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90Z6

93213-00801

SHOP MANUAL Operational Performance Test Troubleshooting

Printed in Japan (K) （トルコ用）

93213-00801

October 2018

SHOP MANUAL WHEEL LOADER

90Z6 Operational Performance Test Troubleshooting

93213-00801

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

Group 5 Component Test Group 6 Adjustment

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

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

MEMO

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

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

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

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

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

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

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

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

IN-01

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

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

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

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

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

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

fNOTE: Indicates supplementary technical information.

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.

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

Quantity

To Convert From

Into

Multiply By

Length

0.03937

0.003281

US gal

0.2642

US qt

1.057

yd3

1.308

Weight

2.205

Force

kgf

0.10197

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

MPa

psi

145.0

1.360

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Power

Flow rate

-1

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

IN-02

0.10197 2

10.197

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

Name

Explanation

Shop Manual Torque Converter Transmission Main Controller

ECM

Engine Control Module

ICF CAN

Information Controller 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. Stores the operating information and alarms. 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-1

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

Group 4 Machine Performance Test

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

Group 5 Component Test

Hydraulic Circuit................................................................... T4-5-1 Loading Pilot Circuit...................................................... T4-5-1 Primary Pilot Pressure (Including Brake Circuit)....... T4-5-2 Secondary Pilot Pressure................................................... T4-5-4 Secondary Pilot Pressure Adjustment Procedure....................................................................... T4-5-5 Main Pump Delivery Pressure......................................... T4-5-6 Loading Circuit Main Relief Set Pressure..................... T4-5-8 Loading Main Relief Pressure Adjustment ........... T4-5-9 Steering Circuit Main Relief Set Pressure.................. T4-5-10 Steering Main Relief Pressure Adjustment..........T4-5-11 Overload Relief Valve Set Pressure..............................T4-5-12 Overload Relief Valve Pressure Adjustment .......T4-5-14 Main Pump Flow Rate Measurement.........................T4-5-16 Regulator Adjustment................................................T4-5-22 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.............................................T4-5-36

Group 6 Adjustment

Transmission Learning....................................................... T4-6-1 Lift Arm Angle Sensor Learning...................................... T4-6-4 Digging Position Adjustment.......................................... T4-6-6

90Z6 Trbl

(Blank)

90Z6 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.

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: 55±5 °C (131±9 °F)

For EXP Specifications (S/N ~9152) Performance Test Designation

Unit

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

min-1

Performance Standard 800±50 2070±50 1920±100 1800±100

min-1 800±50 2070±50 1950±100 1800±100 mm (in)

In: 0.36 (0.014) Ex: 0.69 (0.027)

Performance Test Designation

Unit

Performance Standard

min-1

Remarks Power mode switch: OFF Value indicated on MPDr. Value indicated on MPDr. Second- speed forward, Value indicated on MPDr. Second- speed forward, Value indicated on MPDr. Power mode switch: ON Value indicated on MPDr. Value indicated on MPDr. Second- speed forward, Value indicated on MPDr. Second- speed forward, Value indicated on MPDr. With the engine cold

Reference Page T4-3-1

T4-3-1

Refer to Engine Manual

For EU Specifications (S/N 9153~)

800±50 1830±50 1770±100 1740±100 min-1 800±50 2070±50 1950±100 1800±100 mm (in)

In: 0.36 (0.014) Ex: 0.69 (0.027)

T4-2-1

Reference Page T4-3-1

T4-3-1

Refer to Engine Manual

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Travel Speed (S/N ~9152) First Speed (Forward/Reverse) Second Speed (Forward/Reverse) Third Speed (Forward/Reverse) Fourth Speed (Forward/Reverse) Travel Speed (S/N 9153~) First Speed (Forward/Reverse) Second Speed (Forward/Reverse) Third Speed (Forward/Reverse) Fourth Speed (Forward/Reverse) Travel Speed First Speed (Forward/Reverse) Second Speed (Forward/Reverse) Third Speed (Forward/Reverse) Fourth Speed (Forward/Reverse) Service Brake Function Check

km/h (mph)

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

Performance Standard 6.8±0.7 (4.2±0.4) 11.5±1.2 (7.1±0.7) 21.6±2.2 (13.4±1.4) 34.7±3.5 (21.6±2.2)

km/h (mph) 5.9±0.6 (3.7±0.4) 9.8±1.0 (6.1±0.6) 18.0±1.8 (11.2±1.1) 27.7±2.8 (17.2±1.7) km/h (mph)

m (ft)

6.8±0.7 (4.2±0.4) 11.5±1.2 (7.1±0.7) 21.6±2.2 (13.4±1.4) 34.7±3.5 (21.6±2.2) 12 (39) or less

mm (in)

mm/5 min mm (in)

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

6.2 (0.2) 5.0 (0.2) 5.0 (0.2) 0 2.2 (0.087) 2.4 (0.094) 0 0 to 3 (0 to 0.12) 0.3 (0.01)

T4-2-2

Remarks

Reference Page T4-4-1

Power mode switch: OFF Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Power mode switch: OFF Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Power mode switch: ON T4-4-1 Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Value indicated on MPDr. Machine speed: 35±3 km/h T4-4-4 (21.7±1.8 mph) T4-4-6 Allowable limit: 5.3 (0.2) Allowable limit: 4.5 (0.18) Allowable limit: 4.5 (0.18) T4-4-7 Allowable limit: 2.0 (0.079) Allowable limit: 2.2 (0.087) 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 (S/N ~9152) Lift Arm Raise Lift Arm Lower (Float) Bucket Dump Steering (engine: high idle speed) Hydraulic Cylinder Cycle Time (S/N 9153~) Lift Arm Raise Lift Arm Lower (Float) Bucket Dump Steering (engine: high idle speed) Hydraulic Cylinder Cycle Time Lift Arm Raise Lift Arm Lower (Float) Bucket Dump Steering (engine: high idle speed) Cylinder Drift Check Lift Arm Cylinder Bucket Cylinder Bucket Bottom Bucket Levelness

sec

Performance Standard

Remarks Power mode switch: OFF

Reference Page T4-4-10

Power mode switch: OFF

T4-4-10

Power mode switch: ON

T4-4-10

5.5±0.3 3.2±0.3 1.2±0.3 2.9±0.3 sec 5.6±0.3 3.2±0.3 1.2±0.3 2.9±0.3 sec 5.4±0.3 3.2±0.3 1.2±0.3 2.9±0.3 mm (in)/15 min

mm (in)

T4-4-12 45 (1.77) or less 35 (1.38) or less 200 (7.87) or less 10 (0.4) or less

T4-2-3

T4-4-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Control Lever Operating Force N (kgf ) (lbf ) 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 (Rollback) Bucket Control Lever Tilt (Rollback) (Detent) Bucket Control Lever Tilt (Rollback) (Detent Release) Bucket Control Lever Dump Steering Forward/Reverse Lever Accelerator Pedal Brake Pedal (Right) Inching Pedal (Left)

Performance Standard

Remarks Two-lever

10 (1.0) (2.3) or less 16 (1.6) (3.6) or less 36 (3.7) (8.1) or less 10 (1.0) (2.3) or less 16 (1.6) (3.6) or less 36 (3.7) (8.1) or less 11 (1.1) (2.5) or less 16 (1.6) (3.6) or less 36 (3.7) (8.1) or less 16 (1.6) (3.6) or less 17 (1.7) (3.8) or less 12 +3/-2 (1.2 +0.3/-0.2) (2.7 +0.7/-0.4) 40±2 (4.1±0.2) (9.0±0.4) 353 to 413 (36.0 to 42.1) (79.4 to 92.8) 333 to 393 (34.0 to 40.1) (74.9 to 88.3)

T4-2-4

Reference Page T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Control Lever Operating Force

N (kgf ) (lbf )

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)

Performance Standard

Remarks MF (Joystick type) lever

20 (2.0) (4.5) or less 40 (4.0) (9.0)or less 50 (5.0) (11.2) or less 20 (2.0) (4.5) or less 40 (4.0) (9.0) or less 50 (5.0) (11.2) or less 20 (2.0) (4.5) or less 40 (4.0) (9.0) or less 50 (5.0) (11.2) or less 30 (3.0) (6.7) or less 17 (1.7) (3.8) or less 12 +3/-2 (1.2 +0.3/-0.2) (2.7 +0.7/-0.4) 40±2 (4.1±0.2) (9.0±0.4) 353 to 413 (36.0 to 42.1) (79.4 to 92.8) 333 to 393 (34.0 to 40.1) (74.9 to 88.3)

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 Brake Pedal Application 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 Brake Pedal Application

mm (in)

Performance Standard

Remarks Two-lever

Reference Page T4-4-16

MF (Joystick type) lever

T4-4-16

42±5 (1.7±0.2) 65±5 (2.6±0.2) 32±5 (1.3±0.2) 55±5 (2.2±0.2) 42±5 (1.7±0.2) 65±5 (2.6±0.2) 55±5 (2.2±0.2) 4.0 to 4.5 (0.16 to 0.18) 50±5 (2.0±0.2) 5 to 15 (0.2 to 0.6) 7 to 16 (0.3 to 0.6) 35 to 45 (1.38 to 1.77) 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) 4.5 to 5.5 (0.18 to 0.22) 50±5 (2.0±0.2) 5 to 15 (0.2 to 0.6) 7 to 16 (0.3 to 0.6) 35 to 45 (1.38 to 1.77)

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 (68°F)) Tire Inflation

deg.

Radial Tire

Bias Tire

Performance Standard

18±1 20.6±0.5 17.0±0.5 1.26

Remarks (without play)

Reference Page T4-4-16

Allowable limit: 1.16

kPa (kgf/cm2) (PSI)

Front: 471 to 490 (4.8 to 5.0) (68 to 71) Rear: 373 to 392 (3.8 to 4.0) (54 to 57) Front: 422 to 441 (4.3 to 4.5) (61 to 64) Rear: 324 to 343 (3.3 to 3.5) (47 to 50)

T4-2-7

26.5R25

26.5-25-20PR

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Primary Pilot Pressure

MPa (kgf/cm2) (PSI)

Cut-out Pressure Cut-in Pressure Secondary Pilot Pressure) Main Pump Delivery Pressure Loading Circuit Main Relief Set Pressure Relief Operation of Lift Arm

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

Relief Operation of Bucket Steering Relief Pressure Overload Relief Pressure Lift Arm Raise Bucket

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

Performance Standard

Remarks Unloader setting pressure

14.7±0.3 (150±3) (2132±43.5) 11.8±1.0 (120±10) (1711±145) 3.7 +0.5/-0.3 (38 +5/-3) (537 +73/-43) 2.0 +1.0/-0.5 (20 +10/-5) (290 +145/-73)

Reference Page T4-5-2

Value indicated on MPDr. Value indicated on MPDr. T4-5-4 In neutral, Value indicated on MPDr.

T4-5-6 T4-5-8

29.4 +2.0/-0.5 (300 +20/-5) Value indicated on MPDr. (4264 +290/-73) 29.4 +2.0/-0.5 (300 +20/-5) Value indicated on MPDr. (4264 +290/-73) 29.4 +2.0/-0.5 (300 +20/-5) Value indicated on MPDr. (4264 +290/-73) Reference values at 35 L/ min 36.8 +1.0/-0 (375 +10/-0) (5337 +145/-0) 32.5 +1.0/-0 (331 +10/-0) (4714 +145/-0)

T4-2-8

T4-5-10 T4-5-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

Main Pump Flow Rate Measurement L/min Service Brake Pressure (Front/Rear) MPa (kgf/cm2) (PSI) Parking Brake Pressure MPa (kgf/cm2) (PSI) Service Brake Accumulator Pressure MPa (kgf/cm2) (PSI) Accumulator Pressure N2 Gas Charging Pressure Brake Warning Pressure (PressureDecreasing) Brake Warning Pressure (PressureIncreasing) Transmission Clutch Pressure Torque Converter Pressure Inlet Pressure Outlet Pressure

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

Performance Standard 4.6±0.6 (47±6) (667±87) 3.7+0.2/-0.1 (38 +2/-1) (536 +29/-14.5)

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

Reference Page T4-5-16 T4-5-24 T4-5-26 T4-5-28

14.7±0.3 (150±3) (2132±43.5) 6.8 (69) (986) 8±0.5 (82±5) (1160±73) 10±0.5 (102±5) (1450±73) 2.2 to 2.4 (22 to 24) (319 to 348)

T4-5-30 T4-5-32 T4-5-34 T4-5-36

0.99 to 1.09 (10.1 to 11.1) (144 to 158) 0.43 to 0.53 (4.4 to 5.4) (62 to 77)

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: 2000 min-1 (rpm)  Hydraulic Oil Temperature: 55±5 °C (131±9 °F)

fNOTE: Refer to T4-5-16.

Points on P-Q Line Delivery Pressure MPa (kgf/cm2) (PSI) 4.9 (50) (711) 19.6 (200) (2849) 26.5 (270) (3853) 29.4 (300) (4274)

A B C D

Flow Rate L/min (gpm) 340±3 (90±0.8) 340±3 (90±0.8) 315±6 (83±1.6) 283±6 (75±1.6)

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: 2000 min-1 (rpm)  Hydraulic Oil Temperature: 55±5 °C (131±9 °F) NOTE: Refer to T4-5-18.

Points on P-Q Line Pump Control Pressure MPa (kgf/cm2) (PSI) 0.39 +0.01/-0 (4 +0.1/-0) (57 +1.5/-0) 1.47±0.05 (15±0.5) (214±7) 1.67 +0.01/-0 (17 +0.1/-0) (243 +1.5/-0)

A B C

Flow Rate L/min (gpm) 340±3 (90±0.8) 100±2 (26±0.5) 51±3 (13±0.8)

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: 55±5 °C (131±9 °F)  Unless specified: Engine Speed High Idle Speed

Power Mode Switch ON

• Monitor each sensor by using MPDr. 2. Sensor Activating Range Unit: MPa (kgf/cm2) (PSI) 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 1.2 to 2.6 (12 to 27) (174 to 377) 28.7 to 32.0 (293 to 326) (4163 to 4641) 1.2 to 2.6 (12 to 27) (174 to 377) 28.7 to 32.0 (293 to 326) (4163 to 4641) 0 to 0.1 (0 to 1) (0 to 14.5) 3.6 to 4.3 (37 to 44) (522 to 624) 0 to 0.1 (0 to 1) (0 to 14.5) 4.0 to 5.2 (41 to 53) (580 to 754)

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

High Idle Speed (with no load)

OFF

Full stroke

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

OFF

Full stroke

OFF

Full stroke

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

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

Low Idle Speed (with no load)

Evaluation: Refer to Operational Performance Standard (p.T4-2-1). Remedy: Refer to Troubleshooting B. NOTE: Engine System Troubleshooting (T5-6-26).

T4-3-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Speed Summary: Measure the time required for the machine to travel a 50 m (164 ft) test track and check the performance of the travel drive system (torque converter to transmission). Preparation: 1. Adjust air pressure of the tires evenly in advance.  Bias Tire: Front: 422 to 441 kPa (4.3 to 4.5 kgf/cm2) (61 to 64 psi) Rear: 324 to 343 kPa (3.3 to 3.5 kgf/cm2) (47 to 50 psi)  Radial Tire: Front: 471 to 490 kPa (4.8 to 5.0 kgf/cm2) (68 to 71 psi) Rear: 373 to 392 kPa (3.8 to 4.0 kgf/cm2) (54 to 57 psi)

a c

e 90Z6-04-04-01

2. Provide a flat, solid test track 50 m (164 ft) in length, with extra length of 70 m (229 ft) on both ends for machine acceleration and deceleration. (For measurement at fourth speed, a 300 m (984 ft) acceleration zone is needed.)

abc-

3. Empty the bucket and hold the lift arm with it floated 0.5 m (1 ft 8 in) above the ground. 4. Maintain the hydraulic oil temperature at 55±5°C (131±9 °F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicators of the coolant temperature monitor and the torque converter oil temperature monitor should rise above the horizontal position.

T4-4-1

0.5 m (1 ft 8 in) Test Track Acceleration/Deceleration Zone

de-

End Start

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

Parking Brake Switch

Accelerator Pedal

Power Mode Switch

First Speed

Second Speed (First OFF Speed Fixed Switch: ON)

Full Stroke

ON/OFF

Second Speed

OFF

Full Stroke

ON/OFF

Third Speed

OFF

Full Stroke

ON/OFF

Fourth Speed

OFF

Full Stroke

ON/OFF

3. Set the forward/reverse lever to the F (forward) position. Start traveling the machine in the acceleration zone with the accelerator pedal depressed to the stroke end. 4. Measure the travel speed (sec) of each travel mode. 5. Repeat the measurement three times and calculate the mean values. 6. Convert the measurement value to be expressed in km/h. Measurement value (seconds) = S (sec) 1

Converted value (hourly speed) = A (km/h) A = (50×3600)/(S×1000)

90Z6-04-04-02

Evaluation:

Refer to Operational Performance Standard (p.T4-2-2). Remedy: Refer to Troubleshooting B. NOTE: Travel System Troubleshooting (p.T5-6-37)

T4-4-2

Machine Speed Sensor

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

T4-4-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Service Brake Function Check Summary: 1. Check the performance of the service brake. 2. The braking capability of the brake is an item of safety control. Be sure to conduct the performance test. Preparation: 1. Adjust air pressure of the tires evenly in advance.  Bias Tire: Front: 422 to 441 kPa (4.3 to 4.5 kgf/cm2) (61 to 64 psi) Rear: 324 to 343 kPa (3.3 to 3.5 kgf/cm2) (47 to 50 psi)  Radial Tire: Front: 471 to 490 kPa (4.8 to 5.0 kgf/cm2) (68 to 71 psi) Rear: 373 to 392 kPa (3.8 to 4.0 kgf/cm2) (54 to 57 psi) 2. On a paved dry road, prepare a 150 m (492 ft) straight travel course (a 100 m (328 ft) of acceleration zone and a 50 m (164 ft) of test track) and set the brake starting point.

a b c

d 90Z6-04-04-03

abc-

3. Empty the bucket and hold the lift arm with it floated 0.5 m (1 ft 8 in) above the ground. 4. Maintain the hydraulic oil temperature at 55±5°C (131±9°F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicators of the coolant temperature monitor and the torque converter oil temperature monitor should rise above the horizontal position.

T4-4-4

0.5 m (1 ft 8 in) Stopping Distance 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

Fourth Speed

OFF

Full Stroke

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

Evaluation: Stopping distance: 12 m (13 yard) or less Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-40)

T4-4-5

Declutch Position Switch OFF

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

Summary: Check the extent of wear of the brake disc at the service brake of the axle by using a wear gauge or thickness gauge (5.3 mm). Preparation: 1. Clean around inspection plug (1) of the axle and loosen it. 2. In case of the rear axle, inspection plug (1) is located below the center line of the differential. Loosen inspection plug (1) after draining axle oil.

T4GB-04-04-004

Measurement: 1. Operate the service brake by stepping on the brake pedal. 2. Insert wear gauge (2) into inspection port (7) until it contacts brake disc (6) between brake ring (3) and brake ring (4).

T4GB-04-04-005

Evaluation: 1. In case wear gauge (2) has entered between brake rings (3 and 4) and the model scale of wear gauge (2) and housing surface (5) have coincided, the wear amount of brake disc (6) does not reach the maximum allowable limit of use. In case wear gauge (2) has not entered between brake rings (3 and 4) and the model scale is sticking above housing surface (5), brake disc (6) is worn in excess of the maximum allowable limit of use. 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 2

 Distance (L) between Housing Surface (5) and Brake Disc (6): 54 mm (2.13 in)  Brake ring (4) thickness (default): 5.0 mm (0.2 in)  Brake ring (3) thickness (default): 5.0 mm (0.2 in)

4 T4GD-04-04-001

T4-4-6

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

Preparation: 1. Measure on a 1/5 slope (approx. 11.3°). 2. Empty the bucket and hold the bucket with it floated 0.5 m (1 ft 8 in) above the ground. 3. Maintain the hydraulic oil temperature at 55±5°C (131±9 °F). Warm the axle oil satisfactorily by repeating travel operation and brake operation. Make a warm up operation so that the indicators of the coolant temperature monitor and the torque converter oil temperature monitor should rise above the horizontal position.

a b 90Z6-04-04-04 ab-

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: No movement. Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-40)

T4-4-7

0.5 m (1 ft 8 in) 11.3°

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

a b

Summary: Measure wear and deformation conditions of the bucket stopper (dump side and rollback side) and the clearance between lever (bell crank) stopper (b) and the cross tube. Preparation: Stop the machine on a flat and level surface and apply the parking brake. Measurement:  Bucket Dump Stoppers (a, b) 1. Raise the lift arm to the highest lifting position and stop the engine.

T4GB-04-04-008

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

Bucket Dump Stopper

Lever (Bell Crank) Stopper

2 c

3. At the same time, measure the contact condition of bucket dump stopper (a) (left and right).  Bucket Roll Back Stopper (c) 1. Raise the lift arm until lift arm cylinder stroke (E) becomes the length of the standard dimension. 2. Set the engine at idling speed and roll back the bucket calmly until it contacts bucket roll back stopper (c).

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

Bucket Rollback Stopper

Bucket Link

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

T4-4-8

90T4GB-04-04-10

Lever

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

2. Bucket Rollback (Tilt) Stopper

 Cylinder Strokes (A and B) Bucket Cylinder (A) Lift Arm Cylinder (B) mm (in) mm (in) 521±2 (20.5±0.08) 1168±2 (46±0.08)

 Cylinder Strokes (D and E) Bucket Cylinder (D) Lift Arm Cylinder (E) mm (in) mm (in) 840±2 (33.1±0.08) 260±2 (10.2±0.08)

 Bucket Dump Angle (C) C (deg.) 48 to 50

 Bucket Roll Back (Tilt) Angle (F) F (deg.) 39.5 to 41.5

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

 Height from Ground to Bucket Hinge Pin (G) G (mm) (in) 290 (11.4)

 Clearance between Bucket Dump Stopper and Lift Arm (a) Clearance at Longitudinal and Unsymmetrical Lateral Clearance of Contact Each Stopper mm (in) mm (in) Standard 0 0 Limit 2.0 (0.08) 5 (0.20)

 Clearance between Bucket Rollback Stopper and Lift Arm (c) Clearance at Longitudinal and Unsymmetrical Lateral Clearance of Contact Each Stopper mm (in) mm (in) Standard 0 0 Limit

tires (standard) at the specified air pressure.

 Clearance at Unsymmetrical Contact (left stop compared to right stop) Clearance limit Right stop

 Longitudinal and Lateral Clearance of Each Stopper

Clearance limit Longitudinal contact

4.0 (0.16)

fNOTE: Standard dimensions indicate those with new

fNOTE:

Left stop

3.0 (0.12)

Lateral contact

T4-4-9

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

Lift Arm Cylinder: (Raising)

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

Preparation: (Lowering)

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

T487-04-03-005

Bucket Cylinder:

2. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F). Select ground filled with sand or dCAUTION: something so that the bucket contacts the ground with buffer.

T487-04-03-006

Travel Position

a 90Z6-4-1-1 a-

T4-4-10

0.5 m (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 Lift Arm (Raising)

Full stroke (engine: high idle speed)

Parking Brake Switch ON

Lift Arm (Lowering)

Neutral (engine: low idle speed)

ON/OFF

Bucket

Full stroke (engine: high idle speed)

ON/OFF

Steering

Full stroke (engine: high idle speed)

OFF

ON/OFF

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

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

Evaluation: Refer to Operational Performance Standard (p.T4-2-3). Remedy: Refer to Troubleshooting B. NOTE: Front Attachment System Troubleshooting (p.T56-31)

T4-4-11

Forward/Reverse Power Mode Lever Switch N ON/OFF

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

Preparation: 1. Load the bucket with either soil or a weight equivalent to the weight standard 6800 kg (14991 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 55±5 °C (131±9 °F). a

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

T4GB-04-04-014 a-

Bucket Bottom Drift Amount

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

Evaluation: Drift amount: Lift Arm Cylinder: 45 mm (1.77 in) or less Bucket Cylinder: 35 mm (1.38 in) or less Bucket Bottom (a): 200 mm (7.87 in) or less

b TNEE-04-04-001 b-

Remedy: Refer to Troubleshooting B. NOTE: Front Attachment System Troubleshooting (p.T56-31)

T4-4-12

Cylinder Drift Amount

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

Preparation: 1. Place the unloaded machine on a horizontal bed 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 T4GB-04-04-011

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: Drift amount: 10 mm (0.4 in) or less

T4-4-13

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

Travel Position

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

Preparation:

1. In the front position, empty the bucket in advance. 2. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

90Z6-4-1-1 a-

T4-4-14

0.5 m (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 Neutral (engine: low ON idle speed)

Forward/Reverse Lever N

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

TNED-04-04-001

are out of the steering area before starting the measurement.

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. 3

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.

12-

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

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

T4-4-15

Knob Accelerator Pedal

2 3-

Brake Pedal

MNDB-01-001

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

Preparation: 1. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

Measurement: 1. Measure as follows.  Measurement of Control Lever  Lower the bucket bottom onto the ground.  Stop the engine.  Measure each lever stroke from neutral to the stroke end of each control lever of lift arm, bucket, and forward/reverse at the grip top center.  Measurement of Pedal  Lower the bucket bottom onto the ground.  Stop the engine.  Measure the stroke from neutral to the stroke end of the pedal at the pedal top.  Measurement of Steering Wheel  Start the engine. (Low idle)  Float the bucket slightly above the ground.  Measure the number of times of rotation required for movement of the steering wheel from the right to the left stroke end and from the left to the right stroke end. 2. Measure the chord length from neutral to the stroke end. Turn the steering wheel at 30~60 rpm. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (p.T4-2-6).

T4-4-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Hydraulic Circuit Loading Pilot Circuit 3

8 1

4 2

90Z6-04-05-04

123-

Pilot Pump Main Pump Multiple Control Valve

456-

Loading Pilot Valve Charging Block Service Brake Accumulator

T4-5-1

789-

Parking Brake Pilot Accumulator Hydraulic Oil Tank

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 p.T5-6-99.)

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 is higher than the pilot circuit pressure. Use a pressure gauge capable of measuring 14.7 MPa (150 kgf/cm2) (2132 psi) or higher.

3 2 Arrow View A 1

Summary: Measure the pilot pressure at charging block (2). NOTE: Measure the pressure by using the monitor or MPDr. (Monitoring - Main (T/M) - Service Brake Primary Pressure)

Preparation: 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Disconnect hose (3) from charging block (2) (port P) and install an adapter (charging block side). Install the pressure gauge to the adapter. 4. Start the engine and keep the speed at low idle. Confirm that no oil leakage is observed at the pressure gauge connection.

90Z6-04-05-03

12-

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

T4-5-2

Pilot Pump Charging Block

34-

Hose Service Brake Accumulator

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

Power Mode Switch

Parking Brake Switch

Forward/Reverse Lever

Full stroke

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

fNOTE: When pressure in the service brake accumulator

decreases during measurement of primary pilot pressure, the measured valve increases to around 16 MPa (163 kgf/ cm2) (2320 psi) for several seconds.

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

14.7±0.3 MPa (2132 PSI) 11.8±1.0 MPa (1711 PSI)

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

T4-5-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure

Preparation: 1. Stop the engine. b1

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

Arrow View A

3. Measure pressure between the pilot valve and multiple control valve (2). Disconnect pilot hose (1) from the circuit to be measured. Install a tee and a pressure gauge.

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

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. a1

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

a2 90Z6-04-05-05

a1- Lift Arm (Raise) a2- Bucket (Roll Back)

Measurement:

b1- Lift Arm (Lower) b2- Bucket (Dump)

1. Select the following conditions: Accelerator Pedal

Power Mode Switch

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

fNOTE: All Actuator System Troubleshooting (p.T5-6-28) Front Attachment System Troubleshooting (p.T5-6-31) Steering System Troubleshooting (p.T5-6-35) Front Attachment System Troubleshooting (p.T5-6-31)

T4-5-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure Adjustment Procedure Adjust the relief valve set-pressure in charging block (3) as necessary. 1. Remove plug (1) from the pilot relief valve. j : 30 mm (1.18 in) 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 (0.06 in) or less.

4. Install shim (2) to the relief valve. Tighten plug (1). m : 98.0±9.8 N·m (10±1.0 kgf·m, 72±7.2 lbf·ft) 5. After adjustment, check the set pressure.

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

Shim (2) Thickness mm (in)

kPa

(kgf/cm2)

(psi)

0.2 (0.008)

61.8

(0.63)

(9)

0.4 (0.016)

124.6

(1.27)

(18)

0.8 (0.031)

249.2

(2.54)

(36)

4 90Z6-04-05-06

3 Section V-V 90Z6-04-05-07

12-

Plug Pilot Relief Valve

34-

Shim Charging Block

T4-5-5

Accumulator Port

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Pump Delivery Pressure Summary: Measure the main pump output pressure at the delivery port in main pump in neutral condition.

Pressure gauge Main pump

fNOTE: Measure the pressure by using the MPDr. Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 1

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

Adapter

TNDB-04-05-008

l : 6 mm (0.24 in) 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

Hose

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

T4-5-6

Pump 1 Delivery Pressure Check Port

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

Power Mode Switch

Parking Brake Switch

Forward/Reverse Lever

Full stroke

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

Evaluation: Standard (neutral): 2.0 +1.0/-0.5 MPa (290 +145/-73 PSI) Remedy: Refer to Troubleshooting A for any accompanied error code. Refer to Troubleshooting B for observed phenomena.

fNOTE: All Actuator System Troubleshooting (p.T5-6-28) Front Attachment System Troubleshooting (p.T5-6-31) Steering System Troubleshooting (p.T5-6-35)

T4-5-7

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Loading Circuit Main Relief Set Pressure Summary: Measure the main relief valve set pressure at the delivery port in main pump while operating the lift arm/bucket control lever.

Pressure gauge

fNOTE: Measure the pressure by using the MPDr. Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 2

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

Adapter

Hose TNDB-04-05-008

l : 6 mm (0.24 in)

Pump Delivery Pressure Check Port

Pump Delivery Pressure Sensor

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

Measurement: 1. Select the following conditions: Accelerator Pedal

Power Mode Switch

Parking Brake Switch

Forward/Reverse Lever

Full stroke

2. Operate the bucket or lift arm control levers slowly, operate each cylinder to the stroke end, and relieve each function. 3. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard (lift arm/bucket relief operation): 29.4 +2.0/-0.5 MPa (4264 +290/-73 PSI)

T4-5-8

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

fNOTE: The main relief valve is installed to the multiple control valve.

Procedure: 1. Loosen lock nut (1). j : 17 mm (0.67 in) 90Z6-04-05-08

2. Turn adjusting screw (2) and adjust the relief pressure to the specification. 1

l : 6 mm (0.24 in) 3. Tighten lock nut (1). m : 29.5 N·m (3 kgf/cm2, 22 lbf·ft)

4. Check the relief set pressure.

T4GB-04-05-011

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (2) 1/4 Turns Change in MPa 4.5 Pressure (kgf/cm2) (46) (psi) (653)

1/2

3/4

8.9 13.4 17.8 (91) (137) (182) (1291) (1944) (2582) a

W107-02-05-129 a-

T4-5-9

Pressure Increase

Pressure Decrease

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

Pressure gauge

fNOTE: Measure the pressure by using the MPDr. Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 1

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

Adapter

Hose TNDB-04-05-008

l : 6 mm (0.24 in)

Pump 1 Delivery Pressure Check Port

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

Measurement: 1. Select the following conditions: Accelerator Pedal

Power Mode Switch

Parking Brake Switch

Forward/Reverse Lever

Full stroke

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

Evaluation: Standard: 29.4 +2.0/-0.5 MPa (4264 +290/-73 PSI)

T4-5-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Steering Main Relief Pressure Adjustment

fNOTE: The main relief valve is installed to the pump device.

Procedure: 1. Secure lock nut (1). Remove nut (3). T4GB-04-05-012

j : 24 mm (0.94 in) 3

2. Secure adjusting screw (2). Loosen lock nut (1).

j : 24 mm (0.94 in) 3. Turn adjusting screw (2) and adjust the relief pressure to the specified value. 4. Secure adjusting screw (2). Tighten lock nut (1). 2

m : 37 N·m (3.8 kgf/cm2, 27 lbf·ft)

T4GB-04-05-013

5. Secure lock nut (1). Tighten nut (3). m : 37 N·m (3.8 kgf/cm2, 27 lbf·ft)

6. Check the relief set pressure.

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (2) 1/4 Turns Change in MPa 3.8 Pressure (kgf/cm2) (39) (psi) (551)

1/2

3/4

7.5 11.3 15.0 (77) (155) (153) (1088) (1639) (2176)

b T105-06-05-002

T4-5-11

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

T4-5-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Preparation:

Pressure gauge

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, the hose, and the pressure gauge. l : 6 mm (0.24 in) 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

1 Adapter

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

TNDB-04-05-008 1-

Pump 1 Delivery Pressure Check Port

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

Power Mode Switch ON

Hose

Parking Brake Switch ON

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

Evaluation: Performance of the overload relief valves are normal if the measured main relief pressures are within the specified value range. Standard: Lift arm raise: 36.8 +1.0/-0 MPa (5337 +145/-0 PSI) Bucket: 32.5 +1.0/-0 MPa (4714 +145/-0 PSI)

fNOTE: The overload relief pressure values at each port are given for reference.

T4-5-13

Forward/Reverse Lever N

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

fNOTE: The overload relief valves are installed to the

multiple control valve.

fNOTE: In principle, adjust the overload relief valve

pressure on a test stand.

Procedure: 1. Loosen lock nut (1). j : 17 mm (0.67 in) b

2. Turn adjusting screw (2) in order to adjust the pressure.

90Z6-03-02-04 abc-

l : 6 mm (0.24 in)

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

3. Tighten lock nut (1). 1

j : 17 mm (0.67 in) m : 29.5 N·m (3 kgf/cm2, 22 lbf·ft) 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 ) (53) (psi)

(754)

1/2

3/4

10.6

15.9

21.1

(108)

(162)

(215)

W107-02-05-128 1-

Lock Nut

(1537) (2306) (3060)

Adjusting Screw

W107-02-05-129 a-

T4-5-14

Pressure Increase

Pressure Decrease

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

T4-5-15

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.

6. Remove the vacuum pump. Loosen plug (8) on top of the pump casing. Bleed air from the casing until only oil comes out.

Preparation:

7. Fully open the loading valve of hydraulic tester (5).

j : 41 mm (1.61 in)

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.

8. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. Connect MPDr. and select the monitoring function.

fNOTE: Operate the vacuum pump while connecting the pump flow rate test line.

Measurement:

2. Disconnect delivery hose (7) from main pump (1). Connect test hose (3) to the main pump delivery port.

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

j : 41 mm (1.61 in)

2. Measure the maximum flow rate.

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 (1.61 in)

3. Select the following conditions: Accelerator Pedal Full stroke

4. Install a pressure gauge to main pump (1) to be measured. (Refer to Main Relief Set Pressure.) l : 6 mm (0.24 in) 5. Disconnect hose (10) from regulator port ST (9). Install the plug (G1/4) to the removed hose (10) and regulator port ST (9). j : 17 mm (0.67 in)

T4-5-16

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

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.

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: 2150 min-1 Ne: Measured Engine Speed: Values indicated on MPDr.

TNED-04-05-005

2. Standard Flow Rate Refer to Operational Performance Standard (p.T4-210). 9 8

2 7 View A

Steering valve

Control valve

90Z6-04-05-09 1234-

Main Pump Charging Block (Port X) Test Hose (1-11/16-12UN) Adapter 1-11/16-12UN×G1-1/2

5678-

Hydraulic Tester Adapter 1-11/16-12UN×G1-1/2 Delivery Hose Plug

T4-5-17

9- Port ST 10- Hose

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test  Pilot Characteristics Summary:

2. Disconnect the hose from regulator port Pi1 (21). Install the plug (G1/4) to the removed hose.

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.

j : 19 mm (0.75 in) 3. Connect regulator port Pi2 (8) to the hydraulic oil tank.

IMPORTANT: This measurement procedure is a simple method. In order to measure accurately, disconnect the return circuit from the manifold valve and connect it to the hydraulic oil tank.

j : 19 mm (0.75 in)

fNOTE: For the machine with the emergency steering,

install tee (24), adapter (25) and hose (26) to port E in the emergency steering block. Install hose (26) to regulator port Pi2.

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.

4. Disconnect the hose from Orbitrol (steering pilot valve) port P (11). Install adapters (15) (3 used) to pressure reducing valve (16). Install adapter (13) and hose (14) between Orbitrol and charging block (2). Connect hose (14) to port P1 of pressure reducing valve (16).

j : 19 mm (0.75 in)

TNED-04-05-005

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 port Pi1 (21). j : 19 mm (0.75 in) 6. Connect hose (19) and tee (20) to port T of pressure reducing valve (16). Disconnect hose (10) from charging block port DR (22). Install tee (20) to charging block port DR (22). Connect hoses (10, 19) to tee (20). j : 22, 27 mm (0.87, 1.06 in) 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 (1.61 in) 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.

T4-5-18

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 8 12

12 8

11 To control valve Pc1

21 To control valve Pc2

22 90Z6-04-05-10

Pressure Reducing Valve Port Position

16 T

20 P1

13 90Z6-04-05-13

To Regulator Port Pi1 (21)

To Orbitrol Port P (11)

1234567-

Main Pump (Regulator) Charging Block Test Hose (1-11/16-12UN) Adapter 1-11/16-12UN×G1-1/2 Hydraulic Tester Adapter 1-11/16-12UN×G1-1/2 Delivery Hose

891011121314-

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

15- Adapter G3/8 16- Pressure Reducing Valve (4325439) 17- Tee G3/8×G1/4×G1/4 18- Pressure Gauge 19- Hose G3/8 20- Tee G3/8×G1/2×G1/2

T4-5-19

To Charging Block Port DR (22)

21- Port Pi1 22- Port DR 23- Tee 3/4-16UNFxG3/8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Maintain the hydraulic oil temperature at 55±5 °C (131±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: 2150 min-1 Ne: Measured Engine Speed: Values indicated on MPDr. 2. Standard Flow Rate Refer to Operational Performance Standard (p.T4-211).

T4-5-20

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

T4-5-21

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 (0.87 in) m : 20 N·m (2 kgf·m, 15 lbf·ft)

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 (0.67 in) m : 20 N·m (2 kgf·m, 15 lbf·ft)

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 Q 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 (1.18 in) m : 30 N·m (3 kgf·m, 22 lbf·ft) Pd

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 Q 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. j : 13 mm (0.5 in) m : 10 N·m (1 kgf·m, 7 lbf·ft) Pd

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: Measure the pressure at the test port of axle assembly when the brake pedal is depressed. Preparation: Set blocks (1) at the front and rear dCAUTION: tires in order not to move the machine. Keep away from the front or back of the machine.

1. Stop the engine. T4GB-04-05-017

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

3. Depress brake pedal at least 50 strokes in order to decrease the accumulated pressure left in the brake circuit.

T4-5-24

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 4. Install a pressure gauge to the test port (G3/8) provided on the axle assembly. Either of two ports in the front axle (2) is usable for the front wheel brake circuit pressure measurement, and ports in the rear axle (3) for the rear wheel brake circuit pressure.

Front Axle

j : 19 mm (0.75 in) m : 30 N·m (3.0 kgf·m) (22 lbf·ft) 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 6. Maintain the hydraulic oil temperature at 55±5°C (131±9°F).

Measurement: 1. Set the following conditions: Accelerator Pedal

Power Mode Switch

Full stroke

Rear Axle 90TNED-04-05-10

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

Evaluation: Standard: 4.6±0.6 MPa (667±87 PSI) Remedy: Refer to Troubleshooting B. Normally, the front and rear wheel brake pressures become equal. If not, malfunction of the brake valve and dirt caught in the valve are suspected. NOTE: Brake System Troubleshooting (p.T5-6-40)

T4-5-25

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Parking Brake Pressure If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil.

Summary: Measure the parking brake release pressure in the parking brake release circuit.

T4GB-04-05-017

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 parking brake (3). Install a pressure gauge to the removed hose. 90Z6-04-05-01

j : 19 mm, 22 mm (0.75 in, 0.87 in) 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F).

fNOTE: Parking brake pressure sensor (4) is installed to

the charging block.

Transmission Assy

T4-5-26

90Z6-04-04-02

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Select the following conditions: Engine Speed High idle

Accelerator Pedal Full stroke

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

Evaluation: Standard: 3.7+0.2/-0.1 MPa (536 +29/-14.5 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-40)

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: 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. T4GB-04-05-017

Preparation:

CAUTION: Set blocks (1) onto the front and rear tires in order not to move the machine. Keep away from the machine. 2

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

3. Depress the brake pedal at least 50 strokes in order to decrease the accumulated pressure left in accumulator (4) of the brake circuit. 4. Remove plug (3) from the pressure check port (G3) of charging block (2). Install a nipple and a pressure gauge to the pressure check port.

4 90Z6-04-05-11

j : 19, 22 mm (0.75, 0.87 in) l : 6 mm (0.24 in) G3

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

3 Arrow View A 90Z6-04-05-12

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

23-

T4-5-28

Charging Block Plug (Port G3)

Service Brake Accumulator

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

Power Mode Switch

Parking Brake Switch

Forward/Reverse Lever

Full stroke (Engine: high idle)

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

Evaluation: Standard: 14.7±0.3 MPa (2132±43.5 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-40)

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: 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

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

4. Remove plug (3) from the pressure check port (G3) of charging block (2). Install a nipple and a pressure gauge to the pressure check port.

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

90Z6-04-05-11

l : 6 mm (0.24 in) 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

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

Arrow View A 90Z6-04-05-12 23-

T4-5-30

Charging Block Plug (Port G3)

Service Brake Accumulator

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

Parking Brake Switch ON (Parking brake applied)

2. Stop the engine. Set the key switch to the ON position. 3. Slowly depress the brake pedal several times. Measure the pressure when the buzzer sounds. 4. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard: 8±0.5 MPa (1160±73 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-40)

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: 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 from the machine.

T4GB-04-05-017

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 (x) of the brake circuit.

4. Remove plug (3) from the pressure check port (G3) of charging block (2). Install a nipple and a pressure gauge to the pressure check port.

j : 19, 22 mm (0.75, 0.87 in) l : 6 mm (0.24 in) 4

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

90Z6-04-05-11

6. Maintain the hydraulic oil temperature at 55±5 °C (131±9 °F). G3

3 Arrow View A 90Z6-04-05-12 23-

T4-5-32

Charging Block Plug (Port G3)

Service Brake Accumulator

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

Parking Brake Switch ON (Parking brake applied)

2. Stop the engine. Set the key switch to the ON position. 3. Depress the brake pedal several times until the buzzer sounds. 4. Start the engine. Measure the pressure when the buzzer stops sounding. Notice that it is difficult to read the gauge as the pressure increases rapidly. 5. Repeat the measurement three times and calculate the mean values.

Evaluation: Standard: 10±0.5 MPa (1450±73 PSI) Remedy: Refer to Troubleshooting B. NOTE: Brake System Troubleshooting (p.T5-6-40)

T4-5-33

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Transmission Clutch Pressure Summary: Measure each operating pressure of the transmission clutch at each check port of the transmission control valve. Preparation: 1. Stop the engine. 2. Remove the plug from the check port. Install a hose, an adapter, and a pressure gauge. l : 8 mm (0.31 in) j : 21 mm (0.83 in)

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 60 to 80°C (140 to 176°F).

T4GB-04-05-017

T4-5-34

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 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

Brake Pedal

Power Mode Switch

Full stroke

MANU (Manual)

Declutch Position Switch OFF

Parking Brake Switch OFF

2. Operate the forward/reverse lever and the shift switch for the desired clutch. Measured Clutch Pressure Forward/Reverse Lever (F/N/R) Shift Switch (Speed)

Forward F 4

Reverse R 4

1st N 1

2nd N 2

3rd N 3

4th N 4

3. Measure each clutch pressure at each test port. 2

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

3 4 5 6

Evaluation: Standard: 2.2 ~ 2.4 MPa

90Z6-04-05-02

Test Port Location 123-

T4-5-35

Forward Reverse First Speed

456-

Second Speed Third Speed Fourth Speed

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Torque Converter Pressure Summary:

Measure the inlet and outlet pressure of torque converter pressure at each check port of torque converter.

Preparation: 1. Stop the engine. 2. Remove the plug from the respective check port (1, 3), and install a hose, an adapter, and a pressure gauge to the open part.  Inlet pressure: Port at regulator valve (2)  Outlet pressure: Port at housing (4)

l : 6 mm (0.23 in) 3. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

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

T4GB-04-05-024

T4-5-36

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

T4GB-04-05-017

1. Select the following conditions: Accelerator Pedal

Brake Pedal

Travel Mode Switch

Full stroke

MANU (Manual)

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

Evaluation: Inlet Pressure: 0.99~1.09 MPa Outlet Pressure: 0.43~0.53 MPa

T4-5-37

Declutch Position Switch OFF

Parking Brake Switch OFF

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.

90Z6-04-06-01

Condition:  Declutch Position Switch: OFF  Travel Mode: Manual Mode  Shift Switch: 4th  Parking Brake Switch: OFF  Brake Pedal: Depressed (Fully)  Accelerator Pedal: Depressed (Fully)  Forward/Reverse Lever: Forward Position 5. Depress the accelerator pedal and raise transmission oil temperature (2) up to 90 °C (194 °F). 1

6. When transmission oil temperature (2) is 90 °C (194 °F), stop transmission stalling with the following machine conditions.

Detail A

90Z6-04-06-02

NOTE: Do not raise the transmission oil temperature above 116 °C (240 °F).

Deactivation Condition:  Accelerator Pedal: Not Depressed  Forward/Reverse Lever: Neutral Position  Parking Brake Switch: ON  Brake Pedal: Not Depressed

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.

TNDB-04-06-013

2. When transmission oil temperature (3) is 110ºC (230ºF), select Start (1) from the pull-down menu on the Transmission Calibration screen and click Set (2). TNDB-04-06-011

3. The message on the inquiry is displayed on the Transmission Calibration screen on MPDr. Click Yes (4).

TNDB-04-06-014

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

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.

T4GB-04-06-006

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

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

TNDB-04-06-015

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.

TNDB-04-06-016

8. Wait 30 seconds after turning the key switch to OFF position. Turn the key switch to ON position and confirm no transmission alarm lamp turns ON.

T4-6-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Lift Arm Angle Sensor Learning 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 handle (1) to UNLOCK position. LOCK

4. Raise lift arms to the highest level by lift arm raise operation.

1 UNLOCK

5. Set front control lever lock handle (1) to LOCK position. 90Z6-04-06-03

6. Set the key switch to the OFF position.

T4-6-4

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.

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).

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

TNDB-04-06-018

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.

TNDB-04-06-019

T4-6-5

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment Digging Position Adjustment 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.) 2. Start the engine. 3. Set front control lever lock switch (1) to UNLOCK Position (3). LOCK

4. Lower the lift arms and set the bucket on the ground horizontally.

1 UNLOCK

5. Set front control lever lock switch (1) to LOCK Position (2). 90Z6-04-06-03

6. Set the key switch to the OFF Position.

T4-6-6

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.

3. Select Start (1) from the pull-down menu on the Digging Position Calibration screen and click Set (2). TNDB-04-06-020

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).

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

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

T4-6-7

TNDB-04-06-021

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment (Blank)

T4-6-8

SECTION 5

TROUBLESHOOTING CONTENTS Group 1 Diagnosing Procedure

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

Group 2 Monitor

Outline..................................................................................... T5-2-1 Monitor Panel.................................................................. T5-2-1 Monitor Display............................................................... T5-2-2 Vehicle Information Display....................................... T5-2-2 Operating Procedures of Service Menu....................... T5-2-3 How to display service menu..................................... T5-2-4 Engine Speed................................................................... T5-2-4 Coolant Temperature.................................................... T5-2-4 Transmission Oil Temperature................................... T5-2-4 Hydraulic Oil Temperature.......................................... T5-2-4 Fault Code......................................................................... T5-2-5 Fuel Consumption.......................................................... T5-2-5 List of Service Menu Display....................................... T5-2-6 Coolant Temperature Gauge and 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 List of Daily Report Data.............................................. T5-3-2 List of Frequency Distribution Data......................... T5-3-4 List of Total Operating Hours..................................... T5-3-5 Snapshot Data....................................................................... T5-3-6 Communication System.................................................... T5-3-7

Group 4 Component Layout

Main Component (Overview).......................................... T5-4-1 Main Component (Travel System)................................. T5-4-3 Electric Component Layout (Overview)...................... T5-4-4 Electrical System (Cab)....................................................... T5-4-5 Controller and Relays.................................................... T5-4-6 Right Console................................................................... T5-4-7 Monitor and Switches................................................... T5-4-8 Monitor Panel.................................................................. T5-4-9 Electrical System (Relays)................................................T5-4-10 Engine/Fan Pump..............................................................T5-4-11 Transmission and Torque Converter Assembly.......T5-4-12 Hydraulic Pump Device...................................................T5-4-13 Multiple Control Valve......................................................T5-4-14 Charging Block....................................................................T5-4-15 Front Axle..............................................................................T5-4-15 Steering Valve......................................................................T5-4-16 Brake Valve...........................................................................T5-4-16 Fan Motor.............................................................................T5-4-16 Pilot Valve.............................................................................T5-4-16 Ride Control Group (Option).........................................T5-4-17 Secondary Steering Group (Option)...........................T5-4-18 Secondary Steering Pump (Option)......................T5-4-18

Group 5 Troubleshooting A

Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure ............................. T5-5-1 MPDr. Fault Code Reference Table................................. T5-5-3 MC Fault Code List............................................................... T5-5-9 Controller Hardware Failure....................................... T5-5-9 CAN Data Reception Failure.....................................T5-5-10 Engine Failure................................................................T5-5-11 Pump Failure..................................................................T5-5-12 Pilot Failure.....................................................................T5-5-13 Proportional Solenoid Valve Failure......................T5-5-15 Revolution Sensor Failure..........................................T5-5-20 Learning Failure............................................................T5-5-21 Switch Failure.................................................................T5-5-21 Temperature Sensor Failure......................................T5-5-22 Other Sensor Failures..................................................T5-5-23 Alarms on Monitor.......................................................T5-5-24 Monitor Controller (Monitor) Fault Code List..........T5-5-26 Monitor Controller (Information) Fault Code List...T5-5-28 Column Display Controller Fault Code List...............T5-5-30 Communication Terminal Fault Code List.................T5-5-32

90Z6 Trbl

Air Conditioner Controller Fault Code List................T5-5-33 ECM Fault Code List...........................................................T5-5-34 MC Fault Codes 111000 to 111002..............................T5-5-41 MC Fault Code 111003.....................................................T5-5-42 MC Fault Codes 111006, 111007, 111014, 111025..............................................................................T5-5-44 Monitor Controller (Monitor) Fault Codes 113002, 113003, 113005, 113007...........................T5-5-45 Monitor Controller (Information) Fault Codes 114010, 114011, 114015............................................T5-5-45 CAN1 Harness Check........................................................T5-5-46 MC Fault Codes 111103, 111105..................................T5-5-49 MC Fault Code 111200.....................................................T5-5-50 MC Fault Codes 111205, 111207..................................T5-5-51 MC Fault Codes 111217, 111312..................................T5-5-52 MC Fault Code 111204.....................................................T5-5-53 MC Fault Code 111206.....................................................T5-5-54 MC Fault Code 111208.....................................................T5-5-55 MC Fault Codes 111311, 111313..................................T5-5-56 MC Fault Code 111411.....................................................T5-5-57 MC Fault Code 111412.....................................................T5-5-58 MC Fault Code 111413.....................................................T5-5-59 MC Fault Codes 111414 to 111419..............................T5-5-60 MC Fault Code 111422.....................................................T5-5-61 MC Fault Codes 111600, 111601, 111602.................T5-5-62 MC Fault Code 111900.....................................................T5-5-63 Torque Converter Oil Temperature Sensor Specification................................................................T5-5-63 MC Fault Code 111901.....................................................T5-5-64 Hydraulic Oil Temperature Sensor Specification................................................................T5-5-64 MC Fault Code 111902.....................................................T5-5-65 Axle Oil Temperature Sensor Specification.........T5-5-65 MC Fault Codes 111700 to 111705..............................T5-5-66 MC Fault Codes 120000 to 120005..............................T5-5-68 MC Fault Code 120014.....................................................T5-5-68 Column Display Controller Fault Code 115001.......T5-5-69 Column Display Controller Fault Code 115011.......T5-5-70 Fuel Level Sensor Specifications.............................T5-5-71 Monitor Controller (Monitor) Fault Code 120300..T5-5-72 Column Display Controller (Information) Fault Codes 120500 to 120503.........................................................T5-5-72 Column Display Controller (Information) Fault Codes 120505 to 120507.........................................................T5-5-73 Air Conditioner Controller Fault Codes 11 to 22.....T5-5-74 Air Conditioner Controller Fault Codes 43 to 92.....T5-5-75

Group 6 Troubleshooting B

Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure.................. T5-6-1 Relationship between Machine Trouble Symptoms and Related Parts..................................... T5-6-3 Correlation between Trouble Symptoms and Part Failures.................................................................T5-6-25 Engine System Troubleshooting.............................T5-6-26 All Actuator System Troubleshooting...................T5-6-28 Front Attachment System Troubleshooting.......T5-6-31 Steering System Troubleshooting..........................T5-6-35 Travel System Troubleshooting...............................T5-6-37 Brake System Troubleshooting................................T5-6-40 Other System Troubleshooting...............................T5-6-41 Engine System Troubleshooting..................................T5-6-45 All Actuator System Troubleshooting.........................T5-6-51 Front Attachment System Troubleshooting.............T5-6-56 Steering System Troubleshooting...............................T5-6-65 Travel System Troubleshooting....................................T5-6-69 Brake System Troubleshooting.....................................T5-6-79 Other System Troubleshooting.....................................T5-6-83 Exchange Inspection........................................................T5-6-97 Air Bleeding Procedures for Brake (Axle)...................T5-6-99

Group 7 Air Conditioner

Outline..................................................................................... T5-7-1 Component Layout........................................................ T5-7-2 Functions of Main Parts..................................................... T5-7-4 Troubleshooting................................................................... T5-7-8 Air Conditioner Controller Fault Code List.................. T5-7-9 Air Conditioner Controller Fault Codes 11 to 22.....T5-7-10 Air Conditioner Controller Fault Codes 43 to 92.....T5-7-11 Faulty cooling................................................................T5-7-12 Faulty heating................................................................T5-7-19 Others...............................................................................T5-7-21 Cooling circuit check by using manifold gauge...........................................T5-7-25 Work after Replacing Components.............................T5-7-27 Refill Compressor Oil........................................................T5-7-28 Charge Air Conditioner with Refrigerant..................T5-7-29 Hose and Pipe Tightening Torque................................T5-7-37

90Z6 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.

 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 service menu of monitor).

Example: Fuse Inspection  Monitor This group contains the display screen of monitor and the operating procedures of service menu.  e-Service (Option) This group contains as follows. Download data from the monitor controller and Upload. Procedures when starting satellite communication, when installing the satellite communication controller and when replacing the monitor controller. Explanation for the satellite communication system.

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

 Component Layout

Example: Fault Code 111000-2: Abnormal EEPROM  Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Refer to troubleshooting B for diagnosis by using trouble symptom. Refer to these procedures when no fault codes are displayed after diagnosing the machine by using MPDr. (or the service menu of monitor). Example: Even if accelerator pedal is operated, engine speed does not change.  Air Conditioner This group contains system of the air conditioner, troubleshooting, and procedures for charging air conditioner with refrigerant.

T5-1-1

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

T107-07-01-001

T4GB-05-01-002

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

T5-1-2

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

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

fNOTE: Note that the fault codes displayed do not

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

T5-1-3

TNED-05-01-001

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

T4GB-05-01-006

T5-1-4

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

T5-1-5

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Precautions for Inspection and Maintenance 1. Disconnect the power source. Disconnect the harness from the negative terminal side in battery first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses and fusible links and, in some cases, cause fire due to short-circuit. In addition, even when the key switch is turned OFF, the controller may be operated for a specified time. Therefore, disconnect the harness from the negative terminal side in battery after setting the key switch to the OFF position and waiting 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

Red

White

Blue

Green

Yellow

Black

Orange

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

Lg Light green

Brown

Pink

Gray

Violet

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 3. Precautions for connecting and disconnecting terminal connectors.  When disconnecting the harnesses, grasp them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate connectors, if a lock is provided. (Refer to Instructions for Disconnecting Connector on page 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 harness near the connector in order to check if it is correctly connected.

TDAA-05-08-002

1 2 3

4 TDAA-05-08-003 12-

Correct Rust

34-

Incorrect (Bent) Incorrect (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 harness end of connector in order not to damage the terminal inside connector.

TDAA-05-08-004

T5-1-7

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

T107-04-05-002

 Raise Lock, Pull, and Separate Type

T107-04-05-003

T4GB-05-06-003

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

T107-04-05-004

T5-1-8

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure  Remove the Bolt, Pull, and Separate Type l : 4 mm (0.16 in)

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 harness end connector with fingers and rotate it counterclockwise while pushing the projection part. Then, the connector will be separated.

T4GB-05-06-007

T5-1-9

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

1. Set the key switch to the ON position. When the key switch is in the ON position, current from key switch terminal M turns the battery relay ON so that electric power is supplied to all circuits. (Refer to the circuit diagram.) 2. Remove the fuse box cover. Set a circuit tester. (Measurement Range: 0 to 30 V) 3. Ground the negative probe of circuit tester to the body. Touch the terminals located (e) of fuse box one-by-one with the positive probe of circuit tester. When normal continuity of a fuse is intact, the circuit tester will indicate 20 to 25 V (battery voltage).

M178-07-034

Terminals connected to the power source

Terminals connected to loads (accessories)

b a, b

c ab-

Fuse Box A Fuse Box B

MNEC-01-047 c-

Relay Box

10 9 8 7 6

20 19 18 17 16

5 4 3 2 1

15 14 13 12 11 M178-07-034

T5-1-10

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Box A

Fuse Box B

Fuse No. Capacity Connected to 1 5A Back-up Alarm, Back-up Lamp 2 5A Brake Lamp, Turn Signal Switch 3 10 A Head Light (Low) 4 10 A Lighting Switch 5 (15 A) (Option 1) (Bt) 6 10 A Horn 7 10 A Flasher Relay, Hazard Light 8 10 A MC (Power), Load Dump Relay, Information Controller (Backup Power), Column Monitor Controller (Power), GPS/GSM (Opt)(Power) 9 10 A ECM1 (Power) 10 10 A ECM2 (Power), INSITE (Engine Tool) (Opt) 11 10 A Position (Tail Lamp, Width Lamp)

Fuse No. Capacity Connected to 1 5A Radio (Power) 2 10 A Cigar Lighter

12 13

(20 A) 10 A

15 16

10 A 10 A

20 A

18 19

5A 10 A

(Option 2) (ACC) Power ON, Battery Relay, Buzzer in Column Monitor Controller, Information Controller, Declutch Position Switch, Shift Up Delay Indicator, ECM, MC (Key ON), ECM Main Relay, Air Conditioner Unit, Parking Brake Relay, Back-up Lamp Relay, Communication Terminal (Opt)(Key ON), Steering Pressure Switch (Opt) Neutral Relay, Alternate Droop Relay MC Proportional Solenoid Valve (PPV) Loader Control, Bucket Detent Coil, Bucket Proximity Switch, Height Kickout Proximity Switch, Lift Arm Height/Lower Kickout Coil (Opt), Pilot Shut-Off Solenoid Valve (Opt), Hydraulic Quick Coupler Switch (Opt) Working Light (Rear) Working Light (CAB Rear) (Opt) Parking Brake Solenoid Head Light (High Beam), Monitor Secondary Steering Pump Relay (Opt)

T5-1-11

3 4 5 6 7 8

15 A 20 A 10 A 10 A 10 A 15 A

Front Wiper/ Washer Working Light (Front) Rear Wiper/ Washer Air Conditioner Compressor Clutch DC/DC Converter (Opt) Seat Heater (Opt)

9 10

10 A 20 A

Beacon Light (Opt) Air Conditioner Blower Motor

12 13

10 A (15 A)

Dome Lamp, Radio (Backup Power) Neutral Relay (Option 3)

(10 A)

(Option 4)

15 16

18 19

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fusible Link Inspection Inspection

1. Visually inspect fusible links (1).

1 90Z6-05-01-01

1, 2

Replacement

1. Disconnect the negative cable from the battery. 2. Remove two bolts (3) and pull up to replace a fusible link (1, 2). 3. Connect the negative cable to the battery.

90Z6-05-01-02

3 12-

T5-1-12

Fusible Link (70 A) Fusible Link (100 A) (3 used)

34-

Bolt Fuse Element

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

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

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

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

90Z6-05-01-03

T5-1-13

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Alternator Check Generally, if the alternator has generated electricity, alternator alarm (1) will disappear. If discharge warning indicator (1) is displayed while the engine is running, the alternator might be defective. How to Check Alternator 1. Set the key switch to the ON position. Confirm that discharge warning indicator (1) is displayed. 2. Measure voltage between terminals B (power supply) and G (ground) of alternator (2). If the measured voltage is around 24 V, the alternator circuit can be considered normal. If the measured voltage is low, a shortage in battery capacity or looseness of the wire connectors of alternator circuit might be the cause of the malfunction. When voltage is 0 V, the wiring between fuse box and alternator might be loose or disconnected. Also, the alternator cannot generate electricity if the ground line is disconnected. 3. Next, start the engine and measure voltage generated while the alternator rotates. Measure voltage between terminals B and G on the alternator side in the same manner as step 2. 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.

T5-1-14

MNDB-01-008

2 G

Image of voltage check

90Z6-05-01-04

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

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

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

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

T107-07-05-003

 Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the 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 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

T5-1-15

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

Key Switch

Location to be Measured One Battery One Battery Two Batteries Battery Power Fusible Link A (65A) Backup Current *1

Specification

OFF OFF OFF OFF OFF OFF

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

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 Between (7) and Ground: Intake Air Heater *2

20 to 25 V 20 to 25 V

ON ON ON

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

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

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

ON ON ON

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

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

20 to 25 V

Stopped Stopped Stopped

ON ON ON

Between (15) and Ground: Monitor Controller, Switch Panel, Air Conditioner Unit, ECM, MC Between (18) and Ground: Radio Between (19) and Ground: Fusible Link (140 A) Between (6) and Ground: Battery Relay

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

T5-1-16

26 to 30 V

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

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

c f

Key Switch (g)

Preheat OFF ACC ON Start

Monitor

d i

18 14

ICF

90Z6-05-01-05

abcd-

Battery Alternator Fusible Link A (70A) Battery Relay

efgh-

Intake Air Heater Load Dump Relay Key Switch Fuse Box A

ijkl-

T5-1-17

Information Controller (ICF) Fusible Link (100 A) Column Monitor Controller Fuse Box B

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

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

Location to be Measured Between (20) and Ground: Between (21) and Ground: Between (22) and Ground: Between (23) and Ground: Between (24) and Ground: Between (25) and Ground: Between (26) and Ground: Between (27) and Ground: Between (28) and Ground: Between (29) and Ground: Between (30) and Ground: Between (32) and Ground: Between (33) and Ground: Between (34) and Ground: Between (35) and Ground:

Battery Relay (Coil) Battery Relay (Switch) Starter (B) Starter (C) Magnetic Switch (Switch) Voltage Relay (Switch) Fuse Box A (#4 ~ #10), Fuse Box B (#11) Key Switch Neutral Relay (Switch) Information Controller (C-8) MC (E04) ECM Main Relay 1 (Switch) ECM Main Relay 1 (Coil) ECM Main Relay 2 (Switch) ECM Main Relay 2 (Coil)

T5-1-18

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

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

22 Key Switch (e)

Preheat OFF ACC ON Start

24 f

33 ECM

ICF

26 i

32 90Z6-05-01-06

abc-

Starter Magnetic Switch Battery Relay

def-

Voltage Relay Key Switch Neutral Relay

ghi-

T5-1-19

Information Controller (ICF) ECM Main Relay 1 ECM Main Relay 2

jk-

ECM MC

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

Key Switch

ON ON ON ON ON

Location to be Measured

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

Key Switch Fuse Box A (#14) MC (E13) Neutral Relay (Coil) Neutral Relay (Switch)

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

T5-1-20

Specification

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

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

34 Key Switch (a) Preheat OFF ACC ON Start

a e c

39 37

MC d

90Z6-05-01-07

ab-

Key Switch Fuse Box A

cd-

Forward/ Reverse Lever Main Controller (MC)

T5-1-21

Neutral Relay

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

Two Polarities 1

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

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

T107-07-05-007

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

Two Polarities 1

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

T107-07-05-008

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

Three Polarities 1

T107-07-05-009

T5-1-22

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

Two Polarities 1

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

T107-07-05-010

Three Polarities

fNOTE: Some kinds of sensors can be monitored by the

service menu of the monitor.

T107-07-05-011

T5-1-23

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Test Harness Install a test harness between connectors. Check the circuit condition depending on whether the test harness lamp lights or extinguishes during operation.  Wire Test Lamp Use in order to check a single-line (discontinuity and/ or voltage). T107-07-05-012

 During Operation: Light is ON.

 Solenoid Test Lamp Use in order to check the solenoid valve unit circuits.

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

4 2

1 T107-07-06-015

 Pressure Sensor Test Harness Connect a test harness to the harness end connector of pressure sensor. Check the state of pressure sensor circuit.

TDAA-05-06-003

T5-1-24

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

fNOTE: The connecting procedures of test harness of 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) to harness end connector (4) of pump delivery pressure sensor (1). 3. Connect dummy sensor (2) to the female end connector of test harness (3). 4. Check the output voltage.

TDAA-05-06-002

4 TDAA-05-06-003

T5-1-25

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure (Blank)

T5-1-26

SECTION 5 TROUBLESHOOTING Group 2 Monitor Outline Monitor Panel

7 8

9 10

37 12 36 35

14 15

33 16

32 31 30

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 Axle Oil Temperature Indicator Brake Oil Low Pressure Indicator

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 27- Monitor Display 28- Fan Reverse Rotation Indicator 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- Water Separator Indicator 36- Hydraulic Oil Level Indicator

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

T5-2-1

MNDB-01-034

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

9- Ride Control Indicator (Option) 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

f 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. MNDB-01-008

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

Coolant Temperature (Figure B)

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

Transmission Oil Temperature (Figure C)

Current Transmission Oil Temperature (7) is displayed. When pushing monitor display selection switch (3) once on this screen, Hydraulic Oil Temperature is displayed. 7

Hydraulic Oil Temperature (Figure D)

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

T5-2-4

TNDB-05-02-005

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

MNDB-01-008

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

4 6

TNDB-05-02-006

Fuel Consumption (Figure F)/ Average Fuel Consumption (Figure G)

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

TNDB-05-02-007

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-05-02-008

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 MC 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) (ºF) 25 (77) 40 (104) 95 (203) 105 (221) (120) (248)

No. A B C D E

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

A TNED-05-02-003

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

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

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 (E) zone, indictor (a) on the monitor panel is ON.

T5-2-8

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

Fuel Sensor (Ω) 10 +5/0 32.9±2.5 77±2.5 90±2.5

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)

Details Frequency distribution of main pump delivery pressure Total hours when coolant temperature is less than 80°C (176°F) during a day. Radiator Coolant Temperature (80 to 93 °C) Total hours when coolant temperature is 80°C (176°F) or more and less than 94°C (201°F) during a day. Radiator Coolant Temperature (94 to 104 °C) Total hours when coolant temperature is 94°C (201°F) or more and less than 105°C (221°F) during a day. Radiator Coolant Temperature (105 °C or more) Total hours when coolant temperature is 105°C (221°F) or more during a day. Hydraulic Oil Temperature (49 °C or less) Total hours when hydraulic oil temperature is less than 50°C (122°F) during a day. Hydraulic Oil Temperature (50 to 89 °C) Total hours when hydraulic oil temperature is 50°C (122°F) or more and less than 90°C (194°F) during a day. Hydraulic Oil Temperature (90 to 99 °C) Total hours when hydraulic oil temperature is 90°C (194°F) or more and less than 100°C (212°F) during a day. Hydraulic Oil Temperature (100 °C or more) Total hours when hydraulic oil temperature is 100°C (212°F) or more during a day. Torque Converter Oil Temperature (49 °C or less) Total hours when torque converter oil temperature is less than 50°C (122°F) during a day. Torque Converter Oil Temperature (50 to 89 °C) Total hours when torque converter oil temperature is 50°C (122°F) or more and less than 90°C (194°F) during a day. Torque Converter Oil Temperature (90 to 109 °C) Total hours when torque converter oil temperature is 90°C (194°F) or more and less than 110°C (230°F) during a day. Torque Converter Oil Temperature (110 °C or Total hours when torque converter oil temperature is 110°C (230°F) or more) 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).

T5-3-6

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

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

The communication system consists of communication terminal, GPS antenna and communication antenna. The functions of each equipment are as follows.  Communication Terminal: Receives the data from 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)

5 2

1 6

11 10

12345-

Bucket Lever (Bell Crank) Bucket Cylinder Headlight Front Working Light

67-

CAB Rear Working Light (Option) Rear Working Light

T5-4-1

Rear Combination Light (Turn Signal Light, Hazard Light, Clearance Light, Brake Light, Backup Light) Turn Signal Light, Hazard Light, Clearance Light

90Z6T1-2-01

10- Lift Arm (Boom) Cylinder 11- Lift Arm (Boom) 12- Bucket Link

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Main Component

18 17 16 15 14 13

3 4

12 11

10 9

90Z6T1-2-02

6 13 11

123456789101112131415-

Multiple Control Valve (Loading) Pilot Valve Stop Valve Torque Converter Oil Filter Charging Block (Unloader and Accumulators) Engine Fuel Filter Fuel Tank Engine Oil Filter Hydraulic Oil Cooler Inter Charge Air Cooler Fan Motor Torque Converter Oil Cooler Radiator Coolant Level and Surge Tank

161718192021222324-

Air Cleaner Muffler Hydraulic Tank Safety Device (Pilot Shut-off Valve) Front Attachment (Implement) Pressure Sensor (at Pilot Valve) Brake Valve Orbitrol (Steering Pilot Valve) Steering Valve Fuel Cooler

24 90Z6T1-2-02

T5-4-2

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

9 90Z6T1-2-03

8 123-

Front Axle Brake Pressure Sensor Steering Cylinder

456-

Hydraulic Pump Transmission Axle Support (Rear)

789-

T5-4-3

Rear Axle Axle Support (Front) Third (Rear) Propeller Shaft

6 10- Steering Accumulator 11- Second (Front) Propeller Shaft

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

5 4

2 3 90Z6T1-2-23

1 7 8 7 3

9 10

90Z6T1-2-04

12345-

Bucket Leveler Proximity Switch Lift Arm Kickout Proximity Switch Lift Arm Angle Sensor (Option) Hydraulic Oil Temperature Sensor (at Hydraulic Tank Bottom) Air Cleaner Restriction Switch

678910-

Backup Alarm Battery Fuel Level Sensor (at Fuel Tank) Secondary Steering Pump (Option) Outside Temperature Sensor

T5-4-4

11- Components Related with Cab (Refer to T5-4-5)

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

11 3

6 4

9 5 7

90Z6T1-2-05

12345-

Radio Upper Switch Panel (Option) Speaker Rear Wiper Motor Brake Lamp Switch

678-

Front Wiper Motor Outside Temperature Sensor (for A/C) Components in Right Side Console (Refer to T5-4-7)

T5-4-5

90Z7-01-02-01

Components Related with Controllers and Relays (Refer to T5-4-6) 10- Components Related with Monitor and Switches (Refer to T5-4-8) 11- Air Conditioner Control Unit

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Controller and Relays

5 12 11 10 9

17 16 15 14 13 2

22 21 20 19 18

27 26 25 24 23 32 31 30 29 28 7

Arrow View A

1234567891011121314-

Flasher Relay GSM (Option) ICF (Monitor Controller) MCZ (Main Controller) MPDr. Connector Fuse Box A Fuse Box B ECM Relay 1 Head Light Relay High-Beam Relay Bucket Leveler Relay Lift Arm Height Kickout Relay Working Lamp Relay (Front) Working Lamp Relay (Rear)

90Z6T1-2-06

1516171819202122232425262728-

Turn Signal Light Relay (Right) Horn Relay Load Dump Relay 2 Parking Brake Relay 1 Parking Brake Relay 2 Engine Alternate Droop Relay Brake Lamp Relay Load Dump Relay 1 Neutral Relay Turn Signal Light Relay (Left) Front Washer Relay Rear Wiper Relay Rear Washer Relay ECM Relay 2

fNOTE: Refer to “Fuses and Relays” and “Floor Cable Layout” in the Diagrams for the other parts.

T5-4-6

293031323334-

Backup Lamp Relay CAB Working Light Relay (Front) (Option) CAB Working Light Relay (Rear) (Option) Secondary Steering Relay (Option) Pilot Shut-Off Relay (Option) Voltage Relay

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Right Console 20

Fingertip Control Type 4 3 (2)

8 9 10 11 12

2 (1) 1 (3)

18 6

7 17

15 14

90Z6T1-2-07a

MNEC-01-042

fNOTE: The control lever positions can be changed. Multi-Function Joystick Type (Option) 22

1 6 7

19 13

12345678910-

Auxiliary Control Lever (Option) Bucket Control Lever Lift Arm Control Lever Forward/Reverse Switch (Option) Auxiliary Auxiliary Power Mode Switch Forward/Reverse Selector Switch (Option) Fan Reverse Rotation Switch (Option)

15 14

MNEC-01-044

90Z6T1-2-07b

11- Auxiliary 12- Hydraulic Quick Coupler Switch (Option) 13- Secondary Steering Operation Check Switch (Option) 14- Lift Arm Auto Leveler Kickout Switch (Height) (Option) 15- Lift Arm Auto Leveler Kickout Switch (Lower) (Option) 16- Auxiliary 17- Ride Control Switch (Option)

T5-4-7

1819202122232425-

Hold Switch Control Lever Lock Handle (Safety Device) DSS (Down Shift Switch) Horn Switch Quick Power Switch Multi-Function Joystick Lever Hold Switch (Under the Lever) Horn Switch (Under the Lever)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Monitor and Switches

9 10

3 2 11 1

90Z6T1-2-08

1234-

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

5678-

Forward/Reverse Lever, Shift Switch Monitor Panel (Refer to T5-4-9) Travel Mode Selector Switch Key Switch

T5-4-8

9- Declutch Position Sensor 10- Shift Change Delay Mode Switch (Option) 11- Turn Signal Lever, Light Switch, High-Low Beam Switch

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Monitor Panel

39 38

37 12 36 35

14 15

33 32

Left Turn Signal Light Indicator 2- High Beam Indicator 3- Working Light Indicator 4- Right Turn Signal Light Indicator 5- (Not used) 6- (Not used) 7- Service Indicator 8- Maintenance Indicator 9- Parking Brake Indicator 10- Clearance Light Indicator 11- Front Control Lever Lock Indicator

16 31 30

29 28 27 26

25 24 23 22 21 20 19 18 17

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

22- (Not used) 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

T5-4-9

MNDB-01-034

32- Engine Oil Low Pressure Indicator 33- Air Filter Restriction Indicator 34- (Not used) 35- (Not used) 36- (Not used) 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 (Relays)

90Z6T1-2-19

3 90Z6-05-01-01

12-

Battery Relay Fusible Link (100 A) (3 used)

34-

Fusible Link (70 A) Intake Air Heater Relay

T5-4-10

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Engine/Fan Pump 6 7 5

3 16

2 8

9 10

12 14

123456-

Engine Oil Filter Filter Outlet Pressure Coolant Inlet Pressure Coolant Temperature Sensor Alternator Intake Manifold Pressure Sensor

7891011-

After Charge Air Cooler (Intake Manifold) ECM ECM Cooling Plate Engine Position Sensor Engine Oil Pressure and Temperature Sensor

T5-4-11

90Z6T1-2-09

1213141516-

Fuel Filter Fan Pump Fuel Pump Starter DCA4 Coolant Filter

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Transmission and Torque Converter Assembly 2

9 10 11 12 13 14

15 4

90Z6T1-2-10

123456789-

Torque Converter Torque Converter Charging Pump Machine Speed Sensor Transmission Output Speed Sensor Transmission Middle Shaft Sensor Parking Brake Transmission Control Valve Regulator Valve Proportional Solenoid Valve (For Forward Clutch)

10- Proportional Solenoid Valve (For Reverse Clutch) 11- Proportional Solenoid Valve (For 1st Speed Clutch) 12- Proportional Solenoid Valve (For 2nd Speed Clutch) 13- Proportional Solenoid Valve (For 3rd Speed Clutch) 14- Proportional Solenoid Valve (For 4th Speed Clutch)

fNOTE: The parking brake pressure sensor is installed to the charging block. (See p.5-4-15.)

T5-4-12

15- Parking Brake Pressure Port 16- Flange (for 2nd Propeller Shaft) 17- Torque Converter Oil Temperature Sensor 18- Hydraulic Pump Device (Refer to T5-4-13)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Hydraulic Pump Device 1

2 3

12-

Main Pump Regulator

34-

Priority Valve Pump Delivery Pressure Sensor

T5-4-13

T4GB-01-02-009

56-

Pilot Pump Steering Relief Valve

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Multiple Control Valve 9 7

7 6

4 5

90Z6T1-2-11

12-

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

3456-

Overload Relief Valve (Bucket: Rod Side) Make-up Valve (Lift Arm: Rod Side) Main Relief Valve Check Valve (with 1.0 Orifice)

T5-4-14

789-

Check Valve (with 1.2 Orifice) Lift Arm Spool Bucket Spool

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Charging Block 3

4 5 6

1 7 10 8 9

90Z6T1-2-13

1234-

Charging Block Pilot Accumulator Pressure Sensor (Parking) Parking Brake Solenoid Valve

5678-

Pump Torque Control Solenoid Valve Relief Valve (for Cut-in/Cut-out Pressure) Pilot Relief Valve Service Brake Accumulator (Rear)

9- Service Brake Accumulator (Front) 10- Pressure Sensor (Service Brake Primary Pressure)

Front Axle

1 90Z7-05-04-01 1-

Axle Oil Temperature Sensor

T5-4-15

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Steering Valve

Fan Motor

1 2 90Z6T1-2-15 12-

Overload Relief Valve Overload Relief Valve

90Z6T1-2-14 1-

Brake Valve

Fan Speed Control Solenoid Valve (Relief Valve)

Pilot Valve

1 2 90Z6T1-2-17 1-

Pressure Switch (For Stop Lamp)

Pressure Sensor (Service Brake Secondary Pressure for Declutch)

90Z6T1-2-22 12-

T5-4-16

Pilot Valve Pressure Sensor (Pilot Primary Pressure)

SECTION 5 TROUBLESHOOTING Group 4 Component Layout Ride Control Group (Option) 1 4 3

90Z6T1-2-21 12-

Ride Control Valve (Option) Overload Relief Valve

34-

Ride Control Solenoid Valve Ride Control Accumulator (Option)

6 90Z6T1-2-20 56-

Pressure Sensor (Lift Arm Raise) (Option) Multiple Control Valve

T5-4-17

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

Hydraulic Tank

3 2

1 90Z6T1-2-18

Main Pump

Secondary Steering Pump (Option)

Pressure Switch (Secondary Steering) (Option)

Secondary Steering Pump (Option) 1 2

90Z6T1-2-16

123-

Electric Motor Relief Valve Gear Pump

45-

Pressure Sensor (Secondary Steering Pump) Check Valve

T5-4-18

Secondary Steering Block (Check Valve Assy) (Option)

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

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

1 2

T6L4-05-03-001

Harness End Connector

Harness

T5-5-1

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Contents of Diagnosis

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

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

A: B: C, D, E,

Evaluation

Cause

(D) (G)

(E) (H)

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

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

T5-5-2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code Reference Table Fault Code 111000-2 111001-2 111002-2 111003-3 111006-2 111007-2 111014-2 111025-2 111103-3 111103-4 111105-3 111200-3 111200-4 111204-3 111204-4 111205-3 111205-4 111206-3 111206-4 111207-3 111207-4 111208-3 111208-4 111217-3 111217-4 111311-3 111311-4 111312-3 111312-4 111313-3 111313-4

MPDr. Message Abnormal EEPROM Abnormal RAM Abnormal A/D Converter Abnormal Sensor Voltage (MC) Engine Controller Communication Error (MC) Information Controller Communication Error 1 (MC) Air Conditioner Controller Communication Error (MC) Column Monitor Controller Communication Error Accelerator Pedal Circuit High Input Accelerator Pedal Circuit Low Input Abnormal Engine Speed Sensor Lift Arm Raise Pilot Pressure Sensor Circuit High Input * Lift Arm Raise Pilot Pressure Sensor Circuit Low Input * Pump Delivery Pressure Sensor Circuit High Input Pump Delivery Pressure Sensor Circuit Low Input Lift Arm Angle Sensor Circuit High Input * Lift Arm Angle Sensor Circuit Low Input * Hyd. Fan Circuit Pressure Sensor Circuit High Input * Hyd. Fan Circuit Pressure Sensor Circuit Low Input * Refrigerant Pressure Sensor Circuit High Input Refrigerant Pressure Sensor Circuit Low Input Emergency Steering Check Pressure Sensor Circuit High Input * Emergency Steering Check Pressure Sensor Circuit High Input * Pilot Pressure Sensor Circuit High Input Pilot Pressure Sensor Circuit Low Input Service Brake Primary Pressure Sensor Circuit High Input Service Brake Primary Pressure Sensor Circuit Low Input Service Brake Secondary Pressure Sensor Circuit High Input Service Brake Secondary Pressure Sensor Circuit Low Input Parking Brake Pressure Sensor Circuit High Input Parking Brake Pressure Sensor Circuit Low Input

fNOTE: Error with an asterisk mark (*) is for optional function.

T5-5-3

Category MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC

Reference 1 T5-5-9 T5-5-9 T5-5-9 T5-5-9 T5-5-10 T5-5-10 T5-5-10 T5-5-10 T5-5-11 T5-5-11 T5-5-11 T5-5-13 T5-5-13 T5-5-12 T5-5-12 T5-5-23 T5-5-23 T5-5-12 T5-5-12 T5-5-23 T5-5-23 T5-5-12

Reference 2 T5-5-41 T5-5-41 T5-5-41 T5-5-42 T5-5-44 T5-5-44 T5-5-44 T5-5-44 T5-5-49 T5-5-49 T5-5-49 T5-5-50 T5-5-50 T5-5-53 T5-5-53 T5-5-51 T5-5-51 T5-5-54 T5-5-54 T5-5-51 T5-5-51 T5-5-55

T5-5-12

T5-5-55

MC MC MC MC MC

T5-5-13 T5-5-13 T5-5-13 T5-5-13 T5-5-14

T5-5-52 T5-5-52 T5-5-56 T5-5-56 T5-5-52

T5-5-14

T5-5-52

MC MC

T5-5-14 T5-5-14

T5-5-56 T5-5-56

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code Reference Table (Continued) Fault Code 111411-2 111411-3 111411-4 111412-2 111412-3 111412-4 111413-2 111413-3 111413-4 111414-2 111414-3 111414-4 111415-2 111415-3 111415-4 111416-2 111416-3 111416-4 111417-2 111417-3 111417-4 111418-2 111418-3 111418-4 111419-2 111419-3 111419-4

MPDr. Message Category Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB * MC Hydraulic Fan Reverse Rotation P/S Valve FB High MC Current * Hydraulic Fan Reverse Rotation P/S Valve FB Low MC Current * Hyd. Fan P/S Valve Abnormal Feedback MC Hyd. Fan P/S Valve Feedback High Current MC Hyd. Fan P/S Valve Feedback Low Current MC Pump Swash Angle P/S Valve Abnormal FB MC Pump Swash Angle P/S Valve FB High Current MC Pump Swash Angle P/S Valve FB Low Current MC T/M Clutch 1st P/S Valve Abnormal FB MC T/M Clutch 1st P/S Valve FB High Current MC T/M Clutch 1st P/S Valve FB Low Current MC T/M Clutch 2nd P/S Valve Abnormal FB MC T/M Clutch 2nd P/S Valve FB High Current MC T/M Clutch 2nd P/S Valve FB Low Current MC T/M Clutch 3rd P/S Valve Abnormal FB MC T/M Clutch 3rd P/S Valve FB High Current MC T/M Clutch 3rd P/S Valve FB Low Current MC T/M Clutch 4th P/S Valve Abnormal FB MC T/M Clutch 4th P/S Valve FB High Current MC T/M Clutch 4th P/S Valve FB Low Current MC T/M Clutch Forward P/S Valve Abnormal FB MC T/M Clutch Forward P/S Valve FB High Current MC T/M Clutch Forward P/S Valve FB Low Current MC T/M Clutch Reverse P/S Valve Abnormal FB MC MC T/M Clutch Reverse P/S Valve FB High Current T/M Clutch Reverse P/S Valve FB Low Current MC

fNOTE: Error with an asterisk mark (*) is for optional function.

T5-5-4

Reference 1 T5-5-15 T5-5-15

Reference 2 T5-5-57 T5-5-57

T5-5-15

T5-5-57

T5-5-16 T5-5-16 T5-5-16 T5-5-16 T5-5-16 T5-5-16 T5-5-18 T5-5-18 T5-5-18 T5-5-18 T5-5-18 T5-5-18 T5-5-18 T5-5-18 T5-5-18 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19 T5-5-19

T5-5-58 T5-5-58 T5-5-58 T5-5-59 T5-5-59 T5-5-59 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60 T5-5-60

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code Reference Table (Continued) Fault Code 111422-2 111422-3 111422-4 111600-3 111600-4 111601-3 111602-3 111700-xx 111700-31 111701-xx 111701-31 111702-xx 111702-31 111703-xx 111703-31 111704-xx 111704-31 111705-xx 111705-31 111720-2 111900-3 111900-4 111901-3 111901-4 111902-3 111902-4 111904-2 111905-2

MPDr. Message Ride Control P/S Valve Abnormal FB * Ride Control P/S Valve FB High Current * Ride Control P/S Valve FB Low Current * T/M Out Speed Sensor Failure T/M Out Speed Sensor Circuit Low Input Torque Converter Output Speed Sensor Failure Intermediate Shaft Speed Sensor Failure Calibration Abort Forward Calibration Abort Forward: Un-Calibration Calibration Abort Reverse Calibration Abort Reverse: Un-Calibration Calibration Abort 1st Calibration Abort 1st: Un-Calibration Calibration Abort 2nd Calibration Abort 2nd: Un-Calibration Calibration Abort 3rd Calibration Abort 3rd: Un-Calibration Calibration Abort 4th Calibration Abort 4th: Un-Calibration Lift arm angle sensor is uncalibrated. Torque Converter Oil Temperature Sensor Circuit High Input Torque Converter Oil Temperature Sensor Circuit Low Input Hyd. Oil Temp Sensor Circuit High Input Hyd. Oil Temp Sensor Circuit Low Input Axle Oil Temperature Sensor Circuit High Input Axle Oil Temperature Sensor Circuit Low Input Column FNR SW Failure Implement FNR SW Failure

fNOTE: Error with an asterisk mark (*) is for optional function.

T5-5-5

Category MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC MC

Reference 1 T5-5-17 T5-5-17 T5-5-17 T5-5-20 T5-5-20 T5-5-20 T5-5-20 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-21 T5-5-22

Reference 2 T5-5-61 T5-5-61 T5-5-61 T5-5-62 T5-5-62 T5-5-62 T5-5-62 T5-5-66, 67 T5-5-67 T5-5-66, 67 T5-5-67 T5-5-66, 67 T5-5-67 T5-5-66, 67 T5-5-67 T5-5-66, 67 T5-5-67 T5-5-66, 67 T5-5-67 T5-5-63

T5-5-22

T5-5-63

MC MC MC MC MC MC

T5-5-22 T5-5-22 T5-5-22 T5-5-22 T5-5-21 T5-5-21

T5-5-64 T5-5-64 T5-5-65 T5-5-65 -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code Reference Table (Continued) Fault Code 113002-2

114100-2

MPDr. Message (Monitor Controller) Engine Controller Communication Error (Monitor Controller) Main Controller Communication Error 1 (Monitor Controller) ICF Communication Error 1 (Monitor Controller) Column Controller Communication Error Abnormal thermistor temperature (monitor inside temperature) Flash Memory Read/Write Error External RAM Read/Write Error Abnormal EEPROM Abnormal Internal RAM (Information Controller) Engine Controller Communication Error (Information Controller) Main Controller Communication Error 1 (Information Controller) Column Controller Communication Error 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

113003-2 113005-2 113007-2 113303-2 114001-2 114002-2 114003-2 114008-2 114010-2 114011-2 114015-2

T5-5-6

Category Monitor

Reference 1 T5-5-26

Reference 2 T5-5-45

Monitor

T5-5-26

T5-5-45

Monitor Monitor

T5-5-26 T5-5-26

T5-5-45 T5-5-45

Monitor

T5-5-27

Information Information Information Information Information

T5-5-28 T5-5-28 T5-5-28 T5-5-28 T5-5-29

T5-5-45

Information

T5-5-29

T5-5-45

Information

T5-5-29

T5-5-45

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

T5-5-32

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MPDr. Fault Code Reference Table (Continued) Fault Code 115001-2 115002-2 115003-2 115011-3 115011-4 120000-2 120001-2 120002-2 120003-2 120004-2 120005-2 120013-2 120014-2 120300-2 120500-2 120501-2 120502-2 120503-2 120505-2 120506-2 120507-2

MPDr. Message Abnormal REG input H level CAN Communication Error Abnormal EEPROM Fuel Level Sensor Circuit High Input Fuel Level Sensor Circuit Low Input Hydraulic Oil Overheat Alarm Main Pump Pressure Alarm Axle Oil Temperature Alarm Emergency Steering Activated (Option) Emergency Steering Activated Pressure Alarm (Option) Transmission Oil Temperature Overheat Alarm Brake Oil Pressure Alarm Overrun Alarm System Failure Alarm Overheat Alarm Engine Error Engine Oil Pressure Alarm Air Cleaner Restriction Alarm Brake Pressure Alarm Steering Oil Pressure Alarm (Option) T/M Malfunction

Category Column Display Column Display Column Display Column Display Column Display MC MC MC MC MC

Reference 1 T5-5-30 T5-5-30 T5-5-30 T5-5-30 T5-5-30 T5-5-24 T5-5-24 T5-5-24 T5-5-24 T5-5-24

Reference 2 T5-5-69 T5-5-70 T5-5-70 T5-5-68 T5-5-68 T5-5-68 T5-5-68 T5-5-68

MC MC MC Information Column Display Column Display Column Display Column Display Column Display Column Display Column Display

T5-5-24 T5-5-25 T5-5-25 T5-5-29 T5-5-31 T5-5-31 T5-5-31 T5-5-31 T5-5-31 T5-5-31 T5-5-31

T5-5-68 T5-5-68 T5-5-72 T5-5-72 T5-5-72 T5-5-72 T5-5-73 T5-5-73 T5-5-73 T5-5-73

fNOTE:  Refer to page T5-5-33 for the air conditioner controller fault code list.  Refer to page T5-5-34 for the ECM fault code list.

T5-5-7

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-8

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code List Controller Hardware Failure Fault Code Trouble or MP Dr. Message 111000-2 Abnormal EEPROM 111001-2 Abnormal RAM 111002-2 Abnormal A/D Converter 111003-3 Abnormal Sensor Voltage

Cause

Remedy

Faulty MC Faulty MC Faulty MC

Symptoms in Machine Operation When Trouble Occurs -

Faulty MC Faulty sensor Faulty harness

Although the accelerator pedal is operated, the engine speed does not change.

Check the sensor connected to MC. Check the harness. Replace MC.

T5-5-9

Replace MC. Replace MC. Replace MC.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN Data Reception Failure Fault Code Trouble or MP Dr. Message 111006-2 (MC) Engine Controller Communication Error 111007-2 (MC) Information Controller Communication Error 1 111014-2 (MC) Air Conditioner Controller Communication Error 111025-2

(MC) Column Monitor Communication Error

Cause

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

Faulty harness

Check the harness.

Check the CAN1 harness. Replace monitor controller. Faulty air conditioner The air conditioner does not work. Check the CAN1 controller harness. Faulty CAN1 harness Replace the air conditioner controller. Faulty column display The transmission warning indicator Check the CAN1 controller and control lever lock indicator on harness. Replace column Faulty CAN1 harness column display controller do not display controller. light. Overrun alarm control is disabled.

Faulty monitor controller Faulty CAN1 harness

Nothing observed.

Remedy

T5-5-10

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Engine Failure Fault Code Trouble or MP Dr. Message 111103-3 Accelerator Pedal Circuit High Input

Cause Voltage: more than 4.74 V

Symptoms in Machine Operation When Trouble Occurs The engine speed is fixed to 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.

111105-3

Abnormal Engine Speed Sensor

Torque converter input speed sensor = 0 min-1 and Engine speed sent from ECM (CAN) > 500 min-1

The actual engine speed may not be obtained or displayed correctly.

T5-5-11

Remedy Check the harness. Replace the accelerator pedal sensor. Check the harness. Replace the accelerator pedal sensor. Check the harness. Check and adjust the engine speed sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pump Failure Fault Code Trouble or MP Dr. Message 111204-3 Pump Delivery Pressure Sensor Circuit High Input 111204-4 Pump Delivery Pressure Sensor Circuit Low Input 111206-3 Hyd. Fan Circuit Pressure Sensor Circuit High Input 111206-4 Hyd. Fan Circuit Pressure Sensor Circuit Low Input 111208-3 Emergency Steering Check Pressure Sensor Circuit High Input

111208-4

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

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

Symptoms in Machine Operation When Trouble Occurs Engine speed regulator for digging is deactivated.

Remedy

Check the harness. Replace the pump delivery pressure sensor. Engine speed regulator for Check the harness. digging is deactivated. Replace the pump delivery pressure sensor. Fan rotation direction (in normal / Check the harness. reverse) cannot change manually Replace the fan pump or automatically. delivery pressure sensor. Fan rotation direction (in normal / Check the harness. reverse) cannot change manually Replace the fan pump or automatically. delivery pressure sensor. The initial automatic check for Check the harness. Replace the secondary secondary steering operation cannot be performed. (When the steering pump delivery pressure sensor. engine starts) Secondary steering indicator on monitor blinks. The initial automatic check for Check the harness. Replace the secondary secondary steering operation cannot be performed. (When the steering pump delivery pressure sensor. engine starts) Secondary steering indicator on monitor blinks.

T5-5-12

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pilot Failure Fault Code

111200-4

Lift Arm Raise Pilot Pressure Sensor Circuit Low Input

111217-3

Pilot Pressure Sensor Voltage: 4.75 V or Circuit High Input more

Symptoms in Machine Operation When Trouble Occurs Bucket speed is slow during combined operation of lift arm and bucket. Ride control is not activated. Speed shift delay control is always delayed at AUTO 2 mode. Bucket speed is slow during combined operation of lift arm and bucket. Ride control is not activated. Speed shift delay control is always delayed at AUTO 2 mode. Front control lever lock indicator on monitor is always OFF.

111217-4

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

Front control lever lock indicator on monitor is always OFF.

111311-3

Service Brake Primary Pressure Sensor Circuit High Input

Voltage: 4.75 V or more

111311-4

Service Brake Primary Pressure Sensor Circuit Low Input

Voltage: less than 0.25 V

111200-3

Trouble or MP Dr. Message Lift Arm Raise Pilot Pressure Sensor Circuit High Input

Cause Voltage: 4.75 V or more

Voltage: less than 0.25 V

The low brake oil pressure indicator is always ON. Although the service brake is applied, the brake oil pressure gauge points at the minimum value, zero. The low brake oil pressure indicator is always ON. Although the service brake is applied, the brake oil pressure gauge points at the minimum value, zero.

T5-5-13

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

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

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

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

Trouble or MP Dr. Message Service Brake Secondary Pressure Sensor Circuit High Input

Cause Voltage: 4.75 V or more

111312-4

Service Brake Secondary Pressure Sensor Circuit Low Input

Voltage: less than 0.25 V

111313-3

Parking Brake Pressure Sensor Circuit High Input

Voltage: 4.75 V or more

111313-4

Parking Brake Pressure Sensor Circuit Low Input

Voltage: less than 0.25 V

Symptoms in Machine Operation Remedy When Trouble Occurs The declutch control becomes Check the harness. ineffective. The declutch is impossible. Replace the pressure The speed shift does not automatically sensor (brake downshift to first speed with the travel secondary pressure). mode set in AUTO 1 mode. Check the harness. The declutch control becomes ineffective. The declutch is impossible. Replace the pressure The speed shift does not automatically sensor (brake downshift to first speed with the travel secondary pressure). mode set in AUTO 1 mode. Although the parking brake is applied, Check the harness. the parking brake indicator is not ON. Replace the pressure (The parking brake signal is forcibly sensor (parking fixed to the Release side.) brake). Although the parking brake is applied, Check the harness. the parking brake indicator is not ON. Replace the pressure sensor (parking (The parking brake signal is forcibly fixed to the Release side.) brake).

T5-5-14

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Message 111411-2 Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB (Option)

111411-3

111411-4

Cause

Symptoms in Machine Operation When Trouble Occurs Solenoid valve output: The fan reverse rotation control 140 mA or more, and becomes ineffective. Feedback current: more Fan rotation direction (in normal / than 920 mA or less than reverse) cannot change manually 70 mA nor automatically. (both detected) Current: more than 920 Fan rotation direction is fixed in mA reverse.

Hydraulic Fan Reverse Rotation P/S Valve FB High Current (Option) Hydraulic Fan Current: less than 70 mA Fan rotation direction (in normal / Reverse Rotation P/S reverse) cannot change manually Valve FB Low Current and automatically. (Option)

T5-5-15

Remedy Check the harness.

Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Cause Message 111412-2 Hyd. Fan P/S Valve Solenoid valve output: Abnormal Feedback 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) 111412-3 Hyd. Fan P/S Valve Current: more than 920 mA Feedback High Current 111412-4 Hyd. Fan P/S Valve Current: less than 70 mA Feedback Low Current 111413-2 Pump Swash Angle Solenoid valve output: P/S Valve Abnormal 140 mA or more, and FB Feedback current: more than 920 mA or less than 70 mA (both detected) 111413-3 Pump Swash Angle Current: more than 920 P/S Valve FB High mA Current 111413-4 Pump Swash Angle Current: less than 70 mA P/S Valve FB Low Current

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

Remedy

The fan speed is fixed to the minimum.

Check the harness.

The fan speed is fixed to the maximum.

Check the harness.

Engine speed regulator for digging is deactivated.

Check the harness.

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

T5-5-16

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Message 111422-2 Ride Control P/S Valve Abnormal FB (Option)

111422-3

111422-4

Cause

Symptoms in Machine Operation When Trouble Occurs Ride control selector solenoid valve (boom cylinder bottom side) control is disabled.

Solenoid valve output: 140 mA or more, and Feedback current: more than 920 mA or less than 70 mA (both detected) Ride Control P/S Current: more than 920 Ride control selector solenoid Valve FB High mA valve (boom cylinder bottom side) Current (Option) control is always activated. Ride Control P/S Current: less than 70 mA Ride control selector solenoid Valve FB Low Current valve (boom cylinder bottom side) (Option) control is always deactivated.

T5-5-17

Remedy Check the harness.

Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Message 111414-2 T/M Clutch 1st P/S Valve Abnormal FB

111414-3

111414-4

111415-2

111415-3

111415-4

111416-2

111416-3

111416-4

Cause

Symptoms in Machine Operation Remedy When Trouble Occurs Solenoid valve output: 1st speed clutch gear engagement Check the harness. 140 mA or more, and is not possible. Feedback current: more If 1st speed range is selected, 2nd than 920 mA or less than speed clutch gear is engaged. 70 mA (both detected) T/M Clutch 1st Current: more than 920 1st speed clutch gear engagement Check the harness. P/S Valve FB High mA is not possible. Current If 1st speed range is selected, 2nd speed clutch gear is engaged. T/M Clutch 1st P/S Current: less than 70 mA 1st speed clutch gear engagement Check the harness. Valve FB Low Current is not possible. If 1st speed range is selected, 2nd speed clutch gear is engaged. T/M Clutch 2nd P/S Solenoid valve output: 2nd speed clutch gear engagement Check the harness. is not possible. Valve Abnormal FB 140 mA or more, and Feedback current: more If 2nd speed range is selected, 1st than 920 mA or less than speed clutch gear is engaged. 70 mA (both detected) T/M Clutch 2nd Current: more than 920 2nd speed clutch gear engagement Check the harness. P/S Valve FB High mA is not possible. Current If 2nd speed range is selected, 1st speed clutch gear is engaged T/M Clutch 2nd P/S Current: less than 70 mA 2nd speed clutch gear engagement Check the harness. Valve FB Low Current is not possible. If 2nd speed range is selected, 1st speed clutch gear is engaged T/M Clutch 3rd P/S Solenoid valve output: 3rd speed clutch gear engagement Check the harness. Valve Abnormal FB 140 mA or more, and is not possible. Feedback current: more If 3rd speed range is selected, 2nd than 920 mA or less than speed clutch gear is engaged. 70 mA (both detected) T/M Clutch 3rd Current: more than 920 3rd speed clutch gear engagement Check the harness. P/S Valve FB High mA is not possible. Current If 3rd speed range is selected, 2nd speed clutch gear is engaged. T/M Clutch 3rd P/S Current: less than 70 mA 3rd speed clutch gear engagement Check the harness. Valve FB Low Current is not possible. If 3rd speed range is selected, 2nd speed clutch gear is engaged..

fNOTE: If the 1st or 2nd speed clutch becomes defective

after the downshifting, no speed clutch is engaged (becomes neutral condition).

T5-5-18

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble or MP Dr. Message 111417-2 T/M Clutch 4th P/S Valve Abnormal FB

Symptoms in Machine Operation When Trouble Occurs Solenoid valve output: 4th speed clutch gear engagement 140 mA or more, and is not possible. Feedback current: more If 4th speed range is selected, 2nd than 920 mA or less than speed clutch gear is engaged. 70 mA (both detected) T/M Clutch 4th Current: more than 920 4th speed clutch gear engagement P/S Valve FB High mA is not possible. Current If 4th speed range is selected, 2nd speed clutch gear is engaged. T/M Clutch 4th P/S Current: less than 70 mA 4th speed clutch gear engagement Valve FB Low Current is not possible. If 4th speed range is selected, 2nd speed clutch gear is engaged. T/M Clutch Forward Solenoid valve output: Forward clutch gear engagement is not possible. P/S Valve Abnormal 140 mA or more, and FB Feedback current: more If forward is selected, T/M is in the than 920 mA or less than neutral status. 70 mA (both detected) T/M Clutch Forward Current: more than 920 Forward clutch gear engagement is P/S Valve FB High mA not possible. Current If forward is selected, T/M is in the neutral status.

Remedy

111418-4

T/M Clutch Forward P/S Valve FB Low Current

Check the harness.

111419-2

T/M Clutch Reverse P/S Valve Abnormal FB

111419-3

T/M Clutch Reverse P/S Valve FB High Current

111419-4

T/M Clutch Reverse P/S Valve FB Low Current

111417-3

111417-4

111418-2

111418-3

Cause

Current: less than 70 mA Forward clutch gear engagement is not possible. If forward is selected, T/M is in the neutral status. Solenoid valve output: Reverse clutch gear engagement is 140 mA or more, and not possible. Feedback current: more If reverse is selected, T/M is in the than 920 mA or less than neutral status. 70 mA (both detected) Current: more than 920 Reverse clutch gear engagement is mA not possible. If reverse is selected, T/M is in the neutral status. Current: less than 70 mA Reverse clutch gear engagement is not possible. If reverse is selected, T/M is in the neutral status.

fNOTE: If the 1st or 2nd speed clutch becomes defective

after the downshifting, no speed clutch is engaged (becomes neutral condition).

T5-5-19

Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Revolution Sensor Failure Fault Code Trouble or MP Dr. Message 111600-3 T/M Output Speed Sensor Failure

111600-4

111601-3

111602-3

T/M Out Speed Sensor Circuit Low Input

Cause

Symptoms in Machine Operation When Trouble Occurs When forward or reverse Abnormal shift down feeling. Selected speed range is not clutch is engaged, and T/M output revolution = correctly indicated at shift change. 0 min-1, T/M intermediate shaft revolution > 300 min-1, or T/C output revolution > 500 min-1. Harness disconnection detected at starter key turns ON and voltage is 1.8 V or more. Harness disconnection Abnormal shift down feeling. detected at starter key Selected speed range is not turns ON and voltage is correctly indicated at shift change. 1.1 V or less.

Remedy Check the harness. Replace the T/M output revolution sensor (machine speed sensor).

Check the harness. Replace the T/M output revolution sensor (machine speed sensor). Check the harness. When forward or reverse Controls monitoring T/C speed Torque Converter ratio are deactivated as it cannot be Replace the T/C clutch is engaged, and Output Speed output revolution Sensor Failure T/M output revolution = calculated. sensor. 0 min-1, T/M intermediate shaft revolution > 300 min-1, or T/M output revolution > 300 min-1. Check the harness. Intermediate Shaft When forward or reverse Service indicator turns on. If Transmission Output Revolution Replace the T/M Speed Sensor Failure clutch is engaged, and intermediate shaft T/M output revolution = Sensor Error (111600-3) occurs at the same time, machine speed is revolution sensor 0 min-1, T/M intermediate shaft not displayed. (machine speed revolution > 500 min-1, or backup sensor) T/C output revolution > 500 min-1.

T5-5-20

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Learning Failure Fault Code Trouble or MP Dr. Message 111700-xx Calibration Abort Forward 111700-31 Calibration Abort Forward: UnCalibration 111701-xx Calibration Abort Reverse 111701-31 Calibration Abort Reverse: UnCalibration 111702-xx Calibration Abort 1st 111702-31 111703-xx 111703-31 111704-xx 111704-31 111705-xx 111705-31 111720-2

Symptoms in Machine Operation When Trouble Occurs Transmission learning Direction changing to forward may failed. not be smooth. Transmission learning Direction changing to forward may was not done. not be smooth.

Remedy

Transmission learning failed. Transmission learning was not done.

Perform T/M learning. See pp.T5-5-76, 77. Perform T/M learning. See p.T5-5-77.

Transmission learning failed. Calibration Abort Transmission learning 1st: Un-Calibration was not done. Calibration Abort Transmission learning 2nd failed. Calibration Abort Transmission learning 2nd: Un-Calibration was not done. Calibration Abort 3rd Transmission learning failed. Calibration Abort Transmission learning 3rd: Un-Calibration was not done. Calibration Abort 4th Transmission learning failed. Calibration Abort Transmission learning 4th: Un-Calibration was not done. Lift arm angle The lift arm angle sensor (option) is sensor calibration is uncalibrated. not performed. Or, it fails.

Switch Failure Fault Code Trouble or MP Dr. Message 111904-2 Column FNR SW Failure 111905-2

Cause

Implement FNR SW Failure

Cause Shift lever F & R contact ON at the same time. Shift switch F & R contact ON at the same time.

Direction changing to reverse may not be smooth. Direction changing to reverse may not be smooth.

Perform T/M learning. See pp.T5-5-76, 77. Perform T/M learning. See p.T5-5-77.

Speed shifting to the 1st range may Perform T/M learning. not be smooth. See pp.T5-5-76, 77. Speed shifting to the 1st range may Perform T/M learning. not be smooth. See p.T5-5-77. Speed shifting to the 2nd range Perform T/M learning. may not be smooth. See pp.T5-5-76, 77. Speed shifting to the 2nd range Perform T/M learning. may not be smooth. See p.T5-5-77. Speed shifting to the 3rd range may Perform T/M learning. not be smooth. See pp.T5-5-76, 77. Speed shifting to the 3rd range may Perform T/M learning. not be smooth. See p.T5-5-77. Speed shifting to the 4th range may Perform T/M learning. not be smooth. See pp.T5-5-76, 77. Speed shifting to the 4th range may Perform T/M learning. not be smooth. See p.T5-5-77. Dual lift arm auto leveler cannot be Perform lift arm angle set. sensor calibration.

Symptoms in Machine Operation When Trouble Occurs Transmission is in the neutral condition.

Remedy

Transmission is in the neutral condition.

Check the harness. Replace the switch.

T5-5-21

Check the harness. Replace the switch.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Temperature Sensor Failure Fault Code Trouble or MP Dr. Cause Message 111900-3 Torque Converter Oil Voltage: more than Temperature Sensor 4.75 V Circuit High Input

111900-4

111901-3

111901-4

111902-3

111902-4

Symptoms in Machine Operation When Trouble Occurs The fan speed is always fixed to the maximum. Fan reverse rotation control is disabled. Lift arm speed multiplication control is disabled. Torque Converter Oil Voltage: less than The fan speed is always fixed to the maximum. Temperature Sensor 0.25 V Fan reverse rotation control is disabled. Circuit Low Input Lift arm speed multiplication control is disabled. Hyd. Oil Temp Sensor Voltage: more than When hydraulic oil temperature is less Circuit High Input 4.35 V than 0 °C (32 °F), the auto-warm up control is not effective. The fan speed is always fixed to the maximum. The fan reverse rotation control is not activated. Hyd. Oil Temp Sensor Voltage: less than When hydraulic oil temperature is less Circuit Low Input 0.1 V than 0 °C (32 °F), the auto-warm up control is not effective. The fan speed is always fixed to the maximum. The fan reverse rotation control is not activated. Axle Oil Temperature Voltage: more than Nothing observed. Sensor Circuit High 4.75 V Input Axle Oil Temperature Voltage: less than Nothing observed. Sensor Circuit Low 0.1 V Input

T5-5-22

Remedy Check the harness.

Check the harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Other Sensor Failures Fault Code Trouble or MP Dr. Message 111205-3 Lift Arm Angle Sensor Circuit High Input 111205-4

Lift Arm Angle Sensor Circuit Low Input

111207-3

Refrigerant Pressure Circuit High Input

111207-4

Refrigerant Pressure Sensor Circuit Low Input

Cause

Symptoms in Machine Operation When Trouble Occurs Voltage: 4.75 V or Dual lift arm auto leveler operation more (option) is not effective. Speed shift delay control is always delayed at 2nd speed. Voltage: less than Dual lift arm auto leveler operation 0.25 V (option) is not effective. Speed shift delay control is always delayed at 2nd speed. Voltage: more than The fan speed is always fixed to the 4.74 V maximum.

Voltage: less than 0.25 V

The fan speed is always fixed to the maximum.

T5-5-23

Remedy Check the harness. Replace the lift arm angle sensor. Check the harness. Replace the lift arm angle sensor. Check the harness. Replace the refrigerant pressure sensor. Check the harness. Replace the refrigerant pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Alarms on Monitor Fault Code Trouble or MP Dr. Message 120000-2 Hydraulic Oil Overheat Alarm

Cause Hydraulic oil temperature is high.

Symptoms in Machine Operation When Trouble Occurs The alarm is displayed on the monitor.

120001-2

Main Pump Pressure Main pump oil Alarm pressure is high.

The alarm is displayed on the monitor.

120002-2

Axle Oil Temperature Axle oil temperature Alarm is high.

The alarm is displayed on the monitor.

120003-2

Emergency Steering Steering oil pressure is Secondary steering is activated. Activated Alarm low while machine is The alarm is displayed on the moving. monitor.

120004-2

Emergency Steering When the engine The alarm is displayed on the Activated Pressure starts, secondary monitor. Alarm steering pump delivery pressure does not increase up to the specified value (48 MPa (6962 PSI)). Transmission Transmission oil The alarm is displayed on the Oil Temperature temperature is high. monitor. Overheat Alarm

120005-2

T5-5-24

Remedy Check the harness. Replace the hydraulic oil temperature sensor. Check the harness. Replace the main pump oil pressure sensor. Check the harness. Replace the axle oil temperature sensor. Check the harness. Check/replace the steering pressure switch. Check the harness. Replace the pressure sensor.

Check the harness. Replace the torque converter oil temperature sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Alarms on Monitor Fault Code Trouble or MP Dr. Message 120013-2 Brake Oil Pressure Alarm

120014-2

Overrun Alarm

Cause Brake oil pressure is low.

The machine speed is beyond the upper limit.

Symptoms in Machine Operation When Trouble Occurs The alarm is displayed on the monitor.

The buzzer sounds.

T5-5-25

Remedy Check the harness. Check/replace the brake oil pressure sensor. Check the harness. Replace the machine speed sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Monitor) Fault Code List Fault Code 113002-2 113003-2 113005-2 113007-2

Trouble or MP Dr. Message (Monitor Controller) Engine Controller Communication Error (Monitor Controller) Main Controller Communication Error 1 (Monitor Controller) ICF Communication Error 1 (Monitor Controller) Column Controller Communication Error

Cause Faulty monitor controller Faulty CAN1 harness Faulty monitor controller Faulty CAN1 harness Faulty monitor controller Faulty CAN1 harness Faulty monitor controller Faulty CAN1 harness

T5-5-26

Remedy Check the CAN1 harness. Replace the monitor controller. Check the CAN1 harness. Replace the monitor controller. Check the CAN1 harness. Replace the monitor controller. Check the CAN1 harness. Replace the monitor controller.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 113303-2

Trouble or MP Dr. Message Abnormal thermistor temperature (monitor inside temperature)

Cause Thermistor temperature: 85°C (185°F) or more

Symptoms in Machine Remedy Operation When Trouble Occurs The screen of the monitor Cool the monitor and so becomes dark. on until the temperature inside the monitor is less than 85°C (185°F). Replace the monitor.

T5-5-27

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

Trouble or MP Dr. Message Cause Flash Memory Read/Write The internal memory Error of monitor controller is abnormal.

114002-2

External RAM Read/Write Error

The internal memory of monitor controller is abnormal.

114003-2

Abnormal EEPROM

114008-2

Abnormal Internal RAM

The internal memory of monitor controller is abnormal. The internal memory of monitor controller is abnormal.

T5-5-28

Remedy After initializing the monitor controller (information) by using MPDr., retry the troubleshooting. If the fault code is displayed after retry, the monitor controller may be broken. Replace the monitor controller. When initializing the monitor controller (information), all stored data is deleted. After initializing the monitor controller (information) by using MPDr., retry the troubleshooting. If the fault code is displayed after retry, the monitor controller may be broken. Replace the monitor controller. When initializing the monitor controller (information), all stored data is deleted. Retry the troubleshooting by using MPDr. If the fault code is displayed after retry, the monitor controller may be broken. Replace the monitor controller. Retry the troubleshooting by using MPDr. If the fault code is displayed after retry, the monitor controller may be broken. Replace the monitor controller.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code 114010-2 114011-2 114015-2

120300-2

Trouble or MP Dr. Message (Information Controller) Engine Controller Communication Error (Information Controller) Main Controller Communication Error 1 (Information Controller) Column Controller Communication Error

Cause Faulty monitor controller Faulty CAN harness Faulty monitor controller Faulty CAN harness Faulty monitor controller Faulty CAN harness

System Failure Alarm

Faulty CAN communication bus line.

T5-5-29

Remedy Check the CAN harness. Replace the monitor controller. Check the CAN harness. Replace the monitor controller. Check the CAN harness. Check/replace the monitor controller. Check the CAN harness.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display Controller Fault Code List Fault Code 115001-2

Trouble or MP Dr. Message Abnormal REG input H level

115002-2

CAN Communication Error

115003-2

Abnormal EEPROM

115011-3

Fuel Level Sensor Circuit High Input

115011-4

Fuel Level Sensor Circuit Low Input

Cause

Symptoms in Machine Operation Remedy When Trouble Occurs Alternator generating The alternator indicator is ON. Check the harness. voltage: 33.5 V or more Check the battery. Check the alternator. Faulty column display Alarm lamps and indicators do Check the harness. controller not light correctly. Replace the column Faulty CAN1 harness display controller. Faulty column display Replace the column controller. display controller. 131±5 Ω or less The fuel gauge (pointer) points Check the harness. continues for 5 to E. Replace the fuel level seconds. sensor. 4±2 Ω or less continues The fuel gauge (pointer) points Check the harness. for 5 seconds. to E. Replace the fuel level sensor.

T5-5-30

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

Trouble or MP Dr. Message Overheat Alarm

120501-2 120502-2

Engine Error Engine Oil Pressure Alarm

120503-2

Air Cleaner Restriction Alarm

Clogged air cleaner.

120505-2

Brake Pressure Alarm

Brake oil pressure decreases below 6 MPa (870 PSI).

120506-2

Steering Oil Pressure Alarm Steering pressure switch (option) is OFF or defective and steering pressure becomes 0.7 MPa (101.5 PSI) or lower. T/M Malfunction Faulty transmission system Refer to the accompanied T/M related fault code.

120507-2

Cause Coolant temperature is high while the engine runs. Faulty engine system Engine oil pressure is reduced. (Detected by ECM)

T5-5-31

Remedy Check the harness. Replace the overheat switch. Refer to ECM fault code list. Check the harness. Replace the engine oil pressure switch. Check the harness. Replace the air cleaner restriction switch. Check the harness. Replace the pressure sensor (brake primary pressure). Check the harness. Replace the steering pressure switch.

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

Trouble Communication Terminal: Abnormal EEPROM

114101-2

Communication Terminal: Abnormal IB/OB Queue

114102-2

Communication Terminal: Abnormal Local Loop Back

114103-2

Communication Terminal: No Satellite Found Communication Terminal: Remote 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

Cause The internal memory of satellite communication terminal (optional) is abnormal. The internal memory of satellite communication terminal (optional) is abnormal. Abnormality is detected on communication test with the satellite. Satellite can not be caught.

T5-5-32

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 Air Conditioner Controller Fault Code List Fault Code 11

Trouble or MP Dr. Message Open circuit in air circulation sensor

Cause

Symptoms in Machine Operation When Trouble Occurs Voltage: more than Operation is controlled under 4.95 V such circumstance as no air circulation sensor is provided. Shorted circuit in air Voltage: less than 0.3 V Operation is controlled under circulation sensor such circumstance as no air circulation sensor is provided. Open circuit in fresh Voltage: more than Operation is controlled under air sensor 4.88 V such circumstance as no fresh air sensor is provided. Shorted circuit in fresh Voltage: less than Operation is controlled under air sensor 0.096 V such circumstance as no fresh air sensor is provided. Open circuit in solar Operation is controlled under radiation sensor such circumstance as no solar radiation sensor is provided. Shorted circuit in solar Voltage: more than Operation is controlled under radiation sensor 5.04 V such circumstance as no solar radiation sensor is provided. Open circuit in Voltage: more than The compressor clutch is evaporator sensor 4.79 V disengaged. (The compressor stops.) Shorted circuit in Voltage: less than The compressor clutch is evaporator sensor 0.096 V disengaged. (The compressor stops.) Abnormal air vent Shorted circuit: Air vent damper servo motor damper Voltage: 0 V becomes inoperable. Open circuit: Voltage: more than 5 V Abnormal air mix Shorted circuit: Air mix damper servo motor damper Voltage: less than 0.2 V becomes inoperable. Open circuit: Voltage: more than 4.8 V Abnormal high/low Voltage: 0 V The compressor clutch is refrigerant pressure disengaged. (The compressor stops.) CAN communication Faulty CAN1 harness Air conditioner stops. error between monitor controller and air conditioner controller CAN bus off error Faulty air conditioner Air conditioner stops. controller Faulty CAN1 harness

T5-5-33

Remedy Check the harness. Replace the air circulation sensor. Check the harness. Replace the air circulation sensor. Check the harness. Replace the fresh air sensor. Check the harness. Replace the fresh air sensor. Check the harness. Replace the solar radiation sensor. Check the harness. Replace the solar radiation sensor. Check the harness. Replace the evaporator sensor. Check the harness. Replace the evaporator sensor. Check the harness. Replace the air vent damper servo motor. Check the harness. Replace the air vent damper servo motor. Check the harness. Replace the high/low pressure switch. Check the CAN1 harness. Replace air conditioner controller. Check the CAN1 harness. Replace air conditioner controller.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code Trouble or MP Dr. Message Possible Cause Symptoms in Machine Operation When Trouble Occurs MPDr. INSITE 629-12 111 Engine Control Module – Critical Error internal to the ECM related Engine will not start. internal failure to the memory hardware failures or internal ECM voltage supply circuits. 190-2 115 Engine Speed/Position Sensor No engine speed signal detected Engine will shut down and will Circuit - lost both of two signals at both engine position sensor not start. circuits. 190-10 121 Engine Speed/Position Sensor No engine speed signal detected Circuit - lost one of two signals at one of the engine position sensor circuits. 102-3 122 Intake Manifold Pressure Sensor High voltage detected at the Derate in power output of the #1 Circuit - shorted high intake manifold pressure sensor engine. circuit. 102-4 123 Intake Manifold Pressure Sensor Low voltage detected on the Derate in power output of the #1 Circuit - shorted low intake manifold pressure sensor engine. circuit. 91-3 131 Accelerator Pedal Position High voltage detected at Severe derate (power and Sensor Circuit - shorted high accelerator position sensor. speed). Limp home power only. 91-4 132 Accelerator Pedal Position Low voltage detected at the Severe derate (power and Sensor Circuit - shorted low accelerator position sensor speed). Limp home power only. circuit. 974-3 133 Remote Accelerator Pedal High voltage detected at the None on performance if remote Position Sensor Circuit - shorted remote throttle position signal throttle is not used. high circuit. 974-4 134 Remote Accelerator Pedal Low voltage detected at the None on performance if remote Position Sensor Circuit - shorted remote throttle position signal throttle is not used. low circuit. 100-3 135 Engine Oil Pressure Sensor High voltage detected at the oil No engine protection for oil Circuit - shorted high pressure circuit. pressure. 100-4 141 Engine Oil Pressure Sensor Low voltage detected at the oil No engine protection for oil Circuit - shorted low pressure circuit. pressure. 100-18 143 Engine Oil Pressure Low – Engine Oil Rifle Pressure Progressive power derate Warning Data Valid but Below Normal increasing in severity from time Operating Range - Moderately of alert. Severe Level. Engine oil pressure signal indicates engine oil pressure is below the engine protection warning limit. 110-3 144 Engine Coolant Temperature High voltage detected at the Possible white smoke. Fan will Sensor Circuit - shorted high coolant temperature circuit. stay on if controlled by the electronic control module (ECM). No engine protection for coolant temperature.

fNOTE: INSITE is the engine service tool provided by CUMMINS INC.

T5-5-34

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code Trouble or MP Dr. Message MPDr. INSITE 110-4 145 Engine Coolant Temperature Sensor Circuit - shorted low

110-0

151

105-3

153

105-4

154

105-0

155

620-4

187

175-3

212

175-4

213

175-0

214

Possible Cause Low voltage detected at the coolant temperature circuit.

Symptoms in Machine Operation When Trouble Occurs

Possible white smoke. Fan will stay on if controlled by the electronic control module (ECM). No engine protection for coolant temperature. Engine Coolant Temperature Coolant temperature signal Progressive power derate with High – Critical indicates temperature is above increasing time after alert. If 104°C (220°F). engine protection shutdown feature is enabled, engine will shut down 30 seconds after the red lamp starts flashing. Intake Manifold Temperature High voltage detected at the Possible white smoke. Fan will Sensor #1 Circuit - shorted high intake manifold temperature stay on if controlled by the sensor circuit. electronic control module (ECM). No engine protection for intake manifold temperature. Intake Manifold Temperature Low voltage detected at the Possible white smoke. Fan will Sensor #1 Circuit - shorted low intake manifold temperature stay on if controlled by the sensor circuit. electronic control module (ECM). No engine protection for intake manifold temperature. Intake Manifold Temperature #1 Intake manifold temperature Progressive power derate with High - Critical signal indicates temperature is increasing time after alert. If above 93°C (200°F). engine protection shutdown feature is enabled, engine will shut down 30 seconds after the red lamp starts flashing. Sensor Supply Voltage #2 Circuit Low voltage detected on the Engine will run derated. No - shorted low ECM voltage supply line to some engine protection for oil sensors (VSEN 2 supply). pressure or coolant level. Engine Oil Temperature Sensor High voltage detected at the oil No engine protection for oil Circuit - shorted high temperature circuit. temperature. Engine Oil Temperature Sensor Low voltage detected at the oil No engine protection for oil Circuit - shorted low temperature circuit. temperature. Engine Oil Temperature High Oil temperature signal indicates Progressive power derate with Critical oil temperature is above 123.9°C increasing time after alert. If (255°F). engine protection shutdown feature is enabled, engine will shut down 30 seconds after the red lamp starts flashing.

T5-5-35

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code Trouble or MP Dr. Message MPDr. INSITE 108-3 221 Ambient Air Pressure Sensor Circuit – shorted high 108-4

222

620-3

227

190-0

234

632-4

254

632-3

255

639-9

285

639-13

286

91-19

287

108-2

295

1384-31 299

Possible Cause

High voltage detected at the ambient air pressure sensor circuit. Ambient Air Pressure Sensor Low voltage detected at the Circuit – shorted low ambient air pressure circuit. Sensor Supply Voltage #2 Circuit High voltage detected on the - shorted high electronic control module (ECM) voltage supply line to some sensors. (VSEN 2) Engine Speed High – Critical Engine speed signal indicates engine speed is greater than 2650 rpm.

Symptoms in Machine Operation When Trouble Occurs Derate in power output of engine. Derate in power output of engine. Engine will run derated. No engine protection for oil pressure and coolant level.

Fuel shutoff valve is closed until the engine speed drops. The fuel shutoff valve will open when engine speed falls below 2000 rpm. The ECM turns off the fuel Fuel Shutoff Valve Circuit Less than Positive (+) 6 VDC shorted low detected at fuel shutoff circuit or shutoff supply voltage. The an excessive current draw from engine will shut down. the electronic control module (ECM) or faulty ECM output circuit. Fuel Shutoff Valve Circuit Externally supplied voltage None on performance. Fuel shorted high detected going to fuel shutoff shutoff valve stays on. solenoid supply circuit. SAE J1939 Multiplexing PGN The ECM expected information At least one multiplexed device Timeout Error from a multiplexed device but will not operate properly. did not receive it soon enough, or did not receive it at all. SAE J1939 Multiplexing The ECM expected information At least one multiplexed device Configuration Error from a multiplexed device but will not operate properly. only received a portion of the necessary information. SAE J1939 Multiplexing The vehicle electronic control Engine will only idle. Accelerator Pedal Sensor System unit (VECU) detected a fault with Error its throttle pedal. Ambient Air Pressure Sensor An error in the ambient air Engine is derated to no air Circuit - data incorrect pressure sensor signal was setting. detected by the ECM. Engine Shutdown Commanded The engine was shut down by a No action taken by the ECM. by J1939 device other than the keyswitch before the proper engine cool down resulting in a filtered load factor above the maximum shutdown threshold.

T5-5-36

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code Trouble or MP Dr. Message MPDr. INSITE 651-6 311 Injector Solenoid Valve Cylinder #1 Circuit – grounded circuit

Possible Cause

Current detected at the injector for cylinder number 1 when the voltage is turned off. Injector Solenoid Valve Cylinder Current detected at the injector #5 Circuit – grounded circuit for cylinder No. 5 when the voltage is turned off. Injector Solenoid Valve Cylinder Current detected at the injector #3 Circuit – grounded circuit for cylinder No. 3 when the voltage is turned off. Injector Solenoid Valve Cylinder Current detected at the injector #6 Circuit - grounded circuit for cylinder No. 6 when the voltage is turned off. Injector Solenoid Valve Cylinder Current detected at the injector #2 Circuit – grounded circuit for cylinder No. 2 when the voltage is turned off. Real Time Clock - Power Interrupt Real-time clock lost power.

655-6

312

653-6

313

656-6

314

652-6

315

251-2

319

654-6

321

Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit

651-5

322

Injector Solenoid Valve Cylinder #1 Circuit - open circuit

655-5

323

Injector Solenoid Valve Cylinder #5 Circuit – open circuit

653-5

324

Injector Solenoid Valve Cylinder #3 Circuit – open circuit

656-5

325

Injector Solenoid Valve Cylinder #6 Circuit – open circuit

Current detected at the injector for cylinder No. 4 when the voltage is turned off. Injector Solenoid Driver Cylinder 1 Circuit - Current Below Normal or Open Circuit. Current detected at injector number 1 when voltage is turned off. Injector Solenoid Driver Cylinder 5 Circuit - Current Below Normal or Open Circuit. Current detected at injector number 5 when voltage is turned off. Injector Solenoid Driver Cylinder 3 Circuit - Current Below Normal or Open Circuit. Current detected at injector number 3 when voltage is turned off. Injector Solenoid Driver Cylinder 6 Circuit - Current Below Normal or Open Circuit. Current detected at injector number 6 when voltage is turned off.

T5-5-37

Symptoms in Machine Operation When Trouble Occurs The injector for cylinder number 1 is turned off. The injector for cylinder No. 5 is turned off. The injector for cylinder No. 3 is turned off. The injector for cylinder No. 6 is turned off. The injector for cylinder No. 2 is turned off. None on performance. Data in the ECM will not have accurate time and date information. The injector for cylinder No. 4 is turned off. The current to the injector is shut off. The engine can possibly misfire or run rough.

The current to the injector is shut off. The engine can possibly misfire or run rough.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code Trouble or MP Dr. Message MPDr. INSITE 652-5 331 Injector Solenoid Valve Cylinder #2 Circuit – open circuit

Possible Cause

Symptoms in Machine Operation When Trouble Occurs

Injector Solenoid Driver Cylinder 2 Circuit - Current Below Normal or Open Circuit. Current detected at injector number 2 when voltage is turned off. Injector Solenoid Driver Cylinder 4 Circuit - Current Below Normal or Open Circuit. Current detected at injector number 4 when voltage is turned off. Severe loss of data from the ECM due to unswitched battery supply circuit

The current to the injector is shut off. The engine can possibly misfire or run rough.

654-5

332

Injector Solenoid Valve Cylinder #4 Circuit – open circuit

630-2

341

Engine Control Module – data lost

629-12

343

3509-4

352

3509-3

386

1043-3

387

100-1

415

Engine Control Module Warning internal hardware failure Sensor Supply Voltage #1 Circuit Low voltage detected on the - shorted low internal electronic control module (ECM) supply line to some of the sensors. Sensor Supply Voltage #1 Circuit High voltage detected on the - shorted high internal electronic control module (ECM) supply wire to the sensors. Accelerator Pedal Position High voltage detected on the Sensor Supply Voltage Circuit ECM voltage supply line to the shorted high throttle(s) (VTP supply). Engine Oil Pressure Low – Critical Oil pressure signal indicates oil pressure below the very low oil pressure engine protection limit.

97-15

418

1319-2

419

97-3

428

97-4

429

Water in Fuel Indicator High – Maintenance Intake Manifold Boost Pressure Imbalance Water in Fuel Sensor Circuit shorted high Water in Fuel Sensor Circuit shorted low

The current to the injector is shut off. The engine can possibly misfire or run rough.

Possibly no noticeable performance effects, or engine dying, or difficulty in starting the engine. Fault information, trip information, and maintenance monitor data can be inaccurate. Internal ECM error due to bad Possibly none on performance, intelligent device or component or severe derate.

Water has been detected in the fuel filter. An error in the intake manifold pressure sensor signal was detected by the ECM. High voltage detected at waterin-fuel (WIF) sensor circuit. Low voltage detected at waterin-fuel (WIF) sensor circuit.

T5-5-38

Engine is derated to no-air setting.

Engine will only idle.

Progressive power derate with increasing time after alert. If engine protection shutdown feature is enabled, engine will shut down 30 seconds after the red lamp starts flashing. Possible white smoke, loss of power, or hard starting. Engine is derated to no-air setting. -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code Trouble or MP Dr. Message MPDr. INSITE 558-2 431 Accelerator Pedal Idle Validation Circuit - data incorrect

558-13

432

102-2

433

627-2

434

100-2

435

168-18

441

168-16

442

1043-4

443

Possible Cause

Symptoms in Machine Operation When Trouble Occurs

No voltage detected simultaneously on both the idle validation off-idle and on-idle signal pins. Accelerator Pedal Idle Validation Voltage detected at idle Engine will only idle. Circuit - out of calibration validation on-idle circuit when voltage at throttle position circuit indicates the pedal is not at idle or voltage detected at idle validation off-idle circuit when voltage at throttle position circuit indicates the pedal is at rest. Intake Manifold Pressure Sensor Voltage signal at the intake Derate to no-air setting. Circuit - data incorrect manifold pressure circuit indicates high intake manifold pressure but other engine characteristics indicate that intake manifold pressure must be low. Power Lost without Ignition Off Supply voltage to the electronic Possible no noticeable control module (ECM) fell below performance effects or engine (+) 6.2-VDC for a fraction of dying or hard starting. Fault a second or the ECM was not information, trip information, allowed to power down correctly and maintenance monitor data (retain battery voltage for 30 can be inaccurate. seconds after keyswitch is turned off ). Engine Oil Pressure Sensor An error in the oil pressure None on performance; no engine Circuit - data incorrect sensor signal was detected by protection for oil pressure. the ECM. Battery #1 Voltage Low - Warning Battery voltage below Possible no noticeable normal operating level due performance effects or possible to unswitched battery supply rough idle. circuit. Battery #1 Voltage High Battery voltage above Warning normal operating level due to unswitched battery supply circuit. Accelerator Pedal Position Low voltage detected on the Engine will only idle. Sensor Supply Voltage Circuit electronic control module shorted low (ECM) voltage supply line to the throttle(s).

T5-5-39

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List Fault Code Trouble or MP Dr. Message Possible Cause MPDr. INSITE 702-3 527 Auxiliary Input/Output #2 Circuit Less than + 17.0 VDC detected at - shorted high the switched output A signal pin of the 31-pin OEM connector. 703-3 529 Auxiliary Input/Output #3 Circuit Less than + 17 VDC detected at - shorted high the switched output B signal pin at the electronic control module (ECM). 558-4 551 Accelerator Pedal Idle Validation No voltage detected Circuit - shorted low simultaneously on both the idle validation off-idle and on-idle circuits. 167-16 596 Electrical Charging System High battery voltage detected Voltage High - warning level by the battery voltage monitor feature. 167-1 598 Electrical Charging System Very low battery voltage Voltage Low - Critical Level detected by the battery voltage monitor feature.

166-2

951

Cylinder Power Imbalance between cylinders

Cylinder Power Imbalance Between Cylinders. A power imbalance between cylinders was detected by the electronic control module (ECM).

T5-5-40

Symptoms in Machine Operation When Trouble Occurs No action taken by the electronic control module (ECM). No action taken by the ECM.

Engine will only idle.

Yellow lamp will be lit until high battery voltage condition is corrected. Red lamp lit until very low battery voltage condition is corrected. The electronic control module (ECM) can increase idle speed and deactivate idle decrement switch if idle speedup is enabled. Engine can have rough idle or misfire.

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

Trouble or MP Dr. Message Abnormal EEPROM Abnormal RAM Abnormal A/D Converter

Cause Faulty MC Faulty MC Faulty MC

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

T5-5-41

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

Trouble or MP Dr. Message Abnormal Sensor Voltage

111003-3

Inspection Method

Evaluation

Cause

Disconnect connectors from all sensors and accelerator pedal sensor. Retry the troubleshooting by using MPDr. Measure voltage between sensor harness end #1 and chassis. Check shorted circuit in harness between sensor harness end #1 and #3. -

Fault code 111003-3 is not displayed.

Faulty sensor

Voltage: less than 0.25 V Open circuit in harness #1. 0Ω

Shorted circuit in harness #1 and #3.

Normal in above check.

Faulty MC

14 15

16 17 90Z6-05-05-01

123456-

Main Controller (MC) Accelerator Pedal Sensor Pump Delivery Pressure Sensor Primary Pilot Pressure Sensor Lift Arm Raise Pressure Sensor (Option) Steering Pressure Switch

78-

Lift Arm Angle Sensor (Option) Hydraulic Fan Circuit Pressure Sensor (Option) 9- Parking Brake Pressure Sensor 10- Service Brake Primary Pressure Pressure Sensor

11- Service Brake Secondary Pressure Sensor (for Declutch) 12- Refrigerant Pressure Sensor 13- Secondary Steering Check Pressure Sensor (Option) 14- Hydraulic Oil Temperature Sensor

T5-5-42

15- Transmission Oil Temperature Sensor 16- Axle Oil Temperature Sensor 17- Atmospheric 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)  Pressure Sensor (Brake Secondary Pressure)  Pressure Sensor (Primary Pilot Pressure)

 Lift Arm Angle Sensor (Option)

90Z7-05-CN04 90Z7-05-CN01

 Pressure Sensor (Refrigerant Pressure)  Steering Pressure Switch (Option)

90Z7-05-CN05 90Z6-05-CN01

 Accelerator Pedal Sensor  Pressure Sensor (Brake Primary Pressure)  Pump Delivery Pressure Sensor  Hydraulic Fan Circuit Pressure Sensor (Option)  Secondary Steering Pump Delivery Pressure Sensor (Option) 90Z6-05-CN02

90Z7-05-CN03

fNOTE: S: Signal

T5-5-43

G: Ground (chassis) P: 5 V or 24 V power supply

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111006, 111007, 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 T5-5-46 to 48.) Fault Code

Trouble or MP Dr. Message

Inspection Method

Cause

111006-2

(MC) Engine Controller Communication Error

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(MC) Information Controller Communication Error 1

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(MC) Air Conditioner Controller Communication Error

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(MC) Column Monitor Communication Error

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

111007-2

111014-2

111025-2

T5-5-44

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Monitor) Fault Codes 113002, 113003, 113005, 113007 Monitor Controller (Information) Fault Codes 114010, 114011, 114015 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 T5-5-46 to 48.) Fault Code

Trouble or MP Dr. Message

Inspection Method

Cause

113002-2

(Monitor Controller) Engine Controller Communication Error

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(Monitor Controller) Main Controller Communication Error 1

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(Monitor Controller) ICF Communication Error 1

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

113003-2

113005-2

113007-2

114010-2

114011-2

114015-2

(Monitor Controller) Column Continuity check (open circuit) Controller Communication Discontinuity check (shorted circuit) Error

Open circuit in harness.

(Information Controller) Engine Controller Communication Error

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

(Information Controller) Main Continuity check (open circuit) Controller Communication Discontinuity check (shorted circuit) Error 1

Open circuit in harness.

(Information Controller) Column Controller Communication Error

Continuity check (open circuit)

Open circuit in harness.

Discontinuity check (shorted circuit)

Shorted circuit in harness.

T5-5-45

Shorted circuit in harness.

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

Continuity (0 Ω) Correct

Discontinuity (∞ Ω) Disconnected

Shorted circuit

Correct

CAN Harness

Continuity check between High side Main Controller (MC) and each Low side controller Discontinuity check between High side CAN circuit and ground circuit in each controller

Low side

Main Controller (MC) #D2 #D3

Engine Control Module (ECM) #46 #37

Information Controller (ICF) #C-5 #C-11

#D2 - #E1 #D2 - #E2 #D2 - #F4

#46 - #29 #46 - #30 #46 - #39

#D2 - #F5 #D2 - #F6 #D3-#E1 #D3-#E2 #D3-#F4

#46 - #40 #46 - #50 #37 - #29 #37 - #30 #37 - #39

#D3-#F5 #D3-#F6

#37 - #40 #37 - #50

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

T5-5-46

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN1 Harness Check Inspection

CAN Harness

Main Controller (MC)

High side

#D2 - #E5 #D2 - #E6 #D2 - #F1 #D2 - #F2 #D2 - #F3 #D3 - #E5 #D3 - #E6 #D3 - #F1 #D3 - #F2 #D3 - #F3 #D2 - #E04

Engine Control Module (ECM) #46 - #7 #46 - #8 #46 - #17 #46 - #18 #46 - #28 #37 - #7 #37 - #8 #37 - #17 #37 - #18 #37 - #28 #46 - #38

Information Controller (ICF) #C-5 - #C-1 #C-5 - #C-2 #C-11 - #C-1 #C-11 - #C-2 #C-5 - #C-7

Discontinuity check between CAN circuit and power circuit in each controller

High side

Low side

#D3 - #E04

#37 - #38

#C-11 - #C-7

#D2 - #D3

#46-#37

#C-5 - #C-11

Low side

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

T5-5-47

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

 ECM Connector (50-pole)

90Z6-05-MCD

 MC-E Connector 90Z6-05-ECM

90Z7B-05-MCE

 MC-F Connector

90Z6-05-MCF

 Information Controller-A Connector

90Z6-05-ICFA

 Information Controller-C Connector

90Z6-05-ICFC

T5-5-48

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111103, 111105 Preparation  Check the wiring connections first. Fault Code 111103-3

111103-4

111105-3

Trouble or MP Dr. Inspection Method Message Accelerator Pedal Circuit Measure resistance High Input between accelerator pedal sensor end #1 and #2. Accelerator Pedal Circuit Measure voltage between Low Input accelerator pedal sensor connector pins #2 and #6. Measure voltage between accelerator pedal sensor connector pins #1 and #6. ---

Evaluation

Cause

0Ω

Shorted circuit in harness #1 and #2.

Normal in above check. Voltage: less than 0.25 V

Faulty accelerator pedal sensor. Open circuit in rear console harness #2 (power supply line). Open circuit in rear console harness #1 (signal line). Faulty accelerator pedal sensor. Faulty engine speed sensor

Voltage: less than 0.25 V Normal in above check.

Abnormal Engine Speed Torque converter input Sensor speed sensor = 0 min-1 and Engine speed sent from ECM (CAN) > 500 min-1

Connector (Harness end)  Accelerator Pedal Sensor Connector (Rear Console Cable Assy)

Accelerator pedal sensor

90Z6-05-CN02

fNOTE: P: 5 V or 24 V power supply S: Signal G: Ground (chassis)

90Z6-05-05-02

 Accelerator Pedal Sensor Connector (Arrow View X)

123456-

Black: APS signal White: APS ground Red: APS supply (5V) Orange: IVS supply (5V) Blue: Idle active Green: Throttle active

(G) 6

1 (B)

(L) 5

2 (W)

(O) 4

3 (R)

90Z6-05-05-03

T5-5-49

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111200 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111200-3

111200-4

Trouble or MP Dr. Message Lift Arm Raise Pilot Pressure Sensor Circuit High Input (Option) Lift Arm Raise Pilot Pressure Sensor Circuit Low Input (Option)

Inspection Method

Evaluation

Retry by using MPDr.

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

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

fNOTE: Lift arm raise pilot pressure sensor (for ride

control option) is mounted at the multiple control valve. Refer to p. T5-4-17 for the sensor location. C

TDAA-05-06-003

T5-5-50

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

111205-4

111207-3

111207-4

Trouble or MP Dr. Message Lift Arm Angle Sensor Circuit High Input (Option)

Inspection Method

Evaluation

Cause

Measure resistance between lift arm angle sensor end #1 and #2. -

0Ω

Shorted circuit in harness #1 and #2.

Normal in above check. Voltage: less than 0.25 V

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

Lift Arm Angle Sensor Circuit Low Input (Option)

Measure voltage between lift arm angle sensor harness end #1 and chassis. Measure voltage between Voltage: less than lift arm angle sensor 0.25 V harness end #1 and #3. Normal in above check. Refrigerant Pressure Measure resistance 0Ω Circuit High Input between refrigerant pressure sensor end #1 and #2. Normal in above check. Refrigerant Pressure Measure voltage between Voltage: less than Sensor Circuit Low Input refrigerant pressure sensor 0.25 V harness end #1 and chassis. Measure voltage between Voltage: less than refrigerant pressure sensor 0.25 V harness end #1 and #3. Normal in above check.

Open circuit in harness #3.

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

Open circuit refrigerant pressure sensor. Open circuit in harness #1.

Open circuit in harness #3.

Faulty refrigerant pressure sensor.

Connector (Harness end)  Lift Arm Angle Sensor

 Refrigerant Pressure Sensor

90Z7-05-CN05

90Z7-05-CN04

fNOTE: See p. T5-4-4 for the lif arm angle sensor location.

fNOTE: P: 5 V or 24 V power supply S: Signal G: Ground (chassis)

fNOTE: See p. T5-7-2 for the refrigerant pressure sensor location.

T5-5-51

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111217, 111312 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111217-3

111217-4

111312-3

111312-4

Trouble or MP Dr. Message Pilot Pressure Sensor Circuit High Input

Inspection Method

Evaluation

Retry by using MPDr.

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

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

TDAA-05-06-003

fNOTE: The pilot (primary) pressure sensor is installed to

the pilot valve. (See p. T5-4-16) The service brake secondary pressure sensor is installed to the brake valve. (See p. T5-4-16) Refer to the F&S S/M Section 3 for the sensor specifications.

T5-5-52

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111204 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111204-3

111204-4

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

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

TDAA-05-06-003

fNOTE: The pump delivery pressure sensor is installed to the main pump. Refer to p. T5-4-13 for the sensor location. Refer to F&S S/M Section T3-1 for more information.

T5-5-53

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111206 Preparation

 Before inspection, set the key switch to the ON position.

 Check the wiring connections first.  Connect the test harness and dummy sensor. Fault Code 111206-3

111206-4

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

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

fNOTE: The fan circuit pressure sensor is installed to the

 For Reversing Fan (Option)

fan control valve. Refer to the F&S S/M Section 3-3 for the sensor specifications.

1 4 1234-

Fan Motor Radiator Assembly Fan Valve (Option) Fan Circuit Pressure Sensor (Option)

90Z6-03-03-03 C

TDAA-05-06-003

T5-5-54

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

111208-4

Trouble or MP Dr. Message Emergency Steering Check Pressure Sensor Circuit High Input (Option) Emergency Steering Check Pressure Sensor Circuit Low Input (Option)

Inspection Method

Evaluation

Retry by using MPDr.

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

fNOTE: The secondary steering pump delivery pressure sensor (option) is installed to the steering valve. (See p. T5-4-18, lower #4) Refer to the F&S S/M Section 3 for the sensor specifications.

TDAA-05-06-003

T5-5-55

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111311, 111313 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111311-3

111311-4

111313-3

111313-4

Trouble or MP Dr. Message Service Brake Primary Pressure Sensor Circuit High Input

Inspection Method

Evaluation

Cause

Retry by using MPDr.

Un-displayed fault code

Faulty sensor.

Measure voltage between B and chassis. Retry by using MPDr. Measure voltage between A and chassis. Measure voltage between A and C (GND). -

Voltage: 4.75 V or more

Parking Brake Pressure Retry by using MPDr. Sensor Circuit High Input Measure voltage between B and chassis. Parking Brake Pressure Retry by using MPDr. Sensor Circuit Low Input Measure voltage between A and chassis. Measure voltage between A and C (GND). -

Un-displayed fault code

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

Service Brake Primary Pressure Sensor Circuit Low Input

Un-displayed fault code Voltage: less than 0.25 V Voltage: less than 0.25 V Normal in above check.

Voltage: 4.75 V or more Un-displayed fault code Voltage: less than 0.25 V Voltage: less than 0.25 V Normal in above check.

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

TDAA-05-06-003

fNOTE: The service brake primary pressure sensor (for

service brake pressure alarm) and parking brake pressure sensor are installed to the charging block. (See p. T5-415.) Refer to the F&S S/M Section 3-7 for the sensor specifications.

T5-5-56

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 or MP Dr. Message Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB (Option)

Hydraulic Fan Reverse Rotation P/S Valve FB High Current (Option)

Hydraulic Fan Reverse Rotation P/S Valve FB Low Current (Option)

Inspection Method

Evaluation

Cause

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

0/∞Ω (Normal value: 22±0.4 Ω) 0V

Faulty solenoid valve.

Open circuit in harness #1.

0 mA

Open circuit in harness #2.

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

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

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

0 mA

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

Open circuit in harness #1.

Open circuit in harness #2.

Connector (Harness end)

 For Reversing Fan (Option)

 Solenoid Valve Connector 2

90Z6-05-CN03

12345-

1 3 5

90Z6-03-03-03

T5-5-57

Fan Motor Radiator Assembly Fan Valve (Option) Fan Reverse Control Solenoid Valve (Option) Fan Speed Control Solenoid Valve (Option)

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 or MP Dr. Message Hyd. Fan P/S Valve Abnormal Feedback

Hyd. Fan P/S Valve Feedback High Current

Hyd. Fan P/S Valve Feedback Low Current

Inspection Method

Evaluation

Cause

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

0/∞Ω (Normal value: 22±0.4 Ω) 0V

Faulty solenoid valve.

Open circuit in harness #1.

0 mA

Open circuit in harness #2.

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

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

0 mA

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

Open circuit in harness #1.

Open circuit in harness #2.

Connector (Harness end)  Solenoid Valve Connector

90Z7-05-CN10

fNOTE: When the optional reversing fan is installed,

the connector of fan speed control solenoid is as shown below. Refer to the previous page for the solenoid location with optional reversing fan function.

Fan Speed Control Solenoid Valve

90Z6T1-2-14 TNED-05-05-20

fNOTE: Fan speed control solenoid valve is installed to the fan motor.

T5-5-58

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

111413-3

111413-4

Trouble or MP Dr. Message Pump Swash Angle P/S Valve Abnormal FB

Pump Swash Angle P/S Valve FB High Current

Pump Swash Angle P/S Valve FB Low Current

Inspection Method

Evaluation

Cause

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

0/∞Ω (Normal value: 10.3±0.515 Ω) 0V

Faulty solenoid valve.

Open circuit in harness #1.

0 mA

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

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

0 mA

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

Open circuit in harness #1.

Open circuit in harness #2.

Connector (Harness end)  Solenoid Valve Connector

90Z6-05-CN03

fNOTE: The pump torque control (swash angle) solenoid valve is installed to the charging block.

90Z6-03-07-17

T5-5-59

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111414 to 111419 Preparation  Check the wiring connections first. Fault Code 111414-2 111415-2 111416-2 111417-2 111418-2 111419-2 111414-3 111415-3 111416-3 111417-3 111418-3 111419-3 111414-4 111415-4 111416-4 111417-4 111418-4 111419-4

Trouble or MP Dr. Inspection Method Message T/M Clutch 1st P/S Valve Measure resistance Abnormal FB between solenoid valve #1 T/M Clutch 2nd P/S Valve and #2. Abnormal FB Measure voltage between T/M Clutch 3rd P/S Valve solenoid valve harness end Abnormal FB #1 and chassis. T/M Clutch 4th P/S Valve Each clutch P/S FB Abnormal FB T/M Clutch Forward P/S Valve Abnormal FB T/M Clutch Reverse P/S Valve Abnormal FB T/M Clutch 1st P/S Valve Measure resistance between solenoid valve #1 FB High Current T/M Clutch 2nd P/S Valve and #2. FB High Current T/M Clutch 3rd P/S Valve FB High Current T/M Clutch 4th P/S Valve FB High Current T/M Clutch Forward P/S Valve FB High Current T/M Clutch Reverse P/S Valve FB High Current T/M Clutch 1st P/S Valve Measure resistance FB Low Current between solenoid valve #1 T/M Clutch 2nd P/S Valve and #2. FB Low Current T/M Clutch 3rd P/S Valve Measure voltage between FB Low Current solenoid valve harness end T/M Clutch 4th P/S Valve #1 and chassis. FB Low Current T/M Clutch Forward P/S Each clutch P/S FB Valve FB Low Current T/M Clutch Reverse P/S Valve FB Low Current

Connector (Harness end)

Evaluation

Cause

0/∞Ω (Normal voltage: 22±0.4 Ω) 0V

Faulty solenoid valve.

Open circuit in harness #1.

0 mA

Open circuit in harness #2.

Normal in above check.

Shorted circuit in harness #1 and #2.

0Ω (Normal voltage: 22±0.4 Ω)

Faulty solenoid valve.

Normal in above check.

Shorted circuit in harness #1 and #2.

∞Ω (Normal voltage: 22±0.4 Ω)

Faulty solenoid valve.

Open circuit in harness #1.

0 mA

Open circuit in harness #2.

fNOTE: The solenoid valves are installed to the

 Solenoid Valve Connector

transmission control valve. (See p. T5-4-12.)

TNED-05-05-020

T5-5-60

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 or MP Dr. Message Ride Control P/S Valve Abnormal FB (Option)

Inspection Method

Evaluation

Cause

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and chassis. Ride Control (Bottom) P/S FB -

0/∞Ω (Normal voltage: 22±0.4 Ω) 0V

Faulty solenoid valve.

Open circuit in harness #1.

0 mA

Open circuit in harness #2.

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

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

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

Connector (Harness end)  Solenoid Valve Connector

TNED-05-05-20

fNOTE: The ride control solenoid valve is installed to the ride control valve (option). (Refer to p. T5-4-17.)

T5-5-61

0 mA

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

Open circuit in harness #1.

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111600, 111601, 111602 Preparation  Check the wiring connections first.  Connect the test harness and dummy sensor.  Before inspection, set the key switch to the ON position. Fault Code 111600-3

Trouble or MP Dr. Message T/M Output Speed Sensor Failure

Inspection Method

Evaluation

Cause

Check harness

Abnormal in harness check Normal in harness check Abnormal in harness check Normal in harness check Abnormal in harness check Normal in harness check Abnormal in harness check Normal in harness check

Abnormal harness.

111600-4

T/M Output Speed Check harness Sensor Circuit Low Input

111601-3

Torque Converter Output Speed Sensor Failure

Check harness

111602-3

Intermediate Shaft Speed Sensor Failure

Check harness

Faulty sensor. Abnormal harness. Faulty sensor. Abnormal harness. Faulty sensor. Abnormal harness. Faulty sensor.

TDAA-05-06-003

fNOTE: Refer to p. T5-4-12 for each sensor.

T5-5-62

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111900 Preparation  Check the wiring connections first. Fault Code 111900-3

111900-4

Trouble or MP Dr. Message Torque Converter Oil Temperature Sensor Circuit High Input

Torque Converter Oil Temperature Sensor Circuit Low Input

Inspection Method

Evaluation

Cause

Measure resistance between sensor #1 and chassis GND. Measure voltage between sensor harness end #1 and chassis. -

Refer to the table.

Faulty sensor.

Open circuit in harness #1.

Normal in above check. Refer to the table.

Improper grounding between chassis Faulty sensor.

Normal in above check.

Shorted circuit in harness #1.

Measure resistance between sensor #1 and chassis GND. -

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

Resistance (kΩ) (7.6) (4.0) 2.7±0.22 0.92±0.073 (0.56) (0.42) 0.276±0.014

fNOTE: Refer to p. T5-4-12 for the sensor location.  Torque Converter Oil Temperature Sensor

Terminal Bolt

Harness connector (#1) is inserted here.

35829-20130

 Rear Chassis Harness Connector CN.112 #1 CN112

T5-5-63

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

111901-3

Trouble or MP Dr. Message Hyd. Oil Temp Sensor Circuit Low Input

Hyd. Oil Temp Sensor Circuit High Input

Inspection Method

Evaluation

Cause

Measure resistance between sensor #1 and #2. -

Refer to the table.

Faulty sensor.

Normal in above check. Refer to the table.

Shorted circuit in harness #1. Faulty sensor.

Open circuit in harness #1.

Normal in above check.

Open circuit in harness #2.

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

Hydraulic Oil Temperature Sensor Specification Hydraulic Oil Temperature (°C (°F)) -30 (-22) -20 (-4) -10 (14) 0 (32) 10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 60 (140) 70 (158) 80 (176) 90 (194) 100 (212) 110 (230) 120 (248)

Resistance (kΩ) 25.4 15.0 9.16 5.74 3.7 2.45 1.66 1.15 0.811 0.584 0.428 0.318 0.24 0.1836 0.1417 0.1108

2 90Z6-05-05-04 12-

Hydraulic Oil Tank Hydraulic Oil Temperature Sensor

Connector (Harness end)  Hydraulic Oil Temperature Sensor

90Z7-05-CN11

T5-5-64

35829-60160

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 111902 Preparation  Check the wiring connections first. Fault Code 111902-3

111902-4

Trouble or MP Dr. Inspection Method Message Axle Oil Temperature Measure resistance Sensor Circuit High Input between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. Axle Oil Temperature Measure resistance Sensor Circuit Low Input between sensor #1 and #2. -

Evaluation

Cause

Refer to the table.

Faulty sensor.

Open circuit in harness #1.

Normal in above check. Refer to the table.

Open circuit in harness #2. Faulty sensor.

Normal in above check.

Shorted circuit in harness #1.

Axle Oil Temperature Sensor Specification

Connector (Harness end)

Hydraulic Oil Temperature (°C (°F)) -30 (-22) -20 (-4) -10 (14) 0 (32) 10 (50) 20 (68) 25 (77) 30 (86) 40 (104) 50 (122) 60 (140) 70 (158) 80 (176) 90 (194) 100 (212) 110 (230) 120 (248) 130 (266) 140 (284) 150 (302) 160 (320) 170 (338) 180 (356)

 Axle Oil Temperature Sensor

Resistance (kΩ) 112.5 67.9 42.4 27.2 17.9 12.1 10 8.3 5.8 4.2 3.1 2.3 1.7 1.3 1.0 0.78 0.62 0.49 0.39 0.32 0.27 0.22 0.18

90Z7-05-CN12

fNOTE: Axle oil temperature sensor is installed to the front axle. (See p. T5-4-15.)

T5-5-65

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 111700 to 111705 Fault Code

Trouble or MP Dr. Message

111700-6 111701-6 111702-6 111703-6 111704-6 111705-6 111700-7 111701-7 111702-7 111703-7 111704-7 111705-7 111700-8

Calibration Abort Forward: Key-off Calibration Abort Reverse: Key-off Calibration Abort 1st: Key-off Calibration Abort 2nd: Key-off Calibration Abort 3rd: Key-off Calibration Abort 4th: Key-off Calibration Abort Forward: Stop Order from MPDr. Calibration Abort Reverse: Stop Order from MPDr. Calibration Abort 1st: Stop Order from MPDr. Calibration Abort 2nd: Stop Order from MPDr. Calibration Abort 3rd: Stop Order from MPDr. Calibration Abort 4th: Stop Order from MPDr. Calibration Abort Forward: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort Reverse: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort 1st: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort 2nd: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort 3rd: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort 4th: Engine RPM < 600rpm, or RPM > 1000 rpm Calibration Abort Forward: Parking Brakelight Off Calibration Abort Reverse: Parking Brakelight Off Calibration Abort 1st: Parking Brakelight Off Calibration Abort 2nd: Parking Brakelight Off Calibration Abort 3rd: Parking Brakelight Off Calibration Abort 4th: Parking Brakelight Off Calibration Abort Forward: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort Reverse: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort 1st: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort 2nd: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort 3rd: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort 4th: T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC Calibration Abort Forward: Travel Speed != 0 km/h Calibration Abort Reverse: Travel Speed != 0 km/h Calibration Abort 1st: Travel Speed != 0 km/h Calibration Abort 2nd: Travel Speed != 0 km/h Calibration Abort 3rd: Travel Speed != 0 km/h Calibration Abort 4th: Travel Speed != 0 km/h

111701-8 111702-8 111703-8 111704-8 111705-8 111700-9 111701-9 111702-9 111703-9 111704-9 111705-9 111700-10 111701-10 111702-10 111703-10 111704-10 111705-10 111700-11 111701-11 111702-11 111703-11 111704-11 111705-11

T5-5-66

Symptoms in Machine Remedy Operation When Trouble Occurs Transmission learning Perform T/M learning. failed. Refer to T4-6. Shifting may not be smooth.

Transmission learning failed. Shifting may not be smooth.

Perform T/M learning. Refer to T4-6.

Transmission learning failed. Shifting may not be smooth.

Start engine and perform T/M learning. Refer to T4-6.

Transmission learning failed. Shifting may not be smooth.

Apply parking brake and perform T/M learning. Refer to T4-6.

Transmission learning failed. Shifting may not be smooth.

Check and wait until the T/C oil temperature becomes normal. Perform T/M learning. Refer to T4-6.

Transmission learning failed. Shifting may not be smooth.

Apply parking brake and perform T/M learning. Refer to T4-6.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble or MP Dr. Message

111700-12 111701-12 111702-12 111703-12 111704-12 111705-12 111700-13~16 111701-13~16 111702-13~16 111703-13~16 111704-13~16 111705-13~16 111700-17 111701-17 111702-17 111703-17 111704-17 111705-17 111700-18~20 111701-18~20 111702-18~20 111703-18~20 111704-18~20 111705-18~20 111700-21 111701-21 111702-21 111703-21 111704-21 111705-21 111700-31 111701-31 111702-31 111703-31 111704-31 111705-31

Calibration Abort Forward: FNR != N Calibration Abort Reverse: FNR != N Calibration Abort 1st: FNR != N Calibration Abort 2nd: FNR != N Calibration Abort 3rd: FNR != N Calibration Abort 4th: FNR != N Calibration Abort Forward: Step 1-2 errors Calibration Abort Reverse: Step 1-2 errors Calibration Abort 1st: Step 1-2 errors Calibration Abort 2nd: Step 1-2 errors Calibration Abort 3rd: Step 1-2 errors Calibration Abort 4th: Step 1-2 errors Calibration Abort Forward: Step 2 error Calibration Abort Reverse: Step 2 error Calibration Abort 1st: Step 2 error Calibration Abort 2nd: Step 2 error Calibration Abort 3rd: Step 2 error Calibration Abort 4th: Step 2 error Calibration Abort Forward: Step 3 errors Calibration Abort Reverse: Step 3 errors Calibration Abort 1st: Step 3 errors Calibration Abort 2nd: Step 3 errors Calibration Abort 3rd: Step 3 errors Calibration Abort 4th: Step 3 errors Calibration Abort Forward: EEPROM Write Failure Calibration Abort Reverse: EEPROM Write Failure Calibration Abort 1st: EEPROM Write Failure Calibration Abort 2nd: EEPROM Write Failure Calibration Abort 3rd: EEPROM Write Failure Calibration Abort 4th: EEPROM Write Failure Calibration Abort Forward: Un-Calibration Calibration Abort Reverse: Un-Calibration Calibration Abort 1st: Un-Calibration Calibration Abort 2nd: Un-Calibration Calibration Abort 3rd: Un-Calibration Calibration Abort 4th: Un-Calibrationf

T5-5-67

Symptoms in Machine Operation When Trouble Occurs Transmission learning failed. Shifting may not be smooth.

Remedy

Transmission learning failed. Shifting may not be smooth.

Perform T/M learning. Refer to T4-6. Check harness.

Transmission learning failed. Shifting may not be smooth.

Perform T/M learning. Refer to T4-6. Check harness.

Transmission learning failed. Shifting may not be smooth.

Perform T/M learning. Refer to T4-6. Check harness.

Transmission learning failed. Shifting may not be smooth.

Perform T/M learning. Refer to T4-6. Replace MC.

Shifting may not be smooth.

Perform T/M learning. Refer to T4-6.

Set FNR lever to neutral position and perform T/M learning. Refer to Refer to T4-6.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 120000 to 120005 Fault Code 120000-2

120001-2

120002-2

120003-2

120004-2

120005-2

Trouble or MP Dr. Message Inspection Method Hydraulic Oil Overheat Disconnect the connector Alarm from the hydraulic oil temperature sensor (see p. T5-5-74). Retry by using MPDr. Main Pump Pressure Alarm Disconnect the connector from the main pump oil pressure sensor (see p. T5-5-61). Retry by using MPDr. Axle Oil Temperature Disconnect the connector Alarm from the axle oil temperature sensor (see p. T5-5-75). Retry by using MPDr. Emergency Steering Disconnect the connector Activated Alarm (Option) from the steering oil pressure switch (option). Retry by using MPDr. Emergency Steering Disconnect the connector Activated Pressure Alarm from the steering oil (Option) pressure switch (option) (see p. T5-5-22). Retry by using MPDr. Transmission Oil Disconnect the connector Temperature Overheat from the transmission oil Alarm temperature sensor (see p. T5-5-73). Retry by using MPDr.

Evaluation Displayed fault code Un-displayed fault code Displayed fault code Un-displayed fault code Displayed fault code Un-displayed fault code

Cause Faulty MC or shorted circuit in harness. Faulty hydraulic oil temperature sensor. Faulty MC or shorted circuit in harness. Faulty main pump oil pressure sensor. Faulty MC or shorted circuit in harness. Faulty axle oil temperature sensor.

Correct Incorrect

Faulty harness. Faulty secondary steering check switch.

Displayed fault code

Faulty MC or shorted circuit in harness. Faulty steering pressure switch.

Un-displayed fault code Displayed fault code Un-displayed fault code

Faulty MC or shorted circuit in harness. Faulty transmission oil temperature sensor.

Evaluation -

Cause -

MC Fault Code 120014 Fault Code 120014-2

Trouble or MP Dr. Message Inspection Method Overrun Alarm Disconnect the connector from the machine speed sensor. Retry by using MPDr.

T5-5-68

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

Trouble or MP Dr. Message Inspection Method Abnormal REG input H Measurement of voltage level between monitor controller harness end and chassis Measurement of voltage at alternator terminal L -

Connector (Harness end)  Monitor Controller-2B Connector REG Input

90Z6-05-M2B

fNOTE: Refer to p. T5-1-14 for the alternator check.

T5-5-69

Evaluation 13 to 33.5 V

Cause Faulty monitor controller.

13 to 33.5 V

Open circuit in harness. Faulty alternator.

Normal in above check

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

115011-4

Trouble or MP Dr. Message Inspection Method Fuel Level Sensor Circuit Measure resistance High Input between sensor #1 and #2. Measure voltage between sensor harness end #1 and chassis. Fuel Level Sensor Circuit Low Input

Fuel Gauge

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

Cause Faulty sensor.

Open circuit in harness #1.

Normal in above check. Refer to the table.

Open circuit in harness #2. Faulty sensor.

Measure resistance between sensor #1 and #2. Normal in above check. No. A B C

Evaluation Refer to the table.

TNED-05-05-008

Connector (Harness end)  Fuel Sensor

90Z7-05-CN11

T5-5-70

Shorted circuit in harness #1 and #2.

Fuel Sensor (Ω) 10 (+5/0) 32.9±2.5 90±2.5

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

in) 6.3 m( m 0 R16

349.9±10 mm (13.78±0.4 in)

212.5 mm (8.37 in)

100.6±10 mm (3.96±0.4 in)

Fuel Level Sensor Specifications

1/2

Float

35828-60470C

 Fuel Sensor Harness Connector

Unit (Blue)

 Fuel Sensor Circuit

Gauge

GND (Black)

DC12V

Unit

35828-60470

35828-60470C1

fNOTE: Refer to the table on the previous page for the resistance.

T5-5-71

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Monitor) Fault Code 120300 Fault Code 120300-2

Trouble or MP Dr. Message Inspection Method System Failure Alarm Check CAN harness.

Evaluation -

Cause Faulty CAN harness.

Column Display Controller (Information) Fault Codes 120500 to 120503 Fault Code 120500-2

Trouble or MP Dr. Message Inspection Method Overheat Alarm Disconnect a connector from the overheat switch (Coolant temperature switch on the engine). Retry by using MPDr.

120501-2

Engine Error

120502-2

Engine Oil Pressure Alarm

120503-2

Air Cleaner Restriction Alarm

Un-displayed fault code Diagnose on fault codes of ECM. Diagnose on fault codes of ECM. Disconnect a connector Displayed fault code from air filter restriction switch. Retry by using MPDr. Un-displayed fault code

Connector (Harness end)  Column Display Controller (Monitor) 1-A Connector

Overheat (GY)

Air Cleaner Restriction (RL)

Evaluation Displayed fault code

Engine Oil Pressure (V)

90Z6-05-M1A

T5-5-72

Cause Faulty column display controller or shorted circuit in harness. Faulty overheat switch. Faulty column display controller or shorted circuit in harness. Faulty air filter restriction switch.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Column Display Controller (Information) Fault Codes 120505 to 120507 Fault Code 120505-2

120506-2

120507-2

Trouble or MP Dr. Message Inspection Method Brake Pressure Alarm Disconnect brake primary pressure sensor. Retry by using MPDr.

Steering Oil Pressure Alarm Disconnect a connector (for Secondary Steering from the steering oil Option) pressure switch. Retry by using MPDr. Transmission Malfunction

Check the accompanied T/M solenoid or revolution sensor error, and check for the error.

Service Brake Primary Pressure Sensor

Evaluation Displayed fault code

Un-displayed fault code Displayed fault code

Un-displayed fault code -

Cause Faulty column display controller or shorted circuit in harness. Faulty brake primary pressure sensor. Faulty column display controller or shorted circuit in harness. Faulty steering oil pressure switch. -

Connector (Harness end)  Column Display Controller (Monitor) 1-A Connector

90Z6-05-M1A Steering Oil Pressure (RB)

 Column Display Controller (Monitor) 1-B Connector

Brake Pressure (O)

90Z6-05-05-07

fNOTE: Service brake primary pressure sensor is installed to the charging block. Refer to F&S S/M p.T3-7-13 for the specifications. The steering oil pressure switch is installed to the optional secondary steering block. (See p. T5-4-18.)

T5-5-73

90Z6-05-M1B

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Codes 11 to 22 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 11

Trouble or MP Dr. Message Open circuit in recirculated air sensor

Shorted circuit in recirculated air sensor

Open circuit in outdoor ambient temperature sensor

Inspection Method

Evaluation

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

∞ Ω (Normal value: Faulty sensor. 300 to 430 kΩ) 0V Open circuit in harness #1.

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

Shorted circuit in outdoor ambient temperature sensor

Measure resistance between sensor #1 and #2. -

Shorted circuit in solar radiation sensor

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

Open circuit in frost sensor

Shorted circuit in frost sensor

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

T5-5-74

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

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

Cause

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

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

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

Normal in above check. 0 Ω (Normal value: 100 to 115 kΩ) Normal in above check.

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Codes 43 to 92 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 43

Trouble or MP Dr. Message Abnormal air vent damper servo motor

Abnormal air mix damper servo motor

Abnormal refrigerant pressure high and low.

CAN communication error

CAN bus off error

Inspection Method

Evaluation

Cause

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

Faulty air mix damper servo motor. Faulty controller or open circuit in harness between controller and High and low pressure switch. Faulty High and low pressure switch. Faulty controller. Faulty CAN1 harness.

Check continuity in CAN1 harness.

Faulty controller. Faulty CAN1 harness.

T5-5-75

Normal Abnormal

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

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

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-76

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure Refer to troubleshooting B procedures for diagnosis by using trouble symptom when no fault codes are displayed.  Diagnosis Procedure  The diagnosis procedures for the observed machine abnormality without any fault codes are explained in this group.  Perform diagnosis by using MPDr. or the service menu of monitor first.  In case any fault code has not been displayed by diagnosis, perform inspection according to the procedures when diagnosing.  When the fault code is displayed, refer to the troubleshooting A group and diagnose.  On the front section pages of this group, there are the tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if failed. Start the troubleshooting with more probable causes selected by referring to these tables.

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

1 2

T6L4-05-03-001 1-

Harness End Connector

Harness

T5-6-1

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Contents of Diagnosis

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

How to Read Table Procedure (A) (F)

Inspection Method (B) (G)

Condition

Evaluation

Cause

(D) (I)

(E) (J)

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

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

T5-6-2

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Relationship between Machine Trouble Symptoms and Related Parts This table indicates the relationship between machine trouble symptoms and the potential problem parts, which may cause trouble if failed, and the evaluation methods of these components. Parts MC (Main Controller) 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.) The engine speed is fixed to 1000 Although the accelerator pedal Symptoms is operated, hydraulic load is not min-1. in machine As pump displacement is held at released. operation when trouble minimum, all actuator speeds are slow. occurs 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 See p. T5-5-49 for the accelerator pedal sensor. Descriptions T2-2 T2-2 of Control (Refer to 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 of Control (Refer to F&S S/M)

T2-2

Quick Power Switch

Declutch Position Switch

Turns power mode ON/OFF.

Activates or deactivates the declutch control. Declutch control is not activated.

Same as shown below.

Functions of power mode switch become effective.

Although declutch position switch is turned ON, the declutch indicator on monitor is not ON.

MC: Quick Power Switch

MC: Delutch Position Switch

When quick power mode control Brake Pedal Depressing Amount: Two modes, Fully and Lightly is effective. with the declutch position switch (Quick power mode is not activated when travel is in neutral set in the ON position or the travel load is light.) T2-2 T2-2

T5-6-4

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

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. MC holds the travel in neutral.

Symptoms in control system when trouble occurs Symptoms Cooling fan does not rotate in in machine reverse. operation The fan reverse rotation indicator when trouble on monitor is not ON. (The occurs indicator does not blink when shifting.) Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-2, 2-4 of Control (Refer to F&S S/M)

Although forward/reverse lever is operated, machine does not travel forward/reverse. The FNR indication on monitor is not shifted. 111904 (F/R input at the same time) MC: Forward/Reverse Lever (F)/ (N)/(R) -

T2-2, T2-5

T5-6-5

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

Selects forward/reverse lever or Shifts forward clutch solenoid forward/reverse switch operation valve, and reverse clutch solenoid valve of transmission. MC makes forward/reverse switch MC makes forward/reverse lever operation effective. operation effective.

Symptoms in control system when trouble occurs Symptoms Functions of forward/reverse in machine lever become effective. operation when trouble occurs Evaluation by Fault Code Evaluation by MC: Forward/Reverse Selector Monitoring Switch Evaluation by using Test Harness Note The operation is effective with forward/reverse lever and forward/reverse switch set in the neutral position. Descriptions of Control (Refer to F&S S/M)

T2-2, T2-5

Functions of forward/reverse lever become effective.

111905 (F/R simultaneous input) MC: Forward/Reverse Switch (F)/ (N)/(R) -

When forward/reverse lever is operated, forward/reverse selector switch operation becomes ineffective. (forward/ reverse lever has priority) T2-2, T2-5

T5-6-6

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Shift Switch Item Function

Downshift Switch (DSS)

Hold Switch

Shifts speed shift solenoid valves Shifts speed shift solenoid valves (1, 2, and 3) of transmission. of transmission and shifts down the speed shift during automatic speed shift. MC holds the speed shift in Same as shown below. second speed.

Shifts speed shift solenoid valves of transmission and holds the speed shift during automatic speed shift. Same as shown below.

The speed shift is not shifted down although downshift switch (DSS) is turned ON during automatic speed shift. The shift indication on monitor is not shifted. -

The speed shift is not held although hold switch is turned ON during automatic speed shift. The hold indication on monitor is not shifted. -

MC: DSS Switch

MC: Shift Hold Switch

T2-2

Symptoms in control system when trouble occurs Symptoms The speed shift is held in second in machine speed with travel mode set in operation Manual mode or AUTO 2 mode. when trouble The speed shift is automatically occurs changed to first speed from second speed in AUTO 1 mode. Evaluation by Fault Code Evaluation by MC: Shift Switch Monitoring Evaluation by using Test Harness Note Descriptions T2-2, T2-5 of Control (Refer to F&S S/M)

T5-6-7

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Ride Control Switch, Ride Control Switch (AUTO) (Option) Shifts ride control solenoid valves (rod side and bottom side) 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, Ride Monitoring Control Switch (AUTO) Evaluation by using Test Harness Note Descriptions T2-2, T2-4 of Control (Refer to F&S S/M)

T5-6-8

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

Shifts parking brake solenoid valve. Same as shown below.

Shifts pilot shut-off (control lever lock) solenoid valve. Same as shown below.

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. -

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 (Refer to F&S S/M)

Front Control Lever Lock Switch

Column Display Controller: Parking Brake Signal Output -

MC: Pilot Primary Pressure -

Although the parking brake is turned OFF, the parking brake is applied with the engine stopped. T2-2, T2-5 T2-4

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 temperature. Symptoms MC recognizes that hydraulic in control oil temperature is 120°C (248°F) system when when open circuit occurs. trouble occurs (Hydraulic oil temperature: 120°C (248°F) is not displayed on monitoring.) Symptoms When hydraulic oil temperature in machine is 0°C (32°F) or less when starting operation engine, auto-warming up control when trouble is not operated. occurs Evaluation by 111901 Fault Code Evaluation by MC: Hydraulic Oil Temperature Monitoring Evaluation by using Test Harness Note Refer to p. T5-5-64 for the temperature sensor. Descriptions T2-2 of Control (Refer to F&S S/M)

Monitors torque converter oil temperature. MC recognizes that torque converter oil temperature is 120°C (248°F) when open circuit occurs.

The color of transmission oil temperature on monitor is red. The buzzer sounds and the indicator is displayed. 111900 MC: Torque Converter Oil Temperature -

Refer to pp. T5-4-12, T5-5-63 for the temperature sensor. T2-2

T5-6-10

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pump Delivery Pressure Sensor Item Function

Detects pump delivery pressure.

Hyd. Fan Circuit Pressure Sensor (Option)

Secondary Steering Pump Delivery Pressure Sensor (Option)

Detects hydraulic fan circuit 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.

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 The secondary steering pump is in machine not activated. switch is operated, fan rotation operated normally. (When the operation direction can not change. engine starts) when trouble occurs Evaluation by 111204 111206 111208 Fault Code Evaluation by MC: Pump Delivery Pressure MC: Hydraulic Fan Circuit Pressure MC: Secondary Steering Pump Monitoring Delivery Pressure Evaluation by using Test Harness Note Refer to p. T5-4-13 for the sensor. Refer to p. T5-5-54 for the sensor. Refer to p. T5-4-18 for the sensor. Possible to judge if sensor or Possible to judge if sensor or Possible to judge if sensor or harness is faulty by switching harness is faulty by switching harness is faulty by switching pressure sensor with other pressure sensor with other pressure sensor with other pressure sensor. pressure sensor. pressure sensor. Descriptions T2-2 T2-2 T2-2 of Control (Refer to F&S S/M)

T5-6-11

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.

The low brake oil pressure indicator is always ON.

Although the parking brake is applied, the parking brake indicator is not ON. The machine may not accelerate by possible parking brake dragging because parking brake ON/OFF cannot be judged. 111313

MC: Steering Pressure Switch

MC: Parking Brake Pressure

Item Function Detects steering circuit pressure. Symptoms Open circuit: Secondary steering in control operation condition: Steering system when pressure decreases. trouble occurs Symptoms Secondary steering pump is in machine operated when the harness is operation disconnected while traveling. when trouble The low steering oil pressure occurs indicator is always ON.

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

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

111311 MC: Service Brake Primary Pressure -

Refer to p. T5-4-15 for the sensor. Refer to p. T5-4-15 for the sensor. Refer to p. T5-4-18 for the Possible to judge if pressure Possible to judge if pressure pressure switch location. sensor is faulty or port is clogged sensor is faulty or port is clogged Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with by switching pressure sensor with other pressure sensor. by switching pressure switch with other pressure sensor. pump delivery pressure switch. T2-2 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 Declutch) Evaluation by using Test Harness Note Refer to p. T5-4-16 for the sensor.

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

T2-2

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.

111205

Front attachment operation circuit selection control is not activated during combined operation of lift arm and bucket dump. The ride control is not activated. 111200

MC: Lift Arm Angle Sensor

MC: Lift Arm Raise Pilot Pressure

Refer to p. T5-4-4 for the sensor location.

Refer to p. T5-4-17 for the sensor. 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 OFF (Lock) position, front occurs control lever lock indicator is not ON. Evaluation by 111217 Fault Code Evaluation by MC: Pilot Pressure Sensor Monitoring Evaluation by using Test Harness Note Refer to p. T5-4-16 for the sensor. Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. Descriptions T2-2, T2-4 of Control (Refer to F&S S/M)

T5-6-14

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 bad extremely during automatic speed shift. Possible to judge if sensor is faulty by switching sensor with other sensor. -

Nothing special.

111602-3

Torque Converter Output Speed

Possible to judge if speed sensor is faulty by switching pressure sensor with other speed sensor. T2-2

Symptoms in control system when trouble occurs Symptoms The speed change feeling in machine becomes bad extremely during operation automatic speed shift. when trouble Possible to judge if sensor is occurs faulty by switching sensor with other sensor. Evaluation by 111105-3 Fault Code Evaluation by Torque Converter Actual Input Monitoring Speed 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 (Refer to F&S S/M)

fNOTE: Refer to p. T5-4-12 for the sensors.

T5-6-15

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Machine Speed Sensor Item Function

Detects transmission output shaft speed. When abnormality is detected, the following symptoms occur.

Symptoms in control system when trouble occurs Symptoms The speed meter continues to in machine display 0 km/h. operation The overrun alarm control is not when trouble effective. occurs The ride control is not effective. Evaluation by 111600 Fault Code Evaluation by MC: Machine Speed Pulse Monitoring Evaluation by using Test Harness Note Refer to p. T5-4-12 for the sensor location. Possible to judge if speed sensor is faulty by switching pressure sensor with other speed sensor. Descriptions T2-2 of Control (Refer to F&S S/M)

Pressure Sensor (Refrigerant Pressure) Detects air conditioner refrigerant pressure. When output is 0 V or 5 V, the following symptoms occur.

The fan speed is fixed to the maximum. The fan reverse rotation control is not activated.

111207 MC: Air Conditioner Refrigerant Pressure -

Refer to p. T5-7-2 for the sensor.

T2-2

T5-6-16

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Ride Control Solenoid Valve (Option) Shifts ride control main spool in control valve. Connects the rod side circuit to the tank. Same as shown below.

Symptoms in control system when trouble occurs Symptoms High current: The ride control is in machine always activated. operation Low current: The ride control is when trouble not effective. occurs Evaluation by 111422 Fault Code Evaluation by MC: Ride Control P/S Output, Ride Monitoring Control P/S Output FB Evaluation Install light harness tool. by using Test Check output signals from MC Harness and harness condition. Note Refer to pp. T5-4-17 for the solenoid valves. Descriptions T2-2, 2-4 of Control (Refer to F&S S/M)

T5-6-17

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

Applies and releases parking brake by using pilot pressure oil. Same as shown below.

Symptoms in control system when trouble occurs Symptoms When closed: The parking brake in machine is not released. (Pilot pressure oil operation is not supplied to parking brake.) when trouble When open: The parking brake occurs is applied. (Pilot pressure oil is supplied to parking brake.) Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

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

This solenoid valve can be manually turned ON/OFF. Refer to p. T5-4-15 for the solenoid valve location. T2-2, 2-4

Pump Swash Plate Tilt Solenoid Valve (Pump Torque Control Solenoid) Supplies control pressure to main pump. Same as shown below.

High current: Pump torque of main pump is kept minimum. The loading movement becomes slow. Low current: Engine speed regulation for digging is deactivated. 111413 MC: Pump Swash Angle P/S Output, Pump Swash Angle P/S Output FB -

Refer to p. T5-5-59 for the solenoid valve.

T2-2

T5-6-18

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Hyd. Fan Speed Control Solenoid Hyd. Fan Reverse Rotation Valve Control Solenoid Valve (Option) Control hydraulic fan rotation speed. Same as shown below.

Symptoms in control system when trouble occurs Symptoms High current: The fan speed is in machine fixed to the minimum. operation Low current: The fan speed is when trouble fixed to the maximum. occurs Evaluation by 111412 Fault Code Evaluation by MC: Hyd Fan Speed Control P/S Monitoring Output, Hyd Fan Speed Control P/S Output FB Evaluation by using Test Harness Note Refer to p. T5-5-58 for the solenoid valve. Descriptions T2-2, 2-4 of Control (Refer to F&S S/M)

Shifts hydraulic fan reverse rotation spool of fan valve. Same as shown below.

High current: The fan always rotates in reverse. Low current: The fan does not rotate in reverse. 111411 MC: Hyd Fan Reverses Rotation P/S Output, Hyd Fan Reverses Rotation P/S Output FB -

Refer to p. T5-5-57 for the solenoid valve. 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 (1, 2, Valves and 3) Shifts forward spool, and reverse spool of transmission control valve. Same as shown below.

Symptoms in control system when trouble occurs Symptoms Defective clutch gears cannot in machine engage. operation when trouble occurs Evaluation by MC: 111418, 111419 Fault Code Evaluation by T/M Clutch Forward P/S Valve Monitoring Output T/M Clutch Forward P/S Valve FB T/M Clutch Reverse P/S Valve Output T/M Clutch Reverse P/S Valve FB

Evaluation by using Test Harness Note Descriptions of Control (Refer to F&S S/M)

Shifts spools in speed shift solenoid valves (1, 2, and 3) of transmission control valve. Same as shown below.

Defective clutch gears cannot engage.

MC: 111414, 111415, 111416, 111417 T/M Clutch 1st P/S Valve Output T/M Clutch 1st P/S Valve FB T/M Clutch 2nd P/S Valve Output T/M Clutch 2nd P/S Valve FB T/M Clutch 3rd P/S Valve Output T/M Clutch 3rd P/S Valve FB T/M Clutch 4th P/S Valve Output T/M Clutch 4th P/S Valve FB -

Refer to p. T5-4-12 for the solenoid valves. T2-2

fNOTE: Refer to pp. T5-5-18, 19 for the detailed machine operation when trouble occurs.

T5-6-20

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Main Relief Valve for Main Pump Item Function

Prevents pressure in main pump circuit from exceeding the set pressure when a control lever is operated. Same as shown below.

Symptoms in control system when trouble occurs Symptoms If stuck in fully closed position, in machine hose of front attachment may be operation damaged. when trouble If stuck in fully open position, occurs power is weak during digging operation. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Refer to 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

fNOTE: Refer to p. T5-6-57 and F&S S/M Section T3-2 Control Valve for each valve.

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 engine. Machine speed does not increase. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Refer to F&S S/M)

fNOTE: Refer to F&S S/M Section T3-2 Control Valve for each valve.

T5-6-22

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B

Item Function

Parts Ride Control Valve Main Spool (Optional Ride Control Valve)

Fan Reversing Spool (Fan Valve) (Option)

Is shifted by pilot pressure from ride control solenoid valve. Connects the accumulator to lift arm cylinder circuit and increases/decreases the lift arm cylinder bottom pressure. Same as shown below.

Is shifted by pilot pressure from fan reverse rotation control solenoid valve in fan valve. Changes the fan rotation direction (in normal / reverse).

Symptoms in control system when trouble occurs Symptoms If stuck in neutral position, the in machine ride control is not activated. operation If stuck in ride control operating when trouble position, digging operation is not occurs smooth.

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Refer to F&S S/M)

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 Parts Main Relief Valve (Steering) Item Function

Prevents pressure in main pump circuit from exceeding the set pressure when a steering wheel is operated. Same as shown below.

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 steering wheel rotation speed occurs becomes slow. Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-4 of Control (Refer to F&S S/M)

T5-6-24

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.

T5-6-25

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting Trouble Symptom E-1 Starter does not rotate. Parts Main Controller (MC) Engine Control Module (ECM) Information Controller (ICF) 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 Voltage Relay ECM Main Relay Starter Engine Unit Coolant Temperature Sensor Heater Relay Intake Air Heater Pump Delivery Pressure Sensor

: 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)  (#12)    

 (#9, #10)

 (#14) 

 

: Related

T5-6-26

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting

Parts

Trouble Symptom E-4 Power mode is not shifted down when pushing power mode switch.

Main Controller (MC) Engine Control Module (ECM) Information Controller (ICF) Column Display Controller MPDr. Key Switch Accelerator Pedal Sensor Power Mode Switch Parking Brake Switch Forward/Reverse Lever Forward/Reverse Selector Switch (Option) Forward/Reverse Switch (Option) Battery Battery Relay Fuse Box A Fuse Box B Starter Relay 1 ECM Main Relay Engine Actuator Relay Starter Engine Unit Coolant Temperature Sensor Pump Delivery Pressure Sensor Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor Pressure Sensor (Parking Brake)

: Check required



E-5 Even if key switch is turned OFF, engine does not stop.  

   



  

: Related

T5-6-27

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting

Parts

Trouble Symptom A-1 Actuator of only front attachment do not work.

Main Controller (MC) Battery Fuse Box A Pilot Shut-Off Relay (Option) Front Control Lever Lock Switch (Option) Power Mode Switch Pilot Pump Charging Block Brake Priority Valve Charge Relief Valve Pump Torque Control Solenoid Valve Pilot Shut-Off Valve Pilot Valve Pressure Sensor (Primary Pilot Pressure) Pressure Sensor (Lift Arm Raise) (Option) Spool (Multiple Control Valve) Spool (Steering Valve) Main Relief Valve (Multiple Control Valve) Cylinder Main Pump Pump Delivery Pressure Sensor Pump Regulator Pilot Filter

: Check required

A-2 Actuator speed of front attachment and steering are slow. 

 (#16)  

  

  

         



  

   

: Related

T5-6-28

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting

Parts

Trouble Symptom A-3 Actuator of front attachment does not stop even if a control lever is set to neutral.

Main Controller (MC) Engine Control Module (ECM) Information Controller (ICF) Key Switch Accelerator Pedal Sensor Forward/Reverse Lever Pilot Shut-Off Relay Front Control Lever Lock Switch Battery Engine Unit Engine Speed Sensor (Main) Engine Speed Sensor (Sub) Coolant Temperature Sensor Main Pump Fan Pump Pump Regulator Pump Delivery Pressure Sensor Torque Control Solenoid Valve Pressure Sensor (Primary Pilot Pressure)  Pilot Valve  Multiple Control Valve Pilot Filter Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor Pressure Sensor (Parking Brake)

: Check required

: Related

T5-6-29

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting Trouble Symptom A-5 Fan speed does not change. Parts Main Controller (MC) Engine Control Module (ECM) Information Controller (ICF) MPDr. Key Switch Accelerator Pedal Sensor Power Mode Switch Fan Reverse Rotation Switch (Option) Battery Fuse Box A Fuse Box B Fan Speed Control Solenoid Valve Fan Reverse Rotation Control Solenoid Valve (Option) Fan Control Valve (Option) Fan Motor Fan Pump Engine Unit Engine Speed Sensor (Main) Engine Speed Sensor (Sub) Coolant Temperature Sensor Boost Temperature Sensor Hydraulic Fan Circuit Pressure Sensor Hydraulic Oil Temperature Sensor Torque Converter Oil Temperature Sensor Pressure Sensor (Refrigerant Pressure) Pressure Sensor (Parking Brake)

: Check required



A-6 Fan does not rotate in reverse when pushing fan reverse rotation switch. (option)   



 (without reversing fan)  (with reversing fan)   (with reversing fan)  

  



  

 

: Related

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.

Main Controller (MC)

F-2 Some cylinders are not operated or speed are slow.



Battery Fuse Box B Front Control Lever Lock Switch (Option) Power Mode Switch  Pilot Pump  Brake Priority Valve  Pilot Relief Valve  Charge Relief Valve Torque Control Solenoid Valve  Front Control Lever Lock Solenoid Valve (Combination Valve) (Option) Pilot Valve  Pressure Sensor (Primary Pilot Pressure) Pressure Sensor (Lift Arm Raise)  (Option)  Spool (Multiple Control Valve)  Main Relief Valve (Multiple Control Valve)  Pump Control Valve (Multiple Control Valve) Cylinder  Main Pump Pump Delivery Pressure Sensor   Priority Valve Pump Regulator  Pilot Filter

: Check required





  (Overload)



: Related

T5-6-31

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting

Parts

Trouble Symptom F-3 Front attachment drifts remarkably (when the engine is stopped).

Main Controller (MC) Information Controller (ICF) Pilot Valve Shockless Valve Pressure Sensor (Lift Arm Raise) (Option) Spool (Multiple Control Valve) Load Check Valve (Multiple Control Valve) Cylinder Main Pump

: Check required

F-4 Shock during bucket dumping is large when stopping lift arm raise / lower operation.



  (Lift Arm) 

 



: Related

T5-6-32

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting

Parts

Trouble Symptom F-5 F-6 Bucket auto leveler control is Lift arm float control is not not activated. (Detent is not activated. (Detent is not held.) held.)

Main Controller (MC) Information Controller (ICF) Battery Battery Relay Fuse Box A Lift Arm Angle Sensor (Option) Bucket Proximity Switch Charging Block Pilot Valve Bucket Detent Relay Bucket Detent Coil Lift Arm Raise Side Coil (Pilot Valve) Spool (Multiple Control Valve) Cylinder Main Pump

: Check required

 (#16)

  (Bucket)  

 (Lift Arm)

  (Bucket)

 (Lift Arm)

: Related

T5-6-33

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting

Parts

Trouble Symptom F-7 Lift arm auto leveler height kickout control (option) is not activated.

Main Controller (MC) Information Controller (ICF) MPDr.

F-8 Lift arm auto leveler lower kickout control (option) is not activated.

F-9 Ride control (option) is not activated.



 (Lift Arm Angle Sensor Learning)  (#16) 

 (Setting: ON)

Fuse Box A Lift Arm Angle Sensor (Option) Machine Speed Sensor Ride Control Switch (Option) Pilot Valve  (Lift Arm)  Lift Arm Raise Side Coil (Pilot Valve) Lift Arm Lower Side Coil (Pilot Valve) Pressure Sensor (Primary Pilot Pressure) Flow Regulator Valve Pressure Sensor (Lift Arm Raise) (Option) Ride Control Solenoid Valve (Option) Spool (Control Valve)  (Lift Arm) Spool (Ride Control Valve) (Option) Cylinder Accumulator (Ride Control) (Option) Main Pump Pump Delivery Pressure Sensor

: 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 Main Controller (MC) Brake Charge Valve Pilot Relief Valve Charge Relief Valve Torque Control Solenoid Valve Pressure Sensor (Primary Pilot Pressure) Orbitrol (Steering Pilot Valve) 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 Steering Priority Valve Pump Regulator Pilot Filter

: Check required

       

S-3 Shock of steering operation is large.

   





 



 

 





: Related

T5-6-35

 

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting

Parts

Trouble Symptom S-4 Secondary steering (option) does not operate. (Automatic operation check when the engine starts)

Main Controller (MC) Information Controller (ICF) MPDr. Battery Fuse Box A Secondary Steering Relay (Option) Machine Speed Sensor Charging Block Orbitrol (Steering Pilot Valve) Spool (Steering Valve) Steering Pressure Switch (Option) Secondary Steering Pump Delivery Pressure Sensor (Option) Steering Cylinder (Left, Right) Steering Accumulator Main Pump Secondary Steering Motor (Option) Secondary Steering Pump (Option)

: 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.

 Main Controller (MC) Information Controller (ICF) Battery Accelerator Pedal Sensor Brake Valve Forward/Reverse Lever  (Forward / Reverse)  Forward/Reverse Switch (Option)  Forward/Reverse Selector Switch (Option) Declutch Position Switch  Drive Unit (Transmission Assy)  Transmission Control Valve Torque Converter Input Speed Sensor Torque Converter Output Speed Sensor Transmission Intermediate Shaft Speed Sensor Machine Speed Sensor Forward Clutch Solenoid Valve   Reverse Clutch Solenoid Valve  Propeller Shaft  Axle Pressure Sensor (Brake Secondary Pressure) Pressure Sensor (Parking Brake) 

: Check required

T-2 Although forward/reverse lever is set to neutral position, machine travels. (Neutral Control)

T-3 Clutch cut is not operated. (Declutch Control)



 (Neutral) 

  (Forward)



 

    

 

 



: Related

T5-6-37

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting

Parts

Trouble Symptom T-4 Travel mode can not be changed.

 Main Controller (MC) Information Controller (ICF) Battery  Travel Mode Selector Switch Shift Switch Power Mode Switch Drive Unit (Transmission Assy) Transmission Control Valve Torque Converter Input Speed Sensor Torque Converter Output Speed Sensor Transmission Intermediate Shaft Speed Sensor Machine Speed Sensor Speed Shift Solenoid Valve Pressure Sensor (Brake Secondary Pressure)

: Check required

T-5 Although shift switch is operated, speed shift does not change. (Manual Speed Shift Control)

T-6 Although vehicle speed changes, speed shift does not change automatically. (Automatic Speed Shift Control)



 (Manual Mode) 

 (AUTO 1/AUTO 2 Mode)

  

   



 

 

: Related

T5-6-38

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting

Parts

Trouble Symptom T-7 Speed shift is not shifted down when pushing downshift switch (DSS).

 Main Controller (MC) Information Controller (ICF) Key Switch Battery Fuse Box A Fuse Box B Accelerator Pedal Sensor Travel Mode Selector Switch Power Mode Switch Forward/Reverse Lever Forward/Reverse Switch (Option) Forward/Reverse Selector Switch (Option) Shift Switch  Downshift Switch (DSS) Hold Switch  Drive Unit (Transmission Assy)  Transmission Control Valve Torque Converter Input Speed  Sensor Torque Converter Output Speed  Sensor Transmission Intermediate Shaft Speed Sensor  Machine Speed Sensor  Speed Shift Solenoid Valve Pressure Sensor (Parking Brake) Lift Arm Angle Sensor (Option) Pressure Sensor (Lift Arm Raise) (Option)

: Check required

T-8 Speed shift is not held when pushing hold switch. (Effective in automatic speed

T-9 Speed shift retard control is not activated. (Effective in automatic speed

shift control mode) 

shift control mode)    (ON) 

    

  

   

 

   

: Related

T5-6-39

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting

Parts

Trouble Symptom B-1 Parking brake is not released. (When the engine runs. )

Main Controller (MC) Information Controller (ICF) 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 Charging Block Pressure Sensor (Parking Brake) Charge Relief 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 function lowers.

 (ON)  (#13, #18)

 (#13)

 (Released)  (OFF)  (ON)  

 (Operated)  (ON)   

  



      

 

The parking brake can be released with the residual pressure in the service brake accumulator even when the engine is stopped.

: Related

T5-6-40

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting

Parts

Trouble Symptom O-1 Clearance light, tail light, and license plate light are not ON.

Main Controller (MC) Information Controller (ICF) Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Light Switch Dimmer Switch Head Light Relay High Beam Relay Head Light Clearance Light Tail Light License Plate Light (Option)

: Check required

 (Indicator)   (#4, #14) 

O-2 Head light is not ON.

O-3 Head light is not shifted to high beam.

 (Indicator)  (ON)

 (#3, #4)

 (#4, #19)

  

 

   

: Related

T5-6-41

  (High Beam)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting

Parts

Trouble Symptom O-4 O-5 Hazard light is not operated. Turn signal light is not operated.

Main Controller (MC) Information Controller (ICF) 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 Horn Relay Turn Signal Light (Hazard Light) Horn

: Check required

 (Indicator)   (#7)

 (Indicator)  (ON)   (#2, #7)

O-6 Horn does not sound.

  (#6)

    

 



 

: Related

T5-6-42

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting

Parts

Trouble Symptom O-7 Reverse light is not ON. Reverse buzzer does not sound.

Main Controller (MC) Information Controller (ICF) 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 Brake Light Relay Work Light (Front) Relay Work Light (Rear) Relay Reverse Light Reverse Buzzer Brake Light Work Light

: Check required

O-8 Brake light is not ON.

O-9 Work light does not light.

 (ON)

 (Indicator)  (ON)

 (#1, #13)

 (#2)

 (#4, #17)

 (R)

 (R)           

: Related

T5-6-43

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting Trouble Symptom O-10 Wiper is not operated.

O-11 Washer is not operated.

O-12 Cab light is not ON.

Parts Main Controller (MC) Information Controller (ICF) Column Display Controller Key Switch Battery Fuse Box A Fuse Box B Front Wiper/ Washer Switch Rear Wiper/ Washer Switch Cab Light Switch Rear Cab Light Switch Door Open/Close Switch (Cab) Front Wiper Relay 1 Front Wiper Relay 2 Rear Wiper Relay Front Washer Relay Rear Washer Relay Front Wiper Motor Rear Wiper Motor Front Washer Motor Rear Washer Motor

: Check required

  (ON)

 (ON) 

 (#3, #5)  

 (#11)

     (Fast Speed)       

: Related

T5-6-44

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting E-1 Starter does not rotate. Preparation  Check that the forward/reverse lever is in the neutral position.  This trouble has nothing to do with the electronic control system such as Main Controller (MC).

 In case the radio with the key switch set in the ACC position and the horn with the key switch set in the OFF position are operated normally, the harness between battery and key switch terminal B is considered normal.

 Check the wiring connections first. Procedure Inspection Method 1 Measure battery voltage and electrolyte density

Condition -

Set the key switch to START after replacing relays Measure voltage between Key switch: START neutral relay harness end #3 and chassis Replace the starter cut Set the key switch to relay with new one START after replacing relay Measure voltage between Key switch: START starter cut relay harness end #3 and #2 Measure voltage at Key switch: START starter relay harness end terminal C Check continuity Key switch: ON between starter cut relay harness end #2 and chassis

Replace the neutral relay with other general relay

Evaluation The measured values are out of normal range (Normal range: Voltage: 24 V or more, Electrolyte density: 1.26 or more) Starter: Rotating

Cause Faulty battery

Open circuit in harness between key switch and neutral relay Faulty starter cut relay

Starter: Rotating

∞Ω

Connectors  Neural Relay (Harness end)

 Starter Cut Relay (Harness end)

90Z6-05-06-01

90Z6-05-06-02

T5-6-45

Faulty neutral relay

Open circuit in harness between neutral relay and starter cut relay Open circuit in harness between starter cut relay and starter relay Open circuit in harness between starter cut relay and chassis (GND)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (E-1 Starter does not rotate) Procedure Inspection Method 8 Measure voltage at starter terminal B 9 Measure voltage at starter terminal C 10 Check continuity between key switch #1 and #4 11 Monitor Forward/Reverse Lever (N) 12 -

Condition Key switch: ON

Evaluation 0V

Cause Faulty battery relay

Key switch: START

Faulty starter relay

Key switch: START

∞Ω

Faulty key switch

Forward/reverse lever: N

OFF is displayed

The above checks resulted all normal.

Faulty forward/reverse lever Faulty starter

Connectors  Starter Cut Relay (Harness end)

 Key Switch (Switch end)

90Z6-05-06-02

90Z6-05-06-03

T5-6-46

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-2 Even if starter rotates, engine does not start. Preparation  Check that #9, #10 fuses in fuse box A are not abnormal.  Check the wiring connections first.  Check that the fuel filter is not clogged. Procedure Inspection Method Condition 1 Measure voltage Key switch: ON between ECM main relay 1 (A1) harness end #3 and chassis. 2 Measure voltage Key switch: ON between ECM main relay 2 (C1) harness end #3 and chassis. 3 Measure voltage between Key switch: ON ECM main relay 1 (A1), 2 (C1) harness end #1 and chassis. 4 -

Evaluation 0V

The check mentioned above is normal

Connectors  ECM Main Relay (Harness end)

90Z6-05-06-01

T5-6-47

Cause Open circuit in harness between ECM main relay 1 (A1) and fuse #9 in fuse box A. Open circuit in harness between ECM main relay 2 (C1) and fuse #10 in fuse box A. Open circuit in harness between ECM main relay 1 (A1), 2 (C1) and fuse #13 in fuse box A. Faulty ECM or engine unit

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-3 Engine starts with forward/reverse lever set in the positions except N. Preparation  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 (p. T2-5-10).  Refer to SYSTEM / Hydraulic System (F&S S/M T2-4).  Check the wiring connections first. Procedure Inspection Method 1 Check continuity between neutral relay (B6) harness end #2 and FNR switch (column) harness end #2 (R) or #4 (F) 2 Replace the neutral relay with other general relay

Condition -

Evaluation ∞Ω

Cause Open circuit in harness between forward/reverse lever and neutral relay

Forward/reverse lever: F or R Set the key switch to START after replacing relays -

Starter: Not rotating

Faulty neutral relay

The above checks resulted all normal.

Find out cause of trouble by tracing other trouble symptoms

Connectors  Neural Relay (B6) (Harness end)

 FNR Switch (Column) (Harness end)

90Z6-05-06-01

90Z6-05-06-04

T5-6-48

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-4 Power mode is not activated when pushing power mode switch. Preparation  Check the wiring connections first. Procedure Inspection Method 1 Monitor Power Mode Switch

Condition Power mode switch: ON

Evaluation OFF is displayed

The check (1) above resulted normal

T5-6-49

Cause Faulty power mode switch or open circuit in harness between power mode switch and Main Controller (MC) Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-5 Even if key switch is turned OFF, engine does not stop. Preparation  Remove 70 A fusible link (1) and stop the engine as emergency procedures first.  In case other trouble symptoms occur, perform troubleshooting of these troubles first.  If the fault code is not displayed, the key switch may be faulty.  Refer to SYSTEM / Electrical System (F&S S/M T2-5). 1

 Check the wiring connections first. 90Z6-05-01-01

T5-6-50

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.

 Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first.

 Check that #16 fuse in fuse box A is not abnormal.  Pilot valve and multiple control valve spools are unlikely to be faulty at the same time. Procedure Inspection Method 1 Switch pilot shut-off relay (C6)(option) with other general relay 2

Monitor Pilot Primary Pressure

Measure resistance between pilot shut-off solenoid valve #1 and #2 Check continuity between pilot shut-off relay harness end #4 and chassis -

Condition Front control lever lock handle, front control lever lock switch (option): UNLOCK position Front control lever lock switch (option): UNLOCK position -

Evaluation Cause The symptom disappears Faulty pilot shut-off relay

Pressure is not detected

Faulty front control lever lock switch

0/∞ Ω

Faulty pilot shut-off solenoid valve

Connect pilot shut-off ∞Ω solenoid valve harness end terminal #2 to chassis -

The check mentioned above is normal

Connectors  Pilot Shut-off Relay (C6) (Harness end)

90Z6-05-06-01

T5-6-51

Open circuit in harness between pilot shut-off solenoid valve and pilot shut-off relay Faulty pilot valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-2 Actuator speed of front attachment and steering are slow.

Primary Pilot Pressure

Specification Remark 3.7 +0.4/-0.1 MPa (537 +58/-15 PSI) Accelerator pedal: Full stroke

Preparation  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.

 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 (F&S S/M T2-4).

Procedure Inspection Method 1 Monitor Lift Arm Raise Pilot Pressure (option)

Condition Lift arm relief operation

Monitor Pilot Primary Pressure

Disassemble and inspect the priority valve (charging block) Measure pressure at port Accelerator pedal: Fully LS of priority valve (main) depressed without load (Control lever: Neutral)

Main Pump

TNED-05-01-003

T5-6-52

Evaluation The measured values are not within the normal values (Normal value: 3.4 to 4.2 MPa) (493 to 609 PSI) The measured values are not within the normal values (Normal value: 3.7 to 5.3 MPa) (537 to 769 PSI) There is abnormality

The measured values are not within the normal values (Normal value: 1.2 to 2.6 MPa) (174 to 377 PSI) The check mentioned above is normal

Cause Faulty pilot relief valve in manifold valve

Clogged pilot filter

Faulty priority valve (charging block) (stuck spool) Faulty priority valve (main) (stuck spool)

Faulty pump device

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-3 Actuator of front attachment does not stop even if a control lever is set to neutral. Preparation  Stuck spool in the pilot valve or stuck main spool in the multiple control valve is suspected. Procedure Inspection Method Condition 1 Set the front control lever lock switch to LOCK position 2 -

Evaluation Actuator stops

Cause Faulty pilot valve (stuck spool)

The check (1) above resulted normal.

Faulty multiple control valve (stuck spool)

T5-6-53

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-5 Fan speed does not change. Preparation  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.  Refer to SYSTEM / Control System / Fan Speed Control (p. T2-2-48). Procedure Inspection Method 1 Monitor Target Hydraulic Fan Speed

Condition Engine: Running

Monitor Hydraulic Fan Circuit Pressure (option)

Engine: Running

Disassemble and inspect the fan speed control solenoid valve Disassemble and inspect the fan control valve (option) -

Evaluation Cause Fan speed does not Faulty ECM or MC change according to accelerator pedal depressing amount Fan pump delivery Faulty fan pump pressure does not change according to accelerator pedal depressing amount There is abnormality Faulty fan speed control solenoid valve

There is abnormality

Faulty fan control valve

The check mentioned above is normal

Faulty fan motor Fan Speed Control Solenoid Valve

Fan Speed Control Solenoid Valve 90Z6T1-2-14

Fan Motor (Standard)

TNEE-01-02-031

Fan Control Valve (with Reversing Fan Option)

T5-6-54

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 (p. T2-2-50).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Fan Reversing Switch 2

Condition Parking brake is applied Fan reverse rotation switch: ON -

Measure resistance between fan reverse rotation control solenoid valves #1 and #2 Key switch: ON Measure voltage between fan reverse rotation control solenoid valve harness end #1 and chassis -

Evaluation OFF is displayed

Cause Faulty fan reverse rotation switch

0/∞ Ω (Normal value: 22 Ω)

Faulty fan reverse rotation control solenoid valve

Open circuit in harness between fan reverse rotation control solenoid valve and Main Controller (MC) Faulty MC

The above checks resulted all normal.

Fan Reverse Rotation Control Solenoid Valve

TNEE-01-02-031

Fan Control Valve (with Reversing Fan Option)

T5-6-55

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting F-1 All front attachment actuator power are weak. Main Relief Valve Standard Set Pressure Lift arm and bucket 29.4 +0.2/-0.5 MPa (4264 +29/-72.5 PSI) relief operation

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

fNOTE: Refer to p. T4-5-6 for the pump delivery pressure measurement.

3 1234-

90Z6-05-06-05

Overload Relief Valve (Lift Arm Bottom Side, Raise) Overload Relief Valve (Bucket Bottom Side, Roll Back) Overload Relief Valve (Bucket Rod Side, Dump) Main Relief Valve

T5-6-56

Evaluation The measured values are out of the specified range. The check (1) above resulted normal.

Cause Faulty main relief valve (readjust) Find out cause of trouble by tracing other trouble symptoms

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-2 Some cylinders are not operated or speeds are slow. Overload Relief Standard Valve Set Pressure Lift Arm Raise 36.8 +1.0/0 MPa (5337 +145/0 PSI) Bucket 32.5 +1.0/0 MPa (4714 +145/0 PSI)

Remark

Preparation  When parking brake is released normally, the primary pilot pressure is considered to be normal. Procedure Inspection Method 1 Measure Pilot Secondary Pressure

Condition Full operation of bucket roll back/dump and lift arm raise/lower

Replace overload relief valves, of which the set pressure are the same -

fNOTE: Refer to p. T4-5-12 for the overload relief set pressure measurement.

3 1234-

90Z6-05-06-05

Overload Relief Valve (Lift Arm Bottom Side, Raise) Overload Relief Valve (Bucket Bottom Side, Roll Back) Overload Relief Valve (Bucket Rod Side, Dump) Main Relief Valve

T5-6-57

Evaluation The measured values are out of the specified range. (Normal range: 3.4 ~ 4.2 MPa) Symptom is observed with the replaced relief valve. The above checks resulted all normal.

Cause Faulty pilot valve

Faulty overload relief valve Faulty control valve spool (stuck) Faulty cylinder (faulty seal kit)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-3 Front attachment drifts remarkably. Procedure Inspection Method 1 Set the front control lever lock lever to LOCK position 2 Replace the overload relief valve 3 Disassemble and inspect the cylinder 4 -

Condition -

Evaluation The symptom disappears

Cause Faulty pilot valve

The symptom disappears

Faulty overload relief valve

Abnormality found

Faulty cylinder (seal kit)

The above checks resulted all normal.

Damaged control valve spool Broken spring Loosened spool end

Leakage Check Within the Lift Arm Cylinder 1. Lower the bucket edge onto the ground with the bucket cylinder rod slightly extended from the fully retracted position.

3 1

2. Remove the hose from the lift arm cylinder rod side, and drain the oil from the cylinder and the hose. (Cover the removed hose ends to prevent dust or dirt.) 3. Extend the bucket cylinder rod, and lift the bucket. If any oil comes out from the hose connection port and the lift arm cylinder rod retracts, oil leakage occurs within the cylinder. If no oil comes out from the hose connection port but the lift arm cylinder rod retracts, oil leakage occurs in the multiple control valve.

2 12345-

T5-6-58

Overload Relief Valve (Lift Arm Bottom Side, Raise) Overload Relief Valve (Bucket Bottom Side, Roll Back) Overload Relief Valve (Bucket Rod Side, Dump) Lift Arm Spool Bucket Spool

90Z6-05-06-06

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-4 Shock during bucket dump operation is large when stopping lift arm raise / lower operation. Preparation  Check that control levers are not abnormal first.  Refer to SYSTEM / Hydraulic System (F&S S/M T2-4). Procedure Inspection Method 1 Disassemble and inspect the restriction valve (slow return valve) 2 -

Condition -

Evaluation Abnormality found

Cause Faulty restriction valve

The check mentioned above is normal

Stuck control valve spool, or faulty cylinder (faulty seal kit)

T5-6-59

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-5 Bucket auto leveler control is not activated. (Detent is not held.) Preparation  Refer to SYSTEM / Control System / Bucket Auto Leveler Control (p.T2-2-74).  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 roll back side coil harness end #2 and chassis 2 Replace the bucket auto- Bucket roll back detent control lever operation leveler relay with other general relay 3 Measure resistance between pilot valve bucket roll back side coil harness ends #1 and #2 4 Measure voltage between Key switch: ON bucket proximity switch harness end #1 and chassis 5 -

Evaluation 0V

Cause Open circuit in harness between #16 fuse in fuse box A and pilot valve bucket roll back side coil The symptom disappears Faulty bucket autoleveler 0/∞ Ω

Faulty pilot valve bucket roll back side coil

Open circuit in harness between bucket proximity switch and bucket leveler relay Faulty bucket proximity switch

The above checks resulted all normal.

Connectors  Bucket Roll Back Side Coil (Harness end)

 Bucket Roll Back Side Coil (Coil end)

90Z6-05-CN03

 Bucket Roll Back Side Coil (Harness end)

90Z6-05-CN04

T5-6-60

90Z6-05-CN05

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-6 Lift arm float control is not activated. (Detent is not held.) Preparation  Refer to SYSTEM / Control System / Lift Arm Float Control (p.T2-2-76).  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 lift arm lower side coil harness end #2 and chassis 2 Check continuity between pilot valve lift arm lower side coil harness end #1 and chassis 3 -

Evaluation 0V

∞Ω

The above checks resulted all normal.

Connectors  Lift Arm Lower Side Coil (Harness end)

90Z6-05-CN03

T5-6-61

Cause Open circuit in harness between #16 fuse in fuse box A and pilot valve lift arm lower side coil Improper grounding in pilot valve lift arm lower side coil

Faulty pilot valve lift arm lower side coil

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-7 Lift arm auto leveler height kickout control (option) is not activated. Preparation  Refer to SYSTEM / Control System / Lift Arm Auto Leveler Height Kickout Control (Option) (p.T2-2-64).  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 lift arm raise side coil harness end #2 and chassis 2 Monitor Lift Arm Auto Lift arm auto leveler Leveler Switch (Raise) switch (raise): ON (option) 3 -

Connectors  Lift Arm Raise Side Coil (Harness end)

90Z6-05-CN03

T5-6-62

Evaluation 0V

OFF is displayed

The above checks resulted all normal.

Cause Open circuit in harness between #16 fuse in fuse box A and pilot valve lift arm raise side coil Faulty lift arm auto leveler switch (raise) Faulty pilot valve lift arm raise side coil

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 (Option) (p.T2-2-66).  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 lift arm lower side coil harness end #2 and chassis 2 Monitor Lift Arm Auto Lift arm auto leveler Leveler Switch (lower) switch (lower): ON (option) 4 -

Connectors  Lift Arm Lower Side Coil (Harness end)

90Z6-05-CN03

T5-6-63

Evaluation 0V

OFF is displayed

The check mentioned above is normal

Cause Open circuit in harness between #16 fuse in fuse box A and pilot valve lift arm lower side coil Faulty lift arm auto leveler switch (lower) Faulty pilot valve lift arm lower side coil

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-9 Ride control (option) is not activated. Preparation  Check the ride control setting with the monitor or MPDr. first. The activating conditions for ride control are different according to the settings.  Refer to SYSTEM / Control System / Ride Control (Option) (p. T2-2-52).  When other actuator (front attachment) is operated normally, the primary pilot pressure is considered to be normal.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Ride Control Switch (option)

Condition Ride control switch: ON

Evaluation OFF is displayed

0/∞ Ω (Normal value: 22±0.4 Ω)

Cause Faulty ride control switch or open circuit in harness between ride control switch and MC Faulty ride control solenoid valve

The above checks resulted all normal.

Stuck control valve spool or faulty accumulator

Measure resistance between ride control solenoid valve #1 and #2 -

Connector (Harness end)  Solenoid Valve Connector

90Z6-05-CN06

fNOTE: Refer to p.T5-4-17 for the ride control solenoid valve location.

T5-6-64

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Steering System Troubleshooting S-1 Steering operation is weak. Main Relief Valve Set Pressure Steering relief operation

Standard

Remark

29.4 +0.2/-0.5 MPa (4264 +29/-72.5 PSI)

Preparation  If operating speeds are extremely slow, pump control may be faulty. Faulty pilot system may also cause this trouble. Procedure Inspection Method 1 Monitor Pump Delivery Pressure

Condition Steering relief operation

Evaluation The measured values are not within the normal values

The above check resulted Find out cause of trouble normal. by tracing other trouble symptoms

fNOTE: Refer to p. T4-5-10 for the steering relief pressure measurement and adjustment.

T5-6-65

Cause Faulty steering relief valve (readjust)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-2 Steering operation is slow. Standard Steering cylinder 2.9±0.3 operation time (sec)

Remark Accelerator pedal: Fully depressed Power mode switch: OFF Bucket: Empty

Preparation  Check that the steering wheel is not abnormal first.  Refer to SYSTEM / Hydraulic System (F&S S/M T2-4).  If speed of front attachment is also slow, the main system may be faulty (A-2). Procedure Inspection Method 1 Measure Steering Relief Pressure

Condition -

Disassemble and inspect the priority valve -

Evaluation Cause The measured values are Faulty main relief valve not within the normal (steering) values (Normal value: 28.9 to 31.4 MPa) (4192 to 4554 PSI) There is abnormality Faulty priority valve

The above checks resulted all normal.

fNOTE: Refer to p. T4-5-10 for the steering relief pressure measurement and adjustment.

T5-6-66

Stuck steering valve spool or faulty steering cylinder (faulty seal kit)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-3 Shock of steering operation is large. Preparation  Check that the steering wheel is not abnormal first.

 Release any remaining pressure before checking gas pressure in the accumulator.

 The steering valve and stop valve may be faulty.  Refer to SYSTEM / Hydraulic System (F&S S/M T2-4). Procedure Inspection Method 1 Check accumulator gas pressure 2 Disassemble and inspect the stop valve 3 Disassemble and inspect the steering valve 4 -

Condition -

Evaluation There is abnormality

Cause Low gas pressure or leak

There is abnormality

Faulty stop valve

There is abnormality

The above checks resulted all normal.

Faulty steering valve (stuck spool, clogged orifice) Faulty steering cylinder (faulty seal kit)

1 90Z6 07-52-03 1-

Steering Accumulator

Steering Cylinder

fNOTE: Steering Accumulator Gas Pressure: 8.0 MPa

T5-6-67

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-4 Secondary steering (option) is not operated. (Automatic operation check when the engine starts) Preparation  Check the secondary steering control setting with the MPDr. first.  Refer to SYSTEM / Control System / Secondary Steering Control (Option) (p. T2-2-70).  Check that #20 fuse in fuse box A is not abnormal.  Check the wiring connections first.  The secondary steering check switch may be faulty when secondary steering operation cannot be checked manually. Procedure Inspection Method 1 Monitor Secondary Steering Pump Delivery Pressure 2

Condition Engine starts

Evaluation The measured values are not at the normal level (4.8 MPa) Replace secondary steering Set the key switch The symptom disappears relay with other general relay to START after replacing relays The above checks resulted all normal.

T5-6-68

Cause Faulty secondary steering pump unit Faulty secondary steering relay Faulty main controller (MC)

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) (p. T2-2-32).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Forward/Reverse Lever (F)

Condition Forward/reverse lever: F, R

Evaluation OFF is displayed

Measure transmission clutch pressure

Forward/reverse lever: F, R

The measured values are out of normal range (Normal range: 2.2 ~ 2.4 MPa) The above checks resulted all normal.

fNOTE: Refer to p. T4-5-34 for the transmission clutch pressure measurement.

T5-6-69

Cause Faulty forward/reverse lever, or open circuit in harness between forward/ reverse lever and main controller (MC) Faulty transmission control valve

Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-2 Although forward/reverse lever is set to neutral position, machine travels. Preparation  Refer to SYSTEM / Control System / Neutral Control (p. T2-2-30).  Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Forward/Reverse Forward/reverse lever: N Lever (N)

Evaluation OFF is displayed

Pressure is measurable (not "0"). The above checks resulted normal.

Measure transmission clutch pressure -

Forward/reverse lever: N -

fNOTE: Refer to p. T4-5-34 for the transmission clutch pressure measurement.

T5-6-70

Cause Faulty forward/reverse lever, or open circuit in harness between forward/reverse lever and main controller (MC) Faulty transmission control valve Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-3 Declutch is not operated.  Declutch specified operation pressure Declutch Position Switch Brake pedal angle: Lightly applied (N) Speed Shift: 1st 1.25 MPa (181 psi) or more Speed Shift: 2nd 0.6 MPa (91.4 psi) or more

Brake pedal angle: Fully applied (D) 2.5 MPa (363 psi) or more 1.5 MPa (215 psi) or more

Preparation  When other actuator (front attachment) is operated normally, the pilot pump (primary pilot pressure) is considered to be normal.

 Refer to SYSTEM / Control System / Declutch Control (p. T2-2-42).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Declutch Position Switch

Condition Evaluation Declutch position switch: OFF is displayed N, D (0 is displayed on the monitor)

Cause Faulty declutch position switch Open circuit in harness between declutch position switch and main controller (MC) The measured values are Faulty brake system out of the specified range (brake valve) or faulty pressure sensor (brake secondary pressure) Faulty transmission The measured values are out of normal range control valve (Normal range: 2.2 ~ 2.4 MPa) The above checks Faulty MC resulted all normal.

Monitor Service Brake Secondary Pressure (For Declutch)

Declutch/brake pedal operation (Right brake pedal (option))

Measure transmission clutch pressure

fNOTE: Refer to p. T4-5-24 for the service brake secondary pressure measurement.

fNOTE: Refer to p. T4-5-34 for the transmission clutch pressure measurement.

1 2 12-

T5-6-71

Service Brake Secondary Pressure Sensor Brake Valve

90Z6T1-2-17

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-4 Travel mode cannot be changed. Preparation  Check the wiring connections first. Procedure Inspection Method Condition Evaluation 1 Monitor Travel Mode Driving mode switch: Manual mode is always Selector Switch AUTO 1/ AUTO 2 displayed (0 is displayed on mode the monitor) 2

The check (1) above resulted normal.

T5-6-72

Cause Faulty driving mode switch Open circuit in harness between driving mode switch and main controller (MC) Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-5 Although shift switch is operated, speed shift does not change. Preparation  Check that the travel mode is Manual mode.  Refer to SYSTEM / Control System / Manual Speed Shift Control (p. T2-2-34).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Shift Switch and Operate Shift Switch

Condition Shift switch: 1/2/3/4 position

Measure transmission clutch pressure

fNOTE: Refer to p. T4-5-34 for the transmission clutch pressure measurement.

T5-6-73

Evaluation The position of shift switch is not identical to the displayed range on monitor The measured values are out of normal range (Normal range: 2.2 ~ 2.4 MPa) The above checks resulted all normal.

Cause Faulty shift switch Open circuit in harness between shift switch and main controller (MC) Faulty transmission control valve

Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-6 Although vehicle speed changes, speed shift does not change automatically. Preparation  Check that the travel mode is AUTO 1/AUTO 2 mode.  Refer to SYSTEM / Control System / Automatic Speed Shift Control (p. T2-2-36).  Check the wiring connections first. Procedure Inspection Method Condition Evaluation 1 Monitor Travel Mode Driving mode switch: Manual mode is always Selector Switch AUTO 1/ AUTO 2 displayed (0 is displayed on mode the monitor). 2

Monitor Power Mode Power mode switch: Switch ON

OFF is displayed.

The check above resulted normal.

T5-6-74

Cause Faulty driving mode switch Open circuit in harness between driving mode switch and main controller (MC) Faulty power mode switch Open circuit in harness between power mode switch and MC Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-7 Speed shift is not shifted down when pushing downshift switch (DSS). Preparation  Check that the travel mode is AUTO 1/AUTO 2 mode.  Refer to SYSTEM / Control System / Downshift Control (p. T2-2-38).  Check the wiring connections first. Procedure Inspection Method 1 Monitor DSS Switch

Condition Downshift switch (DSS): ON While machine is travelling -

Evaluation OFF is displayed

Cause Faulty downshift switch (DSS) Open circuit in harness between downshift switch (DSS) and main controller (MC) The check (1) above Faulty MC resulted normal.

T5-6-75

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-8 Speed shift is not held when pushing hold switch. Preparation  Check that the travel mode is AUTO 1/AUTO 2 mode.  Refer to SYSTEM / Control System / Shift Holding Control (p. T2-2-44).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Shift Hold Switch

Condition Hold switch: ON

Evaluation OFF is displayed

The check (1) above resulted normal.

T5-6-76

Cause Faulty shift hold switch Open circuit in harness between shift hold switch and main controller (MC) Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-9 Speed shift delay control is not activated. Preparation  Check the speed shift delay control setting with the monitor first.  Check the parking brake is OFF (not applied).  Refer to SYSTEM / Control System / Speed Shift Delay Control (p. T2-2-40).  Check the wiring connections first. Procedure Inspection Method Condition 1 Monitor Forward/ Forward/reverse Reverse Lever (F), (R) lever: F and R

Evaluation N is displayed

Monitor Travel Mode Travel mode: AUTO Selector Switch 1/AUTO 2 mode

Manual mode is displayed (0 is displayed on the monitor)

Monitor Machine Speed (For Speedometer)

Travel operation

Speedometer: 0 km/h (mph)

Monitor Shift Switch

Shift switch: 2nd

Other than 2nd is displayed

Monitor Speed Shift Delay Mode Switch

Speed shift delay mode switch: ON

OFF is kept

The above checks resulted all normal.

T5-6-77

Cause Faulty forward/reverse lever Open circuit in harness between forward/reverse lever and main controller (MC) Faulty driving mode switch Open circuit in harness between driving mode switch and MC Faulty machine speed sensor Open circuit in harness between machine speed sensor and monitor controller Faulty shift switch Open circuit in harness between shift switch and MC Faulty speed shift delay mode switch, or open circuit in harness between speed shift delay mode switch and MC Find out cause of trouble by tracing other trouble symptoms

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-78

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Brake System Troubleshooting B-1 Parking brake is not released. (When the engine runs) Preparation  When other actuator (loading) is operated normally, the primary pilot pressure is considered to be normal.  Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Parking Brake Switch

Condition Evaluation Parking brake switch: ON OFF is displayed (applied) Engine: Running Monitor Parking Brake Parking brake switch: OFF The measured values Pressure (released) are out of normal range Engine: Running (Normal range: 3.6 ~ 3.9 MPa) The measured values Monitor Secondary Front control lever lock Pilot Pressure (Loading switch: UNLOCK position are out of normal range Engine: Running (Normal range: 3.6 ~ 3.9 Primary Pilot Pressure) MPa) Parking brake switch: OFF The measured values Monitor Primary Pilot Pressure (Service Brake Engine: Running are out of normal range Primary Pressure) (Normal range: 11.8 ~ 14.7 MPa) Replace parking brake Parking brake switch: OFF The symptom disappears relay 1 with other general Engine: Running relay Replace parking brake Parking brake switch: OFF The symptom disappears relay 2 with other general Engine: Running relay The above checks resulted all normal.

Cause Faulty parking brake switch

Stuck spool in parking brake solenoid valve

fNOTE:  Refer to p. T4-5-1 for the primary pilot pressure measurement.  Refer to p. T4-5-4 for the secondary piot pressure measurement.  Refer to p. T4-5-26 for the parking brake pressure measurement.

T5-6-79

Faulty charging block (pilot accumulator)

Faulty charging block (brake priority valve)

Faulty parking brake relay 1 Faulty parking brake relay 2 Faulty main controller (MC)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-2

Parking brake is not applied.

Wear amount of parking brake Brake Disc Brake Plate

Specification mm (in) 2.2 (0.087) 2.4 (0.094)

Allowable Limit mm (in) 2.0 (0.079) 2.2 (0.087)

Preparation  Check the wiring connections first. Procedure Inspection Method 1 Monitor Parking Brake Signal Output 2 Monitor Parking Brake Pressure 3 Check the wear amount of parking brake 4 -

Condition Evaluation Parking brake switch: ON ON is displayed Key switch: ON Key switch: ON Pressure is detected -

Allowable limit or less

The above checks resulted all normal.

fNOTE: Refer to p. T4-5-26 for the parking brake pressure measurement.

T5-6-80

Cause Faulty parking brake switch Stuck spool in parking brake solenoid valve Faulty brake disc and faulty brake friction plate Faulty main controller (MC)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B B-3

Service brake function lowers.

Wear amount of service brake Brake Disc Brake Ring

Specification (mm) 6.2 5.0

Allowable Limit (mm) 5.3 4.5

Preparation  Check the wiring connections first. Procedure Inspection Method 1 Monitor Service Brake Primary Pressure

Condition Refer to page T4-5-1.

Monitor Service Brake Secondary Pressure

Brake pedal: Fully depressed

Measure Service Brake Accumulator Pressure

Refer to page T4-5-28.

Check the wear amount of service brake

Refer to page T4-4-6.

fNOTE: The service brake primary pressure sensor is

installed to the charging block (see p. T5-4-15). The service brake secondary pressure sensor is installed to the brake valve (see p. T5-4-16). Refer to F&S S/M for the sensor specifications.

T5-6-81

Evaluation The measured values are out of normal range (Normal range: 11.8 ~ 14.7 MPa) The measured values are not within the normal values (Normal value: 4.6 ± 0.6 MPa) The measured values are not within the normal values (Normal value: 14.7 ± 0.3 MPa) -

Cause Faulty charging block (brake priority valve) Faulty service brake primary pressure sensor Faulty brake valve Faulty service brake secondary pressure sensor Faulty brake accumulator

The wear amount of brake disc is beyond the allowable limit

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-82

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting O-1 Clearance light, tail light, and license plate light are not ON. Preparation  Check that the clearance light, tail light, and license plate light are not broken first.  Check #4, #11 fuses in fuse box A when the clearance lights, tail light, and license plate light on both sides are not ON at the same time.  Failure of the clearance light indicator lighting will be also affected.  Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Lighting Switch

Condition Evaluation Light switch: Clearance OFF is displayed. light position (or Head light position)

The check (1) above resulted normal.

T5-6-83

Cause Faulty lighting switch Open circuit in harness between light switch and fuses #4 or #11 in fuse box A Faulty fuse #4, #11 in fuse box A

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-2 Head light is not ON. Preparation  Check that the head lights are not broken first.

 Check that the light switch is the head light position.

 The light switch may be faulty (O-1) when the head lights on both sides are not ON at the same time.

 Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first.

 Check #3, #4 fuses in fuse box A when the head lights on both sides are not ON at the same time. Procedure Inspection Method 1 Set the light switch to the low beam position

Evaluation The head lights (left/ right) are not ON

Cause Faulty light switch

The head lights (left/ right) are ON

Faulty head light relay (A2)

Open circuit in harness between head light relay (A2) and light switch Faulty light switch Open circuit in harness between head light relay (A2) and #3 fuse in fuse box A Faulty #3 fuse in fuse box A Open circuit in harness between head light (left) and head light relay (A2)

Condition Key switch: ON Light switch: Head light position Replace head light relay Key switch: ON (A2) with other general Light switch: Low beam relay position Measure voltage Key switch: ON between head light Light switch: Low beam relay (A2) harness end position #1 and chassis Measure voltage Key switch: ON Light switch: Low beam between head light relay (A2) harness end position #3 and chassis Key switch: ON Measure voltage Light switch: Low beam between head light (left) harness end #512 position and chassis Key switch: ON Measure voltage Light switch: Low beam between head light (right) harness end #512 position and chassis

Open circuit in harness between head light (right) and head light relay (A2)

Connectors  Head Light (Left/Right)

 Head Light Relay (A2) (Harness end)

#512

90Z6-05-06-01

T5-6-84

90Z7-05-06CN-01

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-3 Head light is not shifted to high beam. Preparation  Check #4, #19 fuse in fuse box A when the high beams at both sides are not ON.

 Failure of the high beam indicator lighting will be also affected.

 Check the wiring connections first.

 Refer to SYSTEM / Electrical System (F&S S/M T2-5).

 Check that the light switch is the head light position. Procedure Inspection Method Condition Evaluation 1 Set the light switch to Key switch: ON High beam is not ON the high beam position Light switch: Head light position 2 Replace high beam Key switch: ON High beam is ON relay (A3) with other Light switch: High beam general relay position 3 Measure voltage Key switch: ON 0V between high beam Light switch: High beam relay harness end #1 position and chassis 4 Measure voltage Key switch: ON 0V between high beam Light switch: High beam relay harness end #3 position and chassis 5 Measure voltage Key switch: ON 0V between head light Light switch: High beam (left) harness end #511 position and chassis 6 Measure voltage Key switch: ON 0V between head light Light switch: High beam (right) harness end #511 position and chassis 7 The above checks resulted all normal.

Cause Faulty light switch

Faulty high beam relay

Open circuit in harness between high beam relay and light switch

Open circuit in harness between high beam relay and #19 fuse in fuse box A Faulty #19 fuse in fuse box A Open circuit in harness between head light (left) and high beam relay (A3) Open circuit in harness between head light (right) and high beam relay (A3) Faulty head light (right/left) Faulty grounding

Connectors  High Beam Relay (A3) (Harness end)

 Head Light (Left/Right) #511

90Z6-05-06-01

T5-6-85

90Z7-05-06CN01

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-4 Hazard light is not operated. Preparation  Check that the turn signal lights (hazard lights) are not broken first.

 Failure of blinking of the turn signal light indicators at both sides will be also affected.

 Check #7 fuse in fuse box A when all turn signal lights do not blink at the same time. Faulty flasher relay may also cause this trouble.

 Refer to SYSTEM / Electrical System (F&S S/M T2-5).

Procedure Inspection Method 1 Turn the hazard light switch ON

 Check the wiring connections first.

Condition Key switch: OFF

Evaluation Hazard light is not operated.

Measure voltage at Flasher relay: remains terminal L in flasher relay installed Hazard light switch: ON Replace turn signal light Hazard light switch: ON relay (left) with turn signal light relay (right) Measure voltage between Hazard light switch: ON turn signal light relay (left/right) harness end #1 and chassis Measure voltage between Hazard light switch: ON turn signal light relay (left/right) harness end #3 and chassis Measure voltage between Hazard light switch: ON hazard lights (right front/ right rear) harness end #501A/#501B and chassis Measure voltage between Hazard light switch: ON hazard lights (left front/ left rear) harness end #531 and chassis -

Symptom is observed on the opposite side. 0V

The above checks resulted all normal.

Cause Faulty hazard light switch Open circuit in harness between hazard light switch and #7 fuse in fuse box A Faulty flasher relay Faulty grounding Faulty turn signal light relay (left or right) Open circuit in harness between turn signal light relay (left/right) and hazard light switch Faulty diode (Hazard 1 or 2) Open circuit in harness between turn signal light relay (left/right) and flasher relay Open circuit in harness between hazard lights (right front/ right rear) and turn signal light relay (right) (A8) Open circuit in harness between hazard lights (left front/ left rear) and turn signal light relay (left) (B7) Faulty #7 fuse in fuse box A

Connectors  Turn Signal Light Relay (Left/Right) (Harness end)

 Hazard Light (Front) (Front chassis F2)

 Hazard Light (Rear) (Rear chassis CLL,CLR)

 Flasher Relay (Harness end)

#501B #502B #502A #501A L

90Z6-05-06-01

90Z6-05-CN07

90Z6-05-CN08

T5-6-86

90Z6-05-CN09

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 (F&S S/M T2-5).  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.

Replace turn signal light Key switch: ON relay (left) (B7) with other Turn signal lever: Left general relay position Measure voltage between Key switch: ON turn signal light relay Turn signal lever: Left (left) (B7)harness end #1 position and chassis Replace turn signal light Key switch: ON relay (right) (A8) with Turn signal lever: Right other general relay position Measure voltage between Key switch: ON Turn signal lever: Right turn signal light relay position (right) (A8) harness end #1 and chassis

Connector  Turn Signal Light Relay (Left/Right) (Harness end)

90Z6-05-06-01

T5-6-87

Cause Faulty turn signal lever Open circuit in harness between turn signal lever and #2 fuse in fuse box A The turn signal light (left) Faulty turn signal light is ON relay (left) 0V

The turn signal light (right) is ON 0V

Open circuit in harness between turn signal light relay (left) and turn signal lever Faulty diode Hazard 2 Faulty turn signal light relay (right) Open circuit in harness between turn signal light relay (right) and turn signal lever Faulty diode Hazard 1

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 (F&S S/M T2-5).  Check the wiring connections first. Procedure Inspection Method 1 Replace horn relay (A9) with other general relay 2 Measure voltage between horn relay harness end #1 and chassis 3

Condition Horn switch: ON

Evaluation Horn sounds

Cause Faulty horn relay

Horn switch: ON

The above checks resulted all normal.

Open circuit in harness between horn relay and #6 fuse in fuse box A Faulty #6 fuse in fuse box A Faulty horn switch Open circuit in harness between horn switch and horn relay

Connector  Horn Relay (Harness end)

90Z6-05-06-01

T5-6-88

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-7 Reverse light is not ON. Reverse buzzer does not sound. Preparation  Check that the reverse light and reverse buzzer are not broken first.

 Check that the forward/reverse lever is in the R position.

 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.

 Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first.

Procedure Inspection Method Condition 1 Replace reverse buzzer relay Key switch: ON (C2) with other general relay Forward/reverse lever: R position 2 Measure voltage between Key switch: ON reverse lights (left/right) Forward/reverse harness end #505 and lever: R position chassis 3 Measure voltage between Key switch: ON reverse buzzer harness end Forward/reverse lever: R position #1 and chassis 4 Measure voltage between Key switch: ON reverse buzzer relay harness end #1 and chassis 5 Measure voltage between Key switch: ON reverse buzzer relay harness end #3 and chassis

Evaluation Reverse light is ON and reverse buzzer sounds. 0V

Cause Faulty reverse buzzer relay

The above checks resulted all normal.

Open circuit in harness between reverse buzzer and reverse buzzer relay Open circuit in harness between reverse buzzer relay and #13 fuse in fuse box A, or faulty #13 fuse Open circuit in harness between reverse buzzer relay and #1 fuse in fuse box A Faulty #1 fuse in fuse box A Faulty reverse lights (left/right) Faulty grounding

Open circuit in harness between reverse lights (left/right) and reverse buzzer relay

Connectors  Reverse Buzzer Relay (Harness end)

 Reverse Buzzer

 Reverse Light (Left/Right)

#505

90Z6-05-06-01

90Z7-05-CN10

T5-6-89

90Z7-05-06CN03

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-8 Brake light is not ON. Preparation  Check that the brake lights are not broken first.  Check #2 fuse in fuse box A when the brake lights at both sides are not ON.  Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first. Procedure Inspection Method 1 Replace brake light relay (B4) with other general relay 2 Measure voltage between brake light relay harness end #1 and chassis 3 -

Condition Evaluation Brake light switch: ON The symptom (Brake pedal is applied) disappears

Cause Faulty brake light relay

The above checks resulted all normal.

Open circuit in harness between brake light relay and #2 fuse in fuse box A Faulty #2 fuse in fuse box A Faulty brake light switch Open circuit in harness between brake light switch and brake light relay

Connector  Brake Light Relay (Harness end)

90Z6-05-06-01

T5-6-90

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-9 Work light does not light. Preparation  Check that the work lights are not broken first.

 Failure of blinking of the work light indicator will be also affected.

 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.

 Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first.

 Check #17 fuse in fuse box A and #4 fuse in fuse box B when only the light at front or rear side is ON. Procedure Inspection Method Condition 1 Set work light switch to ON Key switch: ON 1/ON 2

Evaluation Work light is not ON.

Replace work light relays (front/rear) each other or with other general relay Measure voltage between work light relay (front/rear) harness end #1 and chassis Measure voltage between work light relay (front) (A6) harness end #3 and chassis

Key switch: ON Work light switch: ON 2 position Key switch: ON Work light switch: ON 2 position Key switch: ON

Work light on the opposite side is ON.

Measure voltage between work light relay (front) harness end and chassis Measure voltage between work light relay (rear) (A7) harness end #3 and chassis

Key switch: ON Work light switch: ON 2 position Key switch: ON

Measure voltage between work light (rear) harness end #2 and chassis -

Key switch: ON Work light switch: ON 2 position -

The above checks resulted all normal.

Cause Faulty work light switch Open circuit in harness between work light switch and light switch Faulty work light relay (front/ rear) Open circuit in harness between work light relay (front/rear) and work light switch Open circuit in harness between work light relay (front) and #4 fuse in fuse box A Faulty #4 fuse in fuse box A Open circuit in harness between work light (front) and work light relay (front) Open circuit in harness between work light relay (right) and #17 fuse in fuse box A Faulty #17 fuse in fuse box A Open circuit in harness between work light (rear) and work light relay (rear) Faulty work light (front/rear) Faulty grounding

Connectors  Working Light Relay (Harness end)

90Z6-05-06-01

 Work Light (Front)

90Z7-05-06CN02

T5-6-91

 Work Light (Rear)

90Z7-05-06CN04

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 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.

 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.

 Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first.

 Front Wiper Procedure Inspection Method 1 Monitor Front Wiper Relay 1 Output 2

Monitor Front Wiper Relay 2 Output

Monitor Front Wiper Switch

Replace front wiper relay 1, 2 with each other -

Condition Key switch: ON Front wiper/ washer switch: LOW Key switch: ON Front wiper/ washer switch: HI Key switch: ON Front wiper/ washer switch: LOW/HI

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 on monitor.

Key switch: ON Front wiper/ washer switch: LOW -

The opposite wiper is operated.

Faulty front wiper/ washer switch Open circuit in harness between front wiper/ washer switch and column display controller Open circuit in harness between front wiper relay 1, 2 and column display controller Faulty front wiper relay 1, 2

The above checks resulted all normal.

T5-6-92

Faulty front wiper motor

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.

Replace rear wiper relay Key switch: ON with other general relay Rear wiper/ washer switch: LOW Check continuity Key switch: ON between rear wiper Rear wiper/ washer relay harness end #2 switch: LOW and body Key switch: ON Measure voltage Rear wiper/ washer between rear wiper switch: LOW relay harness end #1 and chassis -

Rear wiper is operated.

Cause Faulty rear wiper/ washer switch Open circuit in harness between rear wiper/ washer switch and rear wiper relay Faulty rear wiper relay

∞Ω

Open circuit in harness between rear wiper relay and rear wiper/ washer switch

Open circuit in harness between rear wiper relay and #5 fuse in fuse box B Faulty #5 fuse in fuse box B Faulty rear wiper motor

The above checks resulted all normal.

Connector  Rear Wiper Relay (B9) (Harness end)

90Z6-05-06-01

T5-6-93

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-11 Washer is not operated. Preparation  Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first.  Front Washer Procedure Inspection Method 1 Replace the front washer relay (B8) with other general relay 2 Check continuity between front washer relay harness end #2 and chassis 3 Measure voltage between front washer relay harness end #1 and chassis 4 Monitor Front Washer Switch

Measure voltage between front washer motor harness end #1 and chassis -

Condition Front wiper/ washer switch: ON position

Evaluation Front washer is operated.

Cause Faulty front washer relay

Front wiper/ washer switch: ON position

∞Ω

Open circuit in harness between front washer relay and front wiper/ washer switch

Key switch: ON

Front wiper/ washer switch: Washer ON

OFF is displayed

Front wiper/ washer switch: ON position

Open circuit in harness between front washer relay and #3 fuse in fuse box B Faulty #3 fuse in fuse box B Faulty front wiper/ washer switch Open circuit in harness between front wiper/ washer switch and column display controller Open circuit in harness between front washer relay and front washer motor

The above checks resulted all normal.

Faulty front washer motor

Connector  Front Washer Motor

 Front Washer Relay (B8) (Harness end)

90Z6-05-06-01

T5-6-94

90Z6-05-CN10

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 Replace the rear washer relay (B10) with other general relay 2 Check continuity between front washer relay harness end #2 and chassis 3 Measure voltage between rear washer relay harness end #1 and chassis 4 Measure voltage between rear washer motor harness end #1 and chassis 5 -

Condition Key switch: ON Rear wiper/ washer switch: Washer ON Key switch: ON Rear wiper/ washer switch: Washer ON

Evaluation Rear washer is operated

Cause Faulty rear washer relay

∞Ω

Open circuit in harness between rear washer relay and rear wiper/ washer switch

Key switch: ON Rear wiper/ washer switch: Washer ON

Open circuit in harness between rear washer relay and #5 fuse in fuse box B

Key switch: ON Rear wiper/ washer switch: Washer ON

Open circuit in harness between rear washer relay and rear washer motor

The above checks resulted all normal.

Faulty rear washer motor Faulty #5 fuse in fuse box B

Connector  Rear Washer Motor

 Rear Washer Relay (B10) (Harness end)

90Z6-05-06-01

T5-6-95

90Z6-05-CN10

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-12 Cab dome light is not ON. Preparation  Check #11 fuse in fuse box B when the cab dome light and rear cab dome light are not ON at the same time.  Refer to SYSTEM / Electrical System (F&S S/M T2-5).  Check the wiring connections first. Procedure Inspection Method Condition 1 Set cab dome light switch to ON position

Set cab dome light switch Door open/close to Door Interlocking switch: ON Position Set cab rear dome light switch to ON position

Evaluation Cause Cab dome light is not ON. Faulty cab dome bulb Open circuit in harness between cab light and #11 fuse in fuse box B Cab dome light is not ON. Faulty door open/close switch Cab rear dome light is not Faulty cab dome bulb ON. Open circuit in harness between cab rear dome light and #11 fuse in fuse box B The above checks Faulty #11 fuse in fuse box B resulted all normal.

T5-6-96

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: Pilot Pressure Sensor Circuit High Input (MC fault code 111217-3) Check Method: 1. Replace pressure sensor (primary pilot) (1) with pressure sensor (parking brake) (2). 2. Retry troubleshooting. Result: In case Parking Brake Pressure Sensor Circuit High Input (MC Fault Code 111313-3) is displayed, the pressure sensor (primary pilot) is considered to be faulty.

In case Pilot Pressure Sensor Circuit High Input (MC fault code 111217-3) is displayed, the pressure sensor (primary pilot) harness is considered to be faulty.

90Z6T1-2-22

90Z6T1-2-13

T5-6-97

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Applicability of Switch-Check Method Fault Code 111204-3 111204-4 111311-3 111311-4 111206-3 111206-4 111208-3 111208-4 111217-3 111217-4 111313-3 111313-4 111200-3 111200-4

Trouble Pump Delivery Pressure Sensor Circuit High Input Pump Delivery Pressure Sensor Circuit Low Input Service Brake Primary Pressure Sensor Circuit High Input Service Brake Primary Pressure Sensor Circuit Low Input Hyd. Fan Circuit Pressure Sensor Circuit High Input (Option) Hyd. Fan Circuit Pressure Sensor Circuit Low Input (Option) Emergency Steering Check Pressure Sensor Circuit High Input (Option) Emergency Steering Check Pressure Sensor Circuit Low Input (Option) Pilot Pressure Sensor Circuit High Input Pilot Pressure Sensor Circuit Low Input Parking Brake Pressure Sensor Circuit High Input Parking Brake Pressure Sensor Circuit Low Input Lift Arm Raise Pilot Pressure Sensor Circuit High Input (Option) Lift Arm Raise Pilot Pressure Sensor Circuit Low Input (Option)

T5-6-98

Remedy Compatible Harness / Sensor

Compatible 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 L (0.13 gal)) is drawn from each wheel (4 places) after bubbles stops.

1 1

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.

90T4GB-05-04-04

1. Set the parking brake switch of front console to the ON position, start the engine, and increases service brake oil pressure. 2

2. Connect clear vinyl tube (2) to either one of two air bleed plugs (1). Insert the other end of clear vinyl tube (2) into clear container (3) filled with hydraulic oil.

3. Depress brake pedal (4) several times. Then, depress and hold brake pedal (4) to the stroke end.

4. Loosen air bleed plug (1) under condition in step 3 and drain hydraulic oil and air for several seconds.

T4GB-05-04-005

5. Tighten air bleed plug (1). 6. Drain hydraulic oil after bubbles stops in steps 3 to 5 repeatedly.

fNOTE: When bubbles do not disappear after hydraulic

oil (about 0.5 L (0.13 gal)) is discharged, repeat step 3 to step 5.

7. Bleed air at other 3 places in the same way as step 3 to step 5. IMPORTANT: After air bleeding is completed at 4 places, bleed air at 4 places again. Bleed air in the same way as step 3 to step 5 twice and check that no air remains inside.

fNOTE: The right brake pedal is optional.

T5-6-99

T4GB-05-04-006

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B (Blank)

T5-6-100

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Outline Operation layout of the air conditioning system is illustrated below.

The vents (operator’s front/rear vent, foot vent, and the front window) can be simultaneously or independently selected by air vent damper servo motor (1) in accordance with the set-ventilation mode.

Either fresh or re-circulated air is induced into the air conditioner unit by operating fresh / re-circulated air damper servo motor (6).

The 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.

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.

6 1

5 2

TDAA-05-07-001

15 12345-

Air Vent Damper Servo Motor Defroster Vent Rear Vent Front Vent Evaporator

6789-

Fresh / Re-circulated Air Damper Servo Motor Re-circulated Air Sensor Fresh Air Induction Port Re-circulated Air Filter

10- Re-circulated Air Induction Port 11- Blower Motor 12- Power Transistor 13- Frost Sensor

T5-7-1

11 14- Air Mix Damper Servo Motor 15- Heater Core 16- Foot Vent

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Component Layout

TNDB-05-07-001

10 11

90Z7-05-07-01

1234-

Solar Radiation Sensor Key Switch Accelerator Pedal Air Conditioner Unit

5678-

Fresh Air Filter Air Conditioner Controller (Switch Panel) Compressor Air Conditioner Condenser

T5-7-2

90Z6-05-07-01

9- Receiver Tank 10- A/C Gas High/Low Pressure Switch (ACP) 11- Refrigerant Pressure Sensor (ACG)

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner

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 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

T5-7-4

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Frost Sensor (CN12) Monitors the fin temperature which is cooled by the evaporator. When the temperature is higher than 3°C (37°F) (approx. 4.2 kΩ), the controller turns the compressor relay ON. When the temperature is lower than 2°C (36°F) (approx. 4.5 kΩ), the controller turns the compressor relay OFF. Therefore, the evaporator in the air conditioner unit is prevented from freezing. The electrical resistance in the frost sensor is 100 Ω to 115 kΩ.

 High/Low Pressure Switch (CN14) Controls the compressor clutch solenoid while monitoring the compressor circuit pressure. The high/low pressure switch consists of a pressure gauge and a switch. The pressure gauge detects the lower pressure range (0.196 MPa ~ 0.216 MPa) (28.4 ~ 31.3 PSI) and the surge pressure range (2.55 ~ 3.14 MPa) (370 ~ 455 PSI). When the circuit pressure is reduced to the lower pressure range or increases to the surge pressure range, the pressure gauge turns the switch OFF so that the compressor operation stops. If the pressure is reduced to the lower range, a lack of refrigerant is suspected. Therefore, damage to the compressor due to a lack of refrigerant is prevented. In case the pressure increases to the surge range, damage to the air conditioner circuit parts due to excessively high circuit pressure is prevented.

 Re-circulated Air Sensor (CN11) Monitors the temperatures 0 ~ 25°C (32 ~ 77°F) around the re-circulated air inlet as the interior air temperatures and converts them to the electrical resistance values. The temperatures 0 ~ 25°C (32 ~ 77°F) corresponds to a resistance of 1.645 kΩ (0°C) (32°F) to 5 kΩ (25°C) (77°F) respectively. The electrical resistance in the air circulation sensor is 300 Ω to 430 kΩ.

TDAA-05-07-006

#A052 #A211 TDAA-05-07-007

TDAA-05-07-014

TDAA-05-07-008

TDAA-05-07-009

 Outdoor Ambient Temperature Sensor (CN15) Monitors the temperature around the rear side of the machine as the fresh air temperature, and converts the temperature to the electrical resistance value. The electrical resistance in the fresh air sensor is 100 Ω to 210 kΩ.

T5-7-5

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Solar Radiation Sensor (CN16) Converts the amount of solar radiation (illumination intensity) at the cab front to the current values. TDAA-05-07-010

 Fresh / Re-circulated Air Damper Servo Motor (CN10) Opens or closes the fresh/re-circulated air selection louvers. The damper consists of a motor, link mechanism, and position sensing switch. The motor opens or closes the fresh/re-circulated air selection louvers via the link mechanism. TDAA-05-07-011

 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).

T5-7-6

TDAA-05-07-012

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Air Vent Damper Servo Motor (CN8) Opens or closes the front and rear air vent, foot vent, and defroster vent louvers. The damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes vent louvers via the link mechanism. The potentiometer converts the link movements (vent louvers strokes) to the voltage. Both ends of the potentiometer are energized by 5 V from terminals #7 (+) and #25 (-) in controller so that the potentiometer outputs voltage of 0.5 to 4.5 V from the center terminal to terminal #20 in controller corresponding to the link movement.

TDAA-05-07-013

Depending on the MODE switch set position, vent louvers are operated as shown below: When the front and rear air vent louvers positions are selected, the controller calculates potentiometer voltage (Vr). Furthermore, the controller checks the vent louvers positions by receiving voltage (Vf ) from the potentiometer. Then, after the controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf, the controller sends out the current from terminals #31 and #32. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr). MODE switch position

Front air vent

Rear air vent

Foot air vent

Defroster vent























TNED-05-07-005

TNED-05-07-006

TNED-05-07-007

TNED-05-07-008

TNED-05-07-009

TNED-05-07-010

: Open : Closes

T5-7-7

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Troubleshooting IMPORTANT:  When replacing the compressor due to the breakage of compressor from internal lock, sufficiently clean the air conditioner circuit or replace all the parts.  When cleaning is insufficient or all the parts are not replaced, the air conditioner may be broken due to contaminants remaining in the circuit.  Using deteriorated LLC (coolant) or lowconcentration LLC, the heater core will receive a bad influence and it may lead water leaks and shorten the service life of machine. Replace coolant and manage LLC concentration according to the Operator's Manual.

T5-7-8

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Code List Fault Code 11

Trouble

Cause

Symptoms in Machine Operation Remedy When Trouble Occurs. Open circuit in reVoltage: more than Operation is controlled under such Check the harness. circulated air sensor 4.95 V circumstance as no re-circulated Replace the reair sensor is provided. circulated air sensor. Shorted circuit in re- Voltage: less than 0.3 V Operation is controlled under such Check the harness. circulated air sensor circumstance as no re-circulated Replace the reair 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 outdoor temperature sensor ambient temperature sensor is ambient temperature provided. 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 outdoor temperature sensor ambient temperature sensor is ambient temperature provided. sensor. Shorted circuit Voltage: more than Operation is controlled under such Check the harness. in solar radiation 5.04 V circumstance as no solar radiation Replace the solar sensor 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 Voltage: less than The compressor clutch is Check the harness. frost 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 vent Open circuit: Voltage: damper servo motor. more than 5 V Abnormal air mix Shorted circuit: Air mix damper servo motor servo Check the harness. damper servo motor Voltage: less than 0.2 V motor becomes inoperable. Replace the air vent Open circuit: Voltage: damper servo motor. more than 4.8 V Abnormal high/low Voltage: 0 V The compressor clutch is Check the harness. refrigerant pressure disengaged. (The compressor Replace the high/low stops.) 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.

T5-7-9

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Codes 11 to 22 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 11

Trouble Open circuit in recirculated air sensor

Shorted circuit in recirculated air sensor

Open circuit in outdoor ambient temperature sensor

Shorted 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. -

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

Cause Faulty sensor.

Normal in above check.

Measurement of resistance between sensor #1 and #2. -

0 Ω (Normal value: 300 kΩ to 430 kΩ) Normal in above check.

Open circuit in harness #2. Faulty sensor.

Measurement of resistance between sensor #1 and #2. Measurement of voltage between sensor harness end #1 and body. -

∞ Ω (Normal value: 100 kΩ to 210 kΩ) 0V

Measurement of resistance between sensor #1 and #2. -

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

Normal in above check.

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

Shorted circuit in Continuity check between solar radiation sensor sensor harness end #1 and #2. Open circuit in frost Measurement of resistance sensor between sensor #1 and #2. Measurement of voltage between sensor harness end #1 and body. -

Normal in above check. ∞ Ω (Normal value: 100 kΩ to 115 kΩ) 0V

Faulty sensor. Faulty sensor.

Normal in above check.

Shorted circuit in frost Measurement of resistance sensor between sensor #1 and #2. -

0 Ω (Normal value: 100 kΩ to 115 kΩ) Normal in above check.

Open circuit in harness #2. Faulty sensor.

T5-7-10

0Ω

Open circuit in harness #1.

Shorted circuit in harness #1 and #2.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Codes 43 to 92 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 43

91 92

Trouble Abnormal air vent damper servo motor

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

Abnormal air mix damper servo motor

Evaluation 0V

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

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

Normal in above check. 0V

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

Measurement of voltage between air mix damper servo motor harness end 7D and body. (AUTO/OFF switch / blower switch: ON) 0V Measurement of voltage between air mix damper servo motor harness end 7D and 25E. (AUTO/OFF switch / blower switch: ON) Normal in above check. Abnormal high/low Measurement of voltage 0V refrigerant pressure between high/low pressure switch harness end A21 and A05. (AUTO/OFF switch / blower switch: ON) Normal in above check. CAN communication Continuity check in CAN1 Normal error harness. Abnormal CAN bus off error Continuity check in CAN1 Normal harness. Abnormal

T5-7-11

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. Faulty controller. Faulty CAN1 harness.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (1) Condition:  Fault code: Un-displayed  Airflow volume: faulty Blower motor rotates

Normal speed

Slow speed

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Frosted evaporator Adhered dirt on evaporator surface Power source decreases

Poor battery terminal contact Faulty blower motor Faulty power transistor Blower motor Faulty blower motor relay does not rotate Faulty blower motor Faulty power transistor Blower interferes with case Faulty controller Faulty ground in 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

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

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

T5-7-12

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 A/M link

Close window and door Readjust fresh / re-circulated air selection damper Setting link again

T5-7-13

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 (42 PSI) or more)

Pressure on highpressure side is too low (pressure is not approx. 0.98 MPa (142 PSI) or more)

Pressure on lowpressure side is too low (pressure is approx. 0.05 MPa (7.25 PSI) or less) Pressure is high on both sides of highpressure and lowpressure Pressure is low on both sides of highpressure and lowpressure

Overcharge air conditioner with refrigerant Faulty compressor

Remove refrigerant thoroughly and recharge refrigerant to proper level after purging Breakage of head gasket Replace compressor Breakage of inlet valve Replace compressor Clogged foreign matter into inlet Replace compressor valve Faulty valve Replace valve

Excessive open of expansion valve Abnormally low ambient temperature Low refrigerant Faulty compressor Swash plate shoe is locked Piston is locked Faulty suction discharge valve Faulty expansion valve Clogged valve (foreign matter) Temporary clogged due to freezing valve (water intrusion)

To B Replace compressor Replace compressor Replace compressor Replace valve Thoroughly perform purging after replacing valve and receiver

Abnormally low ambient temperature Low refrigerant To B Clogged during refrigeration cycle To C Faulty expansion valve To D Frosted evaporator To A Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing) Overcharge air conditioner Remove refrigerant thoroughly and recharge refrigerant to proper with refrigerant level after purging Lack of refrigerant

T5-7-14

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

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

T5-7-15

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 Abnormally high ambient temperature Abnormal high Too high pressure (2.54 MPa Lack of Clogged fin with Cleaning of fin (368 PSI) or condenser dirt or mud (washing) more) cooling Overcharge air Remove refrigerant thoroughly and conditioner with recharge refrigerant to proper level refrigerant after purging Air incorporation Remove refrigerant thoroughly and in refrigeration recharge refrigerant to proper level cycle after purging Too low Abnormally low ambient temperature (0.98 MPa Low refrigerant To B (142 PSI) or Clogged during refrigeration cycle To C less) Faulty expansion valve To D Frosted evaporator To A

T5-7-16

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

T5-7-17

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

T5-7-18

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty heating (1) Condition:  Fault code: Un-displayed Faulty air flow volume

Blower motor rotates

Normal speed

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Frosted evaporator Adhered dirt on evaporator surface

Slow speed

Power source decreases

Poor battery terminal contact Faulty blower motor Faulty power transistor Blower motor Blowout of fuse Replace with the Blower motor is does not rotate same capacity fuse locked Faulty wiring Shorted circuit Faulty blower motor relay Faulty blower motor Faulty power transistor Blower interferes with case Faulty controller Faulty ground in 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

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

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

T5-7-19

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

T5-7-20

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

T5-7-21

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Noise Case connection. Blower fan motor connection.

Gas blowing sound (roaring). Expansion valve connection. Whistle sound. Gas blowing sound. Clutch disengaging sound.

Compressor rotating sound.

Louver resonance. Fan contacts case. Foreign matter enters case. Brush friction noise, metal and/or thrust washer contact. Gas vibration noise (compressor discharge and/or suction gas noise). Abnormal noise from expansion valve. Expansion valve is normally functioning. Faulty clutch bearing, and/or idle pulley bearing. Contact of clutch armature due to resonance. Loose belt. Loose screws. Noisy compressor. Vibration due to V belt looseness. Loose screws.

Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud. No functional problem exists. Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard. Replace. Repair or replace clutch. Re-tighten screws. Repair or replace. Re-adjust belt. Re-tighten screws.

 Others Water leak. Water splash.

Abnormal smell.

Broken heater core. Broken hose. Clogged case drain port and/or drain hose. Absorbed cigarette and dust smell on evaporator fins.

T5-7-22

Replace. Clean. Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L mode for more than 10 minutes, flush smell out by condensed water.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 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

T5-7-23

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 (32˚F) or more first. When fresh air temperature is less than 0˚C (32˚F), the air conditioner controller turns the compressor clutch OFF in order to protect the compressor.  Check that fault code 21 or 22 (abnormal frost sensor) is not displayed. When the frost sensor is abnormal, the compressor clutch does not operate.  Check the wiring connections first. Procedure Inspection Method 1 Switch compressor relay with blower motor relay. 2 Measurement of voltage between terminal #48A of compressor relay harness end and 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.

Open circuit in harness between compressor relay and compressor clutch.

Connector (Harness end)  Compressor Relay

 Compressor Clutch

TDAB-05-07-019

T5-7-24

TDAB-05-07-024

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Cooling circuit check by using manifold gauge Condition:  Engine Speed: 1500 min-1  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh / re-circulated air selection: Re-circulated Air  Air conditioner inlet temperature: 30 ~ 35°C (86 ~ 95°F) 1. In normal  Low-pressure side pressure: 0.15 ~ 0.25 MPa (21.8 ~ 36.3 PSI)  High-pressure side pressure: 1.37 ~ 1.57 MPa (198.7 ~ 227.7 PSI) NOTE: The reading of manifold gauge may depend on conditions.

TDAA-05-07-018

2. Lack of refrigerant quantity Trouble

Pressure is low on both sides of high-pressure and low-pressure. Cooling performance is low. Cause Refrigerant quantity is low. Gas leak. Remedy Check and repair of gas leak. Charge air conditioner with refrigerant.

TDAA-05-07-019

3. Excessive refrigerant, lack of condenser cooling Trouble

Pressure is high on both sides of highpressure and low-pressure. Cooling performance is low. Cause Overcharge air conditioner with refrigerant. Faulty condenser cooling. Remedy Adjust refrigerant quantity. Clean condenser. Check for machine cooling system.

TDAA-05-07-020

4. Water incorporation in circuit. Trouble

After using a certain period of time, lowpressure side gradually indicates negative pressure. Cause Water is mixed in circuit. Remedy Replace receiver tank. Thoroughly perform purging before charging refrigerant to remove water.

TDAA-05-07-021

T5-7-25

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

T5-7-26

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

T5-7-27

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.

 Compressor oil refill container Oil type ND-OIL8

Part No 4422696

Quantity 40 cm3 (2.4 in3)

fNOTE: Compressor oil quantity: 160 cm (9.8 in ) 3

TDAA-05-07-015

New Compressor

Replacing Compressor

T5-7-28

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

T5-7-29

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 low-pressure side charge valve (“S” marked) located on the compressor, respectively. Connect charge hose (5) located on the center of manifold gauge (1) to vacuum pump (4).

7 6 2 3 5 4

W115-02-10-005

2. Open high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Perform purging for 10 minutes or more by operating vacuum pump (4).

1 7

W115-02-10-005

T5-7-30

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT: If the pointer returns to 0, retighten the line connections and perform purging again. 3. When the low pressure gauge reading falls below -0.1 MPa (-750 mmHg) (-14.5 PSI), close high pressure valve (2) and low pressure valve (7) and stop vacuum pump (4). Wait for approximately five minutes and confirm that the pointer does not return to 0.

4. With high pressure valve (2) and low pressure valve (7) on manifold gauge (1) closed, connect charge hose (5) to refrigerant container (8).

W115-02-10-005

W115-02-10-007

5. Open valve (9) of refrigerant container (8). Push air bleed valve (10) on manifold gauge (1) to purge air in charge hose (5) with the refrigerant pressure. When draining refrigerant, immediately release air bleed valve (10).

W115-02-10-007

T5-7-31

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT:  Always stop the engine when charging the air conditioner with refrigerant.  Do not position the refrigerant container upside down during charging operation.  When changing the refrigerant container during charging operation, be sure to purge air from the charge hose, as shown in step 10.  Charge the low-pressure side hose first. 6. Fully tighten charge hose (5) connection to gauge manifold (1). Open high pressure valve (2) and valve (9) of refrigerant container (8). Charge with refrigerant (R134a). Close high pressure valve (2) and valve (9) of refrigerant container (8) when high pressure gauge (11) reading reaches 98 kPa (1 kgf/cm2) (14.2 PSI).

W115-02-10-008

fNOTE: Use warm water of 40˚C (104˚F) or less to warm refrigerant container (8) to aid in charging operation.

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

T5-7-32

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: Low Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool

9 8

W115-02-10-007

IMPORTANT: Do not open high pressure valve (2) on manifold gauge (1). 9. Open low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8) to charge with refrigerant.

1 7

fNOTE: Required refrigerant quantity: 900 ± 50 g (1.98 ± 0.1 lb)

10. If refrigerant container (8) becomes empty during the charging work, replace refrigerant container (8) with a new refrigerant container as follows:  Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1).  Replace the empty container with new refrigerant container (8).  Tighten, then slightly loosen refrigerant container (8) joint.  Slightly open low pressure valve (7) on manifold gauge (1).  When refrigerant container (8) joint starts to leak, immediately tighten refrigerant container (8) joint and close low-pressure valve (7) on manifold gauge (1). 11. After charging, close low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8), and stop the engine.

T5-7-33

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: Low Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool When attempting to disconnect the dCAUTION: high-pressure-side charge hose, refrigerant and

compressor oil may spout. Disconnect the highpressure side charge hose after the high-pressure side pressure drops to less than 980 kPa (10 kgf/ cm2, 142 psi).

13. After checking refrigerant quantity, disconnect the low-pressure-side charge hose first. Disconnect the low-pressure-side charge hose. Wait for the high-pressure-side pressure to drop to less than 980 kPa (10 kgf/cm2, 142 psi). Disconnect the high-pressure-side charge hose.

T5-7-34

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: Low Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool Inspection After warm-up operation, carry out gas leak check and performance check. Refrigerant will produce poisonous dCAUTION: material if exposed to heat of 1000 °C 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

T5-7-35

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 3. The checklist before the summer season is as follows:  Check each air conditioner component for abnormalities.  Check the line connections for oil leaks.  Check refrigerant quantity.  Check the engine cooling circuit.  Check V belt for wear. Replace if necessary.  Check for clogged condenser. 4. Off-Season Maintenance  During off-season, operate the idler pulley and compressor at least once a month for a short time to check for any abnormal sounds.  Do not remove the compressor belts during offseason. Operate the compressor occasionally at slow speed for 5 to 10 minutes with the belt slightly loosened in order to lubricate the machine parts.

fNOTE: When the machine is in normal and the air

conditioner is operated with the following conditions, air vent temperature decrease approx. 20°C (68°F) or less. (it may be different under special environment.)

Operating Conditions of the Air Conditioner  Engine Speed: High Idle  Cab Window: Fully closed  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh / re-circulated air selection: Re-circulated Air  Season: Summer

T5-7-36

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Hose and Pipe Tightening Torque

Use the following tightening torque values when connecting the pipes. Joint Location Tube or Bolt Size Tightening Torque N·m (kgf·m) (lbf·ft) Nut type Pipe with dia. 8 12 to 15 (Fig. A) (1.2 to 1.5) (8.7 to 10.8) Pipe with D1/2 20 to 25 (2.0 to 2.5) (14.5 to 18.1) Pipe with D5/8 30 to 35 (3.0 to 3.5) (21.7 to 25.3) Block joint Receiver M6 Bolt 4.0 to 7.0 (Fig. B) (4T) (0.4 to 0.7) (3.0 to 5.0) M6 Bolt (6T) 8.0 to 12 for other than (0.8 to 1.2) Receiver (5.8 to 8.7)

TDAA-05-07-016 B

TDAA-05-07-017

T5-7-37

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-38

INDEX 111000 to 111002...................................................................T5-5-41 111003.........................................................................................T5-5-42 111006, 111007........................................................................T5-5-44 111014.........................................................................................T5-5-44 111025.........................................................................................T5-5-44 111103.........................................................................................T5-5-49 111105.........................................................................................T5-5-49 111200.........................................................................................T5-5-50 111204.........................................................................................T5-5-53 111205.........................................................................................T5-5-51 111206.........................................................................................T5-5-54 111207.........................................................................................T5-5-51 111208.........................................................................................T5-5-55 111217.........................................................................................T5-5-52 111311.........................................................................................T5-5-56 111312.........................................................................................T5-5-52 111313.........................................................................................T5-5-56 111411.........................................................................................T5-5-57 111412.........................................................................................T5-5-58 111413.........................................................................................T5-5-59 111414 to 111419...................................................................T5-5-60 111422.........................................................................................T5-5-61 111600, 111601, 111602.......................................................T5-5-62 111700 to 111705...................................................................T5-5-66 111900.........................................................................................T5-5-63 111901.........................................................................................T5-5-64 111902.........................................................................................T5-5-65 113002, 113003........................................................................T5-5-45 113005.........................................................................................T5-5-45 113007.........................................................................................T5-5-45 114010, 114011........................................................................T5-5-45 114015.........................................................................................T5-5-45 115001.........................................................................................T5-5-69 115011.........................................................................................T5-5-70 120000 to 120005...................................................................T5-5-68 120014.........................................................................................T5-5-68 120300.........................................................................................T5-5-72 120500 to 120503...................................................................T5-5-72 120505 to 120507...................................................................T5-5-72 24-Volt Circuit...........................................................................T5-1-16 5-Volt Circuit..............................................................................T5-1-22 A Accumulator Pressure, Brake...............................................T4-5-28 Adjustment.................................................................................. T4-6-1 Air Bleeding Procedures for Brake (Axle)........................T5-6-99 Air Conditioner Component Layout............................................................. T5-7-2 Functions of Main Parts..................................................... T5-7-4 Outline..................................................................................... T5-7-1 Troubleshooting................................................................... T5-7-8 Work after Replacing Components.............................T5-7-27 Air Conditioner Controller Fault Code List...... T5-5-33, T5-7-9 Air Conditioner Controller Fault Codes 11 to 22.................................................................T5-5-74, T5-7-10 43 to 92.................................................................T5-5-75, T5-7-11

Alarms on Monitor..................................................................T5-5-24 All Actuator System Troubleshooting.............T5-6-28, T5-6-51 Alternator Check......................................................................T5-1-14 Axle (Service Brake), Air Bleeding......................................T5-6-99 Axle Oil Temperature Sensor Specification....................T5-5-65 B Battery Voltage Check...........................................................T5-1-13 Bell Crank Stopper Clearance................................................ T4-4-8 Brake (Axle), Air Bleeding.....................................................T5-6-99 Brake Accumulator Pressure................................................T4-5-28 Brake Circuit Pilot Pressure.................................................... T4-5-2 Brake Pressure, Test Parking...................................................................................T4-5-26 Service...................................................................................T4-5-24 Brake System Troubleshooting..........................T5-6-40, T5-6-79 Brake Valve.................................................................................T5-4-16 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..............................................................T5-5-46 Charge Air Conditioner with Refrigerant........................T5-7-29 Charging Block.........................................................................T5-4-15 Check by False Signal.............................................................T5-1-23 Column Display Controller (Information) Fault Codes 120500 to 120503..............................................................T5-5-72 120505 to 120507..............................................................T5-5-73 Column Display Controller Fault Code 115001...................................................................................T5-5-69 115011...................................................................................T5-5-70 List...........................................................................................T5-5-30 Communication System......................................................... T5-3-7 Communication Terminal Fault Code List......................T5-5-32 Component Layout................................................................... T5-4-1 Compressor Oil, Refill.............................................................T5-7-28 Continuity Check.....................................................................T5-1-15 Control Lever Operating Force...........................................T4-4-14 Control Lever Stroke...............................................................T4-4-16 Controller..................................................................................... T5-4-6 Controller Hardware Failure.................................................. T5-5-9 Coolant Temperature............................................................... T5-2-4 Coolant Temperature Gauge................................................. T5-2-7 Cooling circuit check by using manifold gauge...........T5-7-25 Correlation between Trouble Symptoms and Part Failures..........................................................................T5-6-25 Cut-in/Cut-out Pressure ......................................................... T4-5-2 Cylinder Drift Check...............................................................T4-4-12 D Daily Report Data, List............................................................. T5-3-2 Diagnosing Procedure, Introduction.................................. T5-1-1 Diagnosis Procedure................................................................ T5-1-2 Digging Position Adjustment............................................... T4-6-6 90Z6 Trbl

INDEX Drift Check, Cylinder..............................................................T4-4-12 E e-Service, Outline...................................................................... T5-3-1 e-Service Data List Daily Report Data................................................................. T5-3-2 Frequency Distribution Data........................................... T5-3-4 Operation Data..................................................................... T5-3-2 Service Menu Display......................................................... T5-2-6 Total Operating Hours........................................................ T5-3-5 ECM Fault Code List................................................................T5-5-34 Electric Component Layout (Overview)............................ T5-4-4 Electric System Inspection..................................................... T5-1-5 Electrical System (Cab)............................................................ T5-4-5 Electrical System (Relays).....................................................T5-4-10 Engine Failure...........................................................................T5-5-11 Engine Speed................................................................T4-3-1, T5-2-4 Engine System Troubleshooting.......................T5-6-26, T5-6-45 Engine Test................................................................................... T4-3-1 Engine/Fan Pump....................................................................T5-4-11 Exchange Inspection..............................................................T5-6-97 F Fan Motor...................................................................................T5-4-16 Fault Code.................................................................................... T5-2-5 Fault Code List Air Conditioner Controller..............................................T5-5-33 Column Display Controller.............................................T5-5-30 Communication Terminal...............................................T5-5-32 ECM.........................................................................................T5-5-34 MC............................................................................................. T5-5-9 Monitor Controller (Monitor).........................................T5-5-26 Monitor Controller (Information).................................T5-5-28 MPDr......................................................................................... T5-5-3 Faulty cooling...........................................................................T5-7-12 Faulty heating...........................................................................T5-7-19 Frequency Distribution Data, List........................................ T5-3-4 Front Attachment System Troubleshooting .................................................................................T5-6-31, T5-6-56 Front Axle...................................................................................T5-4-15 Fuel Consumption..................................................................... T5-2-5 Fuel Gauge................................................................................... T5-2-8 Fuel Level Sensor Specifications........................................T5-5-71 Fuse Box A..................................................................................T5-1-11 Fuse Box B..................................................................................T5-1-11 Fuse Inspection........................................................................T5-1-10 Fusible Link Inspection..........................................................T5-1-12 H Hose Tightening Torque........................................................T5-7-37 How to display service menu................................................ T5-2-4 Hydraulic Circuit........................................................................ T4-5-1 Hydraulic Cylinder Cycle Time............................................T4-4-10 Hydraulic Oil Temperature..................................................... T5-2-4 Hydraulic Oil Temperature Sensor Specification..........T5-5-64 Hydraulic Pump Device.........................................................T5-4-13

I Instructions for Disconnecting Connectors..................... T5-1-8 L Learning Failure.......................................................................T5-5-21 Lever Stopper Clearance......................................................... T4-4-8 Lift Arm Angle Sensor Learning........................................... T4-6-4 List, e-Service Data Daily Report Data................................................................. T5-3-2 Frequency Distribution Data........................................... T5-3-4 Operation Data..................................................................... T5-3-2 Service Menu Display......................................................... T5-2-6 Total Operating Hours........................................................ T5-3-5 Loading Circuit Main Relief Set Pressure.......................... T4-5-8 Loading Main Relief Pressure Adjustment....................... T4-5-9 Loading Pilot Circuit................................................................. T4-5-1 M 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 MC Fault Code 111000 to 111002..............................................................T5-5-41 111003...................................................................................T5-5-42 111006, 111007..................................................................T5-5-44 111014...................................................................................T5-5-44 111025...................................................................................T5-5-44 111103...................................................................................T5-5-49 111105...................................................................................T5-5-49 111200...................................................................................T5-5-50 111204...................................................................................T5-5-53 111205...................................................................................T5-5-51 111206...................................................................................T5-5-54 111207...................................................................................T5-5-51 111208...................................................................................T5-5-55 111217...................................................................................T5-5-52 111311...................................................................................T5-5-56 111312...................................................................................T5-5-52 111313...................................................................................T5-5-56 111411...................................................................................T5-5-57 111412...................................................................................T5-5-58 111413...................................................................................T5-5-59 111414 to 111419..............................................................T5-5-60 111422...................................................................................T5-5-61 111600, 111601, 111602.................................................T5-5-62 111700 to 111705..............................................................T5-5-66 111900...................................................................................T5-5-63 111901...................................................................................T5-5-64 111902...................................................................................T5-5-65 120000 to 120005..............................................................T5-5-68 120014...................................................................................T5-5-68 List............................................................................................. T5-5-9 Monitor......................................................................................... T5-4-8 Monitor, Outline......................................................................... T5-2-1

90Z6 Trbl

INDEX Monitor Controller (Information) Fault Code 114010, 114011..................................................................T5-5-45 114015...................................................................................T5-5-45 List...........................................................................................T5-5-28 Monitor Controller (Monitor) Fault Code 113002, 113003..................................................................T5-5-45 113005...................................................................................T5-5-45 113007...................................................................................T5-5-45 120300...................................................................................T5-5-72 List...........................................................................................T5-5-26 Monitor Display.......................................................................... T5-2-2 Monitor Panel...............................................................T5-2-1, T5-4-9 MPDr. Fault Code Reference Table...................................... T5-5-3 Multiple Control Valve...........................................................T5-4-14 O Operating Procedures of Service Menu............................ T5-2-3 Operation Data, List.................................................................. T5-3-2 Operational Performance Standard Table........................ T4-2-1 Operational Performance Tests............................................ T4-1-1 Other Sensor Failures.............................................................T5-5-23 Other System Troubleshooting.........................T5-6-41, T5-6-83 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 Performance Test....................................................................... T4-4-1 Pilot Failure................................................................................T5-5-13 Pilot Valve...................................................................................T5-4-16 Pipe Tightening Torque.........................................................T5-7-37 Precautions for Inspection and Maintenance ................ T5-1-6 Preparation for Performance Tests...................................... T4-1-2 Primary Pilot Pressure.............................................................. T4-5-2 Proportional Solenoid Valve Failure.................................T5-5-15 Pump Delivery Pressure.......................................................... T4-5-6 Pump Failure.............................................................................T5-5-12 Pump Output Pressure............................................................ T4-5-6

Service Brake Function Check............................................... T4-4-4 Service Brake Pressure (Front and Rear) .........................T4-5-24 Service Brake Wear Amount.................................................. T4-4-6 Service Menu, How to display.............................................. T5-2-4 Service Menu, Operating Procedures................................ T5-2-3 Snapshot Data............................................................................ T5-3-6 Standard Table............................................................................ T4-2-1 Steering Circuit Main Relief Set Pressure........................T4-5-10 Steering Main Relief Pressure Adjustment.....................T4-5-11 Steering System Troubleshooting....................T5-6-35, T5-6-65 Steering Valve...........................................................................T5-4-16 Switch Failure............................................................................T5-5-21 Switches........................................................................................ T5-4-8 T Temperature Sensor Failure.................................................T5-5-22 Test Harness..............................................................................T5-1-24 Torque Converter Assembly................................................T5-4-12 Torque Converter Oil Temperature Sensor Specification........................................................................T5-5-63 Torque Converter Pressure...................................................T4-5-36 Total Operating Hours, List.................................................... T5-3-5 Transmission Assembly.........................................................T5-4-12 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, T5-6-69 Troubleshooting A (By Fault Codes)................................... T5-5-1 Troubleshooting B (By Troubleshooting Symptom)..... T5-6-1 V Vehicle Information Display.................................................. T5-2-2 Voltage and Current Measurement..................................T5-1-16

R Refill Compressor Oil..............................................................T5-7-28 Refrigerant, Charge Air Conditioner.................................T5-7-29 Regulator Adjustment...........................................................T4-5-22 Relationship between Machine Trouble Symptoms and Related Parts.......................................................................... T5-6-3 Relays............................................................................................. T5-4-6 Revolution Sensor Failure.....................................................T5-5-20 Ride Control Group (Option)...............................................T5-4-17 Right Console.............................................................................. T5-4-7 S Secondary Pilot Pressure........................................................ T4-5-4 Secondary Pilot Pressure Adjustment Procedure.......... T4-5-5 Secondary Steering Group (Option).................................T5-4-18 Secondary Steering Pump (Option).................................T5-4-18 Sensor Activating Range......................................................T4-2-12

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INDEX (Blank)

90Z6 Trbl