (Right) Switch  Travel Mode Selector Switch Shift Switch Power Mode Switch Drive Unit Transmission Control Valve Torque Converter Input Speed Sensor Torque Converter Output Speed Sensor Transmission Intermediate Shaft Speed Sensor Vehicle Speed Sensor Speed Shift Solenoid Valve (Y3, Y4, and Y6) Pressure Sensor (Brake Secondary Pressure) Remark

: Check required

T-5 Although shift switch is operated, speed shift does not change.

T-6 Although vehicle speed changes, speed shift does not change automatically.



 

 (#14)  (Manual Mode) 

 (AUTO 1/AUTO 2 Mode)

  

   



 

 

Manual Speed Shift Control

Automatic Speed Shift Control

: Related

T5-6-38

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom T-7 Speed shift is not shifted down when pushing downshift switch (DSS).

MC  TCU Information Controller Monitor Key Switch Battery Fuse Box A  (#14) Fuse Box B Accelerator Pedal Sensor Brake Pedal (Right) Switch Travel Mode Selector Power Mode Switch Forward/Reverse Lever Forward/Reverse Switch (Option) Forward/Reverse Selector Switch (Option) Shift Switch  Downshift Switch (DSS) Hold Switch Shift Change Delay Mode Switch  Drive Unit  Transmission Control Valve Torque Converter Input Speed  Sensor Torque Converter Output Speed  Sensor Transmission Intermediate Shaft Speed Sensor  Vehicle Speed Sensor  Speed Shift Solenoid Valve Transmission Oil Filter Transmission Oil Filter Restriction Switch Pressure Sensor (Parking Brake) Lift Arm Angle Sensor (OP) Pressure Sensor (Lift Arm Raise) (OP) Remark

: Check required

T-8 T-9 Speed shift is not held when Speed shift retard control pushing hold switch. (Option) is not activated.



    (ON) 

 (#14)

    

   

   

 

  Effective wher travel mode selector is AUTO 1 mode or AUTO 2 mode.

: Related

T5-6-39

Effective wher travel mode selector is AUTO 1 mode or AUTO 2 mode.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-40

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting

Parts

Trouble Symptom B-1 Parking brake is not released. (When the engine runs)

MC Information Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Parking Brake Switch Parking Brake Relay 1 Parking Brake Relay 2 Parking Brake Solenoid Valve Parking Brake Parking Brake Accumulator Brake Charge Valve Pressure Sensor (Parking Brake) Pilot Relief Valve (Brake Charge Valve) Pressure Sensor (Brake Primary Pressure) Service Brake Accumulator Brake Valve Axle (Service Brake) Pressure Sensor (Brake Secondary Pressure) Pilot Pump Pilot Filter Engine Remark

: Check required



B-2 B-3 Parking brake is not applied. Service brake braking force becomes weak. 

  (ON)  (#14, #18)

 (#14, #18)

 (Released)  (OFF)  (ON)  

 (Operated)  (ON)   

  



      

 

The parking brake can not be released as the parking brake release pressure is not supplied with the engine stopped.

: Related

T5-6-41

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-42

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting

Parts

Trouble Symptom O-1 O-2 Clearance light and tail light, Head light is not ON. are not ON.

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

: Check required

 (Indicator)   (#4, #11) 

O-3 Head light is not shifted to high beam.

 (Indicator)  (ON)

 (#3, #4)

 (#19, #4)

   

 

   

: Related

T5-6-43

  (High Beam)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom O-4 O-5 Hazard light is not operated. Turn signal light is not operated.

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

: Check required

 (Indicator)   (#7)

O-6 Horn does not sound.

 (Indicator)  (ON)  (#2, #7)

  (#6)

     

   



 

: Related

T5-6-44

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Parts

Trouble Symptom O-7 O-8 Reverse light is not ON. Brake light is not ON. Reverse buzzer (Option) does not sound.

MC TCU Information Controller Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Forward/Reverse Lever Forward/Reverse Selector Switch (Option) Forward/Reverse Switch (Option) Brake Light Switch (Brake Pedal) Light Switch Work Light Switch Reverse Buzzer Relay (OP) Brake Light Relay Work Light (Front) Relay Work Light (Rear) Relay Reverse Light Reverse Buzzer (OP) Brake Light Work Light Remark

: Check required

O-9 Work light does not light.



 (ON)

 (#1, #13)

 (#2)

 (Indicator)  (ON)  (#4, #17)  (#4)

 (R)

 (R)           

: Related

T5-6-45

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 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

  (ON)

 (ON) 

 (#3, #5)*1  

 (#11)

     (Fast Speed)       

: Check required : Related NOTE: *1) Fuse #3: Front Wiper, Fuse #5: Rear Wiper

T5-6-46

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting E-1 Starter does not rotate. Preparation  In case the radio with the key switch set in the ACC position and the horn with the key switch set in the OFF position are operated normally, the wire harness between battery and key switch terminal B is considered normal.

 Check that the forward/reverse lever is in the neutral position.  This trouble has nothing to do with the electronic control system such as MC.  Check the wiring connections first. Procedure Inspection Method 1 Measure battery voltage and electrolyte density

Condition -

Switch the neutral relay with other general relay

Set the key switch to START after switching relays Key switch: START

Measure voltage between neutral relay harness end #1 and #3 Measure voltage at starter Key switch: START relay 1 harness end terminal S

Measure voltage at battery relay terminal A Measure voltage at starter terminal #50 Check continuity between key switch #1 and #6 Monitor Forward/Reverse Lever (N) -

Key switch: ON

Open circuit in wire harness between key switch and neutral relay Open circuit in wire harness between starter cut relay and starter relay 1 Faulty battery relay

Key switch: START

Faulty starter relay 1

Key switch: START

∞Ω

Faulty key switch

Forward/reverse lever: N -

OFF is displayed

Faulty forward/reverse lever

5 6 7 8 9

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

The check mentioned Faulty starter above is normal

T5-6-47

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-2 Even if starter rotates, engine does not start. Preparation  Check that #10 fuse in fuse box A is not abnormal.  Check the wiring connections first.

Procedure Inspection Method 1 Measure voltage between ECM main relay harness end #B and the body. 2 Measure voltage between ECM main relay harness end #C2 and the body. 3 Switch fuel pump relay with other general relay 4 -

 Check that the fuel filter is not clogged.  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 check mentioned Faulty ECM or engine unit above is normal

Connector (Wire harness end)  ECM main Relay

TNDJ-05-06-001

T5-6-48

Cause Open circuit in wire harness between ECM main relay and fuse #10 in fuse box A. Open circuit in wire harness between ECM main relay and fuse #13 in fuse box A. Faulty fuel pump relay

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-3 Engine starts with forward/reverse lever set in the positions except N. Preparation  Even if the key switch is set to the START position with the forward/reverse lever set in the positions except N (neutral), the starter does not rotate.  Check #14 fuse in fuse box A.  Refer to SYSTEM/Electrical System/Neutral Engine Start Circuit.  Refer to SYSTEM/Hydraulic System.  Check the wiring connections first. Procedure Inspection Method 1 Measure voltage at neutral relay harness end #1

Condition Forward/reverse lever: F or R

Evaluation 0V

Switch the neutral relay with other general relay

Starter: Rotating

Set the key switch to START after switching relays -

Cause Open circuit in wire harness between forward/reverse lever and neutral relay Faulty neutral relay

The check mentioned Find out cause of trouble by above is normal tracing other trouble symptoms

Connector (Wire harness end)  Neutral Relay

T183-05-04-003

T5-6-49

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-4 Power mode is not shifted when pushing power mode switch. Preparation  Check the wiring connections first. Procedure Inspection Method 1 Monitor Power Mode Switch

Condition Power mode switch: ON

Evaluation OFF is displayed

Cause Faulty power mode switch or open circuit in wire harness between power mode switch and MC The check mentioned Faulty MC above is normal

T5-6-50

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-5 Even if key switch is turned OFF, engine does not stop. Preparation

 Remove fusible link A (65A) (1) and stop the engine as emergency procedures first.  In case other trouble symptoms occur, perform troubleshooting of these troubles first.  If the fault code is not displayed, the key switch may be faulty.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

MNEC-01-503

T5-6-51

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-52

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting A-1 Actuator of only front attachment do not work. Preparation  If the pilot system is faulty, the cause of trouble may exist in the pilot shut-off circuit.  Check that #16 fuse in fuse box A is not abnormal.  Pilot valves, travel motors, and/or control valve spools are unlikely to be faulty at the same time. Procedure Inspection Method 1 Switch pilot shut-off relay with other general relay 2 Monitor Pilot Primary Pressure 3

Measure resistance between pilot shut-off solenoid valve #1 and #2 Check continuity between pilot shut-off relay harness end #4 and body

 Refer to SYSTEM/Electrical System.  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

Cause Faulty pilot shut-off relay

Connect pilot shut-off solenoid valve harness end terminal #2 to body -

Open circuit in wire harness between pilot shut-off solenoid valve and pilot shut-off relay

∞Ω

Faulty control lever lock switch

Faulty pilot shut-off solenoid valve

The check mentioned Faulty pilot valve above is normal

Connector (Wire harness end)  Pilot Shut-Off Relay

T183-05-04-003

T5-6-53

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-2 Actuator speed of front attachment and steering are slow.

Primary Pilot Pressure

Specification (MPa) 4.5±0.8

Remark Accelerator pedal: Full stroke

Preparation  If actuator speed of only front attachment is slow, the pilot system may be faulty (A-1) or the circuit after the pilot valve may be faulty (F-2).  If actuator speed of only steering is slow, the circuit after the steering valve may be faulty (S-3).  Refer to SYSTEM/Hydraulic System.

 The pump flow rate is minimized due to some reasons.  Check fuse of the torque control solenoid valve.  Even if speed is satisfactory, in case power is weak, refer to the troubleshooting for faulty main relief valve (F-1/S-1).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Lift Arm Raise Pilot Pressure

Condition Lift arm relief operation

Monitor Pilot Primary Pressure

Disassemble and inspect the priority valve (brake) Measure pressure at port LS of priority valve (main)

Accelerator pedal: Fully depressed without load (Control lever: Neutral) -

Evaluation The measured values are not within the normal values (Normal value: 3.4 to 4.2 MPa) The measured values are not within the normal values (Normal value: 3.7 to 5.3 MPa) There is abnormality

Cause Faulty pilot relief valve in manifold valve

Clogged pilot filter

Faulty priority valve (brake) (stuck spool) The measured Faulty priority valve (main) values are not within (stuck spool) the normal values (Normal value: 1.2 to 2.6 MPa) The check mentioned Faulty pump device above is normal

T5-6-54

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-3 Actuator of front attachment does not stop even if a control lever is set to neutral. Preparation  Stuck spool in the pilot valve or stuck main spool in the control valve is suspected. Procedure Inspection Method 1 Set the control lever lock switch to LOCK position 2 -

Condition -

Evaluation Actuator stops

The check mentioned Faulty control valve (stuck spool) above is normal

T5-6-55

Cause Faulty pilot valve (stuck spool)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-5 Fan speed does not change. Preparation  Refer to SYSTEM/Control System/Fan Reverse Rotation Control.

 The sensors detect the conditions necessary to operate fan speed control. Therefore, if these sensors fails, fan speed control becomes ineffective.  Accelerator pedal sensor, coolant temperature sensor, boost temperature sensor, hydraulic oil temperature sensor, torque converter oil temperature sensor, and pressure sensor (refrigerant pressure) are also 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

Cause Faulty ECM, TCU, or MC

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 check mentioned Faulty fan motor above is 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

T5-6-56

Faulty fan pump

Faulty fan speed control solenoid valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-6 Fan does not rotate in reverse when pushing fan reverse rotation switch (Option). Preparation  Refer to SYSTEM/Control System/Fan Reverse Rotation Control.  Check the wiring connections first. Procedure Inspection Method 1 Monitor fan reverse rotation 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 check mentioned Faulty MC above is normal

T5-6-57

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-58

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) 27.4+1.9−0

Remark

Preparation  If operating speeds are extremely slow, pump control may be faulty. Faulty pilot system may also cause this trouble. Procedure Inspection Method 1 Monitor Pump Delivery Pressure

Condition Lift arm relief operation

Evaluation Cause The measured values Faulty main relief valve (Front are not within the Attachment) (readjust) normal values The check mentioned Find out cause of trouble by above is normal tracing other trouble symptoms

T5-6-59

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-2 Some cylinders are not operated or speeds are slow. Overload Relief Specification Valve Set Pressure (MPa) Lift Arm Raise 34.3+1.0−0 Bucket 30.4+1.0−0

Remark

Preparation  When other actuator (brake) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal. Procedure Inspection Method 1 Measure Pilot Secondary Pressure

Condition Refer to T4-5

Switch 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: 3.4 to 4.2 MPa) Symptom is reversed Faulty overload relief valve

The check mentioned Stuck control valve spool, or above is normal faulty cylinder (faulty seal kit)

T5-6-60

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-3 Front attachment drifts remarkably. Procedure Inspection Method 1 Set the control lever lock switch to LOCK position 2 Switch 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

Cause Faulty pilot valve Faulty overload relief valve Faulty cylinder (seal kit)

The check mentioned Scored control valve spool, above is normal broken spring, or loose spool end

T5-6-61

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-4 Shock is large when stopping lift arm raise/lower operation or bucket dump/tilt operation. Preparation  Check that control levers are not abnormal first.  Refer to SYSTEM/Hydraulic System. Procedure Inspection Method 1 Disassemble and inspect the slow return valve 2 -

Condition -

Evaluation There is abnormality

The check mentioned Stuck control valve spool, or above is normal faulty cylinder (faulty seal kit)

T5-6-62

Cause Faulty slow return valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-5 Bucket auto leveler control is not activated. (Detent is not held.) Preparation  Refer to SYSTEM/Control System/Bucket Auto Leveler Control.  Check #16 fuse in fuse box A.  Check the wiring connections first.

Procedure Inspection Method Condition 1 Measure voltage between Key switch: ON pilot valve bucket tilt side coil harness end #081A and body

Evaluation 0V

Check continuity between Bucket tilt detent pilot valve bucket tilt side coil control lever harness end #431 and body operation

Measure voltage between bucket leveler relay harness end #2 and body -

Bucket proximity switch: ON: ∞ Ω Bucket proximity switch: OFF: 0 Ω 0V

Key switch: ON

Cause Open circuit in wire harness between #16 fuse in fuse box A and pilot valve bucket tilt side coil Faulty pilot valve bucket tilt side coil

Open circuit in wire harness between bucket proximity switch and bucket leveler relay The check mentioned Faulty bucket proximity switch above is normal

Connector (Wire harness end)  Pilot Valve (Fingertip Control Lever Type)

 Bucket Leveler Relay

#081A

T183-05-04-003

 Pilot Valve (Multi-Function Joystic Lever Type)

#431 #081A T8UC-05-04-004

T5-6-63

#431

TNDJ-05-06-003

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-6 Lift arm float control is not activated. (Detent is not held.) Preparation  Refer to SYSTEM/Control System/Lift Arm Float Control.  Check #16 fuse in fuse box A.  Check the wiring connections first. Procedure Inspection Method 1 Measure voltage between pilot valve lift arm lower side coil harness end #081D and body 2 Check continuity between pilot valve lift arm lower side coil harness end #G36B and body 3 -

Condition Key switch: ON

Evaluation 0V

Cause Open circuit in wire harness between #16 fuse in fuse box A and pilot valve lift arm lower side coil Faulty ground in pilot valve lift arm lower side coil

Lift arm lower control lever operation

0Ω

The check mentioned Faulty pilot valve lift arm lower above is normal side coil

Connector (Wire harness end)  Pilot Valve (Multi-Function Joystic Lever Type)

 Pilot Valve (Fingertip Control Lever Type)

#081D

#G36B #G36B #081D TNDJ-05-06-003

T5-6-64

T8UC-05-04-004

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-7 Lift arm auto leveler height kickout control (Option) is not activated. Preparation  Refer to SYSTEM/Control System/Lift Arm Auto Leveler Height Kickout Control. Procedure Inspection Method 1 Measure voltage between pilot valve lift arm raise side coil harness end #081C and body 2 Check continuity between pilot valve lift arm raise side coil harness end #535 and body 3 Monitor Lift Arm Auto Leveler Switch (raise) 4

 Check #16 fuse in fuse box A.  Check the wiring connections first.

Condition Key switch: ON

Evaluation 0V

Lift arm raise, detent control lever operation

0Ω

Lift arm auto leveler switch (raise): ON -

OFF is displayed

Cause Open circuit in wire harness between #16 fuse in fuse box A and pilot valve lift arm raise side coil Faulty ground in pilot valve lift arm raise side coil

Faulty lift arm auto leveler switch (raise)

The check mentioned Faulty pilot valve lift arm raise above is normal side coil

Connector (Wire harness end)  Pilot Valve (Multi-Function Joystic Lever Type) Dual Auto Leveler (Option)

 Pilot Valve (Fingertip Control Lever Type) Dual Auto Leveler (Option)

#535

#081C

#535 TNDJ-05-06-003

T5-6-65

#081C

T8UC-05-04-004

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-8 Lift arm auto leveler lower kickout control (Option) is not activated. Preparation  Refer to SYSTEM/Control System/Lift Arm Auto Leveler Lower Kickout Control. Procedure Inspection Method 1 Measure voltage between pilot valve lift arm lower side coil harness end #081D and body 2 Check continuity between pilot valve lift arm lower side coil harness end #536 and body 3 Monitor Lift Arm Auto Leveler Switch (lower) 4

 Check the wiring connections first.  Check #16 fuse in fuse box A.

Condition Key switch: ON

Evaluation 0V

Cause Open circuit in wire harness between #16 fuse in fuse box A and pilot valve lift arm lower side coil Faulty ground in pilot valve lift arm lower side coil

Lift arm lower, detent control lever operation

0Ω

Lift arm auto leveler switch (lower): ON -

OFF is displayed

Faulty lift arm auto leveler switch (lower)

The check mentioned Faulty pilot valve lift arm lower above is normal side coil

Connector (Wire harness end)  Pilot Valve (Multi-Function Joystic Lever Type) Dual Auto Leveler (Option)

 Pilot Valve (Fingertip Control Lever Type) Dual Auto Leveler (Option)

#536 #081D

#081D

#536 TNDJ-05-06-003

T5-6-66

T8UC-05-04-004

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-9 Ride control (Option) is not activated. Preparation  Check the ride control setting with the MPDr. first. The activating conditions for ride control are different according to the settings.  Refer to SYSTEM/Control System/Ride Control. Procedure Inspection Method 1 Monitor Ride Control Switch

 When other actuator (front attachment) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal.  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 wire harness between ride control switch and MC 0/∞ Ω (Normal value: Faulty ride control solenoid 22±0.4 Ω) valve The check mentioned Stuck ride control valve spool or above is normal faulty accumulator

Connector (Wire harness end)  Solenoid Valve Connector

TNED-05-05-020

T5-6-67

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-68

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting S-1 Steering operation is weak. Main Relief Valve Set Pressure Steering relief operation

Specification (MPa) 27.4+1.9−0

Remark

Preparation  If operating speeds are extremely slow, pump control may be faulty. Faulty pilot system may also cause this trouble. Procedure Inspection Method 1 Monitor Pump Delivery Pressure

Condition Steering relief operation

Evaluation Cause The measured values Faulty steering relief valve are not within the (readjust) normal values

The check mentioned Find out cause of trouble by above is normal tracing other trouble symptoms

T5-6-69

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-2 Steering operation is slow. Specification (seconds) Steering cylinder 2.5±0.4 operation time

Remark Accelerator pedal: Fully depressed Power mode switch: OFF The bucket should be empty

Preparation  If speed of front attachment is also slow, the main system may be faulty (A-2).  Check that the steering wheel is not abnormal first.  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: 27.4 to 29.3 MPa) There is abnormality

Cause Faulty main relief valve (steering)

Faulty priority valve

The check mentioned Stuck steering valve spool or above is normal faulty steering cylinder (faulty seal kit)

T5-6-70

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-3 Shock of steering operation is large. Preparation  Check that the steering wheel is not abnormal first.  The steering valve may be faulty.  Refer to SYSTEM/Hydraulic System. Procedure Inspection Method 1 Check gas pressure in the accumulator 2 Disassemble and inspect the steering valve 3 -

 Set machine to carry position before checking gas pressure in the accumulator.

Condition -

Evaluation There is abnormality

There is abnormality

Cause Gas leakage of accumulator

Faulty steering valve (stuck spool, clogged orifice) The check mentioned Faulty steering cylinder (faulty above is normal seal kit)

T5-6-71

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-4 Secondary steering (option) is not operated. (Check automatic operation when the engine starts) Preparation  Check the secondary steering control setting with the MPDr. first.  Refer to SYSTEM/Control System/Secondary Steering Control (Option).  Check that #20 fuse in fuse box A is not abnormal.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Secondary Steering Pump Delivery Pressure

Condition Engine starts

Switch secondary steering Set the key switch relay with other general relay to START after switching relays -

 The secondary steering check switch may be faulty when secondary steering operation cannot be checked manually.

Evaluation The measured values are not within the normal values (Normal value: 4.8 MPa) The symptom disappears

Cause Faulty secondary steering pump unit

Faulty secondary steering relay

The check mentioned Faulty MC above is normal

T5-6-72

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting T-1 Although forward/reverse lever is operated, machine does not travel forward/reverse. Preparation  The transmission may be faulty when the transmission warning indicator lights.  Refer to SYSTEM/Control System/Forward/Reverse Lever Priority Control (Option).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (F) and (R)

Condition Forward/reverse lever: F, R

Evaluation OFF is displayed

Measure transmission clutch pressure

Forward/reverse lever: F, R

The measured values are not within the normal values (Normal value: Clutch ON: 1.6 to 1.8 MPa) The check mentioned Faulty TCU above is normal

T5-6-73

Cause Faulty forward/reverse lever, or open circuit in wire harness between forward/reverse lever and TCU Faulty transmission control valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-2 Although forward/reverse lever is set to neutral position, machine travels. Preparation  Refer to SYSTEM/Control System/Neutral Control.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (N)

Condition Forward/reverse lever: N

Measure transmission clutch pressure

Forward/reverse lever: N

Evaluation OFF is displayed

Cause Faulty forward/reverse lever, or open circuit in wire harness between forward/reverse lever and TCU The measured Faulty transmission control values are not within valve the normal values (Normal value: 0 MPa) The check mentioned Faulty TCU above is normal

T5-6-74

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-3 Declutch is not operated.  Declutch pressure Declutch Position Brake pedal Brake pedal Switch depressing depressing amount: Small (N) amount: Large (D) Speed Shift: First 1.68 MPa or more 2.87 MPa or more Speed Shift: 1.44 MPa or more 3.35 MPa or more Second Preparation  Refer to SYSTEM/Control System/Declutch Control.  When other actuator (front attachment) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Declutch Position Switch

Monitor Service Brake Secondary Pressure (For Declutch)

Measure transmission clutch pressure

Condition Declutch position switch: N, D

Evaluation OFF is displayed (0 is displayed on the monitor)

Cause Faulty declutch position switch or open circuit in wire harness between declutch position switch and MC Brake pedal (right) The measured Faulty brake system (brake operation values are not within valve) or faulty pressure sensor the normal values (brake secondary pressure) (Normal value: Above) The measured Faulty transmission control values are not within valve the normal values (Normal value: Declutch: 0 to 0.3 MPa) The check mentioned Faulty MC above is normal

T5-6-75

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-4 Travel mode can not be shifted. Preparation  Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Travel Mode Selector Travel mode Switch selector switch: AUTO 1/AUTO 2 mode 2 -

Evaluation Cause Manual mode is Faulty travel mode selector always displayed (0 switch, or open circuit in wire is displayed on the harness between travel mode monitor) selector switch and MC The check mentioned Faulty MC above is normal

T5-6-76

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-5 Although shift switch is operated, speed shift does not change. Preparation  Check that the travel mode is Manual mode.  Refer to SYSTEM/Control System/Manual Speed Shift Control.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Shift Switch and Operate Shift Switch

Condition Shift switch: 2/3/4/5 position

Measure transmission clutch pressure

Evaluation Cause The position of shift Faulty shift switch or open switch is not identical circuit in wire harness between to the display of shift switch and TCU monitoring The measured Faulty transmission control values are not within valve the normal values (Normal value: Clutch ON: 1.6 to 1.8 MPa) The check mentioned Faulty TCU above is normal

T5-6-77

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-6 Although vehicle speed changes, speed shift does not change automatically. Preparation  Check that the travel mode is AUTO 1/AUTO 2 mode.  Refer to SYSTEM/Control System/Automatic Speed Shift Control.  Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Travel Mode Selector Travel mode Switch selector switch: AUTO 1/ AUTO 2 mode 2 -

T5-6-78

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-7 Speed shift is not shifted down when pushing downshift switch (DSS). Preparation  Check that the travel mode is AUTO 1/AUTO 2 mode.  Refer to SYSTEM/Control System/Downshift Control.  Check the wiring connections first. Procedure Inspection Method 1 Monitor DSS Switch

Condition Downshift switch (DSS): ON Travel operation

Evaluation OFF is displayed

Cause Faulty downshift switch (DSS), or open circuit in wire harness between downshift switch (DSS) and TCU The check mentioned Faulty TCU above is normal

T5-6-79

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-8 Speed shift is not held when pushing hold switch. Preparation  Check that the travel mode is AUTO 1/AUTO 2 mode.  Refer to SYSTEM/Control System/Shift Holding Control.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Hold Switch

Condition Hold switch: ON

Evaluation OFF is displayed

Cause Faulty hold switch or open circuit in wire harness between hold switch and TCU The check mentioned Faulty TCU above is normal

T5-6-80

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-9 Speed shift retard control (Option) is not activated. Preparation  Refer to SYSTEM/Control System/Speed Shift Retard Control.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (F), (R)

Condition Forward/reverse lever: F and R

Evaluation N is displayed

Cause Faulty forward/reverse lever, or open circuit in wire harness between forward/reverse lever and TCU Monitor Travel Mode Selector Travel mode: Manual mode is Faulty travel mode selector Switch AUTO 1/AUTO 2 displayed (0 is switch, or open circuit in wire mode displayed on the harness between driving mode monitor) switch and MC Monitor Actual Vehicle Speed Travel operation 0 km/h is displayed Faulty vehicle speed sensor, or open circuit in wire harness between vehicle speed sensor and monitor controller Monitor Shift Switch Shift switch: 3rd, 1st or 2nd is Faulty shift switch, or open 4th, or 5th displayed circuit in wire harness between shift switch and TCU Monitor Shift Change Delay SHift change delay OFF is kept Faulty shift change delay mode Mode Switch mode switch: ON switch, or open circuit in wire harness between speed shift retard mode switch and MC The check mentioned Find out cause of trouble by above is normal tracing other trouble symptoms

T5-6-81

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-82

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting B-1 Parking brake is not released. (When the engine runs) Preparation  When other actuator (front attachment) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Parking brake switch Parking brake switch: ON (Release) Engine: Running 2 Monitor Parking brake signal Parking brake switch: ON (Release) Engine: Running 3 Monitor Parking Brake Parking brake Pressure switch: ON (Release) Engine: Running 4

Monitor Service Brake Primary Pressure

Parking brake switch: OFF (Apply) Engine: Running

Switch parking brake relay 1 with other general relay

Switch parking brake relay 2 with other general relay

Parking brake switch: ON (Release) Engine: Running Parking brake switch: ON (Release) Engine: Running -

Evaluation OFF is displayed

Cause Faulty parking brake switch

OFF is displayed

Faulty column display controller

The measured values are not within the normal values (Normal value: 10.8 to 17 MPa) The measured values are not within the normal values (Normal value: 15 to 17 MPa) The symptom disappears

Stuck spool in parking brake solenoid valve

The symptom disappears

Faulty parking brake relay 2

Faulty parking brake accumulator

Faulty parking brake relay 1

The check mentioned Faulty MC above is normal

T5-6-83

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-2

Parking brake is not applied.

Wear amount of Specification parking brake (mm) (mm) Brake Disc 2.2 Brake Friction Pad 6.0

Allowable Limit (mm) 1.9 4.5

Preparation  Check the wiring connections first. Procedure Inspection Method 1 Monitor Parking Brake Signal Output

2 3 4

Monitor Parking Brake Pressure Check the wear amount of parking brake -

Condition Parking brake switch: OFF (Apply) Engine: Running Key switch: ON -

Evaluation ON is displayed

Pressure is detected

Cause Faulty parking brake switch

Stuck spool in parking brake solenoid valve ≤ Allowable limit Faulty brake disc and faulty brake friction pad The check mentioned Faulty MC above is normal

T5-6-84

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-3

Service brake braking force becomes weak.

Wear amount of service brake (mm) Brake Disc

Specification (mm)

Allowable Limit (mm)

4.0

Preparation  When other actuator (front attachment) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Service Brake Primary Pressure

Condition -

Monitor Service Brake Secondary Pressure

Brake pedal: Full stroke

Check the wear amount of service brake

Refer to T4-4

Evaluation The measured values are not within the normal values (Normal value: 10.8 to 17.0 MPa) The measured values are not within the normal values (Normal value: 6.6±0.6 MPa) -

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, and tail light are not ON. Preparation  Check that the clearance light, tail light, and license plate light are not broken first.  Check #4 fuse in fuse box A when the clearance lights at both sides, tail light, and license plate light are not ON at the same time.  Check #11 fuse in fuse box A when only the light at one side is not ON. Procedure Inspection Method 1 Monitor Light Switch

 Failure of the clearance light indicator lighting will be also affected.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Condition Light switch: Clearance light position or Head light position -

Evaluation OFF is displayed

Cause Faulty light switch Open circuit in wire harness between light switch and #4 and #11 fuses in fuse box A The check mentioned Faulty #4, #11 fuses in fuse box A above is normal

T5-6-87

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-2 Head light is not ON. Preparation  Check that the head lights are not broken first.  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.  Check #4 and #3 fuses in fuse box A. Procedure Inspection Method 1 Set the dimmer switch to the low beam position

 Check that the light switch is the head light position.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Switch head light relay with other general relay

Measure voltage between head light relay harness end #1 and body

Condition Evaluation Key switch: ON The head lights (left/ Light switch: Head right) are not ON light position Key switch: ON The head lights (left/ Dimmer switch: right) are ON Low beam position Key switch: ON 0V Dimmer switch: Low beam position

Measure voltage between head light relay harness end #3 and body

Key switch: ON 0V Dimmer switch: Low beam position

Measure voltage between head light (left) harness end #512A and body Measure voltage between head light (right) harness end #512B and body

Key switch: ON 0V Dimmer switch: Low beam position Key switch: ON 0V Dimmer switch: Low beam position

Connector (Wire harness end)  Head Light Relay

 Head Light (Left/Right) #512A #512B

T183-05-04-003

TNED-05-06-003

T5-6-88

Cause Faulty dimmer switch, or open circuit in wire harness between dimmer switch and light switch Faulty head light relay

Open circuit in wire harness between head light relay and light switch, or faulty dimmer switch Open circuit in wire harness between head light relay and #3 fuse in fuse box A, or faulty #3 fuse Open circuit in wire harness between head light (left) and head light relay (left) Open circuit in wire 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  Check #19 fuse in fuse box A when the high beams at both sides are not ON.  Check that the light switch is the head light position.

Procedure Inspection Method 1 Set the dimmer switch to the high beam position 2

Condition Key switch: ON Light switch: Head light position Switch 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: #1 and body High beam position Measure voltage between Key switch: ON 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 -

 Failure of the high beam indicator lighting will be also affected.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Evaluation Cause High beam is not ON Faulty dimmer switch, or open circuit in wire harness between dimmer switch and light switch High beam is ON Faulty high beam relay

Open circuit in wire harness between high beam relay and dimmer switch

Open circuit in wire harness between high beam relay and #19 fuse in fuse box A, or faulty #19 fuse Open circuit in wire harness between head light (left) and high beam relay

Faulty head light (right), or open circuit in wire harness between head light (right) and high beam relay The check mentioned Faulty head light (right/left) or above is normal faulty ground

Connector (Wire harness end)  High Beam Relay

 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  Check that the turn signal lights (hazard lights) are not broken first.  Check #7 fuse in fuse box A when all turn signal lights do not blink at the same time. Faulty flasher relay may also cause this trouble.

 Failure of blinking of the turn signal light indicators at both sides will be also affected.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

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 Switch 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 -

Evaluation Hazard light is not operated

Cause Faulty hazard light switch, open circuit in wire harness between hazard light switch and #7 fuse in fuse box A 0V Faulty flasher relay or faulty ground Symptom is reversed Faulty turn signal light relays (left/right)

Hazard light switch: ON

Open circuit in wire harness between turn signal light relay (left/right) and hazard light switch, or faulty diode P(k) Open circuit in wire harness between turn signal light relay (left/right) and flasher relay

Open circuit in wire harness between hazard lights (right front/ right rear) and turn signal light relay (right) 0V Open circuit in wire harness between hazard lights (left front/ left rear) and turn signal light relay (left) The check mentioned Faulty #7 fuse in fuse box A above is normal

Connector (Wire Harness end)  Turn Signal Light Relay (Left/ Right)

 Hazard Light (Front)

 Hazard Light (Rear)

 Flasher Relay

#501B #502B

#501A #502A

L T183-05-04-003

TNED-05-06-003

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  Check #2 fuse in fuse box A when all turn signal lights do not blink.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Operate the turn signal lever to the right and left

Condition Key switch: ON

Evaluation All turn signal lights do not blink

Measure voltage between turn signal light relay (left) harness end #1 and 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 (Wire harness end)  Turn Signal Light Relay (Left/Right)

T183-05-04-003

T5-6-91

Cause Faulty turn signal lever, or open circuit in wire harness between turn signal lever and #2 fuse in fuse box A Open circuit in wire harness between turn signal light relay (left) and turn signal lever, or faulty diode k Open circuit in wire harness between turn signal light relay (right) and turn signal lever, or faulty diode P

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-6 Horn does not sound. Preparation  Check that the horn is not broken first.  Check #6 fuse in fuse box A when the horn does not sound by pushing two horn switches.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Switch 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

Horn switch: ON

Cause Faulty horn relay

Open circuit in wire harness between horn relay and #6 fuse in fuse box A, or faulty #6 fuse The check mentioned Faulty horn switch or open above is normal circuit in wire harness between horn switch and horn relay

Connector (Wire harness end)  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 (Option) does not sound. Preparation  Check that the reverse light and reverse buzzer are not broken first.  Check #1 fuse in fuse box A when the reverse lights at both sides and reverse buzzer are not operated at the same time. Faulty forward/reverse lever (T-1) may also cause this trouble.

 Check that the forward/reverse lever is in the R position.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Procedure Inspection Method 1 Switch reverse buzzer relay with other general relay

Condition Key switch: ON

Measure voltage between reverse lights (left/right) harness end #505D/#505C and body Measure voltage between reverse buzzer harness end #2 and body Measure voltage between reverse buzzer relay harness end #1 and body

Key switch: ON

Evaluation Reverse light is ON and reverse buzzer sounds 0V

Key switch: ON

Measure voltage between reverse buzzer relay harness end #3 and body

Key switch: ON

 Reverse Light (Left/Right) #505D #505C

T183-05-04-003

Open circuit in wire harness between reverse lights (left/ right) and reverse buzzer relay

Open circuit in wire harness between reverse buzzer and reverse buzzer relay 0V Open circuit in wire harness between reverse buzzer relay and #13 fuse in fuse box A, or faulty #13 fuse 0V Open circuit in wire harness between reverse buzzer relay and #1 fuse in fuse box A, or faulty #1 fuse The check mentioned Faulty reverse lights (left/right) above is normal or faulty ground

Connector (Wire harness end)  Reverse Buzzer Relay

Cause Faulty reverse buzzer relay

TNED-05-06-003

T5-6-93

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-8 Brake light is not ON. Preparation  Check that the brake lights are not broken first.  Check #2 fuse in fuse box A when the brake lights at both sides are not ON.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Switch brake light relay with other general relay 2

Measure voltage between brake light relay harness end #1 and body

Condition Brake light switch: ON (Brake pedal is operated) Brake light switch: ON (Brake pedal is operated)

Evaluation The symptom disappears 0V

Cause Faulty brake light relay

Open circuit in wire harness between brake light relay and #2 fuse in fuse box A, or faulty #2 fuse The check mentioned Faulty brake light switch, or above is normal open circuit in wire harness between brake light switch and brake light relay

Connector (Wire harness end)  Brake Light Relay

T183-05-04-003

T5-6-94

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-9 Work light does not light. Preparation  Check that the work lights are not broken first.  The light switch may be faulty (O-1) when the work lights at both front and rear sides are not ON at the same time.  Check #4 fuse in fuse box B and #17 fuse in fuse box A when only the light at one side is not ON.

 Failure of blinking of the work light indicator will be also affected.  Refer to SYSTEM/Electrical System.  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

Switch work light relays Key switch: ON (front/rear) with other general Work light switch: 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: harness end #3 and body ON 2 position Measure voltage between work light (front) harness end #1 and body Measure voltage between work light relay (rear) harness end #3 and body

Key switch: ON Work light switch: ON 2 position Key switch: ON Work light switch: ON 2 position

Measure voltage between work light (rear) harness end #1 and body -

Key switch: ON Work light switch: ON 2 position -

Open circuit in wire harness between work light relay (front/ rear) and work light switch 0V Open circuit in wire harness between work light relay (front) and #4 fuse in fuse box B, or faulty #4 fuse 0V Open circuit in wire harness between work light (front) and work light relay (front) 0V Open circuit in wire harness between work light relay (rear) and #17 fuse in fuse box A, or faulty #17 fuse 0V Open circuit in wire harness between work light (rear) and work light relay (rear) The check mentioned Faulty work light relay (front/ above is normal rear) or faulty ground

Connector (Wire harness end)  Work Light Relays (Front/Rear)

Cause Faulty work light switch or open circuit in wire harness between work light switch and light switch Faulty work light relay (front/ rear)

 Work Lights Front/Rear

TNED-05-06-006 T183-05-04-003

T5-6-95

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-10 Wiper is not operated. Preparation  The wiper is driven by electric power routed via the relay circuit. The relay circuit of front wiper is controlled by the column display controller.  In case the wiper is not operated, first check if the wiper relay is activated. Next, check if electric power is routed to the wiper motor.  Front Wiper Procedure Inspection Method 1 Monitor Front Wiper Relay 1 Output

Monitor Front Wiper Relay 2 Output

Monitor Front Wiper Switch

Switch front wiper relay 1/2 with other general relay

 In case the front washer is also not operated, check #3 fuse in fuse box B. In case the rear washer is also not operated, check #5 fuse in fuse box B.  Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Condition Key switch: ON Front wiper/ washer switch: LOW Key switch: ON Front wiper/ washer switch: HIGH Key switch: ON Front wiper/ washer switch: LOW/HIGH

Evaluation OFF is displayed

Cause Faulty column display controller

OFF is displayed

Faulty column display controller

The position of front wiper/washer switch is not identical to the display of monitoring

Key switch: ON Front wiper/ washer switch: LOW/HIGH -

Wiper is operated

Faulty front wiper/washer switch, or open circuit in wire harness between front wiper/ washer switch and column display controller, or open circuit in harness between front wiper relay 1/2 and column display controller Faulty front wiper relay 1/2

The check mentioned Faulty front wiper motor above is normal

Connector (Wire harness end)  Front Wiper Relay 1  Front Wiper Relay 2

T183-05-04-003

T5-6-96

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B  Rear Wiper Preparation  The rear wiper/washer switch may be faulty when the rear wiper is not operated. Procedure Inspection Method 1 Set rear wiper/washer switch to LOW

Condition Key switch: ON

Evaluation Rear wiper is not operated

Switch 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

0Ω

Cause Faulty rear wiper/washer switch, or open circuit in wire harness between rear wiper/washer switch and rear wiper relay Faulty rear wiper relay

Open circuit in wire harness between rear wiper relay and rear wiper/washer switch 0V Open circuit in wire harness between rear wiper relay and #5 fuse in fuse box B, or faulty #5 fuse The check mentioned Faulty rear wiper motor above is normal

Connector (Wire harness end)  Rear Wiper Relay

T183-05-04-003

T5-6-97

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-11 Washer is not operated. Preparation  Refer to SYSTEM/Electrical System.  Check the wiring connections first.  Front Washer Procedure Inspection Method Condition 1 Switch the front washer relay Front wiper/ 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

Measure voltage between front washer motor harness end #2 and body -

Evaluation Front washer is operated 0Ω

Open circuit in wire harness between front washer relay and front wiper/washer switch 0V Open circuit in wire harness between front washer relay and #3 fuse in fuse box B, or faulty #3 fuse Front wiper/ OFF is displayed Faulty front wiper/washer washer switch: switch, or open circuit in wire Washer ON harness between front wiper/ washer switch and column display controller Front wiper/ 0V Open circuit in wire harness washer switch: ON between front washer relay and position front washer motor The check mentioned Faulty front washer motor above is normal

Connector (Wire harness end)  Front Washer Relay

T183-05-04-003

Cause Faulty front washer relay

 Front Washer Motor

TNED-05-06-006

T5-6-98

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B  Rear Washer Preparation  The rear wiper/washer switch may be faulty when the rear washer is not operated. Procedure Inspection Method 1 Switch the rear washer relay with other general relay

Evaluation Rear washer is operated

∞Ω

Condition Key switch: ON Rear wiper/washer switch: Washer ON Check continuity between Key switch: ON rear washer relay harness end Rear wiper/washer #2 and body switch: Washer ON Measure voltage between Key switch: ON rear washer relay harness end Rear wiper/washer #1 and body switch: Washer ON Measure voltage between Key switch: ON rear washer motor harness Rear wiper/washer end #2 and body switch: Washer ON -

Open circuit in wire harness between rear washer relay and rear wiper/washer switch 0V Open circuit in wire harness between rear washer relay and #5 fuse in fuse box B 0V Open circuit in wire harness between rear washer relay and rear wiper motor The check mentioned Faulty rear wiper motor or faulty above is normal #5 fuse in fuse box B

Connector (Wire harness end)  Rear Washer Relay

T183-05-04-003

Cause Faulty rear washer relay

 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  Check #11 fuse in fuse box B when the cab light and rear cab light are not ON at the same time.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Set 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 wire harness between cab light and #11 fuse in fuse box B Faulty door open/close switch Faulty rear cab light, open circuit in wire harness between rear cab light and #11 fuse in fuse box B

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Exchange Inspection

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: Service Brake Primary Pressure Sensor High Input (MC Fault Code 111311-3) Check Method: 1. Switch connectors of pressure sensor (brake primary pressure) and pressure sensor (parking brake).

2. Retry troubleshooting. 1-

Result: In case Parking Brake Pressure Sensor High Input (MC fault code 111313-3) is displayed, the pressure sensor (brake primary pressure) is considered to be faulty.

In case Service Brake Primary Pressure Sensor High Input (MC fault code 111311-3) is displayed, the pressure sensor (brake primary pressure) harness is considered to be faulty.

T5-6-101

Pressure Sensor (Brake Primary Pressure) Brake Charge Valve

TNDB-05-06-001

Pressure Sensor (Parking Brake) Parking Brake Solenoid Valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Applicability of Switch-Check Method Fault Code Trouble 111204-3 Pump Delivery Pressure Sensor High Input 111204-4 Pump Delivery Pressure Sensor Low Input 111206-3 Fan Pump Delivery Pressure Sensor High Input 111206-4 Fan Pump Delivery Pressure Sensor Low Input 111311-3 Service Brake Primary Pressure Sensor High Input 111311-4 Service Brake Primary Pressure Sensor Low Input 111313-3 Parking Brake Pressure Sensor High Input 111313-4 Parking Brake Pressure Sensor Low Input 111208-3 Emergency Steering Pump Delivery Pressure Sensor High Input 111208-4 Emergency Steering Pump Delivery Pressure Sensor Low Input 111217-3 Primary Pilot Pressure Sensor High Input 111217-4 Primary Pilot Pressure Sensor Low Input 111200-3 Lift Arm Raise Pilot Pressure Sensor High Input 111200-4 Lift Arm Raise Pilot Pressure Sensor Low Input

T5-6-102

Remedy Applicable (Harness/Sensor)

Applicable (Harness/Sensor)

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 liters) is drawn from each wheel (4 places) after bubbling stops.

fNOTE: Perform this work on all wheels (4 places) by two 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.

TNDJ-05-06-002

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. Repeat steps 3 to 5 until air bubbles stop coming out with the hydraulic oil.

T4GB-05-04-005

fNOTE: When bubbling does not stop after hydraulic oil

(about 0.5 liters) 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 7 Air Conditioner Outline Operation layout of the air conditioning system is illustrated below. Either fresh or re-circulated air is induced into the air conditioner unit by operating fresh / re-circulated air damper servo motor (6). The induced air flows out of the vents through evaporator (5) or heater (15) by blower motor (11). Evaporator (5) is a device used to cool the air. Heater (15) is a device used to warm the air. In the air conditioning system, after the refrigerant is compressed by the compressor, it is sent to evaporator (5) in which the refrigerant expands to cool the air. Heater (15) warms air by first absorbing heat from warmed engine coolant. Evaporator (5) and heater (15) allow the introduced air to circulate in the system to maintain the temperature at the set temperature.

The vents (operator’s front/rear vent, foot vent, and the front window) can be simultaneously or independently selected by air vent damper servo motor (1) in accordance with the set-ventilation mode. The air conditioning controller controls the air conditioning system. The air conditioning controller controls the damper operation by corresponding to the job site conditions such as atmospheric and cab inside air temperatures, coolant temperature, operator’s set-temperature, and the selected ventilation mode. In addition, the air conditioning controller displays the air conditioning system operation status on the monitor.

6 1

5 2

15 12345-

Air Vent Damper Servo Motor Defroster Vent Rear Vent Front Vent Evaporator

6789-

Fresh/Re-circulated Air Damper Servo Motor Re-circulated Air Sensor Fresh Air Induction Port Re-circulated Air Filter

10- Re-circulated Air Induction Port 11- Blower Motor 12- Power Transistor 13- Frost Sensor

T5-7-1

TDAA-05-07-001

14- Air Mix Damper Servo Motor 15- Heater Core 16- Foot Vent

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Component Layout

11 5

TNDF-05-07-001

8 12

13 b

Engine

1568-

Solar Radiation Sensor Accelerator Pedal Key Switch Air Conditioner Unit

9- Fresh Air Filter 10- Air Conditioner Controller (Switch Panel)

TNEJ-05-07-001

To Radiator (Lower) 11- Outdoor Ambient Temperature Sensor 12- High/Low Pressure Switch 13- Air Conditioner Condenser

T5-7-2

14272829-

Receiver Tank Compressor V Belt (A/C) Pulley (A/C)

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Air Conditioner Unit 19

16 15

20 21

22 23 24 25

TNDB-05-07-028

15- Re-circulated Air Filter 16- Compressor Relay 17- Re-circulated Air Sensor

18- Fresh/Re-circulated Air Damper Servo Motor 19- Frost Sensor 20- Evaporator

21222324-

T5-7-3

Heater Core Air Mix Damper Servo Motor Air Vent Damper Servo Motor Blower Motor Relay

25- Power Transistor 26- Blower Motor

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Air Conditioner Condenser

TNCC-05-08-003

Condenser

Electric Fan (Blower)

T5-7-4

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-5

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Functions of Main Parts The functions of the main parts for the air conditioner are described below. The connector No. is shown in the parentheses after the part name.  Controller Controls the air conditioning system. According to the operator’s requests sent via the switches, and the information regarding the air and refrigerant temperature sent from the sensors, the controller judges the air conditioner operating status and controls the blower motor and/or compressor operation as needed by operating the relays. In addition, the controller informs the operator of the air conditioner operating status by displaying the information on the monitor panel.

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

T5-7-6

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Frost Sensor (CN12) Monitors the fin temperature which is cooled by the evaporator. When the temperature is higher than 3 °C (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 MPa to 0.216 MPa) and the surge pressure range (2.55 MPa to 3.14 MPa). 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 to 25 C) around the recirculated air inlet as the interior air temperatures and converts them to the electrical resistance values. The temperatures 0 °C to 25 °C corresponds to a resistance of 1.645 kΩ (0 °C) to 5 kΩ (25 °C) 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.

T5-7-7

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Solar Radiation Sensor (CN16) Converts the amount of solar radiation (illumination intensity) at the cab front to the current values. TDAA-05-07-010

 Fresh/Re-circulated Air Damper Servo Motor (CN10) Opens or closes the fresh/re-circulated air selection louvers. The damper consists of a motor, link mechanism, and position sensing switch. The motor opens or closes the fresh/re-circulated air selection louvers via the link mechanism. TDAA-05-07-011

T5-7-8

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Air Mix Damper Servo Motor (CN9) Controls opening/closing of the air mixing door in response to the set temperature. The damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes the air mix door via the link mechanism. The potentiometer converts the link movements (the mix door strokes) to the voltage. Both ends of the potentiometer are energized by 5 V from terminals #7 (+) and #25 (-) in controller so that the potentiometer outputs voltage of 0.5 to 4.5 V from the center terminal to terminal #19 in controller corresponding to the link movement. When the set temperature is determined by temperature UP/DOWN signal from the controller, the controller calculates voltage (Vr) corresponding the link position. Further more, the controller checks the air mix door position by voltage (Vf ) from the potentiometer. Then, after the controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf, the controller sends out the current from terminals #15 and #16. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr).

TDAA-05-07-012

T5-7-9

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Air Vent Damper Servo Motor (CN8) Opens or closes the front and rear air vent, foot vent, and defroster vent louvers. The damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes vent louvers via the link mechanism. The potentiometer converts the link movements (vent louvers strokes) to the voltage. Both ends of the potentiometer are energized by 5 V from terminals #7 (+) and #25 (-) in controller so that the potentiometer outputs voltage of 0.5 to 4.5 V from the center terminal to terminal #20 in controller corresponding to the link movement. Depending on the MODE switch set position, vent louvers are operated as shown below: When the front and rear air vent louvers positions are selected, the controller calculates potentiometer voltage (Vr). Furthermore, the controller checks the vent louvers positions by receiving voltage (Vf ) from the potentiometer. Then, after the controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf, the controller sends out the current from terminals #31 and #32. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr). MODE switch position

Front air vent

Rear air vent

Foot air vent

Defroster vent























TNED-05-07-005

TNED-05-07-006

TNED-05-07-007

TNED-05-07-008

TNED-05-07-009

TNED-05-07-010

: Open : Closes

T5-7-10

TDAA-05-07-013

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Troubleshooting IMPORTANT:  When replacing the compressor due to the breakage of compressor from internal lock, sufficiently clean the air conditioner circuit or replace all the parts.  When cleaning is insufficient or all the parts are not replaced, the air conditioner may be broken due to contaminants remaining in the circuit.  Using deteriorated LLC (coolant) or lowconcentration LLC, the heater core will receive a bad influence and it may lead water leaks and shorten the service life of machine. Replace coolant and manage LLC concentration according to the Operator's Manual. How to Display and Delete Air Conditioner Controller Fault Code

MNEC-01-052

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. 2. Push Up and Down buttons of temperature control switch (3) beyond three seconds at the same time. 3. The current fault code is displayed at temperature display (a) on LCD panel (4). Example: E11 4. When some fault codes exist and whenever pushing Up or Down button of temperature control switch (3), other fault codes are displayed.

MNDB-01-011 a 123-

How to Delete 1. Push Up and Down buttons of blower switch (5) beyond three seconds at the same time. 2. The fault code displayed at temperature display (a) on LCD panel (4) is deleted. E-- is displayed. How to Return to Normal Display 1. When pushing OFF switch (2) or setting the key switch to the ON position from the OFF position, the fault code displayed at temperature display (a) on LCD panel (4) is changed into the normal temperature display.

T5-7-11

Air Conditioner Controller OFF Switch Temperature Control Switch

45-

LCD Panel Blower Switch

SECTION 5 TROUBLESHOOTING Group 7 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. Shorted circuit in Voltage: less than Operation is controlled under Check the harness. outdoor ambient 0.096 V such circumstance as no outdoor Replace the temperature sensor ambient temperature sensor is outdoor ambient provided. temperature sensor. Shorted circuit in solar Voltage: more than Operation is controlled under Check the harness. radiation sensor 5.04 V such circumstance as no solar Replace the solar radiation sensor is provided. radiation sensor. Open circuit in frost Voltage: more than The compressor clutch is Check the harness. sensor 4.79 V disengaged. (The compressor Replace the frost stops.) sensor. Shorted circuit in frost Voltage: less than The compressor clutch is Check the harness. sensor 0.096 V disengaged. (The compressor Replace the frost stops.) sensor. Abnormal air vent Shorted circuit: Air vent damper servo motor Check the harness. damper servo motor Voltage: 0 V becomes inoperable. Replace the air Open circuit: Voltage: vent damper servo more than 5 V motor. Abnormal air mix Shorted circuit: Air mix damper servo motor Check the harness. damper servo motor Voltage: less than 0.2 V servo motor becomes inoperable. Replace the air Open circuit: Voltage: vent damper servo more than 4.8 V motor. Abnormal high/low Voltage: 0 V The compressor clutch is Check the harness. refrigerant pressure disengaged. (The compressor Replace the high/ stops.) low pressure switch. CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1 error between monitor harness. controller and air Replace air conditioner controller conditioner controller. CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1 controller harness. Faulty CAN1 harness Replace air conditioner controller.

T5-7-12

SECTION 5 TROUBLESHOOTING Group 7 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. -

T5-7-13

Evaluation Cause ∞ Ω (Normal value: Faulty sensor. 300 to 430 kΩ) 0V Open circuit in harness #1.

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

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 7 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. Measurement of voltage 0V 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

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

Continuity check in CAN1 harness.

Faulty controller. Faulty CAN1 harness.

T5-7-14

Normal Abnormal

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. Faulty controller. Faulty CAN1 harness.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-15

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (1) Condition:  Fault code: Un-displayed  Airflow volume: faulty Blower motor rotates

Normal speed

Slow speed

Blower motor does not rotate

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 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 Blowout of fuse Replace with the Blower motor is locked same capacity fuse Faulty wiring Shorted circuit

T5-7-16

Filter cleaning Filter cleaning Remove obstacles Replacement of blower To A Evaporator surface cleaning Check battery charging system Repair Replace Replace Replace Replace Replace Repair Replace the controller Make sure to ground Wirings inspection Replace motor Replace blower motor Refer to wiring diagram and check Wirings inspection

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of frost sensor Faulty frost sensor characteristics Frost sensor is out of evaporator range (faulty sensitivity) No voltage applied to magnet clutch

T5-7-17

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor.

Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace magnet clutch

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (2) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Normal Fresh air enters

Disconnection of air mix dumper servo motor link

Close window and door Readjust fresh/re-circulated air selection damper Setting link again

T5-7-18

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-19

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (3) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Abnormal Pressure on lowpressure side is too high (approx. 0.29 MPa or more)

Pressure on highpressure side is too low (pressure is not approx. 0.98 MPa or more)

Pressure on lowpressure side is too low (pressure is approx. 0.05 MPa or less) Pressure is high on both sides of highpressure and lowpressure 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

T5-7-20

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor

Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace magnet clutch

B: Low refrigerant Low refrigerant

Low refrigerant quantity Gas leak

Charge refrigerant to proper level Check leak and charge with refrigerant after repairing faulty

C: Clogged during refrigeration cycle Clogged during refrigeration cycle

Clogged receiver dryer Clogged foreign matter in piping

Replace Replace

D: Faulty expansion valve Faulty expansion valve

Clogged valve (foreign matter) Replace valve Temporary clogged due to freezing valve Thoroughly perform purging after (water intrusion) replacing valve and receiver

T5-7-21

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (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 Abnormal high Too high Abnormally high ambient temperature pressure (2.54 MPa or Lack of Clogged fin with Cleaning of fin more) condenser dirt or mud (washing) 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 or Low refrigerant To B less) Clogged during refrigeration cycle To C Faulty expansion valve To D Frosted evaporator To A

T5-7-22

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor

Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace magnet clutch

B: Low refrigerant Low refrigerant

Low refrigerant quantity Gas leak

Charge refrigerant to proper level Check leak and charge with refrigerant after repairing faulty

C: Clogged during refrigeration cycle Clogged during refrigeration cycle

Clogged receiver dryer Clogged foreign matter in piping

Replace Replace

D: Faulty expansion valve Faulty expansion valve

Clogged valve (foreign matter) Replace valve Temporary clogged due to freezing valve Thoroughly perform purging after (water intrusion) replacing valve and receiver

T5-7-23

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (5) Condition:  Fault Code: 44 (Abnormal air mix damper servo motor) Faulty wiring, open circuit, disconnection of connector Faulty servo motor Clogged foreign matter

Wirings inspection

Replace Remove foreign matter

Condition:  Fault Code: 51 (Abnormal high/low refrigerant pressure) High pressure cut is operated

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

T5-7-24

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-25

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty heating (1) Condition:  Fault code: Un-displayed Faulty air flow volume

Blower motor rotates

Blower motor does not rotate

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 Blowout of fuse Replace with the Blower motor is 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

T5-7-26

Filter cleaning Filter cleaning Remove obstacles Replacement of blower To A Evaporator surface cleaning Check battery charging system Repair Replace Replace Replace blower motor Refer to wiring diagram and check Wirings inspection Replace Replace Replace Repair Replace the controller Make sure to ground Wirings inspection Replace motor

Setting link again Air Bleeding Circuit Repair or replace. Charge engine coolant to proper level Replace heater core

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of evaporator sensor Faulty the frost sensor characteristics Frost sensor is out of evaporator range (faulty sensitivity) No voltage applied to magnet clutch

T5-7-27

Check of clutch circuit

Replace clutch relay

Shorted circuit check

Repair

Characteristic check

Replace frost sensor

Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace magnet clutch

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty heating (2) Condition:  Fault Code: 44 (Abnormal air mix damper servo motor) Clogged foreign matter Faulty wiring, open circuit, disconnection of connector Faulty damper

Remove foreign matter Wirings inspection Replace

T5-7-28

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Others  Faulty air vent switch Fault code is un-displayed Disconnection of link Fault code 43 (Abnormal air vent damper Faulty wiring, open circuit, servo motor) disconnection of connector Faulty servo motor Clogged foreign matter

Setting link again Wirings inspection Replace Remove foreign matter

 Faulty fresh/re-circulated air selection Fault code is un-displayed

Disconnection of link Faulty wiring, open circuit, disconnection of connector Faulty servo motor Clogged foreign matter

Setting link again Wirings inspection Replace Remove foreign matter

 Ambient temperature is higher or lower than set-temperature Fault code 11 (Open circuit in recirculated air sensor) Fault code 12 (Shorted circuit in recirculated air sensor) Fault code is un-displayed (Normal recirculated air sensor)

Open circuit in harness, disconnection Wirings inspection of connector Open circuit in air circulation sensor Replace Shorted circuit in harness Wirings inspection Shorted circuit in air circulation sensor Replace Faulty cooling, faulty heating Check by referring to the items of faulty cooling and faulty heating

T5-7-29

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Noise Case connection. Blower fan motor connection.

Gas blowing sound (roaring). Expansion valve connection. Whistle sound. Gas blowing sound. Clutch disengaging sound.

Compressor rotating sound.

Louver resonance. Fan contacts case. Foreign matter enters case. Brush friction noise, metal and/or thrust washer contact. Gas vibration noise (compressor discharge and/or suction gas noise). Abnormal noise from expansion valve. Expansion valve is normally functioning. Faulty clutch bearing, and/or idle pulley bearing. Contact of clutch amature due to resonance. Loose belt. Loose screws. Noisy compressor. Vibration due to V belt looseness. Loose screws.

Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud. No functional problem exists.

Broken heater core. Broken hose. Clogged case drain port and/or drain hose. Absorbed cigarette and dust smell on evaporator fins.

Replace. Clean.

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.

T5-7-30

Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L mode for more than 10 minutes, flush smell out by condensed water.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-31

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Blower motor does not operate. Preparation  Check the wiring connections first. Procedure Inspection Method Condition 1 Switch compressor relay with Key Switch: ON blower motor relay. Blower Switch: ON 2 Measurement of voltage Key Switch: ON between terminal #41B of blower motor relay harness end and body. 3 Measurement of voltage Key Switch: ON between terminal #43B of blower Blower Switch: ON motor harness end and body. 4 Continuity check between terminals #1 and #2 of blower motor harness end. 5 Measurement of voltage Key Switch: ON between terminal #44B of power Blower Switch: ON transistor harness end and body. 6 Measurement of voltage Key Switch: ON between terminal #9B of power Blower Switch: ON transistor harness end and body. 7 -

Connector (Harness end)  Blower Motor Relay

Evaluation Cause (check point) Blower motor Faulty blower motor relay. does not operate. 0V Open circuit in harness between fuse #3 and blower motor relay. 0V

0Ω

Open circuit in harness between blower motor relay and blower motor. Faulty blower motor.

Open circuit in harness between blower motor and power transistor. Faulty air conditioner controller.

Procedures as Faulty power transistor. steps 1 to 6 above are normal.

 Blower motor

TDAB-05-07-020

 Power Transistor

TDAB-05-07-028

T5-7-32

TDAB-05-07-027

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Compressor clutch does not operate. Preparation  Check that fresh air temperature is 0 ˚C or more first. When fresh air temperature is less than 0 ˚C, the air conditioner controller turns the compressor clutch OFF in order to protect the compressor.  Check that fault code 21 or 22 (abnormal frost sensor) is not displayed. When the frost sensor is abnormal, the compressor clutch does not operate.  Check the wiring connections first. Procedure Inspection Method 1 Switch compressor relay with blower motor relay. 2 Measurement of voltage between terminal #48A of compressor relay harness end and body. 3 Measurement of voltage between terminal #42A of compressor clutch relay harness end and body. 4 -

Condition Key Switch: ON Blower Switch: ON Key Switch: ON

Evaluation Cause (check point) Compressor is not Faulty compressor relay. operable. 0V Open circuit in harness between fuse #3 and compressor relay.

Key Switch: ON Blower Switch: ON

Procedures as Faulty compressor clutch. steps 1 to 3 above are normal.

Connector (Harness end)  Compressor Relay

Open circuit in harness between compressor relay and compressor clutch.

 Compressor Clutch

TDAB-05-07-019

T5-7-33

TDAB-05-07-024

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Cooling circuit check by using manifold gauge Condition:  Engine Speed: 1500 min-1  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh / re-circulated air selection: Re-circulated Air  Air conditioner inlet temperature: 30 to 35 °C 1. In normal  Low-pressure side pressure: 0.15 to 0.25 MPa  High-pressure side pressure: 1.37 to 1.57 MPa NOTE: The reading of manifold gauge may depend on conditions.

TDAA-05-07-018

2. Lack of refrigerant quantity Trouble

Pressure is low on both sides of high-pressure and low-pressure. Cooling performance is low. Cause Refrigerant quantity is low. Gas leak. Remedy Check and repair of gas leak. Charge air conditioner with refrigerant. TDAA-05-07-019

3. Excessive refrigerant, lack of condenser cooling Trouble

Pressure is high on both sides of highpressure and low-pressure. Cooling performance is low. Cause Overcharge air conditioner with refrigerant. Faulty condenser cooling. Remedy Adjust refrigerant quantity. Clean condenser. Check for machine cooling system.

TDAA-05-07-020

4. Water incorporation in circuit. Trouble

After using a certain period of time, lowpressure side gradually indicates negative pressure. Cause Water is mixed in circuit. Remedy Replace receiver tank. Thoroughly perform purging before charging refrigerant to remove water. TDAA-05-07-021

T5-7-34

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 5. Faulty compression of compressor Trouble

Low-pressure side is high and high-pressure side is low. High-pressure becomes equal to low-pressure immediately after stopping the air conditioner. Cause Faulty compressor. Remedy Check and repair of compressor. TDAA-05-07-022

6. Refrigerant does not circulate (clogged circuit) Trouble

When absolutely clogging, low-pressure side indicates negative pressure quickly. When slightly clogging, low-pressure side gradually indicates negative pressure. Cause Dirt or water adheres or freezes to expansion valves, refrigerant does not flow. Remedy Replace receiver tank. Perform purging.

TDAA-05-07-023

7. Air incorporation in circuit Trouble

Pressure is high on both sides of highpressure and low-pressure. When touching low-pressure piping, it is not cold. Cause Air is mixed in system. Remedy Replace refrigerant. Perform purging. TDAA-05-07-024

8. Excessive open of expansion valve Trouble

Pressure is high on both sides of highpressure and low-pressure. Frost (dew) adheres to low-pressure piping. Cause Faulty expansion valve. Remedy Check for installation of thermal cylinder. TDAA-05-07-025

T5-7-35

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Work after Replacing Components The following work is required after replacing compressor, high pressure hose, low pressure hose, condenser, receiver tank, liquid hose, and air conditioner unit. The same work is required when gas leakage is found. 1. Refill Compressor Oil 2. Charge Air Conditioner with Refrigerant  Purging  Charge air conditioner with refrigerant  Warm-up operation  Inspection

T5-7-36

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Refill Compressor Oil When replacing the cooling circuit parts, refill compressor oil to the specified level. Replacement Compressor parts

Condenser

Evaporator

Receiver

D hose (between compressor and condenser)

L hose (between condenser and unit)

S hose (between unit and compressor)

Oilreplenishing quantity

40 cm3 (2.4 in3)

20 cm3 (1.2 in3)

6 to 9 cm3/m (0.4 to 0.5 in3/m)

2 to 4 cm3/m (0.1 to 0.2 in3/m)

8 to 11 cm3/m (0.5 to 0.7 in3/m)

Refer to the following.

 In case of replacing compressor New compressor (1) is charged with oil required for cooling circuit. When replacing new compressor (1), drain excess oil from new compressor (1). Adjust oil level so that it is the same level as oil (B) in compressor (2) to be replaced. NOTE: Compressor oil quantity: 160 cm3 (9.8 in3)

 Compressor oil refill container Oil type ND-OIL8

Part No 4422696

Quantity 40 cm3 (2.4 in3)

TDAA-05-07-015

New Compressor

Replacing Compressor

T5-7-37

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Charge Air Conditioner with Refrigerant Necessity of Purging Be sure to purge the air conditioner circuit with a vacuum before charging with refrigerant (R134a) because the following problems can arise if air or other gases remain in the A/C circuit. 1. Pressure rise in the high pressure side If air remains in the air conditioner circuit, this disturbs the heat exchange between refrigerant and air in the condenser, causing pressure to rise in the high pressure side (compressor side). Usually, refrigerant gas is easily liquefied; however, air cannot be liquefied and remains as a gas in the condenser because the temperature at which air liquefies is extremely low. That is, liquidation of the refrigerant gas in the condenser decreases by the amount of air in the circuit, and the gas pressure in the high pressure side increases accordingly.

W115-02-10-001

2. Metal corrosion If air remains in the air conditioner circuit, a chemical reaction between refrigerant and moisture in the air takes place, and as a result, hydrochloric acid, that corrodes metals such as aluminum, copper and iron, is produced.

W115-02-10-002

3. Plugging of the expansion valve by moisture When high pressure refrigerant gas passes through the expansion valve, gas pressure decreases and temperature drops. Moisture included in high pressure refrigerant gas in the air conditioner circuit freezes at the expansion valve orifice, plugging refrigerant flow. Operation of the air conditioner becomes unstable and cooling efficiency lowers.

W115-02-10-003

T5-7-38

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Procedures for charging air conditioner with refrigerant

IMPORTANT: Do not mistake the charge hose connections. 1. Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Connect high-pressure side charge hose (3) and low-pressure side charge hose (6) on manifold gauge (1) to the high-pressure side charge valve (“D” marked) and to the lowpressure side charge valve (“S” marked) located on the compressor, respectively. Connect charge hose (5) located on the center of manifold gauge (1) to vacuum pump (4).

7 6 2 3 5 4

W115-02-10-005

2. Open high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Perform purging for 10 minutes or more by operating vacuum pump (4).

1 7

W115-02-10-005

T5-7-39

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT: If the pointer returns to 0, retighten the line connections and perform purging again. 3. When the low pressure gauge reading falls below -0.1 MPa (-750 mmHg), 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 highpressure valve (2) and lowpressure valve (7) on manifold gauge (1) closed, connect charge hose (5) to refrigerant container (8).

W115-02-10-005

 Refrigerant Specification R134a

Part No. 4333767 4454005 4351827

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

T5-7-40

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT:  Always stop the engine when charging the air conditioner with refrigerant.  Do not position the refrigerant container upside down during charging operation.  When changing the refrigerant container during charging operation, be sure to purge air from the charge hose, as shown in step 10.  Charge the low-pressure side hose first. 6. Fully tighten charge hose (5) connection to gauge manifold (1). Open high pressure valve (2) and valve (9) of refrigerant container (8). Charge with refrigerant (R134a). Close high pressure valve (2) and valve (9) of refrigerant container (8) when high pressure gauge (11) reading reaches 98 kPa (1 kgf/ cm2).

W115-02-10-008

fNOTE: Use warm water of 40˚C 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

T5-7-41

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 8. Confirm that high pressure valve (2) and low pressure valve (7) on gauge manifold (1) and valve (9) of refrigerant container (8) are closed. Start the engine and operate the air conditioner.

1 7

Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool

9 8

W115-02-10-007

IMPORTANT: Do not open high pressure valve (2) on manifold gauge (1). 9. Open low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8) to charge with refrigerant.

1 7

fNOTE: Required refrigerant quantity: 950±50 g 2

10. If refrigerant container (8) becomes empty during the charging work, replace refrigerant container (8) with a new refrigerant container as follows:  Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1).  Replace the empty container with new refrigerant container (8).  Tighten, then slightly loosen refrigerant container (8) joint.  Slightly open low pressure valve (7) on manifold gauge (1).  When refrigerant container (8) joint starts to leak, immediately tighten refrigerant container (8) joint and close low-pressure valve (7) on manifold gauge (1). 11. After charging, close low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8), and stop the engine.

T5-7-42

9 8

W115-02-10-007

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT: If the air conditioner is operated with very low refrigerant, a bad load will be exerted on the compressor. If the air conditioner is overcharged with refrigerant, cooling efficiency will lower and abnormal high pressure will arise in the air conditioner circuit, causing danger. 12. Start the engine and operate the air conditioner again. Check that cold air blow out from the vents. Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool CAUTION: When attempting to disconnect the 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). 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.

T5-7-43

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Warm-up Operation After charting the air conditioner, carry out warmup operation five minute to lubricate system with compressor oil. Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool Inspection After warm-up operation, carry out gas leak check and performance check. CAUTION: Refrigerant will produce poisonous material if exposed to heat of 1000 °C or more. Never bring refrigerant close to a fire. 1. Check the air conditioner for gas leaks using a leak tester.

 Perform checking under well-ventilated conditions.  Thoroughly wipe off dust from the charge hose connections of the compressor.  Pay special attention to check the line connections.  If any gas leaks are found, retighten the line connections. 2. Performance Check. Carry out performance check of the air conditioner after checking each air conditioner component.

W115-02-10-013

 Check each component for abnormalities.  Carry out ON-OFF check of the compressor clutch.  Check compressor fan belt tension.  Check the coolant level in the radiator.  Operate the air conditioner and check the performance.

W115-02-10-014

T5-7-44

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 3. The checklist before the summer season is as follows:  Check each air conditioner component for abnormalities.  Check the line connections for oil leaks.  Check refrigerant quantity.  Check the engine cooling circuit.  Check V belt for wear. Replace if necessary.  Check for clogged condenser. 4. Off-Season Maintenance  During off-season, operate the idler pulley and compressor at least once a month for a short time to check for any abnormal sounds.  Do not remove the compressor belts during offseason. Operate the compressor occasionally at slow speed for 5 to 10 minutes with the belt slightly loosened in order to lubricate the machine parts. NOTE: When the machine is in normal and the air conditioner is operated with the following conditions, air vent temperature decrease approx. 20 °C or less. (it may be different under special environment.) Operating Conditions of the Air Conditioner  Engine Speed: Fast Idle  Cab Window: Fully closed  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh / re-circulated air selection: Re-circulated Air  Season: Summer

T5-7-45

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Hose and Pipe Tightening Torque

Use the following tightening torque values when connecting the pipes. Joint Location

Nut type (Fig. A)

Block joint (Fig. B)

Tube or Bolt Size Tightening Torque N·m (kgf·m) Pipe with dia. 8 12 to 15 (1.2 to 1.5) Pipe with D1/2 20 to 25 (2.0 to 2.5) Pipe with D5/8 30 to 35 (3.0 to 3.5) Receiver M6 Bolt 4.0 to 7.0 (4T) (0.4 to 0.7) M6 Bolt (6T) 8.0 to 12 for other than (0.8 to 1.2) Receiver

TDAA-05-07-016 B

TDAA-05-07-017

T5-7-46

INDEX 111000 to 111002...................................................................T5-5-61 111003.........................................................................................T5-5-62 111006, 111007........................................................................T5-5-65 111011.........................................................................................T5-5-65 111014.........................................................................................T5-5-70 111025.........................................................................................T5-5-70 111100.........................................................................................T5-5-71 111103 ........................................................................................T5-5-72 111106, 111107........................................................................T5-5-72 111200.........................................................................................T5-5-74 111203.........................................................................................T5-5-74 111204.........................................................................................T5-5-76 111206.........................................................................................T5-5-76 111208.........................................................................................T5-5-77 111217.........................................................................................T5-5-75 111311.........................................................................................T5-5-78 111312.........................................................................................T5-5-75 111313.........................................................................................T5-5-78 111411.........................................................................................T5-5-79 111412.........................................................................................T5-5-80 111413.........................................................................................T5-5-81 111422.........................................................................................T5-5-82 111901.........................................................................................T5-5-83 120003, 120004........................................................................T5-5-84 120014.........................................................................................T5-5-85 24-Volt Circuit...........................................................................T5-1-18 5-Volt Circuit..............................................................................T5-1-24 A Adjustment.................................................................................. T4-6-1 Air Bleeding, Brake (Axle).................................................. T5-6-103 Air Conditioner Component Layout............................................................. T5-7-2 Functions of Main Parts..................................................... T5-7-6 Outline..................................................................................... T5-7-1 Troubleshooting.................................................................T5-7-11 Air Conditioner Controller Fault Code.............................T5-7-11 How to Display....................................................................T5-7-11 Air Conditioner Controller Fault Code List....T5-5-24, T5-7-12 Air Conditioner Controller Fault Codes E11 to E22.............................................................................T5-7-13 E43 to E92.............................................................................T5-7-14 All Actuator System Troubleshooting.............T5-6-27, T5-6-53 Alternator Check......................................................................T5-1-15 Average Fuel Consumption................................................... T5-2-5 Axle (Brake), Air Bleeding.................................................. T5-6-103 B Battery Voltage Check...........................................................T5-1-14 Bell Crank Stopper Clearance................................................ T4-4-8 Blower motor does not operate.........................................T5-7-30 Brake (Axle), Air Bleeding.................................................. T5-6-103 Brake Accumulator Pressure................................................T4-5-28 Brake Charge Valve.................................................................T5-4-18 Brake Primary Pressure............................................................ T4-5-1

Brake System Troubleshooting..........................T5-6-41, T5-6-83 Brake Warning Pressure (Pressure-Decreasing)............T4-5-30 Brake Warning Pressure (Pressure-Increasing).............T4-5-32 Bucket Levelness.....................................................................T4-4-13 Bucket Stopper Clearance...................................................... T4-4-8 C CAN Data Reception Failure................................................T5-5-10 CAN1 Harness Check..............................................................T5-5-66 Charge Air Conditioner with Refrigerant........................T5-7-36 Check by False Signal.............................................................T5-1-25 Column Display Controller (Information) Fault Codes 120500 to 120503..............................................................T5-5-89 120505...................................................................................T5-5-89 Column Display Controller Fault Code 115001...................................................................................T5-5-87 115011...................................................................................T5-5-88 120506, 120507..................................................................T5-5-90 120510 to 120512..............................................................T5-5-90 120515, 120516..................................................................T5-5-90 120518...................................................................................T5-5-90 Column Display Controller Fault Code List....................T5-5-21 Communication System......................................................... T5-3-7 Communication Terminal Fault Code List......................T5-5-24 Component Layout................................................................... T5-4-1 Component Test........................................................................ T4-5-1 Compressor clutch does not operate...............................T5-7-31 Compressor Oil, Refill.............................................................T5-7-35 Continuity Check.....................................................................T5-1-16 Control Lever Operating Force...........................................T4-4-14 Control Lever Stroke...............................................................T4-4-16 Control Valve.............................................................................T5-4-15 Controller..................................................................................... T5-4-7 Controller Hardware Failure.................................................. T5-5-9 Coolant Temperature............................................................... T5-2-4 Coolant Temperature Gauge................................................. T5-2-7 Cooling circuit check by using manifold gauge...........T5-7-32 Correlation between Trouble Symptoms and Part Failures..........................................................................T5-6-24 Cylinder Drift Check...............................................................T4-4-12 D Daily Report Data...................................................................... T5-3-2 Diagnosing Procedure, Introduction.................................. T5-1-1 Diagnosis Procedure................................................................ T5-1-2 Digging Position Adjustment............................................... T4-6-7 Drive Unit...................................................................................T5-4-17 E e-Service, Outline...................................................................... T5-3-1 ECM Fault Code List................................................................T5-5-25 Electric System Inspection..................................................... T5-1-5 Electrical System (Around Fuel Tank and Radiator Assembly).............................................................................T5-4-13 80Z6 Trbl

INDEX Electrical System (Around Hydraulic Oil Tank)...........................................T5-4-12 (Cab).......................................................................................... T5-4-6 (Components Related with Relays).............................T5-4-11 (Overview).............................................................................. T5-4-5 Engine..........................................................................................T5-4-14 Engine Failure...........................................................................T5-5-11 Engine Speed................................................................T4-3-1, T5-2-4 Engine System Troubleshooting.......................T5-6-25, T5-6-47 Engine Test................................................................................... T4-3-1 Exchange Inspection........................................................... T5-6-101 F Fan Pump...................................................................................T5-4-14 Fan Valve (Option)...................................................................T5-4-16 Fault Code.................................................................................... T5-2-5 Fault Code List Air Conditioner Controller..............................................T5-5-24 Column Display Controller.............................................T5-5-21 Communication Terminal...............................................T5-5-24 ECM.........................................................................................T5-5-25 MC............................................................................................. T5-5-9 MPDr......................................................................................... T5-5-3 TCU..........................................................................................T5-5-41 Faulty cooling (1).....................................................................T5-7-16 Faulty cooling (2).....................................................................T5-7-17 Faulty cooling (3).....................................................................T5-7-18 Faulty cooling (4).....................................................................T5-7-20 Faulty cooling (5).....................................................................T5-7-22 Faulty heating (1).....................................................................T5-7-24 Faulty heating (2).....................................................................T5-7-26 Frequency Distribution Data................................................. T5-3-4 Front Attachment System Troubleshooting .................................................................................T5-6-31, T5-6-59 Front Axle...................................................................................T5-4-17 Fuel Consumption..................................................................... T5-2-5 Fuel Gauge................................................................................... T5-2-8 Fuse Box A..................................................................................T5-1-11 Fuse Box B..................................................................................T5-1-12 Fuse Inspection........................................................................T5-1-10 Fusible Link Inspection..........................................................T5-1-13 H Hose Tightening Torque........................................................T5-7-44 How to display service menu................................................ T5-2-4 Hydraulic Cylinder Cycle Time............................................T4-4-10 Hydraulic Oil Tank, Electrical System................................T5-4-12 Hydraulic Oil Temperature..................................................... T5-2-4 Hydraulic Oil Temperature Sensor....................................T5-5-83 Specification........................................................................T5-5-83 I Instructions for Disconnecting Connectors..................... T5-1-8

L Learning Failure.......................................................................T5-5-18 Lever Stopper Clearance......................................................... T4-4-8 Lift Arm Angle Sensor Learning........................................... T4-6-5 List of Operation Data.............................................................. T5-3-2 List of Service Menu Display................................................. T5-2-6 Loading Circuit Main Relief Set Pressure.......................... T4-5-8 Loading Main Relief Pressure Adjustment....................... T4-5-9 Loading Pilot Primary Pressure............................................. T4-5-4 Lubricant Consumption.......................................................... T4-3-3 M Machine Information Display................................................ T5-2-2 Main Component...................................................................... T5-4-2 Main Component (Overview)............................................... T5-4-1 Main Component (Travel System)....................................... T5-4-3 Main Pump Delivery Pressure............................................... T4-5-6 Main Pump Flow Rate Measurement...............................T4-5-16 Main Pump P-Q Diagram......................................................T4-2-10 Manifold Valve..........................................................................T5-4-18 MC Fault Codes 111000 to 111002..............................................................T5-5-61 111003...................................................................................T5-5-62 111006, 111007..................................................................T5-5-65 111011...................................................................................T5-5-65 111014...................................................................................T5-5-70 111025...................................................................................T5-5-70 111100...................................................................................T5-5-71 111103...................................................................................T5-5-72 111106, 111107..................................................................T5-5-72 111200...................................................................................T5-5-74 111203...................................................................................T5-5-74 111204...................................................................................T5-5-76 111205...................................................................................T5-5-73 111206...................................................................................T5-5-76 111208...................................................................................T5-5-77 111217...................................................................................T5-5-75 111311...................................................................................T5-5-78 111312...................................................................................T5-5-75 111313...................................................................................T5-5-78 111411...................................................................................T5-5-79 111412...................................................................................T5-5-80 111413...................................................................................T5-5-81 111422...................................................................................T5-5-82 111901...................................................................................T5-5-83 120003...................................................................................T5-5-84 120004...................................................................................T5-5-84 120014...................................................................................T5-5-85 MC Fault Code List.................................................................... T5-5-9 Monitor......................................................................................... T5-4-9 Monitor, Outline......................................................................... T5-2-1 Monitor Display.......................................................................... T5-2-2 Monitor Panel............................................................ T5-2-1, T5-4-10 MPDr. Fault Code Reference Table...................................... T5-5-3 Multiple Control Valve...........................................................T5-4-15 80Z6 Trbl

INDEX O Operating Procedures of Service Menu............................ T5-2-3 Operational Performance Standard Table........................ T4-2-1 Operational Performance Tests............................................ T4-1-1 Other Failures............................................................................T5-5-19 Other System Troubleshooting.........................T5-6-43, T5-6-87 Overload Relief Valve Pressure Adjustment...................T4-5-14 Overload Relief Valve Set Pressure....................................T4-5-12 P Parking Brake Function Check.............................................. T4-4-7 Parking Brake Pressure..........................................................T4-5-26 Parking Brake Solenoid Valve Block..................................T5-4-18 Pilot Failure................................................................................T5-5-13 Pipe Tightening Torque.........................................................T5-7-44 Precautions for Inspection and Maintenance................. T5-1-6 Preparation for Performance Tests...................................... T4-1-2 Primary Pilot Pressure (Including Brake Circuit)............. T4-5-1 Primary Pilot Pressure Adjustment Procedure................ T4-5-3 Priority Valve.............................................................................T5-4-16 Proportional Solenoid Valve Failure.................................T5-5-16 Pump Device.............................................................................T5-4-15 Pump Failure.............................................................................T5-5-12 R Radiator Assembly.................................................................... T5-4-4 Refill Compressor Oil..............................................................T5-7-35 Refrigerant, Charge Air Conditioner.................................T5-7-36 Regulator Adjustment...........................................................T4-5-22 Relationship between Machine Trouble Symptoms and Related Parts................................................................. T5-6-3 Relays............................................................................ T5-4-7, T5-4-11 Ride Control Valve (Option).................................................T5-4-20 Right Console.............................................................................. T5-4-8

Switches........................................................................................ T5-4-9 T TCU Fault Code List.................................................................T5-5-41 Test Harness..............................................................................T5-1-26 Torque Converter Oil Temperature Gauge....................... T5-2-7 Torque Converter Pressure (Inlet)......................................T4-5-36 Total Operating Hours............................................................. T5-3-5 Transmission Clutch Pack Combination..........................T4-5-35 Transmission Clutch Pressure.............................................T4-5-34 Transmission Learning............................................................. T4-6-1 Transmission Oil Temperature.............................................. T5-2-4 Transmission Oil Temperature Gauge................................ T5-2-7 Travel Speed................................................................................ T4-4-1 Travel System Troubleshooting.........................T5-6-37, T5-6-73 Troubleshooting A (Base Machine Diagnosis by Using Fault Codes) Procedure................................... T5-5-1 Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure..... T5-6-1 V Vehicle Information Display.................................................. T5-2-2 Voltage and Current Measurement..................................T5-1-18 W Work after Replacing Components...................................T5-7-34

S Secondary Pilot Pressure........................................................ T4-5-4 Secondary Steering Pump (Option).................................T5-4-19 Secondary Steering Valve (Option)...................................T5-4-19 Sensor Activating Range......................................................T4-2-12 Service Brake Accumulator Pressure................................T4-5-28 Service Brake Function Check............................................... T4-4-4 Service Brake Pressure (Front and Rear)..........................T4-5-24 Service Brake Primary Pressure............................................ T4-5-1 Service Brake Wear Amount.................................................. T4-4-6 Service Menu Display List....................................................... T5-2-6 Service menu, How to display.............................................. T5-2-4 Service Menu, Operating Procedures................................ T5-2-3 Snapshot Data............................................................................ T5-3-6 Specification of Hydraulic Oil Temperature Sensor....T5-5-83 Standard Values......................................................................... T4-2-1 Steering Circuit Main Relief Set Pressure........................T4-5-10 Steering System Troubleshooting....................T5-6-35, T5-6-69 Steering Valve...........................................................................T5-4-19 80Z6 Trbl

INDEX (Blank)

80Z6 Trbl