Professional Documents
Culture Documents
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 materials listed below in addition
to this manual.
The Operators Manual
The Parts Catalog
MANUAL COMPOSITION
This manual consists of three portions: the Technical Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Manual.
Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
PAGE NUMBER
Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual
W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL 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.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting
heavy parts.
CAUTION:
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
m3
kg
N
N
Nm
Nm
Into
in
ft
US gal
US qt
yd3
lb
kgf
lbf
kgfm
lbfft
Quantity
Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375
Pressure
Power
Temperature
Velocity
Flow rate
IN-02
To Convert
From
MPa
MPa
kW
kW
C
km/h
min-1
L/min
mL/rev
Into
kgf/cm2
psi
PS
HP
F
mph
rpm
US gpm
cc/rev
Multiply By
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0
TECHNICAL MANUAL
(Troubleshooting)
SECTION 4 OPERATIONAL
PERFORMANCE TEST
Group
Group
Group
Group
Group
Group
1 Introduction
2 Standard
3 Engine Test
4 Wheel Loader Test
5 Component Test
6 Adjustment
SECTION 5 TROUBLESHOOTING
Group
Group
Group
Group
Group
Group
Group
Group
1 Diagnosing Procedure
2 Dr-ZX
3 e-Wheel
4 Component Layout
5 Troubleshooting A
6 Troubleshooting B
7 Troubleshooting C
8 Electrical System Inspection
SECTION 1 GENERAL
SECTION 3 COMPONENT OPERATION
Group 1 Specification
Group 1 Pump Device
Group 2 Component Layout
Group 2 Control Valve
Group 3 Component Specifications Group 3 Hydraulic Fan Motor
SECTION 2 SYSTEM
Group 4 Steering Pilot Valve
Group 1 Control System
Group 5 Steering Valve
Group 2 ECM System
Group 6 Pilot Valve
Group 3 Hydraulic System
Group 7 Charging Block
Group 8 Ride Control Valve
Group 4 Electrical System
Group 9 Drive Unit
Group 10 Axle
Group 11 Brake Valve
Group 12 Others
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic
Oil Tank
SECTION 2 BASE MACHINE (UPPER
STRUCTURE)
Group 1 Cab
Group 2 Counterweight
Group 3 Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Pilot Valve
Group 7 Ride Control Valve
Group 8 Pilot Shutoff Valve
Group 9 Hydraulic Fan Motor
SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.
When you see these symbols on your machine or
in operator`s manual, be alert to the potential for
personal injury.
Follow recommended precautions and safe operating practices.
001-E01A-0001
SA-688
To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided,
could result in damage to the machine.
SA-1
SA-1223
SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the
SA-003
003-E01B-0003
SA-2
SA-437
SAFETY
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
SA-438
Operating equipment safely requires the full attention of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
006-E01A-0434
SA-434
NSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal injury.
In the walk-around inspection be sure to cover all
points described in the PRE-START INSPECTION chapter in the operators manual.
007-E01A-0435
SA-435
SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
Before entering the cab, thoroughly remove all dirt
SA-4
SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you get on and off the machine, always
face the machine and maintain a three-point
contact with the steps and handrails.
Do not use any controls as hand-holds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
008-E01A-0439
SA-439
SA-5
SA-462
SAFETY
FASTEN YOUR SEAT BELT
If the machine should overturn, the operator may
become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.
Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If
any item is damaged or worn, replace the seat
belt or component before operating the machine.
Be sure to remain seated with the seat belt securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent condition.
SA-237
010-E01A-0237
SA-398
011-E01A-0398
SA-6
SA-293
SAFETY
OPERATE
SEAT
ONLY
FROM
OPERATOR'S
SA-431
012-E01B-0431
JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to
SA-7
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
When working at the edge of an excavation or on a
road shoulder, the machine could tip over, possibly
resulting in serious injury or death.
Investigate the configuration and ground conditions of the job site beforehand to prevent the
machine from falling and to prevent the ground,
stockpiles, or banks from collapsing.
Make a work plan. Use machines appropriate to
the work and job site.
Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
When working on an incline or on a road shoulder,
employ a signal person as required.
Confirm that your machine is equipped a FOPS
cab before working in areas where the possibility
of falling stones or debris exist.
When the footing is weak, reinforce the ground
before starting work.
When working on frozen ground, be extremely
alert. As ambient temperatures rise, footing becomes loose and slippery.
Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.
015-E01B-0447
SA-8
SA-447
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure
FOPS: Falling Object Protective Structure
SA-521
018-E01A-0481
SA-481
SA-9
SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as being struck by foreign objects and being thrown off
the machine.
Only the operator should be on the machine.
Keep riders off.
Riders also obstruct the operators view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0427
SA-427
DRIVE SAFELY
SA-448
019-E07A-0448
SA-449
SA-450
SA-10
SAFETY
DRIVE SAFELY WITH BUCKET LOADED
If the machine is incorrectly operated while driving
with the bucket loaded, turning over of the machine
may result. Be sure to follow all the instructions indicated below.
When driving the machine on a job site with the
bucket loaded, hold the bucket as low as possible
to keep the machine balanced and to have good
visibility.
Do not exceed the rated load capacity. Always
operate the machine within the rated load capacity.
Avoid fast starts, stops, and quick turns. Failure to
do so may result in personal injury and/or death.
Avoid rapid drive direction changes which could
possibly cause personal injury and/or death.
SA-400
051-E02A-0400
SA-452
052-E02A-0452
053-E02A-0453
SA-453
SA-11
SAFETY
AVOID INJURY FROM ROLLAWAY ACCIDENTS
Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
Select level ground when possible to park machine.
Do not park the machine on a grade.
Lower the bucket to the ground.
Place the F-N-R lever in neutral, and put the park
brake switch in the ON (parking brake) position.
Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the lock lever to LOCK position.
Block both tires and lower the bucket to the
ground.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.
SA-457
020-E02A-0516
SA-458
SA-12
SAFETY
AVOID ACCIDENTS FROM BACKING UP
AND TURNING
Make sure no one is working under or close to the
machine before backing up or turning the machine
to avoid personal injury and/or death by being run
over or entangled in the machine.
Keep all personnel away from the machine by
sounding the horn and/or using hand signals. Use
extra care to be sure no one is in from the articulation area before turning the machine.
Keep windows, mirrors, and lights in good condition.
Reduce travel speed when dust, heavy rain, fog,
etc., reduce the visibility.
In case good visibility is not obtained, use a signal
person to guide you.
SA-383
021-E02A-0517
SA-312
SA-13
SAFETY
AVOID POSITIONING
ANYONE
BUCKET
OVER
023-E02A-0518
SA-518
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE. MACHINE WILL TIP OVER FASTER
THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR
DEATH. IF TIPPING OVER OF THE MACHINE IS
PREDICTED, SECURELY HOLD THE STEERING
WHEEL TO PREVENT YOUR BODY FROM BEING
THROWN OUT OF THE MACHINE.
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:
Be extra careful before operating on a grade.
Prepare machine operating area flat.
Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or slipping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 5 degrees if crossing the grade is unavoidable.
Reduce swing speed as necessary when swinging loads.
SA-14
SA-463
SAFETY
NEVER UNDERCUT A HIGH BANK
The edges could collapse or a land slide could occur
causing serious injury or death.
026-E01A-0519
SA-519
027-E01A-0396
SA-396
028-E01A-397
SA-397
SA-15
SAFETY
AVOID POWER LINES
Serious injury or death can result from contact with
electric lines.
Never move any part of the machine or load closer to
any electric line than 3 m (10 ft) plus twice the line
insulator length.
29-E01A-0455
SA-455
OBJECT HANDLING
If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it, resulting in serious injury or death.
When using the machine for craning operations,
be sure to comply with all local regulations.
Do not use damaged chains or frayed cables,
sables, slings, or ropes.
Before craning, position the upperstructure with
the position of the bucket support located on the
chassis at the front.
Move the load slowly and carefully. Never move it
suddenly.
Keep all persons well away from the load.
Never move a load over a person's head.
Do not allow anyone to approach the load until it
is safely and securely situated on supporting
blocks or on the ground.
Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0132
SA-16
SA-132
SAFETY
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.
Keep bystanders away from the working area
before striking any object.
031-E01A-0432
SA-432
SA-17
SA-456
SAFETY
STORE ATTACHMENTS SAFELY
Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious
injury or death.
Securely store attachments and implements to
prevent falling. Keep children and bystanders
away from storage areas.
504-E01A-0034
SA-034
TRANSPORT SAFELY
Take care the machine may turn over when loading
or unloading the machine onto or off of a truck or
trailer.
Observe the related regulations and rules for safe
transportation.
Select an appropriate truck or trailer for the machine to be transported.
Be sure to use a signal person.
Always follow the following precautions for loading or unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to
support the machine weight.
3. Use the low speed gear.
4. Never steer the machine while on the ramp. If the
traveling direction must be changed while the
ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading
again.
5. After loading, install the lock bar to securely hold
the articulation mechanism.
6. Wedge the front and rear of tires. Securely hold
the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the
TRANSPORTING section.
035-E07A-0454
SA-18
Less than 15
SA-454
SAFETY
HANDLE FLUIDS SAFELY-AVOID FIRES
Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.
Do not refuel the machine while smoking or when
near open flame or sparks.
Always stop the engine before refueling the machine.
Fill the fuel tank outdoors.
SA-018
034-E01A-0496
SA-019
SA-19
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before starting
work.
Keep the work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is
moving.
Keep hands, feet and clothing away from
power-driven parts.
Before servicing the machine:
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for
5 minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by
moving the control levers several times.
7. Remove the key from the switch.
8. Attach a Do Not Operate tag on the control
lever.
9. Lower the lock lever to the LOCK position.
10. Lock bar connects the front and rear frames.
11. Allow the engine to cool.
SA-028
SA-312
SA-134
500-E02C-0520
SA-527
SA-20
SAFETY
Sufficiently illuminate the work site. Use a maintenance work light when working under or inside
the machine.
Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
SA-037
501-E01A-0287
SS2045102
Never attempt to work on the machine without securing the machine first.
Always lower the attachment to the ground before
you work on the machine.
If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a machine that is supported solely by a jack.
519-E01A-0527
SA-527
502-E01A-0026
SA-026
SA-21
SAFETY
SUPPORT MAINTENANCE PROPERLY
Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire unless you have
the proper equipment and experience to perform
the job. Have it done by your authorized dealer or
a qualified repair service.
Always maintain the correct tire pressure. DO
NOT inflate tire above the recommended pressure.
When inflating tires, use a chip-on chuck and extension hose long enough to allow you to stand to
one side and not in front of or over the tire assembly. Use a safety cage it available.
Inspect tires and wheels daily. Do not operate with
low pressure, cuts bubbles, damaged rims, or
missing lug bolts and nuts.
Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion.
SA-249
521-E02A-0249
SA-344
SA-22
SAFETY
PREVENT BURNS
Hot spraying fluids:
SA-039
REPLACE
CALLY
RUBBER
HOSES
PERIODI-
SA-23
SA-019
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-031
507-E03A-0499
SA-292
SA-044
SA-24
SAFETY
PREVENT FIRES
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to
fires.
Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose
oil-cooler flange bolts.
Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
Short circuits can cause fires.
Clean and tighten all electrical connections.
Check before each shift or after eight(8) to ten(10)
hours operation for loose, kinked, hardened or
frayed electrical cables and wires.
Check before each shift or after eight(8) to ten(10)
hours operation for missing or damaged terminal
caps.
DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.
Check Key Switch:
If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
Always check key switch function before operating
the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm
that the engine stops.
SA-25
SA-019
SAFETY
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the following way:
Stop the engine by turning the key switch to the
OFF position if there is time.
Use a fire extinguisher if there is time.
Exit the machine.
518-E01A-0393
SA-393
SA-016
PRECAUTIONS
GRINDING
FOR
WELDING
AND
SA-26
SA-818
SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area. Install temporary fireresistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc..
SA-030
510-E01B-0030
SA-27
SA-029
SAFETY
BEWARE OF ASBESTOS DUST
Take care not to inhale dust produced in the work
site. Inhalation of asbestos fibers may be the cause
of lung cancer.
Depending on the wok site conditions, the risk of
inhaling asbestos fiber may exist. Spray water to
prevent asbestos from becoming airborne. Do not
use compressed air.
When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask
rated to prevent the inhalation of asbestos.
Keep bystanders out of the work site during operation.
Asbestos might be present in imitation parts. Use
only genuine Hitachi Parts.
SA-029
SA-032
SA-28
SA-405
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides
specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what the risks are and how to do the job
safely. Then follow procedures and use recommended equipment.
See your authorized dealer for MSDSs (available
only in English) on chemical products used with
your machine.
SA-309
515-E01A-0309
516-E01A-0226
SA-29
SA-226
SAFETY
BEFORE RETURNING THE MACHINE TO
THE CUSTOMER
After maintenance or repair work is complete,
confirm that:
The machine is functioning properly, especially
the safety systems.
Worn or damaged parts have been repaired or
replaced.
S517-E01A-0435
SA-435
SA-30
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Travel Speed.................................................T4-4-1
Group 2 Standard
Operational Performance
Standard Table ........................................... T4-2-1
Clearances ..................................................T4-4-6
4GBT-4-1
Group 6 Adjustment
Transmission Learning................................. T4-6-1
Lift Arm Angle Sensor
Learning (Optional)................................... T4-6-6
Drive Belt Tension Adjustment ..................... T4-6-8
4GBT-4-2
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 machines working hours.
Definition of Performance Standard
1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, 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
FOR
PERFORMANCE
T4-1-2
T105-06-01-003
Performance
Standard
84025
2240/233025
2010/192050
1780/177050
3.04 (31.0, 442)
0.4
45 or less
6 to 8
49 (0.5, 7)
T4-2-1
NOTE: 1 mm=0.03937 in
Reference
Remarks
Page
T4-3-1
Value indicated on Dr. ZX
T4-3-3
T4-3-4
T4-3-7
T4-6-8
-
Performance
Standard
7.0/7.10.7
12.0/12.61.2
23.0/23.82.3
36.53.6
5.0 or less
Remarks
Reference
Page
T4-4-1
T4-4-2
T4-4-3
6.2
15.0
5.0
0
2.2
2.4
0
T4-4-4
-
T4-4-6
T4-4-6
2
-
0.3
14
T4-4-11
T4-4-8
5.30.3
2.90.3
1.20.3
2.80.3
2.50.3
T4-4-10
45 or less
15 or less
150 or less
T4-2-2
Performance Standard
11 (1.1, 2.5)/
19 (1.9, 4.3) or less
17 (1.7, 3.8)/
30 (3.1, 6.8) or less
40 (4.1, 9)/
20(2.0, 4.5) or less
11 (1.1, 2.5)/
19 (1.9, 4.3) or less
17 (1.7, 3.8)/
30 (3.1, 6.8) or less
40 (4.1, 9)/
20 (2.0, 4.5) or less
12 (1.2, 2.7)/
22 (2.2, 5) or less
18 (1.8, 4)/
33 (3.3, 7.4) or less
40 (4.1, 9)/
20 (2.0, 4.5) or less
17(1.7, 3.8)/
28 (2.9, 6.3) or less
17 (1.7, 3.8)/
17 (1.7, 3.8) or less
Forward/Reverse Lever
11.8+1-2
(1.2+0.1-0.2, 2.7+0.2-0.5)/
11.8+1-2
(1.2+0.1-0.2, 2.7+0.2-0.5)
Accelerator Pedal
25.03.5
(3. 60.4, 5.60.8)
318+65-45
(32.4+6.6-4.6, 71.6+14.6-10.1)
288+80-30 (29.4+8.2-3.1,
64.8+18-6.8)
T4-2-3
Remarks
Reference
Page
T4-4-12
Remarks
Reference
Page
T4-4-13
345/6310
545/8010
345/6310
545/8010
345/6310
545/8010
545/8010
3.5 to 4.0
505/505
18.01.5
18.41.0
17.41.0
5 to 15
12 to 20
1.26
325 (3.32, 47.3)
T4-2-4
Performance
Standard
4.0+1.0-0.5
+10
(41 -5, 580+142-71)
3.7+0.5-0.3
+5
(38 -3, 538+73-64)
Remarks
Reference
Page
T4-5-1
T4-5-3
T4-5-4
T4-5-6
T4-5-8
(L/min)
2
27.4+2.0-0.5
(280+20-5, 3983+284-71)
27.4+2.0-0.5
(280+20-5, 3983+284-71)
(Reference values at
50 L/min)
34.3+1.0-0
(350+10-0, 4987+142-0)
30.4+1.0-0
(310+10-0, 4420+142-0)
30.4+1.0-0
(310+10-0, 4420+142-0)
+2.0
27.4 -0.5
(280+20-5, 3983+291-73)
4.180.85
(42.78.7, 608124)
10.8 to 15.0
(110 to 153,
1570 to 2181)
T4-5-16
T4-5-12
T4-5-22
T4-5-24
T4-5-26
Service Brake
Parking Brake
BRAKE WARNING PRESSURE
2
(Pressure-Decreasing)
MPa (kgf/cm , psi)
BRAKE WARNING PRESSURE
2
(Pressure-Increasing)
MPa (kgf/cm , psi)
TRANSMISSION CLUTCH PRESSURE
2
14.71.0
(15010, 2137145)
14.70.5
(1505, 213773)
80.5
(825, 116373)
100.5
(1025, 145473)
1.6 to 1.8
(16 to 18, 233 to 262)
1.1 to 1.3 (11 to 13,
160 to 189)/ 0.43 to
0.73 (4.3 to 7.4, 63 to
106)
T4-2-5
T4-5-28
T4-5-30
T4-5-32
T4-5-34
Acceletor Pedal
: Full Stroke
Driving Mode Switch
: H Mode
Work Mode Switch : N Mode
Hydraulic Oil Temperature : 505 C (12241 F)
Performance
Standard
84025
2310/230025
2060/198050
1800/179050
3.04 (31.0, 442)
0.4
45 or less
6 to 8
49 (0.5, 7)
T4-2-6
NOTE: 1 mm=0.03937 in
Reference
Remarks
Page
T4-3-1
Value indicated on Dr. ZX
T4-3-3
T4-3-4
T4-3-7
T4-6-8
-
Performance
Standard
7.0/7.00.7
12.0/12.51.2
23.0/23.72.3
36.03.6
5.0 or less
Remarks
Reference
Page
T4-4-1
T4-4-2
T4-4-3
6.2
15.0
5.0
0
2.2
2.4
0
T4-4-4
-
T4-4-6
T4-4-6
2
-
0.3
14
T4-4-11
T4-4-8
5.30.3
2.90.3
1.10.3
2.80.3
2.50.3
T4-4-10
45 or less
15 or less
150 or less
T4-2-7
Performance Standard
11 (1.1, 2.5)/
19 (1.9, 4.3) or less
17 (1.7, 3.8)/
30 (3.1, 6.8) or less
40 (4.1, 9)/
20(2.0, 4.5) or less
11 (1.1, 2.5)/
19 (1.9, 4.3) or less
17 (1.7, 3.8)/
30 (3.1, 6.8) or less
40 (4.1, 9)/
20 (2.0, 4.5) or less
12 (1.2, 2.7)/
22 (2.2, 5) or less
18 (1.8, 4)/
33 (3.3, 7.4) or less
40 (4.1, 9)/
20 (2.0, 4.5) or less
17(1.7, 3.8)/
28 (2.9, 6.3) or less
17 (1.7, 3.8)/
17 (1.7, 3.8) or less
Forward/Reverse Lever
11.8+1-2
(1.2+0.1-0.2, 2.7+0.2-0.5)/
11.8+1-2
(1.2+0.1-0.2, 2.7+0.2-0.5)
Accelerator Pedal
25.03.5
(3. 60.4, 5.60.8)
318+65-45
(32.4+6.6-4.6, 71.6+14.6-10.1)
288+80-30 (29.4+8.2-3.1,
64.8+18-6.8)
T4-2-8
Remarks
Reference
Page
T4-4-12
Remarks
Reference
Page
T4-4-13
345/6310
545/8010
345/6310
545/8010
345/6310
545/8010
545/8010
3.5 to 4.0
505/505
18.01.5
18.41.0
17.41.0
5 to 15
12 to 20
1.26
375 (3.75, 47.3)
T4-2-9
Performance
Standard
4.0+1.0-0.5
+10
(41 -5, 580+142-71)
3.7+0.5-0.3
+5
(38 -3, 538+73-64)
Remarks
Reference
Page
T4-5-1
T4-5-3
T4-5-4
T4-5-6
T4-5-8
(L/min)
2
29.4+2.0-0.5
(300+20-5, 4274+284-71)
29.4+2.0-0.5
(300+20-5, 4274+284-71)
(Reference values at
50 L/min)
36.8+1.0-0
(375+10-0, 5350+142-0)
32.5+1.0-0
(332+10-0, 4725+142-0)
32.5+1.0-0
(332+10-0, 4725+142-0)
+2.0
29.4 -0.5
(300+20-5, 4274+291-73)
4.180.85
(42.78.7, 608124)
10.8 to 15.0
(110 to 153,
1570 to 2181)
T4-5-16
T4-5-12
T4-5-22
T4-5-24
T4-5-26
Service Brake
Parking Brake
BRAKE WARNING PRESSURE
2
(Pressure-Decreasing)
MPa (kgf/cm , psi)
BRAKE WARNING PRESSURE
2
(Pressure-Increasing)
MPa (kgf/cm , psi)
TRANSMISSION CLUTCH PRESSURE
2
14.71.0
(15010, 2137145)
14.70.5
(1505, 213773)
80.5
(825, 116373)
100.5
(1025, 145473)
1.6 to 1.8
(16 to 18, 233 to 262)
1.1 to 1.3 (11 to 13,
160 to 189)/ 0.43 to
0.73 (4.3 to 7.4, 63 to
106)
T4-2-10
T4-5-28
T4-5-30
T4-5-32
T4-5-34
L/min
B
C
Flow
Rate
Delivery Pressure
MPa (kgf/cm2)
ZW220
A
B
C
D
T4GB-04-02-001
ZW250
Delivery Pressure
MPa (kgf/cm2, psi)
Flow Rate
L/min (gpm)
Delivery Pressure
MPa (kgf/cm2, psi)
Flow Rate
L/min (gpm)
2713 (720.8)
2703 (710.8)
2406 (631.6)
2106 (551.6)
2913 (770.8)
2903 (770.8)
2756 (731.6)
2256 (591.6)
T4-2-11
L/min
Flow
Rate
MPa (kgf/cm2)
T4GB-04-02-002
Pi1Pi2
ZW220
A
B
C
ZW250
Flow Rate
L/min (gpm)
Flow Rate
L/min (gpm)
2713 (1720.8)
802 (210.5)
363 (100.8)
2913 (770.8)
1002 (260.5)
553 (150.8)
T4-2-12
Work Mode
Switch
N
Specification
MPa (kgf/cm2, psi)
Neutral
1.2 to 2.6 (12 to 27, 174 to 378)
Relieved
26.7 to 30.0 (272 to 306, 3882 to 4361)
Neutral
1.2 to 2.6 (12 to 27, 174 to 378)
Implement Lever: Relieved
26.7 to 30.0 (272 to 306, 3882 to 4361)
Parking Brake Switch: ON
0 to 0.1 (0 to 1, 0 to 15)
Parking Brake Switch: OFF
10.5 to 15.7 (107 to 160, 1526 to 2282)
Brake Pedal: Neutral
0 to 0.1 (0 to 1, 0 to 15)
Brake Pedal: Fully De- 3.3 to 5.0 (34 to 51, 480 to 727)
pressed
Operation
ZW250
Item
Pump Delivery Pressure
Implement Pressure
Parking Brake Pressure
Service Brake Pressure
Specification
MPa (kgf/cm2, psi)
Neutral
1.2 to 2.6 (12 to 27, 174 to 378)
Relieved
28.7 to 32.0 (293 to 327, 4172 to 4652)
Neutral
1.2 to 2.6 (12 to 27, 174 to 378)
Implement Lever: Relieved
28.7 to 32.0 (293 to 327, 4172 to 4652)
Parking Brake Switch: ON
0 to 0.1 (0 to 1, 0 to 15)
Parking Brake Switch: OFF
10.5 to 15.7 (107 to 160, 1526 to 2282)
Brake Pedal: Neutral
0 to 0.1 (0 to 1, 0 to 15)
Brake Pedal: Fully De- 3.3 to 5.0 (34 to 51, 480 to 727)
pressed
Operation
T4-2-13
T4-2-14
M4GB-01-039
Measurement:
1. Measure the items as followings: slow idle with
no load), fast idle (with no load), fast idle (when
engine stalls) and fast idle (when engine stalls
and is relieved).
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 Accelerator Pedal Travel Mode Switch
Slow Idle
N
No depression
M
(with no load)
Fast Idle
Forward third/fourth gear Full depression
M
(with no load)
Fast Idle
N
Full depression
M
(when engine stalls)
Fast Idle
(when engine stalls Forward third/fourth gear Full depression
M
and is relieved)
T4-3-1
Slow Idle
(with no load)
Fast Idle
(with no load)
Fast Idle
(when engine
stalls)
Fast Idle
(when engine stalls
and is relieved)
Brake Pedal
Parking Brake
Switch
ON
Full depression
ON
OFF
Full depression
OFF
Transporting position
No control lever operation
OFF
Full depression
OFF
Transporting position
Bucket is raised and
relieved.
Evaluation:
Refer to Operational Performance Standard in Group
T4-2.
Remedy:
Refer to Troubleshooting in Section T5.
T4-3-2
Injector
Connector
T1V7-04-03-002
Measurement:
1. Turn the starter and measure compression pressure of each cylinder.
2. Repeat the measurement three times and calculate the mean values.
Evaluation:
Refer to Operational Performance Standard in Group
T4-2.
Remedy:
Refer to the engine shop manual.
T4-3-3
T1V1-04-03-005
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting any work, clean the head cover
mounting area and avoid contamination in the
engine.
Preparation:
1. Remove the head cover.
2. Remove the terminal nut which secures the harness to the injector.
2 Nm (0.2 kgfm, 1.5 lbfft)
3. Remove the harness assembly from the injector.
4. Remove the leak off pipe.
Harness
Injector
T1V1-04-03-008
T1V1-04-03-007
Top Mark
Crank Pulley
TDC Mark
T4-3-4
T1V7-04-03-001
Adjusting Screw
Cylinder No.
Valve locations
When the measurement is
started from No.1 cylinder
When the measurement is
started from No.6 cylinder
No.1
I
E
{
No.2
I
E
{
No.3
I
E
{
Bridge Cap
T4GB-04-03-003
No.4
I
E
{
No.5
I
E
No.6
I
E
Rocker Arm
Evaluation:
Refer to Operational Performance Standard in Group
T4-2.
T4GB-04-03-004
T4-3-5
Adjusting
Screw
Rocker Arm
T1V1-04-03-002
Lock Nut
Bridge
Bridge Cap
T1V1-04-03-003
Valve Head
T4-3-6
Bridge
T4-3-7
T4-3-8
Summary:
1. The overall performance of the travel drive system
(torque converter through transmission) is judged
by measuring the time necessary for traveling 50
m (164 ft).
A=
Preparation:
1. Adjust air pressure of the tires evenly in advance.
Air pressure:
ZW220: 325 kPa (3.32 kgf/cm2, 47 psi)
ZW250: 375 kPa (3.83 kgf/cm2, 55 psi)
2. On a firm level and uniform supporting surface,
prepare a 50 m (164 ft) straight travel course, and
70 m (230 ft) forward and backward runways. (For
measurement at Speed 4, a forward runway of
300 m (984 ft) is needed.)
3. Empty the bucket, and hold the lift arm afloat 0.4
to 0.5 m (1 ft 4 in to 1 ft 8 in) above the ground.
4. Keep the hydraulic oil temperature at 505 C
(12241 F). Warm the axle oil satisfactorily by
repeating travel and brake operations.
Make a warm up operation so that the indicators
of the engine water temperature monitor and the
torque converter oil temperature monitor rise
above the horizontal positions.
50 600
S 1000
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting in Section T5.
0.4 to 0.5 m
(14 to 18)
Ending Point
Travel Course
Runway
Starting Point
T4GB-04-04-001
Measurement
CAUTION: Avoid measurement at reverse for
fear of dangers involved.
1. Make measurement for each mode (Speeds 1 to
4).
2. Select the switches as follows.
Parking Brake
Accelerator
Shift Switch
Switch
Pedal
Speed 1
Speed 1
OFF
Full depression
Speed 2
Speed 2
OFF
Full depression
Speed 3
Speed 3
OFF
Full depression
Speed 4
Speed 4
OFF
Full depression
3. Put the forward-reverse lever at the F (Forward)
position. From the runway, travel by depression
the accelerator pedal to the stroke end.
4. Measure the travel speed (sec) of each travel
mode.
5. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
T4-4-1
Travel Mode
Switch
H
H
H
H
Work Mode
Switch
N
N
N
N
Summary:
1. The overall performance of the service brake is
judged.
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.
Air pressure:
ZW220: 325 kPa (3.32 kgf/cm2, 47 psi)
ZW250: 375 kPa (3.83 kgf/cm2, 55 psi)
2. On a paved dry road, prepare a 100 m (328 ft)
straight travel course (a 50 m (164 ft) of runway
and a 50 m (164 ft) of measurement road), and
set the brake starting point.
3. Empty the bucket, and hold the lift arm afloat 0.4
to 0.5 m (1 ft 4 in to 1 ft 8 in) above the ground.
4. Keep the hydraulic oil temperature at 505 C
(12241 F). Warm the axle oil satisfactorily by
repeating travel and brake operations.
Make a warm up operation so that the indicators
of the engine water temperature monitor and the
torque converter oil temperature monitor rise
above the horizontal positions.
Remedy:
Refer to the Trouble Shooting in Section T5.
0.4 to 0.5 m
(14 to 18)
Stopping Distance
Stopping Point
Brake Starting
Point
T4GB-04-04-002
Measurement
CAUTION: Avoid measurement at reverse for
fear of dangers involved. (Forward-reverse
lever: F)
1. Make measurement for high-speed mode.
2. Select the switches as follows.
Shift Switch
Speed 4
OFF
Accelerator
Pedal
Full depression
T4-4-2
Travel Mode
Switch
Work Mode
Switch
OFF
Summary:
The extent of wear of the brake disc at the service
brake of the axle is judged by the wear gauge.
Preparation:
1. Clean the inspection plug (1) of the axle, and
loosen it.
2. In the case of the rear axle, the inspection plug (1)
is located below the center line of the differential,
so loosen the inspection plug (1) after draining the
axle oil.
T4GB-04-04-004
Measurement:
1. Operate the service brake by depression the
brake pedal.
2. Insert the wear gauge (2) into the inspection port
until it contacts the brake disc (6) between the
brake ring (3) and the brake ring (4).
Inspection Port
T4GB-04-04-005
Evaluation:
1. In case the wear gauge (2) has entered between
the brake rings (3 and 4), and the model scale of
the wear gauge (2) and the housing face (5) have
coincided, the wear amount of the brake disc (6)
is not reached the maximum allowable limit of use.
In case the wear gauge (2) has not entered between the brake rings (3 and 4), and the model
scale is sticking above the housing face (5), the
brake disc (6) is worn in excess of the maximum
allowable limit of use.
2. In the method above, in case the maximum allowable limit of use has not reached, or in case
the service brake portion has been assembled,
refer to the Performance Standard Table in Group
T4-2.
Distance between Housing Face (5) and Brake
Disc (6)
Model
Dimensions (L) mm
ZW220
52
ZW250
54
T4-4-3
3
4
T4GB-04-04-006
0.4 to 0.5 m
(14 to 18)
11.31 (20%)
T4GB-04-04-003
Measurement:
1. Travel up the slope, and put the parking brake
switch at the P position.
2. Stop the engine.
3. After the body has stopped, put a mark (white
line) on the tire and the ground surface respectively.
4. After Five minutes have passed, measure the
amount of movement of the white line of the tire
from that of the ground surface.
5. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-4
T4-4-5
Bucket Dump
Stopper
Bell Crank Stopper
Measurement:
1. Bucket dump stopper
1-1. Raise the lift arm to the highest lifting position,
and stop the engine.
1-2. At stop of the engine, dump calmly until the
buket contacts the dump stopper. At this time,
measure the Strokes (A and B) of the bucket
cylinder and the lift arm and the dump angle (C)
of the bucket. In addition, measure the clearance between the bell crank stopper and the
cross tube.
1-3. At the same time, make measurement of the
contact conditions of the bucket dump stoppers
(left and right).
2. Bucket crowd stopper
1-1. Raise the lift arm until the lift arm cylinder stroke
(E) becomes the length of the standard dimension.
1-2. Set the engine at idling speed, and make
crowding operation until the bucket calmly contacts the bucket crowd stopper.
1-3. At this time, measure the strokes (D and E) of
the bucket cylinder and the lift arm cylinder and
the crowd angle (F) of the bucket. In addition,
measure the height (G) from the ground to the
bucket lowest portion.
1-4. Also measure the contact conditions of the
bucket crowd stoppers (left and right).
T4GB-04-04-008
Bucket Crowd
Stopper
T4GB-04-04-010
T4-4-6
Limit
Right
Left
Clearance Limit
Right
Left
Right
T4GB-04-04-009
Right
T4GB-04-04-009
T4-4-7
Summary:
1. The overall performance of the cylinders drive
system (main pump through each cylinder) is
judged by measuring the operating time of the
cylinders for the lift arm, bucket, and steeering.
2. The bucket is made empty in advance.
(for Lifting)
Preparation:
1. Measurement is made for the following positions.
1-1. Measurement of Lift Arm Cylinder (for Liftig)
Fully crowd the bucket, and lower the lift arm.
1-2. Measurement of Lift Arm Cylinder (for Lowering)
Lower the lift arm until the bucket bottom face
touches the ground horizontally.
1-3. Measurement of Bucket Cylinder
Lift the lift arm to the highest position.
1-4. Measurement of Steering Cylinder
Empty the bucket, and take the travel forward
position.
T4GB-04-04-016
(for Lowering)
T487-04-03-005
Bucket Cylinder:
T487-04-03-006
Travel Position
0.4 to 0.5 m
(14 to 18)
M4GB-04-001
T4-4-8
T4-4-9
Forward-reverse
Lever
Work Mode
Switch
Bucket Cylinder
Lift Arm
Cylinder
Measurement:
1. Stop the engine.
2. After 15 minutes have passed, measure the
shrinkage of the lift arm cylinder, shrinkage of the
bucket cylinder, and the settlement of the bucket
bottom respectively.
3. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4GB-04-04-014
B
A
T4GB-04-04-015
Remedy:
Refer to the Trouble Shooting in Section T5.
T4-4-10
Measurement:
1. Have the bucket bottom float slightly above the
bed.
2. Measure the vertical distance from the bed and
the bottom face of the cutting edge on the left and
right ends, and confirm the difference.
3. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
CAUTION: Never put hands, feet, and measuring instruments under the bucket.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-11
T4GB-04-04-011
0.4 to 0.5 m
(14 to 18)
M4GB-04-001
T4-4-12
T4GB-04-04-013
Knob
M4GB-01-004
Brake Pedal
Accelerator Pedal
Measurement:
1. Measurement of Operating Lever
1-1. Have the bucket bottom contact the ground.
1-2. Stop the engine.
1-3. Measure the stroke from the neutral position to
the stroke end of each of the lift arm, bucket,
and forward-reverse operating levers at the top
center of the grip.
2. Measurement of Pedal
2-1. Have the bucket contact the ground.
2-2. Stop the engine.
2-3. Measure the stroke from the neutral position to
the stroke end of the pedal at the top of the
pedal.
3. Measurement of Steering Wheel
3-1. Start the engine. (Low idling)
3-2. Have the bucket float slightly above the ground.
3-3. Measure the number of times of rotation required for reaching the left stroke end from the
right, and vice versa of the steering wheel.
4. make measurement corresponding to a straight
line.
5. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-13
T4-4-14
Hose
(3/4-16UNF)
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the hose end from the pilot filter inlet or
outlet port. Install adapter (13/16-16UNF), nipple,
pressure gauge and coupling.
: 22 mm, 24 mm, 27 mm
Pilot Filter
T4GB-04-05-001
T4-5-1
T1F3-04-05-001
Charging Block
M4GB-07-100
Change in Pressure
(mm)
kPa
(kgf/cm2)
(psi)
0.2
61.8
(0.63)
(9)
0.4
124.6
(1.27)
(18)
0.8
249.2
(2.54)
(36)
1
X
T4GB-04-05-002
Section X-X
T4GB-04-05-003
T4-5-2
Pilot Valve
T4-5-3
Pilot Hose
Signal Control
Valve
Pressure Gauge
Tee
T4GB-04-05-004
Charging Block
Solenoid
Valve
Measurement:
1. Set engine speed at fast idle.
2. Measure without depressing the accelerator
pedal.
Measure with the accelerator pedal fully depressed.
3. Read the values on both Dr. ZX and the pressure
gauge.
4. Repeat the measurement three times and calculate the average values.
Port X
T4GB-04-05-005
Pressure Gauge
Evaluation:
Refer to the performance Standard Table in Group
T4-2.
To Port X
T4GB-04-05-006
Hose
T4-5-4
Tee
Adapter
T4GB-04-05-007
Charging Block
T4GB-04-05-002
Pressure
Increase
Pressure
Decrease
W107-02-05-129
T4-5-5
Pressure
Gauge
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install an adapter, a hose and a pressure
gauge.
: 6 mm
(If Dr. ZX is used, install Dr. ZX and select the
controller function diagnosing.)
4. Start the engine. Check for any leaks at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).
Measurement:
1. Set engine speed at fast idle. Depress the accelerator pedal fully.
2. Measure pressure without load (with the control
levers in neutral).
3. Repeat the measurement three times and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting in Section T5.
T4-5-6
Pressure
Check Port
T4GB-04-05-008
Adapter
T4-5-7
T4-5-8
Pressure
Gauge
Pressure
Check Port
T4GB-04-05-008
Adapter
ZW220
1. Secure lock nut (1). Remove nut (3).
: 17 mm
2. Secure adjusting screw (2). Loosen lock nut (1).
: 17 mm
3. Turn adjusting screw (2) and adjust the relief
pressure to the specification.
4. Secure adjusting screw (2). Tighten lock nut (1).
: 19.5 Nm (2 kgfm, 14 lbfft)
5. Secure lock nut (1). Tighten nut (3).
6. Check the relief set pressure.
T4GB-04-05-009
T4GB-04-05-010
Pressure
Increase
Pressure
Decrease
T105-06-05-002
T4-5-9
2
T4GB-04-05-011
MPa
(kgf/cm2)
(psi)
4.5
(46)
(654)
8.9
(91)
(1294)
13.4
(137)
(1948)
17.8
(182)
(2588)
Pressure
Increase
Pressure
Decrease
W107-02-05-129
T4-5-10
T4-5-11
Summary:
Measure the steering relief valve set pressure at the
main pump delivery port in order to check performance of the steering relief valve.
Preparation:
1. Stop the engine.
2. Pusht the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install an adapter, a hose and a pressure
gauge.
: 6 mm
(If Dr.ZX is used, install Dr.ZX and select the controller function diagnosing.)
4. Start the engine. Check for any oil leaks at the
pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).
Measurement:
1. Set engine speed at fast idle. Depress the accelerator pedal fully.
2. Install the articulation lock bar. Slowly operate the
steering handle and relieve the steering.
3. Repeat the measurement three times and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-12
Pressure
Check Port
Adapter
T4GB-04-05-008
Steering Relief
Valve
T4GB-04-05-012
MPa
(kgf/cm2)
(psi)
3.8
(39)
(552)
7.5
(77)
(1050)
11.3
(155)
(1643)
15.0
(153)
(2181)
2
T4GB-04-05-013
Pressure
Increase
Pressure
Decrease
T105-06-05-002
T4-5-13
RELIEF
VALVE
SET
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, in
case a main relief valve designed to leak a small
quantity of oil before reliving is used, its
pre-leaking start pressure must be increased
more than the overload relief valve set-pressure.
However, the pre-leaking start pressure is not
always increased more than the overload relief
valve set-pressure as the adjustable upper limit of
the main relief valve set-pressure is provided.
Accordingly, the overload relief valve assembly
should be removed from the machine and
checked on a specified test stand at a correct oil
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil
passage. When this type of overload relief valve is
checked, the control valve body must be precisely
finished as the test unit. Provide one control valve
other than that on the machine as a test kit.
T4-5-14
Pressure
Check Port
Adapter
T4GB-04-05-008
Valve
Pressure
Adjusting
2
W107-02-05-128
Pressure
Increase
Pressure
Decrease
W107-02-05-129
T4-5-15
T4-5-16
Qc = (Ns Q) Ne
Qc : Converted Flow Rate
Q : Measured Flow Rate
Ns : Specified Engine Speed: ZW220: 2170 min-1
ZW250: 2240 min-1
Ne : Measured Engine Speed:
Value by Dr. ZX
1
Delivery Hose
(To Control Valve)
T1F3-04-05-010
10
11
T4GB-04-05-014
1 - Pipe
2 - Test Hose
3 - Adapter (PF1 UNF1-7/8)
456-
Hydraulic Tester
Adapter (PF1UNF1-7/8)
Joint
789-
T4-5-17
Flange
Split Flange
Bolt (4 Used)
10 - Plug
11 - Hose
T4-5-18
Delivery Hose
(To Control Valve)
T1F3-04-05-010
Port Pi2
Port Pi1
Pilot Steering Valve
Port P
Pilot Steering
Valve Port P Hose
T4GB-04-05-025
Charging Block
T4GB-04-05-026
Pressure Reducing
Valve Port Position
Emergency
Steering
Check Block
Return Pipe
17
L
P1
P2
19
13
To Regulator
Port Pi2
12
16
13
To Hydraulic
Oil Tank
To Port P in Pilot
Steering Valve
To Regulator
Port Pi1
12
Charging
Block
15
13
6 - Test Hose
2 - Test Hose
7 - Flange
12
13
14
1 - Pipe
18
Port E
11
10
T4-5-19
T1F3-04-05-009
16 - Pressure Gauge
17 - Tee
18 - Adapter
19 - Hose
7
8
10
T4GB-04-05-016
Adjustment Item
1. Maximum Flow Rate
7 - Lock Nut
(For P-Q Control)
8 - Adjusting Screw
(For P-Q Control)
9-
Lock Nut
(For P-Q Control)
10 - Adjusting Screw
(For P-Q Control)
Adjustment Procedure
Remarks
ZW220
1) Do not turn adjusting screw (6) more
Loosen lock nut (5) and turn
than two turns.
adjusting screw (6).
2) Do not increase the maximum flow
Rotate adjusting screw (6) 1/4 a
rate.
turn clockwise and the maximum
In other words, do not turn adjusting
pump flow rate decreases by
screw (6) counterclockwise.
11.26 cm3/rev. (0.69 in3/rev).
3) Secure tighten lock nut (5) after the
: 32 mm
adjustment.
: 40 Nm
(4.1 kgfm, 30 lbfft)
ZW250
1) Do not turn the adjusting screw (4)
Loosen lock nut (3) and turn
more than two turns.
adjusting screw (4).
2) Do not increase the maximum flow
Rotating adjusting screw (4) 1/4
rate.
a turn clockwise and maximum
In other words, do not turn adjusting
pump flow rate decreases by
screw (4) counterclockwise.
12.58 cm3/rev. (0.77 in3/rev).
3) Securely retighten lock nut (3) after
: 22 mm
the adjustment.
: 20 Nm
(2 kgfm, 15 lbfft)
T4-5-20
3. P-Q Control
(Torque Adjustment)
Q
Pd
A: Loosen lock nut (7) and turn 1) Do not turn the adjusting screws (8,
adjusting screw (8).
10) more than one turn.
Rotating adjusting screw (8) 2) Rotate the adjusting screws (8, 10)
1/4 a turn clockwise increases
while
watching
the
engine
and the pump flow rate
performance.
increase by Y cm3/rev. (Y 3) Securely tighten lock nuts (7, 9)
after the adjustment.
in3/rev.).
ZW220: Y=13.6 (0.83)
ZW250: Y=15.5 (0.95)
: 30 mm
: 30 Nm
(3.1 kgfm, 22 lbfft)
Pd
T4-5-21
T4GB-04-05-017
Block
Brake Valve
T4-5-22
2
T4GB-04-05-018
T4-5-23
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting B in Group T5-6.
Preparation:
1.
2.
3.
4.
5.
T4GB-04-05-017
Block
Measurment:
1. Release the parking brake and measure the
pressure at this time.
2. Repeat the measurement three times and
calculate the average values.
T4GB-04-05-020
T4-5-24
T4-5-25
Block
T4GB-04-05-019
T4-5-26
T4-5-27
SET
PRESSURE
T4GB-04-05-017
Block
Blake Valve
1
T4GB-04-05-018
T4-5-28
T4-5-29
T4GB-04-05-017
Block
Blake Valve
1
T4GB-04-05-018
T4-5-30
T4-5-31
T4-5-32
T4GB-04-05-017
Parking Brake
Switch
OFF
Block
4
1
5
2
T4GB-04-05-021
1 - Second Gear
2 - Slow Forward
Gear (F1)
Forward
Second Gear
(F2)
Forward
Third Gear
(F3)
Forward
Fourth Gear
(F4)
Reverse First
Gear (R1)
Reverse
Second Gear
(R2)
Reverase
Thir Gear
(R3)
34-
Third Gear
Fast Forward
56-
Reverse
First Gear
NOTE: When the forward/reverse lever and shift switch are turned to each speed stage, operating pressure is
applied to the clutch with mark .
T4-5-33
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Preparation:
1. Stop the engine.
2. Inlet pressure:
Remove the plug from the port of transmission
control valve (1). Install a hose, an adapter and a
pressure gauge to the open part.
: 5 mm
Outlet pressure:
Remove the temperature sensor from torque
converter housing (2). Install a hose, an adapter
and a pressure gauge to the open part.
: 19 mm
3. Start the engine. Check for any oil leaks at the
pressure gauge connection.
4. Maintain the torque converter oil temperature at
80 to 95 C (176 to 203 F).
Measurement:
CAUTION: Set the block onto the front and
rear tires in order not to move the machine.
Keep away from the machine.
1. Select the following switch positions:
Accelerator
Clutch Cut-Off
Brake Pedal
Travel Mode
Pedal
Position Switch
Fully
Fully
M
OFF
Depressed
Depressed
2. Set the front/reverse lever to F (Forward) and
the shift switch to 4 (Fourth Gear). Measure the
pressure.
3. Repeat the measurement three times and
calculate the average values.
T4-5-34
T4GB-04-05-017
Block
Parking Brake
Switch
OFF
T4GB-04-05-021
View X
View Y
Outlet Pressure
of Torque
Converter
T4GB-04-05-022
T4-5-35
T4-5-36
T4GB-04-06-007
T4GB-04-06-001
Clutch Cut-Off
Position Switch
Shift Switch
Parking Brake
Switch
Brake Pedal
OFF
Second Gear
OFF
Fully
Depressed
T4-6-1
Accelerator
pedal
Fully
Depressed
Forward/Reverse
Lever
F
Calibration Switch
Calibration Start
Switch
T4GB-04-06-002
Start of Learning
T4GB-04-06-005
T4GB-04-06-006
T4-6-2
Error Display
Figure 1
Error
Error No.
T4GB-04-06-009
Figure 2
T/M
Temperature
T4GB-04-06-010
Figure 3
Engine Speed
T4-6-3
T4GB-04-06-011
T4-6-4
Error
Failure of learning at first
gear
Failure of learning at
second gear
Failure of learning at third
gear
Failure of learning at fast
forward
Failure of learning at slow
forward
Failure of learning at
reverse
T4GB-04-06-012
Error No.
Cause of Error
The forward/reverse lever is operated during
calibration for the clutch at speed stage in which
error occurs.
The parking brake switch is turned OFF during
calibration for the clutch at speed stage in which
error occurs.
The machine travels during calibration for the
clutch at speed stage in which error occurs.
The transmission oil temperature is lower than
specification (100 C (212 F)) during calibration
for the clutch at speed stage in which error occurs.
Engine speed is beyond specificated range during
calibration for the clutch at speed stage in which
error occurs. (Ex. The accelerator pedal is
depressed.)
The key switch is turned OFF during calibration for
the clutch at speed stage in which error occurs.
The clutch at speed stage in which error occurs is
beyond the correctable range. (Malfunction of the
parts in drive unit)
T4-6-5
T4GB-04-06-008
3
LOCK
M4GB-01-050
T4-6-6
Relay Box
T4GB-04-06-007
T4GB-04-06-001
Lift Arm
T/M
T4GB-04-06-003
T4-6-7
1
Push Here
Evaluation:
Slack of drive belt: 6 to 8 mm (0.24 to 0.31 in)
M4GB-07-082
Adjustment:
1. Loosen nut (3) and bolt (5).
2. Adjust tension of the drive belt to specification with
bolt (4).
3. Tighten nut (3) and bolt (5).
After tightening, check slack of the drive belt.
3
4
T4-6-8
T4GB-04-03-001
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure
Group 3 e-Wheel
Outline ...................................................... T5-3-1
List of Daily Report Data ........................... T5-3-2
Group 2 Dr.ZX
ICF............................................................ T5-3-7
4GBT-5-1
Cross-Sectional Drawing of
Other Failures
Cross-Sectional Drawing of
Group 5 Troubleshooting A
Troubleshooting A Procedure ................... T5-5-1
MC Fault Code List................................... T5-5-2
ECM Fault Code List .............................. T5-5-16
TCU Fault Code List ............................... T5-5-40
ICF Fault Code List................................. T5-5-58
Satellite Terminal Fault Code List ........... T5-5-60
Monitor Unit Fault Code List ................... T5-5-62
Controller Hardware Failure
MC Fault Codes 11000 to 11002 ............ T5-5-63
MC Fault Code 11003............................. T5-5-64
MC Fault Code 11004............................. T5-5-65
CAN Harness Check .............................. T5-5-66
Engine Failure
MC Fault Code 11103 ............................. T5-5-91
Pump Failure
MC Fault Code 11204............................. T5-5-92
MC Fault Code 11209............................. T5-5-93
Pilot Failure
MC Fault Code 11313............................. T5-5-94
Proportional Solenoid Valve Failure
MC Fault Code 11412............................. T5-5-95
MC Fault Code 11413............................. T5-5-96
4GBT-5-2
Malfunction of Forward/Reverse
13308 ....................................................T5-5-131
Group 6 Troubleshooting B
Indicator.................................................. T5-7-26
Indicator.................................................. T5-7-28
Indicator.................................................. T5-7-30
Indicator.................................................. T5-7-34
Indicator.................................................. T5-7-40
Indicator.................................................. T5-7-41
Group 7 Troubleshooting C
4GBT-5-3
4GBT-5-4
Dr. ZX
e-Wheel
Refer to these procedures if any fault codes are
displayed when ICF (information controller) and
satellite communication controller are diagnosed
by using Dr. ZX. (ICF and satellite communication
controller self-diagnosing functions retain a record of the electrical signal system malfunction in
the form of fault codes. At the same time, as the
satellite communication controller sends information onto CAN, the fault code of satellite communication controller can be checked by using ICF.)
This group contains as follows.
Download data from ICF and Upload
Various setting procedures when starting satellite
communication, when installing the satellite
communication controller and when replacing
ICF
Explanation for the satellite communication system
IMPORTANT: Each
controller self-diagnosing
function retains a record of the electrical signal system malfunction in
the form of fault codes. At the same
time, as each controller sends information onto CAN, the fault code
of all controllers can be checked by
using ICF.)
ICF records the fault code of each
controller and the date when the
malfunction occurs.
Component Layout
Refer to this group when required to check where
the components and inner parts are located.
T5-1-1
story
of
T4GB-05-01-001
T4GB-05-01-002
T4GB-05-01-003
T5-1-2
T5-1-3
T4GB-05-01-004
T4GB-05-01-005
T4GB-05-01-006
T5-1-4
T5-1-5
When the monitor is started in service mode according to the following procedures, the items that can be
displayed in normal mode, the fault code and one part
of monitor items can be displayed. (Refer to the next
page.)
Liquid Crystal
Display (LCD)
Information
Display
T4GB-01-02-001
Monitor Display
Selector (Down)
Monitor Display
Selector (Up)
T5-1-6
Mode Selection
Switch
Description
Model
Clock (24 hour)
Hour Meter
Fuel
Consumption
Amount
Average Fuel Consumption Amount
Monitored Result
{{{{{{
{{:{{
{{{{{.{ h
{{{{{.{
Unit
hh:mm
hour
L/h
{{{{{.{
L/h
Remark
Service Mode
Normal Mode
Normal Mode
Normal Mode
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
4 displayed, Re-set when
pushing the mode selection
switch)
Normal Mode
Normal Mode (Displayed
when pushing the monitor
display selector down) with
5 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-1 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-2 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-3 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-4 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-5 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-6 displayed)
Service Mode (Mile is displayed when pushing the
mode selection switch.)
Service Mode
Service Mode
Service Mode
5
5-1
Other Information
Remainder Time when
Hydraulic Oil can be
used
InFo
{{{{{.{
hour
5-2
{{{{{.{
hour
5-3
{{{{{.{
hour
5-4
{{{{{.{
hour
5-5
{{{{{.{
hour
5-6
{{{{{.{
hour
5-7
{{{{{.{
hour
Odometer
{{{{{{
km or mile
7
8
9
Engine Speed
Coolant Temperature
Transmission Oil Temperature
Hydraulic Oil Temperature
Fault Code
{{{{{
{{{{{
{{{{{
min-1
C
C
{{{{{
Service Mode
ERROR
Service Mode
10
11
{{{{{{
T5-1-7
T5-1-8
TROUBLESHOOTING / Dr. ZX
OUTLINE
Dr. ZX is used for diagnosis of electrical system
including MC (main controller), ECM (engine control
module), ICF (information controller), monitor unit and
TCU (transmission control unit).
Dr. ZX is connected to ICF and failure of each
controller and each sensor is displayed as a fault code.
(Self-Diagnostic Result)
Dr. ZX displays the input status of sensors and
switches connected to each controller and the output
status to actuator including solenoid valve from
controller with the machine operated in real time.
(Controller Diagnosis)
T5-2-1
TROUBLESHOOTING / Dr. ZX
Operation
1. Connect Palm (Dr. ZX) to the diagnosing
connector in the cab by using the Hot Sync cable
and connecting harness.
2. Turn the key switch ON or start the engine.
3. When turning Palm ON, the following screen is
displayed on the display of Palm.
Fuse Box
Dr. ZX Connector
T4GB-05-01-007
Palm
Dr. ZX
Download
Cable for
Portable
Communication
T1V1-05-07-002
T5-2-2
TROUBLESHOOTING / Dr. ZX
Start
Initial Screen
Input Password
Input
the
former
password (6 characters
or more).
Next time, input the
same password in order
to check and push OK.
Communication
Error
Service Software
Selection Screen
Select ZX-3 Mid
Self-Diagnostic
Result Function
Self-Diagnostic
Result of Each
Controller
Select
Function
Record
T1V7-05-03-165
Select Controller
Main
Controller
Main Menu
Monitor Display
Setup
Disp. Record
Select Controller
Password
Engine
Controller
Main Menu
Monitor Display
Disp. Record
Password
Change
Transmission
Controller
Main Menu
Monitor Display
Disp. Record
Password
Change
Monitor
Controller
ICF
Controller
Main Menu
Monitoring
Main Menu
Information C/U
Password
Change
Data Download
Save
Data
Various Setup
Various Setup
Check
Password
Change
Change
Op. Manual.
Retry B
Self-Diagnostic
Result
T5-2-3
TROUBLESHOOTING / Dr. ZX
Self-Diagnostic Result
The self-diagnostic result of each controller is
displayed.
After starting Dr. ZX, push Self-Diagnostic Result.
T1V7-05-03-001
T1V7-05-03-008
T4GB-05-02-003
MC
ECM
TCU
Monitor Unit
ICF
T5-2-4
TROUBLESHOOTING / Dr. ZX
Self-Diagnosis
push
To the
lower
T1V7-05-03-001
T4GB-05-02-002
T1V7-05-03-008
Trouble
Retry B
ESC
ESC
T1V7-05-03-003
T1V7-05-03-005
T1V7-05-03-007
Retry B Screen
If the message of Details is
long, push the arrow and
change the screen.
Retry B
ESC
T4GB-05-02-003
T5-2-5
TROUBLESHOOTING / Dr. ZX
SELECT CONTROLLER
Select the failure-diagnosis controller.
After starting Dr. ZX, push Select Controller.
T4GB-05-02-003
T1V7-05-03-001
MC
ECM
TCU
Monitor Unit
ICF
T5-2-6
TROUBLESHOOTING / Dr. ZX
MAIN CONTROLLER
Main Menu
Monitor Display
Displays the control signals of MC and the input
signals from each switch and sensor.
Setup
Adjusts target engine idling speed, engine
warming-up speed and so on.
Title Screen
Recorded Data
Displays data recorded in MC by one day by using Dr.
ZX.
Password Change
Changes the password input when setting.
T1V7-05-03-011
Password
Change
Return to Controller
Selection Screen.
Disp. Record
T1V7-05-03-012
Monitor Display
Setup
T5-2-7
TROUBLESHOOTING / Dr. ZX
MAIN MENU MONITOR DISPLAY
Dr. ZX displays the input signals from switches and
sensors and the control signals from MC.
List of Monitor Item
Item
Required Engine Speed
Hydraulic Fan Target Speed
Actual Engine Speed
Engine Speed Deviation
Data
Control instruction value of engine speed to ECM
Control instruction value to fan flow rate control valve
Detected valve of torque converter input rotation sensor
Difference between required engine speed and actual engine speed
min-1
min-1
min-1
min-1
Unit
Torque Converter Speed Ratio of the detected value of torque converter out- No unit
Ratio
put rotation sensor in that of torque converter input
rotation sensor
Travel Speed
Value converted the detected value of travel speed Km/h
sensor into speed per hour
Pump Pressure
T5-2-8
MPa
MPa
mA
MPa
mA
mA
mA
V
MPa
MPa
MPa
MPa
V
ON OFF
ON OFF
ON
ON
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
TROUBLESHOOTING / Dr. ZX
Item
Data
Unit
1234
LD/Cry Normal
Power
Selection status (auto/manual) of travel mode selec- Manual Auto
tion switch
Selection status (gear shifting timing) of travel mode Low
Normal
selection switch
High
Selection status (ON/OFF) of clutch cut-off position ON OFF
switch
Selection status (clutch cut-off position) of clutch Low Medium
cut-off position switch
High
Instruction signal to hydraulic drive fan reversing so- ON OFF
lenoid valve
Magnetizing Status of solenoid valve at lift arm raise ON OFF
side in pilot valve
Magnetizing Status of solenoid valve at lift arm lower ON OFF
side in pilot valve
Magnetizing status of parking brake relay 1 and con- ON OFF
tinuity status to parking brake indicator
Detected value of ambient temperature sensor
C
Detected value of hydraulic oil temperature sensor
C
Lift arm angle sensor learning status
Not Learn
Finish Failure
T5-2-9
TROUBLESHOOTING / Dr. ZX
Monitor Display
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
Push Start.
T4GB-05-02-004
To the
lower
T4GB-05-02-005
T1V7-05-03-012
T1V7-05-03-011
Title Screen
T4GB-05-02-008
T4GB-05-02-007
T4GB-05-02-006
Monitor Screen
To the next page
T5-2-10
TROUBLESHOOTING / Dr. ZX
Push Record.
To the
lower
T4GB-05-02-008
T1V7-05-03-096
Monitor Screen
If Rec. No. has already been
recorded and push Over Write,
data is overwritten. Push ESC and
return to Main Menu Screen.
T1V7-05-03-097
Push Comment.
Push ESC and return to Main
Menu Screen.
To the
lower
T4GB-05-02-009
Recording Screen
T4GB-05-02-010
T1V7-05-03-100
Recording Screen
T4GB-05-02-011
T4GB-05-02-012
T5-2-11
T4GB-05-02-013
TROUBLESHOOTING / Dr. ZX
SETTING
Target engine idling speed, engine warming-up speed
and so on can be adjusted.
MC List of Parameter Change Item
Item
Unit
Request Speed Calibration
min-1
Warning Up Speed Calibration
min-1
Warming Up Control Deactivation
ON, OFF
Flag
Set Torque Calibration
Nm
Data
Adjustment of engine idling speed
Adjustment of engine warming-up speed
Selection (enable/ disable) of engine warming-up control
Adjustment of main pump target torque
Adjustment
Minimum Unit
1 min-1
1 min-1
0 to 200
-200 to 200
Adjustment Value
When Delivering
0 min-1
0 min-1
ON or OFF
ON
3 Nm
-45 to 45
0 Nm
Adjustable Range
T5-2-12
Remark
TROUBLESHOOTING/ Dr. ZX
Setting
Parameter Change
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
Push Start.
Push Setup.
T4GB-05-02-004
To the
lower
T1V7-05-03-011
T1V7-05-03-012
Title Screen
T1V7-05-03-016
To the
Next Page
T1V7-05-03-022
T4GB-05-02-014
T5-2-13
T4GB-05-02-015
TROUBLESHOOTING/ Dr. ZX
Parameter Input
Example: Engine Control
Correction
Input Value = Normal Value
Target
Speed
To the
lower
T4GB-05-02-016
T4GB-05-02-017
T1V7-05-03-107
T5-2-14
T4GB-05-02-018
TROUBLESHOOTING/ Dr. ZX
Input Value = Current Value
To the
lower
T4GB-05-02-016
T4GB-05-02-019
T1V7-05-03-107
T5-2-15
T1V7-05-03-108
TROUBLESHOOTING/ Dr. ZX
Input Value > Maximum Value
(Input Value < Minimum Value)
To the
lower
T4GB-05-02-016
T4GB-05-02-020
T1V7-05-03-107
T5-2-16
T4GB-05-02-021
TROUBLESHOOTING/ Dr. ZX
When the input value cannot be divided
Example: Pump Control Set Torque Calibration
To the
lower
T4GB-05-02-022
T4GB-05-02-023
T1V7-05-03-107
T5-2-17
T4GB-05-02-024
TROUBLESHOOTING/ Dr. ZX
Status Selection
Example: Engine Control Warming Up Control
Deactivation Flag
Push
Warming
Deactivation Flag.
Up
Ctrl
To the
lower
T4GB-05-02-016
T4GB-05-02-025
T1V7-05-03-107
T5-2-18
T4GB-05-02-026
TROUBLESHOOTING/ Dr. ZX
Recorded Data Display
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
T1V7-05-03-124
T1V7-05-03-011
Title Screen
T4GB-05-02-004
T5-2-19
T4GB-05-02-027
TROUBLESHOOTING/ Dr. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T4GB-05-02-003
Push Password.
T4GB-05-02-004
To the
lower
T1V7-05-03-126
T1V7-05-03-011
Title Screen
Input the new password again and
push OK.
Push OK
Screen.
and
return
to
Title
T1V7-05-03-128
T1V7-05-03-169
T5-2-20
T1V7-05-03-127
TROUBLESHOOTING / D r. ZX
ENGINE CONTROLLER
Main Menu
Monitor Display
Dr. ZX displays the input signals from sensors and
the control signals of ECM.
T1V7-05-03-079
T5-2-21
TROUBLESHOOTING / D r. ZX
MONITOR DISPLAY
ECM List of Monitor Item
Item
Selecting
Engine Torque
Actual Engine Speed
(Engine Speed)
Target Engine Speed
Glow Signal
Coolant
Temperature
(Engine
Coolant
Temperature)
Fuel Temperature
Engine Oil Pressure
Fuel Flow Rate
Atmospheric Pressure
Suction
Temperature
(Intake Air Temperature)
Boost Pressure
Boost Temperature
Battery Voltage
Total Amount of Fuel Use
Unit
Monitoring
Engine Torque
%
Actual Engine
min-1
Speed
Target Engine
min-1
Speed
Glow Signal
OFF, ON
Coolant
Temperature
C
(E)
Fuel
C
Temperature
Engine
Oil
kPa
Pressure
Fuel Flow
L/h
Barometric
kPa
Pressure
Intake Air
C
Temperature
Boost Pressure
kPa
Boost
C
Temperature
Battery Voltage
V
Total
Used
L
Fuel
Data
Input signal from ECM
Input signal from crank speed sensor and cam angle
sensor
Input signal from accelerator pedal
Glow relay ON/OFF status
Input signal from coolant temperature sensor
Input signal from fuel sensor
Input signal from engine oil pressure sensor
Input signal from ECM
Input signal from atmospheric pressure sensor
Input signal from intake-air temperature sensor
Input signal from boost pressure sensor
Input signal from boost temperature sensor
Input signal from ECM
Input signal from ECM
T5-2-22
TROUBLESHOOTING / D r. ZX
(Blank)
T5-2-23
TROUBLESHOOTING / D r. ZX
Monitor Display
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
Push Start.
T4GB-05-02-004
To the
lower
Title Screen
T4GB-05-02-028
T1V7-05-03-011
T4GB-05-02-005
Start
recoding.
To the
next page
T1V7-05-03-132
T4GB-05-02-006
T5-2-24
T1V7-05-03-133
Monitor Screen
TROUBLESHOOTING / D r. ZX
Push Record.
To the
lower
Monitor Screen
T1V7-05-03-133
T1V7-05-03-134
T1V7-05-03-135
Push Comment.
Push ESC and return to Main
Menu Screen.
To the
lower
T4GB-05-02-009
Recording Screen
T4GB-05-02-030
T4GB-05-02-031
Recording Screen
T4GB-05-02-032
T4GB-05-02-033
T5-2-25
T4GB-05-02-034
TROUBLESHOOTING / D r. ZX
RECORDED DATA DISPLAY
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
T1V7-05-03-010
T1V7-05-03-124
T1V7-05-03-011
Title Screen
T5-2-26
T1V7-05-03-141
TROUBLESHOOTING / D r. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T4GB-05-02-003
T4GB-05-02-004
Push Password.
To the
lower
T1V7-05-03-126
T1V7-05-03-011
Title Screen
Push OK
Screen.
and
return
to
Title
T1V7-05-03-128
T1V7-05-03-169
T5-2-27
T1V7-05-03-127
TROUBLESHOOTING / D r. ZX
(Blank)
T5-2-28
TROUBLESHOOTING / Dr. ZX
ICF CONTROLLER
Main Menu
Information C/U Various Setup
Initialization of information C/U, setting of model,
serial No. and time, and initialization of control
data can be done.
Data Download
Daily report data, frequency distribution data, total
operating hours, alarm and fault code, which are
recorded in ICF, can be downloaded to Dr. ZX.
Save Data Check
Daily report data, frequency distribution data, total
operating hours, alarm and fault code, which are
saved in ICF, can be checked by using Dr. ZX.
Password
The password can be changed.
T1V7-05-03-166
T5-2-29
TROUBLESHOOTING / Dr. ZX
INFORMATION C/U VARIOUS SETUP
ICF List of Controller Data Setting Item
Item
Information C/U: Initialize
Enter Model and Serial No.
Range of Data
Model
Serial No.
YY
MM
DD
HH
MM
Date
Time
Control Data: Initialize
Satellite Terminal: Initialize
Satellite Terminal No. Confirmation
Communicating State Check
Connect
Comm.
Power
Comm.
Rod Aerial
GPS Aerial
Wave State
Un-Transmit Data Number
Last Transmitting Time
Enter Satellite Comm.
Start/Stop
T5-2-30
Initialize/ESC
ASCII (4 characters) 0 to 9, A to Z
000000 to 999999
2000 to 2100
1 to 12
1 to 31
0 to 23
0 to 59
Initialize/ESC
DEL/ESC
12 digits: 0 to 9, A to Z
Conn/UnConn
OK/NG
ON/OFF
Enable/Stop
OK/NG
OK/NG
ON/OFF
099
YYYY/MM/DD hh: mm: ss
Start/Stop
TROUBLESHOOTING / Dr. ZX
INFORMATION C/U: INITIALIZE
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.
Push OK.
To the
lower
T1V7-05-03-001
Push Information
Setup.
Push Start.
C/U:
T4GB-05-02-035
Various
T4GB-05-02-036
To the
lower
Title Screen
T1V7-05-03-025
T1V7-05-03-026
T1V7-05-03-027
Init
ESC
T1V7-05-03-029
T1V7-05-03-028
T1V7-05-03-027
T5-2-31
TROUBLESHOOTING / Dr. ZX
ENTER MODEL AND SERIAL No.
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.
Push OK.
To the
lower
T4GB-05-02-035
T1V7-05-03-001
T4GB-05-02-036
Push Start.
Push Information
Setup.
C/U:
Various
To the
lower
T1V7-05-03-026
T1V7-05-03-025
Title Screen
T1V7-05-03-027
ESC
Exec
ESC
OK
T4GB-05-02-037
T4GB-05-02-038
T1V7-05-03-027
T5-2-32
TROUBLESHOOTING / Dr. ZX
ENTER DATE AND TIME
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.
Push OK.
To the
lower
T4GB-05-02-035
T1V7-05-03-001
Push Information
Setup.
Push Start.
C/U:
Various
T4GB-05-02-036
To the
lower
T1V7-05-03-026
T1V7-05-03-025
Title Screen
T1V7-05-03-027
T5-2-33
TROUBLESHOOTING / Dr. ZX
CONTROL DATA: INITIALIZE
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.
Push OK.
To the
lower
T4GB-05-02-035
T1V7-05-03-001
Push Start.
C/U:
T4GB-05-02-036
To the
lower
Title Screen
T1V7-05-03-025
T1V7-05-03-026
T1V7-05-03-027
Init
ESC
T1V7-05-03-034
T1V7-05-03-033
T1V7-05-03-027
T5-2-34
TROUBLESHOOTING / Dr. ZX
SATELLITE TERMINAL: INITIALIZE
Push T and ICF controller
Selection Screen is displayed.
Push ICF Controller.
Push OK.
To the
lower
T4GB-05-02-035
T1V7-05-03-001
Push Start.
T4GB-05-02-036
Push Information
Setup.
C/U:
Various
To the
lower
T1V7-05-03-026
T1V7-05-03-025
Title Screen
Push Exec.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.
T1V7-05-03-035
Exec
ESC
T1V7-05-03-145
T1V7-05-03-036
T5-2-35
T1V7-05-03-035
TROUBLESHOOTING / Dr. ZX
SATELLITE TERMINAL No. CONFIRMATION
Push OK.
To the
lower
T4GB-05-02-035
T1V7-05-03-001
Push Start.
T4GB-05-02-036
Push Information
Setup.
C/U:
Various
To the
lower
T1V7-05-03-026
T1V7-05-03-025
Title Screen
T1V7-05-03-035
T1V7-05-03-037
T5-2-36
T1V7-05-03-035
TROUBLESHOOTING / Dr. ZX
COMMUNICATING STATE CHECK
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T4GB-05-02-035
Push Information
Setup.
C/U:
Various
T4GB-05-02-036
To the
lower
T1V7-05-03-026
T1V7-05-03-025
Title Screen
T1V7-05-03-035
ESC
T1V7-05-03-143
T1V7-05-03-142
T1V7-05-03-035
T5-2-37
TROUBLESHOOTING / Dr. ZX
ENTER SATELLITE COMM. START / STOP
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.
Push OK.
To the
lower
T1V7-05-03-001
T4GB-05-02-035
Push Information
Setup.
Push Start.
C/U:
Various
T4GB-05-02-036
To the
lower
Title Screen
T1V7-05-03-026
T1V7-05-03-025
T1V7-05-03-035
Exec
ESC
T1V7-05-03-147
T1V7-05-03-146
T5-2-38
T1V7-05-03-035
TROUBLESHOOTING / Dr. ZX
DATA DOWNLOAD
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T4GB-05-02-035
T4GB-05-02-036
To the
lower
Title Screen
T1V7-05-03-025
Alarm Screen
T1V7-05-03-026
T5-2-39
T1V7-05-03-038
T1V7-05-03-148
T1V7-05-03-039
T1V7-05-03-026
TROUBLESHOOTING / Dr. ZX
SAVE DATA CHECK
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T4GB-05-02-035
T1V7-05-03-001
Push Start.
T1V7-05-03-026
T1V7-05-03-025
Title Screen
T4GB-05-02-036
T5-2-40
T1V7-05-03-040
TROUBLESHOOTING / Dr. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T4GB-05-02-035
T1V7-05-03-001
Push Password.
T4GB-05-02-036
To the
lower
T1V7-05-03-126
T1V7-05-03-025
Title Screen
Input the new password again and
push OK.
Push OK
Screen.
and
return
to
Title
T1V7-05-03-128
T1V7-05-03-169
T5-2-41
T1V7-05-03-127
TROUBLESHOOTING / Dr. ZX
(Blank)
T5-2-42
TROUBLESHOOTING / Dr. ZX
MONITOR UNIT
Main Menu
Monitoring
Dr. ZX displays the input signals from each sensor
and switch.
Various Settings
Dr. ZX can set inner hour meter synchronization.
Password
The password can be changed.
T4GB-05-02-039
T5-2-43
TROUBLESHOOTING / Dr. ZX
MONITORING
List of Monitoring Item
Item
Radiator Coolant Temperature
Fuel Level
T/M Torque Converter Oil
Temperature
Steering Pressure
Brake Oil Level Switch of
Service Brake
Data
Signal to coolant temperature gauge
Signal to fuel gauge
Signal to transmission oil temperature gauge
Unit
C
%
C
ON OFF
ON OFF
ON OFF
MPa
ON OFF
ON OFF
ON OFF
ON OFF
Emergency
Steering Continuity status in emergency steering check switch
Operation Check Switch
Front Wiper Switch
Continuity status in front wiper switch
Engine Warning Switch
Continuity status to engine warning indicator
Engine STOP Switch
Continuity status to stop indicator
Model Selector Switch 1
Model Selector Switch 2
Glow Switch
T/M Warning Switch
Buzzer Output
Load Dump Relay Output
Emergency Steering Relay
Output
Front Wiper Relay Output
Heated Window Relay Output
Parking Brake Signal Output
Parking
Brake
Pressure
Switch
Neutral Signal
Axle Oil Temperature
ON OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON OFF
C
T5-2-44
TROUBLESHOOTING / Dr. ZX
Monitoring
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
Push Start.
T4GB-05-02-040
Push Monitoring.
To the
lower
Title Screen
T1V7-05-03-025
T1V7-05-03-042
T4GB-05-02-042
Monitoring Screen
T5-2-45
T4GB-05-02-041
TROUBLESHOOTING / Dr. ZX
VARIOUS SETTINGS
Monitor Unit List of Setup Item
Item
Internal Hour Meter Sync.
Data
Synchronization of hour meter data in both monitor unit and ICF
Adjustment
Minimum Unit
-
Adjustable Range
T5-2-46
ON only
Adjustment
Minimum Unit
-
Remark
TROUBLESHOOTING / Dr. ZX
INTERNAL
HOUR
SYNCHRONIZATION
After starting Dr. ZX, push Select
Controller.
METER
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
T4GB-05-02-040
Push Start.
To the
lower
T1V7-05-03-042
T1V7-05-03-025
Title Screen
T1V7-05-03-086
T1V7-05-03-085
T5-2-47
T4GB-05-02-043
TROUBLESHOOTING / Dr. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
T4GB-05-02-040
Push Password.
To the
lower
T1V7-05-03-126
T1V7-05-03-025
Title Screen
Push OK
Screen.
and
return
to
Title
T1V7-05-03-128
T1V7-05-03-169
T5-2-48
T1V7-05-03-127
TROUBLESHOOTING / D r. ZX
TCU CONTROLLER
Main Menu
Monitor Display
Dr. ZX displays the control signals of TCU and the
input signals from each sensor.
T1V7-05-03-079
T5-2-49
TROUBLESHOOTING / D r. ZX
MONITOR DISPLAY
TCU List of Monitor Display Item
Item
T/C Output Speed
T/M Output Speed
Actual Engine Speed
Selected Gear
Data
Detected value in torque converter output rotation
sensor
Detected value in travel speed sensor
Detected value in torque converter input rotation sensor
Selected speed stage
Current Gear
FNR Switch
OPT FNR Switch
Selected Gear
Pedal Brake Pressure
DSS Switch
USS Switch
Hold Switch
OPT FNR Replace Switch
Hold Mode
OPT FNR Mode
T5-2-50
Unit
Min-1
Min-1
Min-1
R3 R2 R1 N F1 F2
F3 F4
R3 R2 R1 N F1 F2
F3 F4
F N R
F N R
1 2 3 4
Mpa
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
OPE mode 1st
2nd
3rd
4th
F
R
Finish
Abort
1st Abort
2nd Abort
3rd Abort
4th Abort
F Abort
R Abort
Go Calib
FNR is not N
PB is not ON
Speed Not 0 km
TC Oil Tmp Low
TC Oil Tmp High
Eng Speed Low
Eng Speed High
C
0 to 50 dig
TROUBLESHOOTING / D r. ZX
(Blank)
T5-2-51
TROUBLESHOOTING / D r. ZX
Monitor Display
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
Push Start.
T4GB-05-02-004
To the
lower
Title Screen
T4GB-05-02-028
T1V7-05-03-011
T4GB-05-02-005
Start
recoding.
To the
next page
T4GB-05-02-044
T4GB-05-02-006
T5-2-52
T4GB-05-02-045
Monitor Screen
TROUBLESHOOTING / D r. ZX
Push Record.
To the
lower
Monitor Screen
T4GB-05-02-045
T1V7-05-03-134
T1V7-05-03-135
Push Comment.
Push ESC and return to Main
Menu Screen.
To the
lower
T4GB-05-02-046
Recording Screen
T4GB-05-02-047
T1V7-05-03-136
Recording Screen
T4GB-05-02-048
T4GB-05-02-049
T5-2-53
T4GB-05-02-050
TROUBLESHOOTING / D r. ZX
RECORDED DATA DISPLAY
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T4GB-05-02-003
T1V7-05-03-001
T4GB-05-02-004
T1V7-05-03-124
T1V7-05-03-011
Title Screen
T5-2-54
T1V7-05-03-141
TROUBLESHOOTING / D r. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T4GB-05-02-003
T4GB-05-02-004
Push Password.
To the
lower
T1V7-05-03-126
T1V7-05-03-011
Title Screen
Input the newpassword again and
push OK.
Push OK
Screen.
and
return
to
Title
T1V7-05-03-128
T1V7-05-03-169
T5-2-55
T1V7-05-03-127
TROUBLESHOOTING / D r. ZX
(Blank)
T5-2-56
TROUBLESHOOTING / e-Wheel
OUTLINE
ICF (Information Controller) saves the input signals
from various sensors and switches of the machine as
data by using CAN bus line from each controller.
Various input signals are recorded as list of daily
report data, list of frequency distribution data, list of
total operating hours, list of alarm and list of failure
in ICF.
The recorded data is downloaded to the personal
computer and is uploaded to the center server via
LAN, so that the data can be used as e-Service.
The machine equipped with the optional satellite
communication terminal can send the data to center
server by using satellite communication. (As for the
satellite communication system, refer to T5-3-24.
T5-3-1
TROUBLESHOOTING / e-Wheel
LIST OF DAILY REPORT DATA
Item
1.
Date
2.
Fuel Level
3.
4.
5.
6.
7.
8.
9.
Details
Date of daily report data
The value of the final remained fuel during a day when
the engine stops
The value of fuel used during a day
Hour meter cumulative hours
Total engine operating hours during a day
Traveling distance during a day
Total manual transmission operating hours during a day
Total automatic transmission operating hours during a
day
Total hours operating L mode of work mode selection
switch during a day
Total hours operating N mode of work mode selection
switch during a day
Total hours operating P mode of work mode selection
switch during a day
The highest radiator coolant temperature during a day
The highest hydraulic oil temperature during a day
The highest intake air temperature during a day
The highest fuel temperature during a day
The highest torque converter oil temperature during a
day
Engine operating hour distribution during a day
(Operating hours are recorded only when alternator
output signal is continuously delivered for more than 10
minutes.)
T5-3-2
TROUBLESHOOTING / e-Wheel
LIST OF FREQUENCY DISTRIBUTION DATA
1.
2.
3.
4.
5.
6.
7.
8.
9.
Item
Fuel Temperature Distribution
Pump Load Distribution
Travel Load Distribution
Radiator Coolant Temperature Distribution
Hydraulic Oil Temperature Distribution
Torque converter oil Temperature Distribution
Radiator Coolant Temperature - Intake Air
Temperature Distribution
Hydraulic Oil Temperature - Intake Air
Temperature Distribution
Torque Converter Oil Temperature - Intake
Air Temperature Distribution
Details
Frequency distribution of fuel temperature
Frequency distribution of main pump delivery pressure
Frequency distribution of travel torque
Frequency distribution of coolant temperature
Frequency distribution of hydraulic oil temperature
Frequency distribution of torque converter oil
temperature
Frequency distribution on temperature in which intake air
temperature is pulled from coolant temperature
Frequency distribution on temperature in which intake air
temperature is pulled from hydraulic oil temperature
Frequency distribution on temperature in which intake air
temperature is pulled from torque converter oil
temperature
Frequency distribution of coolant temperature and intake
air temperature
Frequency distribution of hydraulic oil temperature and
intake air temperature
Frequency distribution of torque converter oil
temperature and intake air temperature
Frequency distribution of speed in manual transmission
Frequency distribution of speed in automatic
transmission
Frequency distribution of engine speed and engine
torque
T5-3-3
TROUBLESHOOTING / e-Wheel
LIST OF TOTAL OPERATING HOURS
1.
2.
3.
4.
5.
6.
7.
Item
Hour Meter (ICF)
Hour Meter (Monitor Unit)
Engine Operating Hour
Traveling Distance
Manual Transmission Operating Hours
Automatic Transmission Operating Hours
L mode Operating Hours
8.
9.
Details
Hour meters value accumulated inside ICF
Hour meters value accumulated in monitor unit
Total engine operating hours
Total traveling Distance
Total manual transmission operating hours
Total automatic transmission operating hours
Total hours operating L mode of work mode selection
switch
Total hours operating N mode of work mode selection
switch
Total hours operating P mode of work mode selection
switch
T5-3-4
TROUBLESHOOTING / e-Wheel
LIST OF ALARM
1.
2.
3.
4.
5.
6.
7.
8.
9.
Item
Overheat Alarm
Engine Warning Alarm
Engine Oil Pressure Alarm
Alternator Indicator Alarm
Air Filter Restriction Alarm
Water Separator Alarm
Service Brake Oil Level Alarm
Service Brake Oil Pressure Alarm
Emergency Steering Operation Alarm
Details
Date when the overheat indicator lights
Date when the engine warning indicator lights
Date when the engine oil pressure indicator lights
Date when the alternator indicator lights
Date when the air filter restriction indicator lights
Date when the water separator indicator lights
Date when the service brake oil level indicator lights
Date when the service brake oil pressure indicator lights
Date when the emergency steering operation indicator
lights
Date when the steering oil pressure indicator lights
Date when the transmission oil temperature indicator
lights
Date when the hydraulic oil temperature indicator lights
Date when the transmission filter restriction indicator
lights
Date when the transmission failure indicator lights
T5-3-5
TROUBLESHOOTING / e-Wheel
LIST OF FAILURE
When the fault code occurs, ICF records the fault
code and the date.
Use the list of failure when the malfunction, which is
difficult to identify, occurs as the remedy information.
Refer to Troubleshooting A.
If the machine is operated properly with the fault code
recorded, the machine can continue to be operated.
T5-3-6
TROUBLESHOOTING / e-Wheel
HOW TO DOWNLOAD AND UPLOAD DATA
OF ICF
After the data saved in ICF is downloaded to Dr. ZX, is
uploaded to the personal Computer, and is uploaded
to the center server by using LAN, the data can be
used as e-Service.
Dr.ZX Connector
T4GB-05-01-007
Dr. ZX
(Palm)
Hot Sync
Cable
Download Cable
for Portable
Communication
System
T1V1-05-07-002
T5-3-7
TROUBLESHOOTING / e-Wheel
Data Download
After starting Dr. ZX, push Select
Controller.
Select Function
+
Select failure-diagnosis
controller
Self-Diagnostic Result
Push OK.
Select Controller
Engine Controller
Main Controller
Monitor Controller
ICF Controller
ESC
ICF
controller Ver.: XXYY
Satellite terminal Controller
Ver.: XXYY
Is it correct?
ESC
OK
ESC
Push Start.
Select Item
Password
Data Download
Data Download
Downloading.
Do not turn off the Palm or
disconnect the download
cable.
27%
+
Op. Manual
Start
Back
ESC
Cancel
Title Screen
CAUTION
Initialization has been
The completed.
download has been
interrupted.
No
data
has
been
transferred to the Dr. ZX
OK
Normal End Screen
To the
lower
Data Download
OK
ESC
Main Menu Screen
Alarm Screen
T5-3-8
To the
lower
TROUBLESHOOTING / e-Wheel
How to Upload Data from Dr. ZX (Palm) to
Personal Computer
1. Set Dr. ZX (Palm) to the cradle. Connect the USB
cable to the personal computer.
2. Push the Hot Sync button.
NOTE: When pushing the Hot Sync button and
uploading the data to the personal
computer, the Palm Desktop software
attached with Dr. ZX (Palm) need to be
installed.
Dr. ZX
(Palm)
Cradle
Hot Sync
Button
T178-05-07-033
T5-3-9
TROUBLESHOOTING / e-Wheel
VARIOUS SETUP OF ICF AND SATELLITE
COMMUNICATION TERMINAL BY USING
Dr. ZX
Before starting satellite communication, installing the
satellite communication terminal and replacing ICF,
perform the following procedures by using Dr. ZX.
ICF Setup Procedures
Start Dr. ZX
1.1
1.2
1.3
1.4
1.5
Communication
1.6
1.7
1.8
No Communication
2. Self-Diagnosing
T5-3-10
TROUBLESHOOTING / e-Wheel
1.1 Select Information Controller
1.2 Select Information C/U: Various Setup
Push OK.
Select failure-diagnosis
controller
Select Function
+
Self-Diagnostic Result
Select Controller
Engine Controller
Main Controller
Monitor Controller
ICF Controller
ESC
Function Selection Screen
ICF
Controller Ver.: XXYY
Satellite Terminal
Controller Ver.: XXYY
To the
lower
Is it correct?
ESC
Controller Selection Screen
OK
ESC
Push Start.
C/U:
Various
Select Item
Password
+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd
+
+
Select Item
Op. Manual
Start
Title Screen
Back
ESC
Main Menu Screen
T5-3-11
ESC
Information C/U: Various Setup
Screen
TROUBLESHOOTING / e-Wheel
1.3 Enter Date and Time
Push Enter Date and Time.
Push ESC and return to Main
Menu Screen.
Select Item
+
YY 2004 MM
01
HH
01
01
MM
DD
Set
ESC
Information C/U: Various Setup
Screen
01
ESC
Select Item
+
Data Download
ESC
Main Menu Screen
T5-3-12
TROUBLESHOOTING / e-Wheel
1.4 Enter Model and Serial No.
Push Enter Model and Serial No.
Select Item
+
To the
lower
ESC
Information C/U: Various Setup
Screen
After inputting model and serial No.,
push OK and return to Enter Model
and Serial No. Screen.
Push ESC and return to Information
C/U: Various Setup Screen.
Model
04GB
Select Item
Model |
Exec
Exec
ESC
ESC
Ex. Mach.No.(HCM4GB00P00
0001) Model(01G6)
Serial No.
Ex. Mach.No.(HCM4GB00P00
0001) Serial No.(000001)
OK
ESC
ESC
OK
ESC
Information C/U: Various Setup
Screen
T5-3-13
TROUBLESHOOTING / e-Wheel
1.5 Information C/U: Initialize
Push Information C/U: Initialize.
Select Item
+
To the
lower
ESC
Information C/U: Various Setup
Screen
Push Init and the controller
operating data are initialized.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.
Select Item
ESC
Init
ESC
OK
ESC
Information C/U: Various Setup
Screen
T5-3-14
TROUBLESHOOTING / e-Wheel
1.6 Satellite Terminal: Initialize
Display the next screen of
Information C/U: Various Setup
Screen.
Select Item
+ Information C/U: Initialize
ESC
Push Exec.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.
ESC
Next Screen of Information C/U:
Various Setup Screen
Exec
ESC
Select Item
+
+
+
+
OK
Select Item
Data Download
ESC
Information C/U: Various Setup
Screen
T5-3-15
ESC
Main Menu Screen
To the
lower
TROUBLESHOOTING / e-Wheel
1.7 Satellite Terminal Serial No. Check
Push
Satellite
Terminal
No.
Confirmation.
Push ESC and return to Main
Menu Screen.
Select Item
+
+
+
+
Select Item
+
+
+
+
ESC
ESC
ESC
Information C/U: Various Setup
Screen
Select Item
+
Data Download
ESC
Main Menu Screen
T5-3-16
TROUBLESHOOTING / e-Wheel
1.8 Satellite
Check
Terminal,
Push
Communicating
State
Check.
Push ESC and return to Main
Menu Screen.
Select Item
+
+
+
+
Communicating State
Comm.
UnCon
UnCon
OK
NG
Satellite Terminal
Power
ON
OFF
Comm.
Enable
Stop
ESC
Information C/U: Various Setup
Screen
ICFSatellite Terminal
Conn
ESC
Communicating State Check
Rod Aerial
OK
NG
GPS Aerial
OK
NG
Wave State
ON
OFF
2004/07/01 135000
ESC
Select Item
Select Item
Data Download
ESC
ESC
Information C/U: Various Setup
Screen
T5-3-17
TROUBLESHOOTING / e-Wheel
1.9 Enter Satellite Comm. Start/Stop
Push and move to the next
screen of Information C/U: Various
Setup Screen.
Push Enter Satellite Comm.
Start/Stop.
Select Item
+
+
+
+
To the
lower
ESC
Information C/U: Various Setup
Screen
Stop
Exec
ESC
Select Item
+
+
Exec
Start
+
+
OK
ESC
Information C/U: Various Setup
Screen
T5-3-18
TROUBLESHOOTING / e-Wheel
1.10 Control Data: Initialize
Push Control Data: Initialize.
Select Item
+
ESC
Information C/U: Various Setup
Screen
ESC
Init
ESC
OK
ESC
Information C/U: Various Setup
Screen
T5-3-19
TROUBLESHOOTING / e-Wheel
2. Self-Diagnosing
After starting Dr. ZX,
Self-Diagnostic Result.
push
Self-diagnosing of controllers
below hasn completed.
Select Function
+
Self-Diagnostic Result
Select Controller
Self-Diagnosing
Engine Controller
No Problem
Main Controller
Fault
To the
lower
ESC
ESC
ESC
ICF Controller
Problem was detected.
14000
Fault
14001
Details
Details
CAN Communication Error
ESC
Corrective Action
1)Retry B
2)Check Harness
3)
Retry B
Do you want to escape?
ESC
Details
ESC
ESC
Retry B
Retry B Screen
Execute
Retry B
Self-diagnosing of controllers
below hasn completed.
Engine Controller
Main Controller
ESC
No Problem
Fault
Fault
ESC
T5-3-20
ESC
TROUBLESHOOTING / e-Wheel
(Blank)
T5-3-21
TROUBLESHOOTING / e-Wheel
LIST OF ICF FAULT CODE
Fault Code
Details
14000-2
14001-2
14002-2
14003-2
Abnormal EPROM
Sum Check Error
Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, check the following
item.
Check the CAN communication line (check the
h retry) B in self-diagnosing and execute the following
Execute
item.
Execute 1.5 Information C/U: Initialize (T5-3-14).
14006-2
Communication Error
Execute retry B in self-diagnosing.
Impossible to communicate with MC If this error code is displayed after re-try, check the following
item.
Check the communication line.
Check the power source line of satellite terminal.
Check the fuse.
Then, execute self-diagnosing and execute retry B.
14008-2
Abnormal RAM
Road / Write Error
T5-3-22
TROUBLESHOOTING / e-Wheel
LIST OF FAULT CODE OF SATELLITE
COMMUNICATION TERMINAL
Fault Code
Details
14100-2
Inside Error
Abnormal EPROM
14101-2
Inside Error
Abnormal IB/OB Queue
14102-2
Inside Error
Abnormal Local Loup Back
14103-2
Communication Error
The satellite is not found.
14104-2
Inside Error
Fail 1 of Remote Loup Back
14105-2
Communication Error
Fail 2 of Remote Loup Back
14106-2
Abnormal Harness
Sending and receiving data are
unmatched.
Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, replace the
controller.
T5-3-23
TROUBLESHOOTING / e-Wheel
SATELLITE COMMUNICATION SYSTEM
The satellite communication system is used for
maintenance of the machine, e-Service by
transmitting various data of the machine regularly via
a low earth orbit satellite.
Communication
Aerial
GPS
Aerial
T4GB-05-07-001
Satellite
Communication
Terminal
T4GB-05-07-002
T5-3-24
TROUBLESHOOTING / e-Wheel
On the machine equipped with the satellite
communication system, the data are sent according to
the condition as follows:
Kinds of data sent from the machine by using satellite
communication:
Items
Kinds of Data
Periodical
Daily Report Data, Latest
Transmission
Information, Fuel Level
Condition
Location The data are sent once a day. In order to
avoid
congested
traffic
in
the
communication line, the data is sent
randomly between 0:00 and 02:00.
Transmitting Data at Latest Location Information
The data is sent only when the machine
Engine Start
is moved more than 5 km from the place
where it is recorded lastly.
Emergency
Alarm and Error Information
The transmission starts immediately
Transmission
when the alarm and error occurs.
Hour Meter 100 Hours Frequency Distribution Information
The data is sent when the hour meter
Transmission
exceeds every 100 hours.
T5-3-25
TROUBLESHOOTING / e-Wheel
(Blank)
T5-3-26
4
5
12
7
11
10
9
T4GB-01-02-005
1 - Bucket
2 - Bell Crank
4 - Head Light
5 - Front Working Light
3 - Bucket Cylinder
T5-4-1
12 - Bucket Link
20
21
19
18
17
16
15
6
7
8
9
10
14
13
12
11
T4GB-01-02-002
123456-
Charging Block
Pilot Valve
Brake Valve
Steering Pilot Valve
Steering Valve
Control Valve
78910 11 12 -
Stop Valve
Pilot Shutoff Valve
Engine Oil Filter
Pilot Filter
Engine
Fuel Tank
13 14 15 16 17 18 -
T5-4-2
19 - Muffler
20 - Air Cleaner
21 - Hydraulic Tank
2
3
4
7
T4GB-01-02-004
1 - Front Axle
2 - Propeller Shaft (Front)
3 - Steering Cylinder
45-
Pump Device
Transmission
5 - Rear Axle
6 - Propeller Shaft (Rear)
T5-4-3
7 - Steering Accumulator
8 - Brake Pressure Sensor
14
Cab
(Refer to T5-4-5)
13
12
11
3
4
8
Pump Device
(Refer to T5-4-11)
Drive Unit
(Refer to T5-4-11)
10
T4GB-01-02-019
5-
Battery
67-
4 - Reverse Buzzer
8-
Hydraulic Oil
Temperature Sensor
7 - Emergency Steering
Pump Delivery Pressure
Switch
8 - Lift Arm Angle Sensor
(Optional)
9 - Bucket Proximity Switch
T5-4-4
1
2
3
Monitor and Switches
(Refer to T5-4-8)
Right Consol
(Refer to T5-4-7)
1 - Radio
2 - Auxiliary Switch Panel
(Optional)
3 - Speaker
4 - Rear Wiper Motor
T5-4-5
T4GB-01-02-006
11
15
16
17
18
19
20
21
22
23
24
12
13
14
10
1 - Flasher Relay
2 - Option Controller
(Optional)
3 - TCU
5 - ICF
6 - Dr.ZX Connector
26
27
28
29
30
31
32
33
34
T4GB-01-02-021
4 - MC
7 - Fuse Box
25
T4GB-01-02-022
T5-4-6
T4GB-01-02-006
9
10
18
17
16
15
14
13
12
T4GB-01-02-023
11
1 - Down Shift Switch
2 - Bucket Control Lever
3 - Lift Arm Control Lever
4 - Forward/Reverse Switch
5 - Hone Switch
15 - Forward/Reverse Selector
Switch
16 - Cigar Lighter
17 - Up-shift/Down-shift Switch
18 - Hold Switch
T5-4-7
T4GB-01-02-006
14
13
12
4
5
11
6
7
10
9
8
1 - Monitor Panel
(Refer to T5-4-9)
2 - Driving Mode Switch
3 - Turn Signal Lever/Head Light
Switch/Dimmer Switch
4 - Parking Brake Switch
T4GB-01-02-024
7 - Ignition Key
8 - Steering Column Tilt
/Telescopic Lever
T5-4-8
10
11
34
12
33
13
14
32
15
31
T4GB-01-02-001
30
29
28
1 - Coolant Temperature
Gauge
2 - Transmission Oil
Temperature Gauge
3 - Turn Signal Indicator
(Left)
4 - High Beam Indicator
5 - Working Light Indicator
6 - Turn Signal Indicator
(Right)
7 - Monitor Display
8 - Stop Indicator
9 - Service Indicator
27
26
25
24 23
22
21
20
19
18
12 - Fuel Gauge
21 - Glow Signal
18 - Discharge Warning
Indicator
T5-4-9
17
16
10
11
4
14
13
12
T4GB-01-02-025
1 - Glow Plug
9 - EGR Valve
2 - Injector
5 - Coolant Temperature
Sensor
6 - Overheat Switch
10 - Supply Pump
4 - Fan Pump
T5-4-10
T4GB-01-02-009
DRIVE UNIT
7
View A
12
8
18
11
17
10
16
13
14
15
T4GB-01-02-026
1 - Main Pump
2 - Regulator
7 - Air Breather
3 - Priority Valve
8 - Transmission Control
Valve
9 - Oil Filter
4 - Pump Delivery
Pressure Switch
5 - Pilot Pump
10 - Torque Converter
Output Speed Sensor
T5-4-11
5
4
1
2
3
T4GB-01-02-027
ZW250
5
T4GB-03-02-002
4 - Make-up Valve
(Lift Arm: Rod)
T5-4-12
CHARGING BLOCK
3
4
Unused
T4GB-01-02-014
FAN MOTOR
10
11
T4GB-01-02-013
14
13
15
T4GB-01-02-012
T4GB-01-02-011
T5-4-13
T4GB-01-02-020
6
T4GB-01-02-010
3 - Electric Motor
4 - Gear Pump
5 - Check Valve
T5-4-14
6-
Relief Valve
T5-4-15
11
7
7
10
T5-4-16
T4GB-03-02-003
B
C
D
T4GB-03-02-004
7 - Restriction Valve
8 - Low-pressure Relief Valve
9 - Main Relief Valve
T5-4-17
11
5
6
10
T5-4-18
T4GB-03-02-003
9
Section A
T4GB-03-02-005
Section B
8
T4GB-03-02-006
7-
Restriction Valve
8-
9-
Refer to T5-4-17.
T5-4-19
11
5
6
7
7
10
T5-4-20
T4GB-03-02-003
Section C
10
Section D
4
11
Section E
2
T4GB-03-02-007
Refer to T5-4-17
7-
Restriction Valve
8-
9-
T5-4-21
7
8
11
10
T4GB-03-02-008
T5-4-22
10
C
6
8
A
T4GB-03-02-009
7-
Make-up Valve
(Lift Arm: for Rod)
8 - Restriction Valve
9-
T5-4-23
6
8
7
8
11
10
T4GB-03-02-008
T5-4-24
Section A
11
7
Section B
5
4
T4GB-03-02-010
4-
7-
Make-up Valve
(Lift Arm: for Rod)
8 - Restriction Valve
9-
Refer to T5-4-23
.
T5-4-25
7
8
10
11
T4GB-03-02-008
T5-4-26
Section C
10
Section D
C
Section E
T4GB-03-02-011
4-
7-
Make-up Valve
(Lift Arm: for Rod)
8 - Restriction Valve
9-
Refer to T5-4-23.
T5-4-27
Port T
Port A
Port B
Port Pa
Port Pb
Port DR
Port P
Port LS
T5-4-28
T4GB-03-04-002
C
B
T4GB-03-04-001
1 - Spool
2 - Overload Relief Valve
5 - Variable Orifice
6 - Fixed Orifice
T5-4-29
Port T
Port A
Port B
Port Pa
Port Pb
Port DR
Port P
Port LS
T5-4-30
T4GB-03-04-002
Section A
Port P
Port DR
Port T
Section B
Port LS
Port B
Port A
2
Port Pb
Port Pa
Section C
T4GB-03-04-003
T4GB-03-04-006
1 - Spool
2 - Overload Relief Valve
56-
: Refer to T5-4-29.
T5-4-31
Variable Orifice
Fixed Orifice
7 - Passage A
22
9
10
11
21
12
13
14
15
20
16
17
18
19
9-
Priority Valve
3 - Port M2
(To Rear End of Brake Valve)
4 - Check Valve
5 - Port M1
(To Front End of Brake Valve
and Parking Brake)
6 - Service Brake Accumulator
(Front)
7 - Service Brake Pressure Sensor
T5-4-32
T4GB-03-06-002
Pump Torque
Control
Proportional
Solenoid Valve
13
17
Port for Attaching
Pilot Accumulator
T4GB-03-06-001
T5-4-33
22
9
10
11
21
12
13
14
15
20
16
17
18
19
9-
Priority Valve
3 - Port M2
(To Rear End of Brake Valve)
4 - Check Valve
5 - Port M1
(To Front End of Brake Valve
and Parking Brake)
6 - Service Brake Accumulator
(Front)
7 - Service Brake Pressure Sensor
T5-4-34
T4GB-03-06-002
10
Section U-U
14
12
21
Section T-T
15
16
20
19
Section S-S
18
T4GB-03-06-003
Refer to T5-4-33
T5-4-35
22
9
10
11
21
12
13
14
20
15
16
17
18
19
9-
Priority Valve
3 - Port M2
(To Rear End of Brake Valve)
4 - Check Valve
5 - Port M1
(To Front End of Brake Valve
and Parking Brake)
6 - Service Brake Accumulator
(Front)
7 - Service Brake Pressure Sensor
T5-4-36
T4GB-03-06-002
Section Z-Z
Section Y-Y
Section X-X
Section W-W
22
Refer to T5-4-33
T5-4-37
T4GB-03-06-004
Lift Arm
Cylinder
Ride Control
Accumulator
Pi
4
B
A
2
To Hydraulic Oil Tank
T
From Charging
Block
T4GB-03-08-002
5 - Drain Plug
T5-4-38
5
1
T4GB-03-08-001
T5-4-39
Lift Arm
Cylinder
Ride Control
Accumulator
Pi
4
B
A
2
To Hydraulic Oil Tank
T
From Charging
Block
T4GB-03-08-002
34-
5-
T5-4-40
Drain Plug
Section A
Port Pi
To Ride Control
Accumulator
Port SP
Port B
Port A
Port T
Refer to T5-4-39
T5-4-41
T4GB-03-08-003
10
15
14
11
13
12
1 - Torque Converter
2 - Torque Converter Housing
3 - Torque Converter Input
Speed Sensor
4 - Breather
9-
Filter
10 - Parking Brake
11 - Front Accelerator Output
Flange
12 - Nameplate
T5-4-42
T4GB-03-09-002
5
4
T4GB-03-09-003
3 - Parking Brake
4 - Transmission Mount
Base
T5-4-43
7-
10
5
6
7
View Y
11
11
12
Y
13
12
13
T4GB-03-09-009
7 - Single-speed Clutch
Pressure Sensor Port
T5-4-44
11
10
9
T4GB-03-09-004
123-
Single-speed Clutch
High-speed Forward Clutch
Reverse Switch
456-
T5-4-45
789-
Three-speed Clutch
Front Output Flange
Output Shaft
On Main Pump
End
On Engine
End
11
12
10
13
T4GB-03-09-001
1 - Turbine
2 - Stator
3 - Impeller
456-
Oil Seal
Transmission Pump
Seal Ring
789-
T5-4-46
Impeller Shaft
High-speed Drive Gear
Low-speed Drive Gear
10 11 12 13 -
Turbine Shaft
Notch Ring
Drive Tube
Torque Converter Input
Shaft
Valve Body
Connector
Middle Plate
Return Oil
Plate
Channel Plate
T107151
Pressure
Reducing Valve
Pressure
Control Valve
Proportional
Solenoid Valve
(6 Units)
Connector
Cover
Modulation
Circuit
Valve Body
Housing
Spool
Damper
Valve
T107153
T5-4-47
High Speed
Forward Clutch
Damper
Valve
Reverse
Clutch
Speed 1
Clutch
Speed 3
Clutch
Low Speed
Forward Clutch
Speed 2
Clutch
Booster Valve
Y1
Proportional
Solenoid Valve
Y2
Y3
Y4
Transmission Oil
Temperature Sensor
Main Relief
Valve
Y5
Y6
Reducing
Valve
Torque Converter
Torque Converter
Relief Valve
Oil
Filter
Torque Converter
Back Pressure Valve
Oil Filter
By-pass Valve
Torque Converter
Oil Cooler
(Installed on the
Drive Unit)
Torque Converter
Oil Cooler
(Installed on the
Rear of Vehicle)
Oil Filter
Restriction Switch
Charging
Pump
T4GB-03-09-010
T5-4-48
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing by using Dr. ZX
or the service mode of monitor unit.
YES (OK)
(2)
(1)
NO (NOT OK)
Key switch: ON
(3)
Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.
Harness
Open End
Side
T5-5-1
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE LIST
Controller Hardware Failure
Fault
Trouble
Code
11000-2 Abnormal EPROM
Cause
Faulty MC
All Control
Faulty MC
All Control
11001-2
Abnormal RAM
11002-2
11003-3
11004-2
Influenced Control
T5-5-2
All Control
of All Control
TROUBLESHOOTING / Troubleshooting A
Remark
Retrial B
Replace MC
There is something wrong with machine operation.
Retrial B
Replace MC
As the latest, normal value AD (analog to digital) is enabled, the Retrial B
machine may be operated incorrectly or slowly.
Replace MC
Inputs from all sensors are uncertain.
Retrial B
Check Harness
Replace MC
-1
As engine speed is kept at 1000 min (1000 rpm), the work may Retrial B
be inoperable.
Check CAN Harness
Replace MC
T5-5-3
TROUBLESHOOTING / Troubleshooting A
Engine Failure
Fault
Trouble
Code
11103-3 Abnormal Accelerator
High Voltage
11103-4
Abnormal Accelerator
Low Voltage
Cause
Influenced Control
T5-5-4
TROUBLESHOOTING / Troubleshooting A
Remedy
T5-5-5
TROUBLESHOOTING / Troubleshooting A
Pump Failure
Fault
Trouble
Cause
Influenced Control
Code
11204-3 Abnormal Pump Delivery Output voltage: 4.75 V or Disable Pump Torque Decrease
Pressure Sensor High Volt- higher
Control
age
11204-4
Abnormal Pump Delivery Output voltage: Less than Disable Pump Torque Decrease
Pressure Sensor Low Voltage 0.25 V
Control
11209-3
Abnormal Implement Pres- Output voltage: 4.75 V or Disable Pump Torque Decrease
sure Sensor High Voltage
higher
Control
11209-4
Abnormal Implement Pres- Output voltage: Less than Disable Pump Torque Decrease
sure Sensor Low Voltage
0.25 V
Control
T5-5-6
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs
Remedy
As the pump is controlled by pump standard torque control, work ef- Retrial B
ficiency of the front attachment becomes low.
Check Harness
Fuel consumption becomes bad.
Replace Pump Delivery Pressure Sensor
Replace MC
As the pump is controlled by pump standard torque control, work ef- Retrial B
ficiency of the front attachment becomes low.
Check Harness
Fuel consumption becomes bad.
Replace Pump Delivery Pressure Sensor
Replace MC
As the pump is controlled by pump standard torque control, work ef- Retrial B
ficiency of the front attachment becomes low.
Check Harness
Fuel consumption becomes bad.
Replace Implement Pressure Sensor
Replace MC
As the pump is controlled by pump standard torque control, work ef- Retrial B
ficiency of the front attachment becomes low.
Check Harness
Fuel consumption becomes bad.
Replace Implement Pressure Sensor
Replace MC
T5-5-7
TROUBLESHOOTING / Troubleshooting A
Pilot Failure
Fault
Trouble
Cause
Code
11313-3 Abnormal Parking Brake Pres- Output voltage: 4.75 V or higher
sure Sensor High Voltage
11313-4
Influenced Control
Parking Brake Indicator Control
Abnormal Parking Brake Pres- Output voltage: Less than 0.25 Parking Brake Indicator Consure Sensor Low Voltage
V
trol
T5-5-8
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs
Remedy
As the parking brake is forcibly released, the machine can travel Retrial B
with the parking brake switch ON.
Check Harness
Replace Parking Brake Pressure Sensor
Replace MC
As the parking brake is forcibly released, the machine can travel Retrial B
with the parking brake switch ON.
Check Harness
Replace Parking Brake Pressure Sensor
Replace MC
T5-5-9
TROUBLESHOOTING / Troubleshooting A
Proportional Solenoid Valve Failure
Fault
Trouble
Code
11412-2 Abnormal Feedback of Hydraulic
Drive Fan Flow Rate Control Solenoid Valve
Cause
Influenced Control
The feedback current Hydraulic Drive Fan Cooling Conto MC becomes the trol
uncertain value
11412-3
Abnormal Feedback High Current of The feedback current Hydraulic Drive Fan Cooling ConHydraulic Drive Fan Flow Rate Con- to MC exceeds the trol
trol Solenoid Valve
upper limit
11412-4
Abnormal Feedback Low Current of While the command Hydraulic Drive Fan Cooling ConHydraulic Drive Fan Flow Rate Con- from MC is output, the trol
trol Solenoid Valve
feedback current to MC
is 56 mA or less
11413-2
Abnormal Feedback of Pump Torque The feedback current Pump Standard Torque Control
Control Solenoid Valve
to MC becomes the
uncertain value
11413-3
Abnormal Feedback High Current of The feedback current Pump Standard Torque Control
Pump Torque Control Solenoid Valve to MC exceeds the
upper limit
11413-4
Abnormal Feedback Low Current of While the command Pump Standard Torque Control
Pump Torque Control Solenoid Valve from MC is output, the
feedback current to MC
is 56 mA or less
T5-5-10
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs
As the fan rotation is kept at maximum, the machine starts slowly.
Fuel consumption becomes bad.
Remedy
Retrial B
Check Harness (Feedback line from the
flow rate control solenoid valve to MC)
Replace Hydraulic Drive Fan Flow Rate
Control Solenoid Valve
Replace MC
As the fan rotation is kept at maximum, the machine starts slowly. Retrial B
Fuel consumption becomes bad.
Check Harness (Feedback line from the
flow rate control solenoid valve to MC)
Replace Hydraulic Drive Fan Flow Rate
Control Solenoid Valve
Replace MC
As the fan rotation is kept at maximum, the machine starts slowly. Retrial B
Fuel consumption becomes bad.
Check Harness (Feedback line from the
flow rate control solenoid valve to MC)
Replace Hydraulic Drive Fan Flow Rate
Control Solenoid Valve
Replace MC
As the pump is kept at minimum displacement, work efficiency of Retrial B
the front attachment becomes low.
Check Harness (Feedback line from the
torque control solenoid valve to MC)
Replace Pump Torque Control Solenoid
Valve
Replace MC
As the pump is kept at minimum displacement, work efficiency of Retrial B
the front attachment becomes low.
Check Harness (Feedback line from the
torque control solenoid valve to MC)
Replace Pump Torque Control Solenoid
Valve
Replace MC
As the pump is kept at minimum displacement, work efficiency of Retrial B
the front attachment becomes low.
Check Harness (Feedback line from the
torque control solenoid valve to MC)
Replace Pump Torque Control Solenoid
Valve
Replace MC
T5-5-11
TROUBLESHOOTING / Troubleshooting A
CAN Data Reception Failure
Fault
Trouble
Cause
Code
11910-2 Actual Engine Speed Receive Faulty Harness
Error
Faulty ECM
Received from ECM
Influenced Control
Pump Torque Decrease Control
Hydraulic Drive Fan Cooling
Control
11912-2
11913-2
11914-2
11916-2
11917-2
11920-2
Faulty Harness
Faulty ECM
T5-5-12
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs
Remedy
Retrial B
Check CAN Communication Line
Replace ECM
Replace MC
Retrial B
Check CAN Communication Line
Replace TCU
Replace MC
Retrial B
Check CAN Communication Line
Replace TCU
Replace MC
T5-5-13
Retrial B
Check CAN Communication Line
Replace ECM
Replace MC
TROUBLESHOOTING / Troubleshooting A
Other Failures
Fault
Trouble
Cause
Code
11901-3 Hydraulic
Oil
Temperature Voltage: 4.52 V or higher
Sensor High Voltage
11901-4
Hydraulic
Oil
Temperature Voltage: Less than 0.23 V
Sensor Low Voltage
T5-5-14
Influenced Control
Auto-Warming Up Control
Hydraulic Drive Fan Cooling
Control
Auto-Warming Up Control
Hydraulic Drive Fan Cooling
Control
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs
Remedy
Retrial B
Check Harness
Replace Hydraulic Oil Temperature Sensor
Replace MC
Retrial B
Check Harness
Replace Hydraulic Oil Temperature Sensor
Replace MC
T5-5-15
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODE LIST
Sensor System
Fault
Trouble
Code
636-2
Abnormal Cam Angle Sensor (No Signal)
636-2
723-2
723-2
636-7
172-3
172-4
110-3
Cause
Abnormal Intake-Air Temperature Sensor Voltage at the intake-air temperature sensor is beyond
(Abnormal High Voltage)
4.95 V in 3 minutes after the engine starts.
Abnormal Intake-Air Temperature Sensor Voltage at the intake-air temperature sensor is below
(Abnormal Low Voltage)
0.1 V.
Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is beyond
(Abnormal High Voltage)
4.85 V in 3 minutes after the engine starts.
110-4
Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is below 0.1
(Abnormal Low Voltage)
V.
102-4
102-3
10001-3
108-4
108-3
174-3
174-4
T5-5-16
TROUBLESHOOTING / Troubleshooting A
FaultCode
(Tech 2)
While the engine runs, there is nothing abnormal While the engine runs, operate according to P0340
with machine operation.
standard of the crank sensor. When the enAfter the engine is stalled, the re-start is impossible. gine stops, the start is impossible (in order P0341
to prevent the engine from damaging).
The output power may decrease, white smoke may Operate according to standard of the cam P0335
occur and vibration may occur.
sensor.
The engine may be stalled. (If the cam senor is
P0336
normal, the engine can re-start.)
Presumptive Symptoms in Real Machine Operation
While the engine runs, there is nothing abnormal The timing chain and the belt do not turn P1345
with machine operation.
smoothly but turn in reverse.
After the engine is stalled, the re-start is impossible.
When starting: -10 C (14 F) (Start the engine although what state.)
When operating: 25 C (77 F) (Operate
normally.)
Normal temperature: When starting, dark smoke When starting: -20 C (-4 F) (Start the enmay occur and engine combustion sound may be- gine although what state.)
come loud.
When operating: 80 C (176 F) (Operate
While warming up with fresh air in low temperature: normally.)
Rough idle, engine stall or while smoke may occur.
Dark smoke occurs.
Boost pressure cannot be corrected.
Nothing special
P0113
P0112
P0118
P0117
P0238
P0237
Nothing special
T5-5-17
TROUBLESHOOTING / Troubleshooting A
Fault
Code
157-3
157-4
100-4
100-3
105-3
105-4
Trouble
Cause
T5-5-18
TROUBLESHOOTING / Troubleshooting A
The engine may be stalled. The output power de- The supply pump can not be controlled.
creases.
Fault Code
(Tech 2)
P0193
P0192
Nothing special
P0523
P0522
Nothing special
P1113
P1112
T5-5-19
TROUBLESHOOTING/ Troubleshooting A
Fault Code
636-2
636-2
723-2
723-2
636-7
172-3
172-4
110-3
110-4
102-4
102-3
10001-3
108-4
108-3
174-3
174-4
157-3
157-4
Influence to Engine
Performance
(Presumption)
Abnormal Cam Angle Sensor (No No influence during
operation
Signal)
Abnormal Cam Angle Sensor After stopping, the
re-start is impossible.
(Abnormal Signal)
output
power
Abnormal Crank Speed Sensor (No No
decrease
Signal)
Abnormal Crank Speed Sensor
(Abnormal Signal)
Phase Mismatch of Cam Angle No influence during
Sensor
operation
After stopping, the
re-start is impossible.
output
power
Abnormal Intake-Air Temperature No
decrease
Sensor (Abnormal High Voltage)
Abnormal Intake-Air Temperature
Sensor (Abnormal Low Voltage)
output
power
Abnormal
Coolant
Temperature No
decrease
Sensor (Abnormal High Voltage)
Abnormal
Coolant
Temperature
Sensor (Abnormal Low Voltage)
output
power
Abnormal Boost Pressure Sensor No
decrease
(Abnormal High Voltage)
Abnormal Boost Pressure Sensor
(Abnormal Low Voltage)
Abnormal EGR Position (Brushless No
output
power
spec.)
change
output
power
Abnormal Atmospheric Pressure No
decrease
Sensor (Abnormal High Voltage)
Abnormal Atmospheric Pressure
Sensor (Abnormal Low Voltage)
output
power
Abnormal Fuel Temperature Sensor No
decrease
(Abnormal High Voltage)
Abnormal Fuel Temperature Sensor
(Abnormal Low Voltage)
power
Abnormal Common Rail Pressure Output
decrease: 70%
Sensor (Abnormal High Voltage)
Abnormal Common Rail Pressure
Sensor (Abnormal Low Voltage)
Trouble
T5-5-20
Operating Rank
(Current State)
A B C D
Remark
TROUBLESHOOTING/ Troubleshooting A
Fault Code
100-4
100-3
105-3
105-4
Influence to Engine
Operating Rank
Performance
(Current State)
(Presumption)
A B C D
output
power
Abnormal Engine Oil Pressure No
change
Sensor (Abnormal High Voltage)
Abnormal Engine Oil Pressure
Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.
IMPORTANT: When fault code 723-2 (abnormal
crank speed sensor) is displayed
and the engine does not start, the
cam angle sensor is faulty although
fault codes 636-2 (abnormal cam
angle sensor) and 636-7 (phase
mismatch of cam angle sensor) are
not displayed.
T5-5-21
Remark
TROUBLESHOOTING/ Troubleshooting A
External Device System
Fault Code
Trouble
Cause
10002-2
1347-0
Open circuit in suction control valve The suction control valve drive current is beyond 2400 mA or
drive system, Shorted circuit in + B or below 50 mA. Or, difference between the target current and
GND
actual current is 1000 mA or more.
651-3
652-3
653-3
654-3
655-3
656-3
987-3
1485-2
T5-5-22
TROUBLESHOOTING/ Troubleshooting A
Fault Code
(Tech 2)
P0488
P0090
P0201
P0203
P0204
P0205
P0206
P0202
P0650
Nothing
T5-5-23
P1625
TROUBLESHOOTING/ Troubleshooting A
Fuel System
Fault Code
Trouble
Cause
rail
157-0
Abnormal common
(First stage)
157-0
157-2
633-7
1239-1
No pressure to pump (Fuel leakage) When pressure to the suction control valve is 900 min-1 (900
rpm) or more, actual rail pressure is 15 Mpa (150 kgf/cm2,
2180 psi) or less.
T5-5-24
TROUBLESHOOTING/ Troubleshooting A
Fault Code
(Tech 2)
Vibration of the engine may be large, Rough idle, Prevention the injection system (pump) from
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the RP sensor by over-pressure)
occur, output power may be too large.
P0088
Vibration of the engine may be large, Rough idle, Prevention the injection system from damage
output power decrease may occur, faulty (Pressure is too much as PR is clogged.)
increasing of rotation speed, dark smoke may
occur, output power may be too large.
P0088
Vibration of the engine may be large, Rough idle, Prevention the injection system (pump) from
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the RP sensor by over-pressure)
occur, output power may be too large.
P0089
P1095
T5-5-25
P0087
P1093
TROUBLESHOOTING/ Troubleshooting A
Fault
Code
Influence to Engine
Performance
(Presumption)
Trouble
Operating Rank
(Current)
A
651-3
652-3
653-3
654-3
655-3
656-3
987-3
1485-2
Fault
Code
157-0
157-0
157-2
633-7
1239-1
No
output
power
change
Open circuit in suction control valve Output
power
drive system, Shorted circuit in + B or decrease: 50%
GND
decrease: 15%
drive system
Open circuit in injection nozzle 2 (Five cylinders drive.)
drive system
Open circuit in injection nozzle 3
drive system
Open circuit in injection nozzle 4
drive system
Open circuit in injection nozzle 5
drive system
Open circuit in injection nozzle 6
drive system
Abnormal check engine lamp
No
output
power
change
Abnormal main relay system
The engine stops.
Nothing (The engine
cannot
re-start
according to battery
voltage.)
Remark
Influence to Engine
Performance
(Presumption)
Trouble
Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.
T5-5-26
power
power
power
power
power
Operating Rank
(Current)
A
Remark
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-5-27
TROUBLESHOOTING/ Troubleshooting A
Engine Protection System
Fault Code
Trouble
110-0
Overheating
190-0
Overrunning
Cause
Coolant temperature is beyond 120 C (248 F) when
operating the engine.
In case the engine speed is beyond 2500 min-1 (2500 rpm)
T5-5-28
TROUBLESHOOTING/ Troubleshooting A
T5-5-29
TROUBLESHOOTING/ Troubleshooting A
Fault
Code
Influence to Engine
Performance
(Presumption)
Trouble
110-0
Overheating
190-0
Overrunning
No
output
change
No
output
decrease
Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.
T5-5-30
power
power
Operating Rank
(Current)
A
Remark
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-5-31
TROUBLESHOOTING/ Troubleshooting A
Internal Circuit System
Fault Code
Trouble
Cause
10005-1
10006-1
10008-2
1077-2
Abnormal A/D Converter (Analog to A/D conversion (analog to digital) cannot be done.
Digital)
Abnormal CPU
Within 100 msec after the key switch is turned ON, failure of
main CPU is detected by sub CPU.
(Sub CPU resets CPU.)CPU is recovered.
Within 100 msec after the key switch is turned ON, failure of
main CPU is detected by sub CPU.
(Sub CPU resets CPU.)CPU is not recovered.
Abnormal IC for CPU Watching
No change of RUN-SUB pulse in 20 msec
628-2
Abnormal ROM
ROM is broken.
10013-2
Abnormal EPROM
EPROM is broken.
1079-2
10007-2
1080-2
10009-2
10010-2
10011-2
10003-2
10004-2
T5-5-32
of
of
of
of
of
TROUBLESHOOTING/ Troubleshooting A
P1630
CPU is broken.
P0606
Fault Code
(Tech 2)
P0611
P0612
P0606
P0606
P1601
P1603
P1632
P1633
P1634
P1635
P1261
T5-5-33
P1631
P1262
TROUBLESHOOTING/ Troubleshooting A
Fault Code
Trouble
10005-1
10006-1
10008-2
10007-2
Abnormal CPU
1077-2
628-2
10013-2
Abnormal ROM
Abnormal EPROM
1079-2
1080-2
10009-2
10010-2
10011-2
10003-2
10004-2
Influence to Engine
Performance
(Presumption)
Output
power
decrease: 60%
(Three cylinders drive.)
Output
power
decrease: 50%
Output
power
decrease: 50%
The engine cannot
start.
Output
power
decrease: 50%
The engine stops.
No
output
power
decrease
Idle speed operation
No
output
power
decrease
No
output
power
change
No
output
power
decrease
Output
power
decrease: 50%
Output
power
decrease: 60%
(Three cylinders drive.)
Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.
T5-5-34
Operating Rank
(Current)
A B C D
Remark
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-5-35
TROUBLESHOOTING/ Troubleshooting A
Communication System
Fault Code
Trouble
Cause
639-2
639-3
T5-5-36
TROUBLESHOOTING/ Troubleshooting A
Fault Code
(Tech 2)
U2104
U2106
T5-5-37
TROUBLESHOOTING/ Troubleshooting A
Fault
Code
Trouble
639-2
639-3
Influence to Engine
Performance
(Presumption)
Idle speed
Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.
T5-5-38
Operating Rank
(Current)
A B C D
Remark
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-5-39
TROUBLESHOOTING/ Troubleshooting A
TCU FAULT CODE LIST
Fault Code
Trouble
Cause
5000-12
5010-12
5040-12
5110-3
Transmission
Oil
Sensor High Voltage
5110-4
Transmission
Oil
Sensor Low Voltage
Temperature
Temperature
5313-12
5140-3
5140-4
5140-12
Torque Converter Input Shaft Sensor Faulty contact because of faulty harness or faulty
Signal Error
connector
Feedback voltage to TCU: Uncertain Internal fault in the rotation sensor
value
Sensor mounting space error
5150-3
T5-5-40
TROUBLESHOOTING/ Troubleshooting A
Behavior of TCU
Fixed to neutral
Repair Procedure
Fixed to neutral
Connect the clutch according to the backup Check the harness between TCU and sensor
program.
Check the connectors
Shock when shifting travel speed may become Check the rotation sensor (1050 at 20 )
strong.
Connect the clutch according to the backup Check the harness between TCU and sensor
program.
Check the connectors
Shock when shifting travel speed may become Check the rotation sensor
strong.
Check the sensor gap (1050 at 20 )
Connect the clutch according to the backup Check the harness between TCU and sensor
program.
Check the connectors
Shock when shifting travel speed may become Check the rotation sensor (1050 at 20 )
strong.
If the travel speed sensor is abnormal, return the
forward/reverse lever to neutral and operate again.
Then, machine can travel at first or second speed
stage.
T5-5-41
TROUBLESHOOTING/ Troubleshooting A
Fault Code
Trouble
Cause
5150-4
Abnormal Torque Converter Output Grounding to vehicle frame because of faulty harness
Shaft Sensor Low Voltage
Internal fault in the rotation sensor
Feedback voltage to TCU: 0.45 V or
less
5150-12
Torque Converter Output Shaft Faulty short because of faulty harness or faulty connector
Sensor Signal Error
Internal fault in the rotation sensor
Feedback voltage to TCU: Uncertain Sensor mounting space error
value
5160-3
5160-4
5160-12
Transmission Intermediate Shaft Faulty short because of faulty harness or faulty connector
Sensor Signal Error
Internal fault in the rotation sensor
Feedback voltage to TCU: Uncertain Sensor mounting space error
value
5170-3
5170-4
5170-12
5180-2
Travel Speed Sensor Pulse Output Internal fault in the travel speed sensor
Error
Sensor gap dimension error
T5-5-42
TROUBLESHOOTING/ Troubleshooting A
Behavior of TCU
Repair Procedure
T5-5-43
TROUBLESHOOTING/ Troubleshooting A
Fault Code
Trouble
Cause
5480-3
Abnormal
First
Stage
Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve
5480-4
Abnormal
First
Stage
Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Faulty short to other proportional solenoid valve output
circuit in TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve
5480-5
Open Circuit in First Stage Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve
5490-3
Abnormal Second Stage Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve
5490-4
Abnormal Second Stage Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU
Internal fault in the proportional solenoid valve
5490-5
Open Circuit in Second Stage Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve
5500-3
Abnormal Third Stage Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve
T5-5-44
TROUBLESHOOTING/ Troubleshooting A
Behavior of TCU
Repair Procedure
T5-5-45
TROUBLESHOOTING/ Troubleshooting A
Fault Code
Trouble
Cause
5500-4
Abnormal Third Stage Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve
5500-5
Open Circuit in Third Stage Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve
5510-3
Abnormal Fast Forward Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve
5510-4
Abnormal Fast Forward Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve
5510-5
Open Circuit in Fast Forward Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve
5520-3
Abnormal Slow Forward Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve
T5-5-46
TROUBLESHOOTING/ Troubleshooting A
Behavior of TCU
Repair Procedure
T5-5-47
TROUBLESHOOTING/ Troubleshooting A
Fault Code
Trouble
Cause
5520-4
Abnormal Slow Forward Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve
5520-5
Open Circuit in Slow Forward Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve
5530-3
Abnormal
Reverse
Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve
5530-4
Abnormal
Reverse
Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve
5530-5
Open Circuit in Reverse Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve
5560-4
5560-3
T5-5-48
TROUBLESHOOTING/ Troubleshooting A
Behavior of TCU
Repair Procedure
T5-5-49
TROUBLESHOOTING/ Troubleshooting A
Fault Code
Trouble
Cause
5560-5
Faulty Open Circuit in Reverse Light Faulty connection of harness and TCU
Relay Exciting Circuit
Internal fault in the reverse light relay
TCU detects wrong voltage similar to Faulty contact of connector and TCU
voltage during faulty open circuit.
5620-4
Abnormal Output Signal Circuit of Grounding to vehicle machine because of faulty harness
Transmission Failure Low Voltage
Internal fault in the monitor unit
Grounding the connector pin to vehicle frame
Open Circuit in Output Signal Circuit Faulty connection of harness and TCU
of Transmission Failure
Internal fault in the monitor unit
Faulty connection of connector and TCU
Abnormal Output Signal Circuit of Short in power circuit because of faulty harness
Transmission Failure High Voltage
Internal fault in the monitor unit
Short in power circuit by the connector pin
First Stage Clutch Slipping
First stage clutch pressure is low.
When operating the first stage clutch, Main clutch pressure is low.
if the value calculated by the signal of Faulty transmission intermediate shaft sensor
transmission
intermediate
shaft Faulty travel speed sensor
sensor is different from the actual Sensor mounting space error
value of travel speed sensor, TCU Faulty clutch
determines that the clutch slipping
occurs.
5620-5
5620-3
5660-2
5665-2
5670-2
T5-5-50
TROUBLESHOOTING/ Troubleshooting A
Behavior of TCU
Repair Procedure
TCU
Check reverse light relay
sensor
Check the signal of travel speed sensor
T5-5-51
TROUBLESHOOTING/ Troubleshooting A
Fault Code
Trouble
5675-2
5680-2
5685-2
5700-0
5730-0
5745-15
Overrunning
TCU detects transmission output
speed beyond the specified value.
5755-15
Cause
T5-5-52
TROUBLESHOOTING/ Troubleshooting A
Behavior of TCU
Repair Procedure
sensor
Check the signal of travel speed sensor
Replace the clutch
Check slow forward clutch pressure
Check main system pressure
Check the sensor gap in transmission intermediate
shaft sensor
Check the sensor gap in travel speed sensor
Check the signal of transmission intermediate shaft
sensor
Check the signal of travel speed sensor
Replace the clutch
Check reverse clutch pressure
Check main system pressure
Check the sensor gap in transmission intermediate
shaft sensor
Check the sensor gap in travel speed sensor
Check the signal of transmission intermediate shaft
sensor
Check the signal of travel speed sensor
Replace the clutch
Machine cooling
Check oil level
Check the sensor
Check the transmission oil filter
Check the harness between TCU and restriction switch
Check the restriction switch (resistance measurement)
T5-5-53
TROUBLESHOOTING/ Troubleshooting A
Fault Code
5770-4
5770-3
5770-5
5810-3
5810-4
Trouble
Cause
5820-4
5820-3
5830-2
T5-5-54
TROUBLESHOOTING/ Troubleshooting A
Behavior of TCU
Repair Procedure
Fixed to neutral
Fixed to neutral
Fixed to neutral
TCU
Check the power at terminal #3 in TCU (5V)
Replace TCU
Check fuse #7 in fuse box A and fuse #3 in fuse box B
Check the harness and connector between fuse #7 in
fuse box A, fuse #3 in fuse box B and TCU
Check fuse #7 in fuse box A and fuse #3 in fuse box B
Check the harness and connector between fuse #7 in
fuse box A, fuse #3 in fuse box B and TCU
Check fuse #3 in fuse box B
Check the harness between transmission control valve
and TCU
Check the connector between transmission control
valve and TCU
Replace TCU
T5-5-55
TROUBLESHOOTING/ Troubleshooting A
Fault Code
Trouble
5890-2
Broken EPROM
TCU cannot make out the memory.
Broken Program
Transmission control is disabled.
Application Error
Application is defective.
Learning Failure in Transmission
Learning Control Program
No Correcting Data of Transmission
Learning Control Program and
Clutch Cut Control Pressure
5900-13
5910-13
5930-7
5930-13
Cause
Faulty TCU
Failure in data save
Install new TCU or the used one for other machine
One of the learning values in transmission learning control
program is beyond normal range.
Failure in data save to the memory
New TCU
T5-5-56
TROUBLESHOOTING/ Troubleshooting A
Behavior of TCU
Repair Procedure
Replace TCU
Fixed to neutral.
Replace TCU
Fixed to neutral.
Replace TCU
Fixed to neutral.
T5-5-57
TROUBLESHOOTING/ Troubleshooting A
ICF FAULT CODE LIST
Fault Code
14000-2
14001-2
Trouble
Cause
14002-2
ICF: External RAM: Read / Write In case the internal memory is abnormal when the key is
Error
turned ON
14003-2
14006-2
14008-2
T5-5-58
TROUBLESHOOTING/ Troubleshooting A
Remedy
If trouble is not resolved after retrial B, check for CAN communication bus line.
After initializing the information C/U by using Dr. ZX, re-try in the troubleshooting.
If the error code is displayed after re-try, ICF may be broken.
Replace ICF.
NOTE: When initializing the information C/U, all stored data is deleted.
After initializing the information C/U by using Dr. ZX, re-try in the troubleshooting.
If the error code is displayed after re-try, ICF may be broken.
Replace ICF.
NOTE: When initializing the information C/U, all stored data is deleted.
If trouble is not resolved after retrial B, ICF may be broken. Replace ICF.
Check for the items below.
1. Retrial B.
2. Check if the communication line is abnormal.
3. Check if the electrical power source of communication terminal is abnormal.
Electrical power source
Fuses
3. Check if the satellite terminal is broken.
Re-try in the troubleshooting by using Dr.ZX.
If the error code is displayed after re-try, ICF may be broken. Replace ICF.
T5-5-59
TROUBLESHOOTING/ Troubleshooting A
SATELLITE TERMINAL FAULT CODE LIST
Fault Code
14100-2
14101-2
14102-2
Trouble
Cause
14103-2
14104-2
14105-2
14106-2
T5-5-60
TROUBLESHOOTING/ Troubleshooting A
Remedy
Retrial B.
Replace the ICF controller.
Retrial B.
Replace the ICF controller.
Retrial B.
Check the communication aerial.
Replace the ICF controller.
Retrial B.
Check the communication aerial.
Replace the ICF controller.
Retrial B.
Replace the ICF controller.
Retrial B.
Replace the ICF controller.
Retrial B.
Replace the ICF controller.
T5-5-61
TROUBLESHOOTING/ Troubleshooting A
MONITOR UNIT FAULT CODE LIST
Fault Code
Trouble
Cause
13306-2
13308-2
13312-2
Abnormal EPROM
Abnormal CAN Communication
Abnormal
Transmission
Oil
Temperature Sensor
Service Brake Pressure Sensor High
Voltage
Service Brake Pressure Sensor Low
Voltage
13314-3
13314-4
T5-5-62
TROUBLESHOOTING / Troubleshooting A
CONTROLLER HARDWARE FAILURE
MC FAULT CODES 11000 to 11002
Fault Code
11000-2
11001-2
11002-2
Trouble
Abnormal EPROM
Abnormal RAM
Abnormal A/D Converter
Cause
Faulty MC
Faulty MC
Faulty MC
YES
Influenced Control
All Control
All Control
All Control
*Normal.
T5-5-63
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11003
Fault Code
11003-3
Trouble
Abnormal Sensor Voltage
Cause
Shorted circuit in harness
Faulty sensor
Faulty MC
Influenced Control
All Control
YES
Disconnect connectors of
all sensors corresponding
to the displayed fault code
and connector monitor-1B
in monitor unit. Retry.
Check if fault code
11003-3 disappears.
NO
YES
NO
Monitor Unit
Connector Monitor-1B
(Harness end)
#27
#28
T4GB-05-05-002
T5-5-64
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11004
Fault Code
11004-2
Trouble
Cause
Abnormal
CAN Shorted harness
Communication
Faulty MC
Influenced Control
All Pump Control
All Transmission Control
All Engine Control
Hydraulic Drive Fan Cooling Control
Ride Control
CAN Cycle Data Communication
GPS
Monitor Unit
Dr-ZX
ICF
TCU
ECM
CAN Harness
MC
T5-5-65
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
Check the wiring connections first.
NO
YES Check for continuity in
CAN harness between
MC and ECM.
YES
NO
Normal.
NO
T5-5-66
TROUBLESHOOTING / Troubleshooting A
YES
Disconnect all
connectors in MC,
ICF, ECM, TCU and
monitor unit.
YES Check for continuity
between CAN circuit
and ground circuit in
MC, ICF, ECM, TCU
and monitor unit.
To A
NO
NO
NO
YES
NO
T5-5-67
NO
Key switch: OFF
Refer to Discontinuity
Check between CAN
Circuit and Key Signal
Circuit on T5-5-85 to
88.
To B
TROUBLESHOOTING / Troubleshooting A
Shorted circuit in
CAN harness.
YES
Connect connector
YES in MC.
Check if fault code
11004-2 is
displayed.
Connect all
connectors except
connector MC-C in
MC.
Check if resistance
between terminals
#C4 and #C15 of
NO harness end of
connector MC-C is
within 6010 .
Key switch: ON
NO
Connect connector in
MC. Disconnect
connector ICF-C in
ICF.
Check if resistance
between terminals
#C5 and #C11 of
harness end of
connector is within
6010 .
Faulty MC.
YES
YES
NO
MC
Connector MC-C
(Harness end)
#C4
NO
Check the
connection of ICF
and connector.
Faulty ICF.
YES
Connect connector in
ICF.
Disconnect
connector in ECM.
Check if resistance
between terminals
#18 and #37 of
harness end of
connector is within
12010 .
YES
NO
Connect connector
in ECM. Check if
fault code 11004-2
is displayed.
Key switch: ON
#C15
C10
C1
C23
Connect connector
in ICF.
Check if fault code
11004-2 is
displayed.
Key switch: ON
Connector
Check the
connection of MC
and connector.
NO
C31
Connect connector in
ECM.
Disconnect
connector monitor-2B
in monitor unit.
Check if resistance
between terminals
#33 and #34 of
harness end of
connector is within
12010 .
Key switch: OFF
ICF
Connector ICF-C
(Harness end)
#C5
#C11
ECM
Connector
(Harness end)
T1V1-05-04-002
Monitor Unit
Connector Monitor-2B
(Harness end)
#18
#37
T1GR-05-04-002
T5-5-68
T4GB-05-05-002
#34
#33
TROUBLESHOOTING / Troubleshooting A
NO
Faulty ECM.
YES
YES
Key switch: ON
NO
NO
Connect connector in
monitor unit.
Check if fault code
11004-2 is displayed.
Connect connector in
monitor unit.
Disconnect connector
in TCU.
Check if resistance
between terminals #25
and #26 of harness
end of connector is
within 12010 .
Connect connector in
YES TCU.
Check if fault code
11004-2 is displayed.
NO
YES
NO
#25
#26
T4GB-05-05-001
T5-5-69
TROUBLESHOOTING / Troubleshooting A
Continuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key
switch OFF.
C23
#C15
C10
C31
ECM
Connector
(Harness end)
#18
#37
T1GR-05-04-002
T5-5-70
TROUBLESHOOTING / Troubleshooting A
Between MC and ICF
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #C5 of harness end of connector ICF-C
in ICF.
CAN Harness (Low Side)
Check for continuity between terminal #C15 of
harness end of connector MC-C in MC and
terminal #C11 of harness end of connector ICF-C
in ICF.
Connector
MC
Connector MC-C
(Harness end)
#C4
#C15
C10
C1
C23
C31
ICF
Connector ICF-C
(Harness end)
#C5
#C11
T1V1-05-04-002
T5-5-71
TROUBLESHOOTING / Troubleshooting A
Between MC and Monitor Unit
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #B33 of harness end of connector
monitor-2B in the monitor unit.
CAN Harness (Low Side)
Check for continuity between terminal #C15 of
harness end of connector MC-C in MC and
terminal #B34 of harness end of connector
monitor-2B in the monitor unit.
Connector
MC
Connector MC-C
(Harness end)
#C4
#C15
C10
C1
C23
C31
Monitor Unit
Connector Monitor-2B
(Harness end)
T4GB-05-05-002
#B34
#B33
T5-5-72
TROUBLESHOOTING / Troubleshooting A
Between MC and TCU
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #25 of harness end of connector in TCU.
CAN Harness (Low Side)
Check for continuity between terminal #C15 of
harness end of connector MC-C in MC and
terminal #26 of harness end of connector in TCU.
Connector
MC
Connector MC-C
(Harness end)
#C4
C1
C23
#C15
C10
C31
TCU
Connector
(Harness end)
#25
#26
T4GB-05-05-001
T5-5-73
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Ground Circuit
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit
between CAN circuit and ground
circuit is shorted.
In case of discontinuity, the circuit is
normal.
Connector
Connector MC-C
(Harness end)
#C4
C10
C1
C23
MC
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal #A2
of harness end of connector in MC-A.
C31
Connector MC-A
(Harness end)
#A2
T183-05-04-008
Connector MC-B
(Harness end)
#B8
#B18
T183-05-04-021
T5-5-74
TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Ground
Circuit
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal #A2
of harness end of connector in MC-A.
Connector
Connector MC-C
(Harness end)
#C15
C10
C1
C23
C31
Connector MC-A
(Harness end)
#A2
#A13
T183-05-04-008
Connector MC-B
(Harness end)
#B8
#B18
T183-05-04-021
T5-5-75
TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminals #18 and
#1 of harness end of connector.
ECM
Connector
(Harness end)
#18
#43
#4
#3
#1
T1GR-05-04-002
#81
ECM
Connector
(Harness end)
#37
#43
#4
T5-5-76
#3
#62
#81
#1
T1GR-05-04-002
TROUBLESHOOTING / Troubleshooting A
ICF
Between CAN Circuit (High Side) and Ground
Circuit
ICF
Connector ICF-C
(Harness end)
#C5
#C14
#C15
T5-5-77
T1V1-05-04-002
ICF
Connector ICF-C
(Harness end)
#C9
#C9
#C14
#C15
#C11
T1V1-05-04-002
TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminal #33 of
harness end of connector monitor-2B and terminal
#19 of harness end of connector monitor-2A in the
monitor unit.
Check for continuity between terminal #33 of
harness end of connector monitor-2B and terminal
#4 of harness end of connector monitor-1A in the
monitor unit.
Monitor Unit
Connector Monitor-2B
(Harness end)
T4GB-05-05-002
#33
Monitor Unit
Connector Monitor-2A
(Harness end)
T183-05-04-013
#19
Monitor Unit
Connector Monitor-1A
(Harness end)
#4
T183-05-04-013
Monitor Unit
Connector Monitor-2B
(Harness end)
T4GB-05-05-002
#34
Monitor Unit
Connector Monitor-2A
(Harness end)
T183-05-04-013
#19
Monitor Unit
Connector Monitor-1A
(Harness end)
#4
T183-05-04-013
T5-5-78
TROUBLESHOOTING / Troubleshooting A
TCU
#1
#2
#25
T4GB-05-05-001
#1
#2
#26
T4GB-05-05-001
T5-5-79
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Power Circuit
Connector
Connector MC-C
(Harness end)
#C4
C1
C23
C10
C31
MC
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal #A1
of harness end connector MC-A.
#A1
#A12
Connector MC-A
(Harness end)
T183-05-04-008
Connector MC-B
(Harness end)
#B7
T5-5-80
TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Power
Circuit
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal #A2
of harness end connector MC-A.
Connector
Connector MC-C
(Harness end)
C1
C23
#C15
C10
C31
Connector MC-A
(Harness end)
#A1
#A12
T183-05-04-008
Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-5-81
TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminals #18 and
#2 of harness end of connector.
ECM
Connector
(Harness end)
#18
#5
T1GR-05-04-002
#2
ECM
Connector
(Harness end)
#37
#5
ICF
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminals #C5 and
#C1 of harness end of connector ICF-C.
ICF
Connector ICF-C
(Harness end)
#C1
#C2
T1GR-05-04-002
#C5
T1V1-05-04-002
ICF
Connector ICF-C
(Harness end)
#C2
#C1
#C11
T5-5-82
T1V1-05-04-002
TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and
Circuit
Check for continuity between terminal
harness end of connector monitor2B
monitor unit and terminal #1 of harness
connector monitor1A in the monitor unit.
Power
#33 of
in the
end of
Monitor Unit
Connector Monitor-2B
(Harness end)
#33
T4GB-05-05-002
Monitor Unit
Connector Monitor-1A
(Harness end)
#1
T183-05-04-013
Monitor Unit
Connector Monitor-2B
(Harness end)
#34
T4GB-05-05-002
Monitor Unit
Connector Monitor-1A
(Harness end)
#1
T183-05-04-013
T5-5-83
TROUBLESHOOTING / Troubleshooting A
TCU
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminals #25 and
#23 of harness end of connector in TCU.
#25
#23
#68
T4GB-05-05-001
#26
#23
#68
T4GB-05-05-001
T5-5-84
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Key Signal Circuit
Connector
Connector MC-C
(Harness end)
#C4
C10
C1
C23
MC
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal
#B16 of harness end of connector MC-B.
C31
Connector MC-B
(Harness end)
#B16
T183-05-04-021
Connector
Connector MC-C
(Harness end)
#C15
C1
C23
C10
C31
Connector MC-B
(Harness end)
#B16
T183-05-04-021
T5-5-85
TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminals #18 and
#24 of harness end of connector.
ECM
Connector
(Harness end)
#18
#24
T1GR-05-04-002
ECM
Connector
(Harness end)
#37
#24
T1GR-05-04-002
ICF
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminals #C5 and
#C7 of harness end of connector ICF-C.
ICF
Connector ICF-C
(Harness end)
#C5
#C7
T1V1-05-04-002
ICF
Connector ICF-C
(Harness end)
#C7
#C11
T5-5-86
T1V1-05-04-002
TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminal #33 of
harness end of connector monitor2B in the
monitor unit and terminal #2 of harness end of
connector monitor1A in the monitor unit.
Monitor Unit
Connector Monitor-2B
(Harness end)
T4GB-05-05-002
#33
Monitor Unit
Connector Monitor-1A
(Harness end)
#2
T183-05-04-013
Monitor Unit
Connector Monitor-2B
(Harness end)
T4GB-05-05-002
#34
Monitor Unit
Connector Monitor-1A
(Harness end)
#2
T183-05-04-013
T5-5-87
TROUBLESHOOTING / Troubleshooting A
TCU
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminals #25 and
#45 of harness end of connector in TCU.
#25
T4GB-05-05-001
#45
#26
T4GB-05-05-001
#45
T5-5-88
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit
between CAN (high side) circuit and
CAN (low side) circuit is shorted.
In case of discontinuity, the circuit is
normal.
Connector MC-C
Check for continuity between terminals #C4 and
#C15 of harness end of connector MC-C in MC.
MC
Connector MC-C
(Harness end)
#C4
C1
C23
#C15
C10
C31
Connector ECM
Check for continuity between terminals #18 and
#37 of harness end of connector in ECM.
ECM
Connector
(Harness end)
#18
#37
T1GR-05-04-002
T5-5-89
TROUBLESHOOTING / Troubleshooting A
Connector ICF-C
Check for continuity between terminals #C5 and
#C11 of harness end of connector ICF-C in ICF.
ICF
Connector ICF-C
(Harness end)
#C5
T1V1-05-04-002
#C11
Monitor Unit
Connector Monitor-2B
(Harness end)
T4GB-05-05-002
#B34 #B33
Connector TCU
Check for continuity between terminals #25 and
#26 of harness end of connector TCU.
#25
#26
T4GB-05-05-001
T5-5-90
TROUBLESHOOTING / Troubleshooting A
ENGINE FAILURE
MC FAULT CODE 11103
Fault Code
Trouble
Cause
11103-3 Abnormal Accelerator Pedal Voltage: 4.75 V or higher
High Voltage
11103-4
Influenced Control
Pump
Torque
Decrease
Control
Engine Accelerator Pedal
Control
Pump
Torque
Decrease
Control
Engine Accelerator Pedal
Control
Open circuit in
harness between MC
and accelerator pedal
sensor (terminal #1).
NO
Disconnect connector
MC-C in MC.
Check for continuity
between terminal #C13
YES of harness end of
connector and terminal
#1 of harness end of
connector in
accelerator pedal
sensor.
Check if voltage
between terminal #2 of
harness end of
connector in
NO accelerator pedal
sensor and vehicle
frame is specigication.
Key switch: ON
With connector of
accelerator pedal sensor
connected, insert a tester YES Faulty MC.
probe into rear of
connector of terminal #1.
Operate accelerator
YES pedal.
Faulty accelerator
Check if voltage reaches
pedal sensor.
specification.
NO
Key switch: ON
Open circuit in
YES
Specification: Refer to
harness between MC
the table below.
and accelerator pedal
sensor (terminal #6).
Key switch: ON
Specification: 50.5 V
C1
C23
C31
Accelerator Pedal Sensor Connector
#2
#1
5
#6
T5-5-91
NO
Open circuit in
harness between MC
and accelerator pedal
sensor (terminal #2).
TROUBLESHOOTING / Troubleshooting A
PUMP FAILURE
MC FAULT CODE 11204
Fault Code
11204-3
11204-4
Trouble
Abnormal
Pump
Delivery
Pressure Sensor High Voltage
Abnormal
Pump
Delivery
Pressure Sensor Low Voltage
Cause
Influenced Control
Output voltage: 4.75 V or Pump
Torque
Decrease
higher
Control: Disabled
Output voltage: Less than 0.25 Pump
Torque
Decrease
V
Control: Disabled
Disconnect connector
MC-C in MC. Check for
continuity between
terminal #C2 of
YES harness end of
connector and terminal
#2 of harness end of
connector in pump
delivery pressure
sensor.
Disconnect connector
of pump delivery
pressure sensor.
Check if voltage
NO
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Check if voltage
between terminal #1 of
harness end of
connector in pump
delivery pressure
sensor and vehicle
frame is specification.
Key switch: ON
Specification: 50.5 V.
NO
#C2
C1
C10
3
C23
YES
YES Open circuit in harness
between MC and pump
delivery pressure sensor
(terminal #3).
NO
YES
MC
Connector MC-C
NO
C31
T5-5-92
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11209
Fault Code
11209-3
11209-4
Trouble
Cause
Influenced Control
Abnormal Implement Pressure Output voltage: 4.75 V or Pump
Torque
Decrease
Sensor High Voltage
higher
Control: Disabled
Abnormal Implement Pressure Output voltage: Less than 0.25 Pump
Torque
Decrease
Sensor Low Voltage
V
Control: Disabled
Disconnect connector
MC-C in MC.
Check for continuity
YES between terminal #C12
of harness end of
connector and terminal
#2 of harness end of
connector in implement
pressure sensor.
Disconnect connector
of implement pressure
sensor.
Check if voltage
NO
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Switch implement
pressure sensor with
normal pressure sensor
and retry.
Check if fault code
disappears.
Key switch: ON
NO
Check if voltage
between terminal #1 of
harness end of
connector in implement
pressure sensor and
vehicle frame is
specification.
Key switch: ON
Specification: 50.5 V
#C12
C1
C10
3
C23
YES
YES Open circuit in harness
between MC and
implement pressure
sensor (terminal #3).
NO
YES
MC
Connector MC-C
NO
C31
T5-5-93
TROUBLESHOOTING / Troubleshooting A
PILOT FAILURE
MC FAULT CODE 11313
Fault Code
11313-3
11313-4
Trouble
Abnormal
Parking
Brake
Pressure Sensor High Voltage
Abnormal
Parking
Brake
Pressure Sensor Low Voltage
Cause
Influenced Control
Output voltage: 4.75 V or Parking Brake Indicator Control
higher
Output voltage: Less than 0.25 Parking Brake Indicator Control
V
Disconnect connector
MC-C in MC.
Check for continuity
YES between terminal #C23
of harness end of
connector and terminal
#2 of harness end of
connector in pressure
sensor.
Disconnect connector
of pressure sensor.
Check if voltage
between terminals #1
NO and #3 of harness end
of connector is 50.5
V.
Key switch: ON
Check if voltage
between terminal #1
of harness end of
NO connector in pressure
sensor and vehicle
frame is specification.
Key switch: ON
Specification: 50.5 V
NO
YES
YES
MC
Connector MC-C
C10
C1
C23
C31
#C23
T5-5-94
TROUBLESHOOTING / Troubleshooting A
PROPORTIONAL SOLENOID VALVE FAILURE
MC FAULT CODE 11412
Fault Code
11412-2
11412-3
11412-4
Trouble
Abnormal Feedback of Hydraulic
Drive Fan Flow Rate Control
Solenoid Valve
Abnormal
Feedback
High
Current of Hydraulic Drive Fan
Flow Rate Control Solenoid
Valve
Abnormal
Feedback
Low
Current of Hydraulic Drive Fan
Flow Rate Control Solenoid
Valve
YES
Cause
Influenced Control
The feedback current to MC Hydraulic Drive Fan Cooling
becomes the uncertain value. Control
The feedback current to MC is Hydraulic Drive Fan Cooling
beyond the upper limit.
Control
Switch connectors of
hydraulic drive fan flow
rate control solenoid
valve and normal
solenoid valve.
Retry.
Check if fault code
disappears.
NO
YES
#A32
#A29
T183-05-04-008
T5-5-95
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11413
Fault Code
11413-2
11413-3
11413-4
Trouble
Abnormal Feedback of Pump
Torque Control Solenoid Valve
Abnormal Feedback High
Current of Pump Torque
Control Solenoid Valve
Abnormal
Feedback
Low
Current of Pump Torque
Control Solenoid Valve
YES
Cause
Influenced Control
The feedback current to MC Pump Standard Torque Control
becomes the uncertain value.
The feedback current to MC is Pump Standard Torque Control
beyond the upper limit.
While the command from MC Pump Standard Torque Control
is output, the feedback current
to MC is 56 mA or less.
Switch connectors of
pump torque control
solenoid valve and normal
solenoid valve.
Retry.
Check if fault code
disappears.
Faulty MC.
YES
#A31
T183-05-04-008
NO
T5-5-96
TROUBLESHOOTING / Troubleshooting A
CAN DATA RECEPTION FAILURE
MC FAULT CODES 11910, 11920
Fault Code
11910-2
11920-2
Trouble
Actual Engine Speed Receive
Error
Received from ECM
Fuel Flow Rate Receive Error
Received from ECM
Cause
Faulty Harness
Faulty ECM
Influenced Control
Faulty Harness
Faulty ECM
Engine
Speed
Decrease
Control
GPS
Monitor Unit
Dr. ZX
ICF
TCU
ECM
CAN Harness
MC
T5-5-97
CAN Harness
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
MC FAULT CODES 11910, 11920
Check the wiring connections first.
Disconnect all
connectors of MC, ICF,
ECM, TCU and
monitor unit.
YES Check for continuity
between ground circuit
(MC, ICF, ECM, TCU,
monitor unit) and CAN
circuit.
NO
YES
Normal.
NO
YES
YES
A
Check for continuity
between key signal
circuit in MC, ICF,
NO ECM, TCU, monitor
unit and CAN circuit.
Key switch: OFF
Refer to
Discontinuity
Check between
CAN Circuit and
Key Signal Circuit
on T5-5-85 to 88.
YES
NO
T5-5-98
To B
To C
TROUBLESHOOTING / Troubleshooting A
Connect connector
in MC.
Check if fault code
11004-2 is
displayed.
Key switch: ON
Connect connector
in MC.
YES Check if fault code
11004-2 is
displayed.
NO
YES
NO
Faulty ECM.
YES
Key switch: ON
C
Connect connector in
ECM.
Disconnect
connector ICF-C in
ICF.
Check if resistance
NO between terminals
#C5 and #C11 of
harness end of
connector is within
6010 .
Key switch: OFF
Connect connector
in ICF.
YES Check if fault code
11004-2 is
displayed.
Key switch: ON
NO
YES
YES
NO
Connect connector in
ICF.
Disconnect
connector monitor-2B
in monitor unit.
Check if resistance
between terminals
#33 and #34 of
harness end of
connector is within
12010 .
Key switch: OFF
Connect connector
in monitor unit.
Check if fault code
11004-2 is
displayed.
Key switch: ON
NO
YES
To D
NO
Connector
ECM
Connector
(Harness end)
MC
Connector MC-C
(Harness end)
#C4
C1
C23
#18
#C15
#37
C10
C31
T1GR-05-04-002
T5-5-99
TROUBLESHOOTING / Troubleshooting A
Connect connector in
monitor unit.
Disconnect
connector in TCU.
Check if resistance
between terminals
#25 and #26 of
harness end of
connector is within
12010 .
Connect connector
YES in TCU.
Check if fault code
11004-2 is
displayed.
NO
Check the
connections of TCU
and connector.
Faulty TCU.
YES
Failure in any
controller in MC, ICF,
ECM, TCU or
monitor unit.
NO
Connector
ICF
Connector ICF-C
(Harness end)
#C5
#25
#26
#C11
T1V1-05-04-002
Monitor Unit
Connector Monitor-2B
(Harness end)
T4GB-05-05-002
#34 #33
T4GB-05-05-001
T5-5-100
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11914
Fault Code
11914-2
Trouble
Cause
Radiator
Coolant Faulty Harness
Temperature Receive Error Faulty Monitor Unit
Received from Monitor Unit
Influenced Control
GPS
Monitor Unit
Dr. ZX
ICF
TCU
ECM
CAN Harness
MC
T5-5-101
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
FAULT CODE 11914
Check the wiring connections first.
Disconnect all
connectors of MC, ICF,
ECM, TCU and
YES monitor unit. Check for
continuity between
ground circuit MC, ICF,
ECM, TCU, monitor
unit and CAN circuit.
Check for continuity in
YES CAN harness between
MC and monitor unit.
NO
NO
Normal.
NO
YES
YES
A
Check for continuity
between key signal
circuit in MC, ICF,
NO ECM, TCU, monitor
unit and CAN circuit.
Key switch: OFF
Refer to
Discontinuity
Check between
CAN Circuit and
Key Signal Circuit
on T5-5-85 to 88.
YES
NO
NO
YES
NO
To B
Connect connector in
MC.
Disconnect
connector monitor-2B
in the monitor unit.
Check if resistance
between terminals
#33 and #34 of
harness end of
connector is within
12010 .
Key switch: OFF
T5-5-102
To C
TROUBLESHOOTING / Troubleshooting A
NO
Connect connector
in MC. Check if fault
code 11004-2 is
displayed.
Faulty MC.
Key witch: ON
YES
Connect connector
in the monitor unit.
YES Check if fault code
11004-2 is
displayed.
NO
YES
Key witch: ON
C
Connect connector in
monitor unit.
Disconnect
connector ECM.
Check if resistance
between terminals
#18 and #37 of
NO harness end of
connector is within
12010 .
Connect connector
in ECM.
YES Check if fault code
11004-2 is
displayed.
Key witch: ON
Connect connector in
ECM.
Disconnect
connector ICF-C in
ICF.
Check if resistance
between terminals
#C5 and #C11 of
harness end of
connector is within
6010 .
NO
YES
YES
Connect connector
in ICF.
Check if fault code
11004-2 is
displayed.
Key witch: ON
To D
NO
Connector
MC
Connector MC-C
(Harness end)
#C4
C1
C23
Monitor Unit
Connector Monitor-2B
(Harness end)
#C15
C10
C31
T4GB-05-05-002
#34
T5-5-103
#33
TROUBLESHOOTING / Troubleshooting A
NO
Connect connector
YES in TCU. Check if
fault code 11004-2
is displayed.
Connect connector in
ICF.
Disconnect
connector in TCU.
Check if resistance
between terminals
#25 and #26 of
harness end of
connector is within
12010 .
Check the
connections of TCU
and connector.
Faulty TCU.
YES
Failure in any
controller in MC, ICF,
ECM, TCU or
monitor unit.
NO
Connector
ICF
Connector ICF-C
(Harness end)
#C5
#C11
T1V1-05-04-002
ECM
Connector
(Harness end)
#25
#26
#18
#37
T1GR-05-04-002
T4GB-05-05-001
T5-5-104
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODES 11912, 11913,11916, 11917
Fault Code
Trouble
11912-2 Torque Converter Rotation or
Transmission Rotation Receive
Error
11913-2 Forward/Reverse Switch Enable
Signal Receive Error
11916-2
11917-2
Cause
Faulty Harness
Faulty TCU
Influenced Control
Pump Torque Decrease Control
Faulty Harness
Faulty TCU
Selected
Speed
Position Faulty Harness
Receive Error
Faulty TCU
Actual Speed Position Receive Faulty Harness
Error
Faulty TCU
GPS
Monitor Unit
Dr. ZX
ICF
TCU
ECM
CAN Harness
MC
T5-5-105
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
FAULT CODES 11912, 11913, 11916, 11917
Check the wiring connections first.
Disconnect all
connectors of MC, ICF,
ECM, TCU and
YES monitor unit. Check for
continuity between
ground circuit MC, ICF,
ECM, TCU, monitor
unit and CAN circuit.
NO
To A
NO
Normal.
NO
Shorted circuit in CAN
harness between ground
circuit and CAN circuit.
YES
YES
A
Check for continuity
between key signal
circuit (MC, ICF,
NO ECM, TCU, monitor
unit) and CAN circuit.
Key switch: OFF
Refer to
Discontinuity Check
between CAN Circuit
and Key Signal
Circuit T5-5-85 to
88
YES
NO
NO
YES
NO
To B
Connect connector in
MC.
Disconnect
connector monitor-2B
in the monitor unit.
Check if resistance
between terminals
#33 and #34 of
harness end of
connector is within
12010 .
Key switch: OFF
T5-5-106
To C
TROUBLESHOOTING / Troubleshooting A
Connect connector
in MC.
Check if fault code
11004-2 is
displayed.
Key switch: ON
Connect connector
in monitor unit.
YES
Check if fault code
11004-2 is
displayed.
Check the
connections of MC
and connector.
NO
Faulty MC.
YES
Check the
connections of
monitor unit and
NO
YES
Key switch: ON
C
NO
Connect connector in
monitor unit.
Disconnect
connector ECM.
Check if resistance
between terminals
#18 and #37 of
harness end of
connector is within
12010 .
Connect connector
in ECM.
YES Check if fault code
11004-2 is
displayed.
Key switch: ON
Connect connector in
ECM.
Disconnect
connector ICF-C in
ICF.
Check if resistance
between terminals
#C5 and #C11 of
harness end of
connector is within
6010 .
Check the
connections of ICF
and connector.
NO
Faulty ICF.
YES
YES
Connect connector
in ICF.
Check if fault code
11004-2 is
displayed
NO
Check the
connections of ICF
Faulty ICF.
YES
Key switch: ON
NO
To D
Connector
Monitor Unit
Connector Monitor-2B
(Harness end)
ICF
Connector ICF-C
(Harness end)
#C4
C1
C23
#C15
C10
C31
T4GB-05-05-002
#34 #33
T5-5-107
TROUBLESHOOTING / Troubleshooting A
NO
Connect connector in
ICF.
Disconnect
connector in TCU.
Check if resistance
between terminals
#25 and #26 of
harness end of
connector is within
12010 .
Connect connector
YES in TCU. Check if
fault code 11004-2
is displayed.
Check the
connections of TCU
and connector.
Faulty TCU.
YES
Failure in any
controller in MC, ICF,
ECM, TCU or
monitor unit.
NO
Connector
ICF
Connector ICF-C
(Harness end)
#C5
#C11
T1V1-05-04-002
ECM
Connector
(Harness end)
#25
#18
#26
#37
T1GR-05-04-002
T4GB-05-05-001
T5-5-108
TROUBLESHOOTING / Troubleshooting A
OTHER FAILURES
MC FAULT CODE 11901
Fault Code
Trouble
Cause
11901-3 Hydraulic
Oil
Temperature Voltage: 4.52 V or higher
Sensor High Voltage
11901-4
Hydraulic
Oil
Temperature Voltage: Less than 0.23 V
Sensor Low Voltage
Disconnect connector of
hydraulic oil temperature
sensor.
Check if resistance at
sensor end connector is
specification.
Specification: Refer to
the table below.
Connect terminals #1
and #2 of harness end
of connector in
hydraulic oil
temperature sensor by
YES using a clip.
Disconnect connector
MC-D from MC.
Check for continuity
between terminals #D8
and #D6 of harness
end of connector
MC-D.
Influenced Control
Faulty MC.
YES
NO
NO
NO
#D6
T183-05-04-009
T5-5-109
TROUBLESHOOTING / Troubleshooting A
PROPORTIONAL
TROUBLE CHECK
SOLENOID
VALVE
MC
Proportional
Solenoid Valve
C
T1V1-05-06-008
Trouble
Fault Code
Damaged Parts in MC
None
T1V1-05-06-006
None
T1V1-05-06-007
FET
the ground.
T1V1-05-06-009
FET
T1V1-05-06-010
None
T1V1-05-06-011
None
T1V1-05-06-012
None
the ground.
T1V1-05-06-013
None
T1V1-05-06-014
T5-5-110
TROUBLESHOOTING / Troubleshooting A
MC
Proportional
Solenoid Valve
C
T1V1-05-06-008
Trouble
Fault Code
Damaged Parts in MC
Resistance
C
T1V1-05-06-015
Open circuit in A- B
Harness in side A is shorted to
the power source.
None
T1V1-05-06-016
Open circuit in A- B
Harness in side B is shorted to
None
T1V1-05-06-017
None
T1V1-05-06-018
Resistance
T1V1-05-06-019
None
T1V1-05-06-020
Resistance
T1V1-05-06-021
T5-5-111
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-5-112
TROUBLESHOOTING / Troubleshooting A
ECM, SENSOR SYSTEM
ECM FAULT CODES 100, 102, 105, 108, 110, 157, 172
P0522
Reference Page on
4HK1/6HK1 Engine
Manual Troubleshooting
1E-403
P0523
1E-409
P0237
1E-341
P0238
1E-348
1E-460
108-4
Abnormal
Atmospheric
(Abnormal High Voltage)
Pressure
Sensor P0108
1E-238
110-3
Abnormal
Coolant
Temperature
(Abnormal High Voltage)
Abnormal
Coolant
Temperature
(Abnormal Low Voltage)
Sensor P0118
1E-266
Sensor P0117
1E-259
Sensor P0193
1E-294
Sensor P0192
1E-288
Sensor P0113
1E-251
Sensor P0112
1E-245
Fault
Code
100-3
100-4
102-3
102-4
105-3
105-4
108-3
110-4
157-3
157-4
172-3
172-4
Trouble
T5-5-113
1E-452
1E-231
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 174, 636, 723, 10001
Fault
Code
174-3
174-4
636-2
636-2
636-7
723-2
723-2
10001-3
Trouble
T5-5-114
Reference Page on
4HK1/6HK1 Engine
Manual Troubleshooting
1E-280
1E-274
1E-368
1E-375
1E-524
1E-355
1E-362
1E-391
TROUBLESHOOTING / Troubleshooting A
ECM, EXTERNAL DEVICE SYSTEM
ECM FAULT CODES 651, 652, 653, 654, 655, 656, 1347, 10002
Fault Code
Trouble
651-3
652-3
653-3
654-3
655-3
656-3
1347-0
10002-2
P0201
Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-301
P0202
1E-308
P0203
1E-315
P0204
1E-322
P0205
1E-329
P0206
1E-334
P0090
1E-225
P0488
1E-397
T5-5-115
TROUBLESHOOTING / Troubleshooting A
ECM, FUEL SYSTEM
ECM FAULT CODES 157, 633, 1239, 1240
Fault Code
Trouble
157-0
157-0
157-2
633-7
1239-1
P0088
Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-215
P0088
1E-215
P0089
1E-220
P1095
P0087
P1093
1E-443
1E-207
1E-434
T5-5-116
TROUBLESHOOTING / Troubleshooting A
ECM, ENGINE PROTECTION
ECM FAULT CODES 110, 190
Fault Code
110-0
190-0
Trouble
Overheating
Overrunning
T5-5-117
Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-466
1E-339
TROUBLESHOOTING / Troubleshooting A
ECM, EXTERNAL CIRCUIT SYSTEM
ECM FAULT CODES 987, 1485
Fault Code
987-3
1485-2
Trouble
Abnormal Check Engine Lamp
Abnormal Main Relay System (None)
T5-5-118
Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-429
1E-529
TROUBLESHOOTING / Troubleshooting A
ECM, INTERNAL CIRCUIT SYSTEM
ECM FAULT CODES 628, 1077, 1079, 1080, 10003, 10004, 10005
Fault Code
Trouble
628-2
1077-2
1079-2
1080-2
10003-2
Abnormal ROM
Abnormal IC for CPU Watching
Abnormal 5 V Power Source 1 Voltage
Abnormal 5 V Power Source 2 Voltage
Abnormal Injection Nozzle Common 1
Drive System
Abnormal Injection Nozzle Common 2
Drive System
Abnormal Charge Circuit (Bank 1)
10004-2
10005-1
P0601
P0606
P1631
P1632
P1261
Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-417
1E-421
1E-538
1E-541
1E-476
P1262
1E-487
P0611
1E-423
T5-5-119
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 10006, 10007, 10008, 10009, 10010, 10011, 10013
Fault Code
Trouble
10006-1
10007-2
10008-2
10009-2
10010-2
10011-2
10013-2
P0612
P0606
P1630
P1633
P1634
P1635
P0603
T5-5-120
Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-426
1E-421
1E-536
1E-544
1E-547
1E-550
1E-419
TROUBLESHOOTING / Troubleshooting A
ECM, COMMUNICATION SYSTEM
ECM FAULT CODE 639
Fault Code
639-2
639-3
Trouble
Abnormal CAN Bus Line
Abnormal CAN Time Out
T5-5-121
Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-553
1E-558
TROUBLESHOOTING / Troubleshooting A
ROLE AND CONNECTION OF EACH TERMINAL IN TCU
68 Pin Connector
Signal
Terminal
Direction
Role
Connected to
No.
for TCU
1
Ground
Ground
2
Ground
Ground
3
Output
Wiring terminal #396 in torque converter input
Power source in torque converter input shaft sensor
shaft sensor, output shaft sensor, Wiring terminal #397 in output shaft sensor
transmission middle shaft sensor
Wiring terminal #398 in transmission middle shaft
sensor
4
Output
Travel speed sensor ground
Wiring terminal #403 in travel speed sensor
5
Input
Ground
circuit
formation
for
Terminal #34 of connector 1B in monitor controller
forward/reverse switch mode enable
(wiring terminal #94)
signal light
6
Input
Terminal #18 of connector 1A in monitor controller
Starter operating signal receive
(wiring terminal #452)
7
Input
Ground circuit formation for reverse relay
Wiring terminal #109 in reverse relay
exciting
9
Output
Slow forward clutch proportional solenoid Wiring terminal #392 in slow forward clutch
valve operating signal sending
proportional solenoid valve
10
Output
Reverse clutch proportional solenoid Wiring terminal #389 in reverse clutch proportional
valve operating signal sending
solenoid valve
12
Ground for each clutch solenoid valve
Wiring terminal #386 in each clutch solenoid valve
13
Ground for each clutch solenoid valve
Terminal #12 in TCU (wiring terminal #386)
(backup)
15
Output/ ZF self diagnosing tool connection
ZF self diagnosing tool
Input
terminal
17
Input
Feedback current receive in transmission Wiring terminal #735 in transmission filter
filter restriction switch
restriction switch
18
Output/ ZF self diagnosing tool connection
ZF self diagnosing tool
Input
terminal
19
Input
Feedback current receive in torque Wiring terminal #399 in torque converter input shaft
converter input shaft sensor
sensor
20
Input
Forward/reverse relay neutral signal
Wiring terminal #358 in forward/reverse relay
receive
NOTE: The terminal without No. is not used.
T5-5-122
TROUBLESHOOTING / Troubleshooting A
Signal
Terminal
Direction
No.
for TCU
21
Input
22
Input
23
Input
24
25
28
Output
Output/
Input
Output/
Input
Output/
Input
-
29
30
Input
Input
31
Input
32
Output
37
38
Input
39
Input
41
Input
42
Input
43
Input
44
Input
45
46
Input
Output
49
Input
26
27
Role
Connected to
CAN
CAN
CAN
T5-5-123
TROUBLESHOOTING / Troubleshooting A
Signal
Terminal
Direction
Role
Connected to
No.
for TCU
51
Output
Second stage clutch proportional solenoid Wiring terminal #393 in second stage clutch
valve operating signal sending
proportional solenoid valve
52
Output
Terminal #15 of connector 1A in monitor controller
Transmission failure signal sending
(wiring terminal #458)
55
Output
Third stage clutch proportional solenoid Wiring terminal #391 in third stage clutch
valve operating signal sending
proportional solenoid valve
56
Output
Fast forward clutch proportional solenoid Wiring terminal #388 in fast forward clutch
valve operating signal sending
proportional solenoid valve
62
Input
Feedback signal receive in travel speed
Wiring terminal #404 in travel speed sensor
sensor
63
Input
Shift switch signal A
Wiring terminal #89 in shift switch
64
Input
Forward/reverse lever reverse signal
Wiring terminal #84 in forward/reverse lever
receive
65
Input
Shift switch signal B
Wiring terminal #90 in shift switch
66
Input
Hold switch signal receive
Wiring terminal #104 in hold switch
67
Input
Forward/reverse lever neutral signal
Wiring terminal #82 in forward/reverse lever
receive
68
Input
TCU power source input
Terminal #14 in fuse box B (wiring terminal #3)
NOTE: The terminal without No. is not used.
1
46
49
51
52
55
56
24
25
26
27
28
29
30
31
32
2
3
4
5
6
7
9
10
12
13
37
38 15
62 39 17
63
18
64 41 19
65 42 20
66 43 21
67 44 22
68 45
23
T4GB-05-05-001
T5-5-124
TROUBLESHOOTING / Troubleshooting A
ICF, SATELLITE TERMINAL FAULT CODES 14000 to 14003
Fault Code
Trouble
14000-2 Abnormal CAN Communication
14001-2
14002-2
14003-2
Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, check the following
item.
Check the CAN communication line (harness).
Execute retry B in self-diagnosing and execute the following
item.
Execute Information C/U: Initialize.
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, check the following
item.
Execute Control Data: Initialize.
Execute Enter Model and Serial No..
Then, execute self-diagnosing and execute retry B.
T5-5-125
TROUBLESHOOTING / Troubleshooting A
Information C/U: Initialize
Push
and select the selection
screen of ICF controller.
Push ICF Controller.
Push OK.
Select failure-diagnosis
controller
Select Function
+
Self-Diagnostic Result
Select Controller
ICF
Controller Ver.: XXYY
Satellite Terminal
Controller Ver.: XXYY
ICF Controller
To the
lower
Is it correct?
ESC
ESC
OK
ESC
Push Start.
Push Information
Setup.
C/U:
Various
Select Item
Password
+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd
Select Item
Data Download
Op. Manual
Start
Back
ESC
Title Screen
Init
ESC
ESC
Init
ESC
OK
ESC
T5-5-126
To the
lower
TROUBLESHOOTING / Troubleshooting A
Control Data: Initialize
Push
and select the selection
screen of ICF controller.
Push ICF Controller.
Push OK.
Select failure-diagnosis
controller
Select Function
+
Self-Diagnostic Result
Select Controller
ICF
Controller Ver.: XXYY
Satellite Terminal
Controller Ver.: XXYY
ICF Controller
To the
lower
Is it correct?
ESC
ESC
OK
ESC
Push Start.
Push Information
Setup.
C/U:
Various
Select Item
Password
+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd
Select Item
Data Download
Op. Manual
Start
Back
ESC
Title Screen
ESC
Information C/U: Various Setup
Screen
ESC
Init
ESC
OK
ESC
T5-5-127
To the
lower
TROUBLESHOOTING / Troubleshooting A
Enter Model and Serial No.
Push
and select the selection
screen of ICF controller.
Push ICF Controller.
Push OK.
Select failure-diagnosis
controller
Select Function
+
Self-Diagnostic Result
Select Controller
ICF
Controller Ver.: XXYY
Satellite Terminal
Controller Ver.: XXYY
ICF Controller
To the
lower
Is it correct?
ESC
ESC
OK
ESC
Push Start.
Push Information
Setup.
C/U:
Various
Select Item
Password
+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd
+
+
Select Item
Op. Manual
Start
Back
ESC
Main Menu Screen
Title Screen
04GB
Select Item
Model |
Exec
Exec
Model
ESC
ESC
ESC
Ex. Mach.No.(HCM4GB00P00
0001) Model(04GB)
Serial No.
Ex. Mach.No.(HCM4GB00P00
0001) Serial No.(000001)
OK
ESC
ESC
OK
ESC
Information C/U: Various Setup
Screen
T5-5-128
To the
lower
TROUBLESHOOTING / Troubleshooting A
ICF, SATELLITE TERMINAL FAULT CODES 14006, 14008, 14100 to 14106
Fault Code
Trouble
Remedy
14006-2 ICF:
Satellite
Communication Execute retry B in self-diagnosing.
Terminal Communication Error
If this error code is displayed after re-try, check the following
item.
Check the communication line.
Check the power source line of satellite terminal.
Check the fuse.
14008-2
14100-2
T5-5-129
TROUBLESHOOTING / Troubleshooting A
Fault Codes 14102-2, 14103-2
GPS Aerial
Communication
Aerial
T4GB-05-07-002
Satellite Terminal
Communication
Aerial
GPS Aerial
T1V1-05-06-004
T5-5-130
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODES 13306, 13308
Fault Code
Trouble
13306-2
Abnormal EPROM
13308-2
Remedy
If this error code is displayed after re-try, replace the monitor
unit.
Refer to Check CAN Harness (T5-5-70).
T5-5-131
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13312
Fault Code
13312-2
Trouble
Remedy
Abnormal
Transmission
Temperature Sensor
YES
NO
NO
YES
#A5
T183-05-04-013
T5-5-132
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13314
Fault Code
Trouble
13314-3
13314-4
Remedy
Execute re-try.
Check the service brake pressure sensor and harness.
Execute re-try.
Check the service brake pressure sensor and harness.
Disconnect connector
of pressure sensor.
Check if voltage
NO between termnals #1
and #3 of harness end
connector is 50.5 V.
Key switch: ON
Check if haness
between terminal #6 of
hanress end of
YES connector 2-A in
monitor unit and
terminal #2 in pressure
sensor is open or
shorted.
Check if voltage
between termnal #1
of harness end
connector in pressure
NO
sensor and vehicle
frame is 50.5 V.
Replace pressure
sensors and retry.
Check if fault code
disappears.
Key switch: ON
YES
Faulty harness
between monitor unit
and pressure sensor.
Open circuit in
YES harness between MC
and pressure sensor
(terminal #3).
Open circuit in
harness between MC
NO and pressure sensor
(terminal #1).
Faulty service brake
pressure sensor.
YES
T183-05-04-013
T5-5-133
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-5-134
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the service mode (built-in diagnosing
system) in monitor and Dr.ZX although the machine
operation is abnormal.
On the front section pages of this group 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.
(2)
(1)
NO(NOT OK)
(3)
Special instructions or reference item are indicated in the spaces under the box.
Key switch: ON
Use the service mode in monitor and the diagnosing system/controller diagnosing
Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
system in Dr.ZX.
T5-6-1
TROUBLESHOOTING / 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.
Symptoms in control
system when trouble occurs.
Function
Parts
Forward/Reverse Lever
Shift Switch
Symptoms in machine
operation when trouble
occurs.
Travel
Switch
Mode
Work Mode
Switch
Selector
Selector
Down-Shift Switch
Down-Shift/Up-Shift
Switch
Hold Switch
TCU makes
down-shift/up-shift switch
control disabled.
Although the
down-shift/up-shift switch is
pushed, down-shift/up-shift is
not operated.
Although the down-shift
switch is pushed, down-shift
is not operated.
T5-6-2
TROUBLESHOOTING / Troubleshooting B
Evaluation by Monitor
Function
NOTE
T2-1, T2-4
TCU: 5000
T2-1, T2-4
TCU
Monitor
Item:
Selected
speed
gear,
Actual speed gear, Speed
gear
T2-1
T2-1
T2-1
T2-1
T2-1
MC
Monitor
Item:
Auto/manual
selection,
auto speed gear shifting
mode
MC Monitor Item: Engine
torque
control,
Pump
torque control
Descriptions of Control
(Operational Principle
Section in T/M)
T5-6-3
TROUBLESHOOTING / Troubleshooting B
Parts
Symptoms in control
system when trouble occurs.
Function
Forward/Reverse Switch
Forward/Reverse Selec-
tor Switch
Symptoms in machine
operation when trouble
occurs.
Emergency
Check Switch
Steering
T5-6-4
TROUBLESHOOTING / Troubleshooting B
Evaluation by Fault
Code
TCU: 5040
Evaluation by Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
TCU
Monitor
Item:
Optional
FNR
switch,
Selected
speed
gear,
Actual
speed
gear,
Optional FNR mode
T2-1
TCU
Monitor
Item:
Optional
FNR
selector
switch,
Optional
FNR
mode
T2-1
T2-1, T2-3
T2-1T2-3
Ride
T2-1T2-4
T2-1
MC Monitor Item:
control switch
-
T5-6-5
TROUBLESHOOTING / Troubleshooting B
Parts
Accelerator Pedal Sensor
Coolant
Sensor
Temperature
Symptoms in control
system when trouble occurs.
Function
Restriction
Symptoms in machine
operation when trouble
occurs.
T5-6-6
TROUBLESHOOTING / Troubleshooting B
Evaluation by Fault
Code
Evaluation by Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
MC: 11103
T2-1
ECM: 110
T2-1
MC: 11901
T2-1, T2-3
T2-1
-
T2-1
-
T2-1
T5-6-7
TROUBLESHOOTING / Troubleshooting B
Parts
Symptoms in control
system when trouble occurs.
Function
Symptoms in machine
operation when trouble
occurs.
air
Torque
converter
outlet
speed cannot be detected.
Control
Is
installed
to
the
transmission.
Decreases oil presssure from
the drive unit pump and
supplies clutch connection
pressure.
The spool moves according
to
the
transmission
proportional solenoid valve
and
clutch
connection
pressure is supplied to the
certain clutch pack.
Transmission
Propor-
tional Solenoid Valve
Is
installed
to
the
transmission control valve.
Consists of 6 solenoid valves
for slow forward, fast forward,
reverse, first gear, second
gear and third gear. Is
operated by the command
signal from TCU and shifts
the spool in transmission
control valve.
Tem-
Is
installed
to
the
transmission control valve.
Sends the signal on oil
temperature to TCU.
Transmission
Valve
Transmission Oil
perature Sensor
on
T5-6-8
TROUBLESHOOTING / Troubleshooting B
Evaluation by Fault
Code
Evaluation by Monitor
Function
MC Monitor Item: Outside
air temperature
NOTE
TCU: 5140
T2-1, T3-9
TCU: 5150
Descriptions of Control
(Operational Principle
Section in T/M)
T2-1, T3-9
-
T3-9
T2-1, T3-9
T3-9
-
T5-6-9
TROUBLESHOOTING / Troubleshooting B
Parts
Symptoms in control
system when trouble occurs.
Function
Symptoms in machine
operation when trouble
occurs.
Middle
Sends
the
signal
on
trasmission middle shaft
speed to TCU.
Sends
the
signal
on
trasmission
output
shaft
speed to TCU.
Travel speed
second gear.
Oil
MC makes clutch
control disabled.
cut-off
Although S, N or D in the
clutch cut-off mode switch is
selected, clutch cut-off is not
operated when the brake
pedal is depressed.
(Main
The
steering
or
front
attahment is operated slowy
according to malfunction.
Main
Pump
Delivery
Pressure Sensor
Although
engine
torque
control cannot be operated
properly, clear malfunction
may not occur except bad
fuel consumption.
As torque decrease control
cannot be operated, the
engine has a load during
combined operation of travel
and front attachment.
Transmission
Shaft Sensor
Torque Converter
Cooler Check Valve
Axle Oil
Sensor
Temperature
Priority
Pump)
Valve
T5-6-10
is fixed to
TROUBLESHOOTING / Troubleshooting B
Evaluation by Fault
Code
Evaluation by Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T2-1, T3-9
T2-1, T3-9
T3-12
TCU: 5313
T2-1
-
T2-3, T3-1
-
MC: 11204
T2-3, T3-1
T5-6-11
TROUBLESHOOTING / Troubleshooting B
Parts
Implement
Sensor
Symptoms in control
system when trouble occurs.
Function
Pressure
Symptoms in machine
operation when trouble
occurs.
Steering Valve
Steering Accumulator
Absorbs pulsation
steering circuit.
the
Stop Valve
in
T5-6-12
Although
engine
torque
control cannot be operated
properly, clear malfunction
may not occur except bad
fuel consumption.
As torque decrease control
cannot be operated, the
engine has a load during
combined operation of travel
and front attachment.
When travel load is heavy
and the front attachment is
operated, the engine may be
stalled.
If
pressure
difference
becomes small, there is no
efficiency to the machine
operation. In the long and
medium
terms,
fuel
consumption may become
bad.
If
pressure
difference
becomes large, the front
attachment and steering are
operated slowly.
Speed ratio during combined
operation of front attachment
changes.
TROUBLESHOOTING / Troubleshooting B
Evaluation by Fault
Code
MC: 11209
Evaluation by Monitor
Function
MC
Monitor
Implement pressure
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
Item:
T2-3, T3-2
T2-3, T3-2
-
T2-3, T3-2
-
T2-3, T3-2
-
T2-3, T3-5
T2-3
T2-3
T5-6-13
TROUBLESHOOTING / Troubleshooting B
Parts
Symptoms in control
system when trouble occurs.
Function
Symptoms in machine
operation when trouble
occurs.
Pressure
cannot
be
accumulated
in
the
accumulator.
The solenoid valve and main
spool cannot be controlled.
The
normal
signal
on
pressure occurrence is not
sent to the monitor unit.
Emergency
Steering
Pressure Switch
Emergency
Steering
Pump Delivery Pressure
Switch
T5-6-14
TROUBLESHOOTING / Troubleshooting B
Evaluation by Fault
Code
Evaluation by Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T2-3, T3-4
T2-3, T2-4
MC: 11412
T5-6-15
TROUBLESHOOTING / Troubleshooting B
Parts
Symptoms in control
system when trouble occurs.
Function
Charging Block
Service
Valve
Brake
Relief
Symptoms in machine
operation when trouble
occurs.
Parking
brake
circuit
pressure cannot be detected.
MC makes the parking brake
indicator go off forcibly.
MC makes forward/reverse
operation disabled when the
parking brake is applied.
Electromagnet in Pilot
Valve
Brake Valve
Supplies
pilot
pressure
according to brake pedal
depression from the outlet
port and operates the service
brake.
Pilot pressure
controlled.
T5-6-16
cannot
be
TROUBLESHOOTING / Troubleshooting B
Evaluation by Fault
Code
Evaluation by Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T2-3, T3-7
T2-3, T3-7
-
T2-3, T3-7
T2-3, T3-7
MC: 11413
MC: 11313
T2-1, T3-6
-
T5-6-17
TROUBLESHOOTING / 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.
E-1
Starter does not rotate.
E-2
Even if starter rotates, engine
does not start.
E-3
Engine is difficult to start at
low temperature.
Parts
Battery Relay
Glow Relay
Safety Relay
Neutral Relay
Main Relay for ECM
MC
ECM
Key Switch
Forward/Reverse Lever
Forward/Reverse Switch
Fan Reverse Switch
Accelerator Pedal Sensor
Main Pump Regulator
Fuel Pump
Pump Delivery Pressure Sensor
Implement Pressure Sensor
z
z
z
z
z
z
z
z
z
Check fuse and battery.
z
Check intake and fuel system.
(filter, piping)
T5-6-18
z
Check fuse and battery.
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
E-4
Even if accelerator pedal is depressed, engine speed remains
unchanged.
z
z
E-5
Even if key switch is turned
OFF, engine does not stop.
E-6
Engine stalls during operation
under adverse condition such as
at high altitude.
z
z
{
z
z
z
z
z
z
z
z
Check wiring
pedal sensor.
{
z
of
accelerator
T5-6-19
TROUBLESHOOTING / Troubleshooting B
F-2
All front attachment operations are slow/ weak.
MC
ECM
TCU
Shift Switch
Work Mode Selector Switch
Accelerator Pedal Sensor
Lift Arm Proximity Switch
Torque Converter Input Speed Sensor
F-3
Certain front attachment is
slow/ weak.
z
{
z
{
z
z
z
z
{
{
{
z
{
z
Cylinder
Steering Valve
Charging Block
z
{
Pilot Valve
Engine Unit
Remarks
T5-6-20
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
F-4
Front attachment moves
with lever in neutral.
F-5
Front attachment drifts
remarkably.
F-6
Bucket is slow during
combined operation.
F-7
Work mode is not effective.
F-8
Lift arm height kickout is
not operated.
z
z
{
z
z
z
z
z
z
z
z
z
z
z
z
z
{
z
z
z
T5-6-21
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
Trouble Symptom
F-9
Lift arm float is
not operated.
F-10
Bucket auto leveler
is not operated.
F-12
Lift arm auto lever
stop position cannot be set. (optional)
F-13
Ride Control is not
effective.
Parts
MC
TCU
z
{
Cylinder
Ride Control Valve
Charging Block
Priority Valve (Charging Block)
Service Brake Relief Valve
Pilot Relief Valve
Electromagnet in Pilot Valve
{
z
{
{
{
{
z
z
When the lift arm angle
sensor does not learn
and the stop position is
not set, lift arm auto
leveler is not operated.
Remarks
T5-6-22
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-23
TROUBLESHOOTING / Troubleshooting B
T-1
Machine does
travel
ward/reverse.
not
for-
T-2
Machine does not
travel forward or reverse.
T-3
Machine moves with
lever in neutral.
T-4
Even if travel speed is
turned up or down,
travel speed gear is
not changed.
Parts
MC (Main Controller)
TCU
Monitor Unit
Forward/Reverse Lever
Shift Switch
Travel Mode Selector Switch
Down-Shift Switch
Down-Shift/Up-Shift Switch
Hold Switch
Forward/Reverse Switch
Forward/Reverse Selector Switch
Drive Unit Charging Pump
Torque Converter
Transmission Control Valve
Transmission
Valve
Proportional
z
z
{
z
z
z
z
z
z
Solenoid
Transmission
Travel Speed Sensor
Axle
Service Brake
Service Brake Pressure Sensor
Propeller Shaft
Parking Brake Pressure Sensor
Brake Valve
Engine Unit
Engine Electrical Equipment
z
z
{
{
z
{
z
z
{
{
Remarks
T5-6-24
z
z
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
T-5
T-6
T-7
Even if up-shift switch is Even if down-shift switch Even if hold switch is
pushed, travel speed gear is pushed, travel speed pushed, travel speed gear
is not turned up.
gear is not turned down.
is not fixed.
{
z
z
z
{
z
T5-6-25
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
Trouble
Symptom
T-9
T-8
Travel mode is not Clutch cut-off is not
shifted.
operated.
Parts
MC (Main Controller)
TCU
Monitor Unit
Travel Mode Selector Switch
Clutch Cut-off Position Switch
Torque Converter Input Speed Sensor
Torque Converter Output Speed Sensor
Travel Speed Sensor
Service Brake Pressure Sensor
z
{
z
z
z
{
z
z
{
{
{
z
Remarks
T5-6-26
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-27
TROUBLESHOOTING / Troubleshooting B
B-1
B-2
B-3
Parking brake is
not locked.
Parts
Parking Brake Relay 1
Parking Brake Relay 2
Monitor Unit
Parking Brake Relay Switch
Parking Brake
Service Brake
Pilot Pump
Charging Block
Priority Valve (Charging Block)
Service Brake Relief Valve
Pilot Relief Valve
Parking Brake Solenoid Valve
Brake Valve
Engine Electrical Equipment
z
z
z
z
z
z
z
z
z
{
{
{
{
{
z
z
z
z
Remarks
T5-6-28
NOTE: 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.
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-29
TROUBLESHOOTING / Troubleshooting B
H-1
O-1
{
{
z
z
{
z
z
z
z
z
{
{
{
z
Check if the steering
shaft is normal.
Remarks
T5-6-30
NOTE: 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.
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-31
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
IMPORTANT: As electric current from the key
YES
Switch neutral relay
YES with other general relay.
Check if starter rotates.
Key switch: START
Key switch: ON
NO
Voltage: 24 V or more
Density: 1.26 or more
NO
NO
Battery Relay:
Key Switch:
Terminal A
#6
#1
#5
T178-05-04-001
T105-07-04-002
T5-6-32
TROUBLESHOOTING / Troubleshooting B
Disconnect connector
of safety relay.
Connect terminal S of
harness end of connector to vehicle
YES frame.
Check for continuity
between terminal #4 of
harness end of connector in neutral relay
and vehicle frame.
Key switch: ON
NO
NO
Safety Relay
E
#1
#3
NO
#4
T183-05-04-003
#S
T5-6-33
TROUBLESHOOTING / Troubleshooting B
E-2 Even if starter rotates, engine does not start.
Related MC Fault Code: None
YES
Connect terminal #5 of
harness end of connector in main relay to vehicle frame.
YES Disconnect connector in
ECM.
Check for continuity
between terminals #2,
#5 of harness end of
connector and vehicle
frame.
Connect terminal #1 of
harness end of connector in main relay to
YES vehicle frame.
Check for continuity
between terminals #21,
#40 of harness end of
connector in ECM and
vehicle frame.
NO
ECM Connector
#21
#24
#5
#1
#2
#5
#3
T183-05-04-003
T1GR-05-04-002
#40
T5-6-34
#2
TROUBLESHOOTING / Troubleshooting B
Check if voltage
YES between terminal
#24 of harness
Check for contiend of connector
nuity between
in ECM and vehiterminal #2 of
cle frame is
YES
harness end of
specification.
connector in main
Key switch: ON
relay and vehicle
Specification: 24
frame.
V
Key
switch:
ON
end of connector
Specification: 24
and vehicle
V
frame is specification.
Key switch: ON NO
Specification: 24
V
NO
NO
NO
Connector MC-B
Connector ICF-C
#B16
B1
B8
B19
B25
#C7
T5-6-35
T1V1-05-04-002
TROUBLESHOOTING / Troubleshooting B
E-3
Engine is difficult to start at low temperature. (During cold weather or in cold districts, engine is difficult to start or does
not start even if pre-heated.)
YES
Disconnect connector of
coolant temperature sensor.
Check if voltage at glow plug
is 20 to 24 V.
Faulty ECM.
YES
Key switch: ON
NO
NO
Voltage Check
Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V
T105-07-04-006
Specification: Below 10
T105-07-04-007
T5-6-36
TROUBLESHOOTING / Troubleshooting B
10 or higher
NO
YES
Connect connector in
glow relay.
Connect terminal #4 of
harness end of connector
to vehicle frame.
Check if voltage at glow
plug is 20 to 24 V.
Key switch: ON
YES
Disconnect connector in
glow relay.
Check if voltages at terLess than 10 minals #1 and #3 of harness end of connector in
glow relay are 20 to 24 V.
Key switch: ON
If terminal #1 is 0 V, open
circuit in 100A fuse or
harness between glow
relay and battery. If terminal #3 is 0 V, open
circuit in fuse or harness
between glow relay and
terminal M in key switch.
NO
#10
#1
#4
#3
T1GR-05-04-002
T183-05-04-003
T5-6-37
TROUBLESHOOTING / Troubleshooting B
E-4 Even if accelerator pedal is depressed, engine speed remains unchanged.
Related MC Fault Code: 11004-2, 11101-3, 11101-4
YES
Check if fault code 11101-3 or
11101-4 is displayed.
Monitor accelerator pedal
(standard voltage) by using
Dr. ZX.
Check if voltage is normal.
Key switch: ON
Standard voltage
Slow idle position: 0.3 to 1 V
Fast idle position: 4.0 to 4.7 V
YES
NO
T5-6-38
TROUBLESHOOTING / Troubleshooting B
E-5 Even if key switch is turned OFF, engine
does not stop.
YES
Check if voltage at
terminal #5 in key
switch is 24 V.
NO
NO
Disconnect connector
in ECM.
Check if voltage between terminal #24 of
harness end of connector and vehicle
frame is 0 V.
Faulty ECM.
Key Switch:
Shorted circuit in
harness between
key switch and ECM.
YES
#24
T1GR-05-04-002
#5
T105-07-04-002
T5-6-39
TROUBLESHOOTING / Troubleshooting B
E-6 Engine stalls during operation under adverse condition such as at high altitude.
Related MC Fault Code: 11004-2, 11910-2, 11209-3,
11209-4,11413-2, 11413-3,11413-4
YES
Engine: Running
NO
Disassemble and
check main pump
YES regulator.
Engine: Running
MC monitor item: Pump
displacement proportional
valve output
Refer to Operational Performance Test section.
Engine: Running
MC monitor item: Actual
engine speed
YES
Engine: Running
Check if fault code
NO 11910-2 is displayed.
Engine: Running
Faulty MC.
NO
T5-6-40
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
F-1 All front attachments do not move.
YES
Check if pressure
at port P in pilot
shut-off valve is
within specification.
YES
Specification:
3.7+0.503 Mpa (38+53
kgf/cm2)
NO
Normal.
Disassemble and
clean pilot valve.
Check if machine
operation is normal.
Faulty pilot pump.
NO
T5-6-41
TROUBLESHOOTING / Troubleshooting B
F-2 All front attachment operations are slow /
weak.
YES
Remove hose connected to port P in
steering pilot valve.
NO Install a plug.
Check if front cylinder operating time
is within specification.
Engine: Running
Refer to Operational Performance Test section.
Remove hose
connected to port
LS in priority valve
Clogging between port
(main pump). In- YES
LS and drain port in
stall a plug. Install
steering valve.
drain hose to port
LS. Put oil into oil
NO pan. Check if lift
arm cylinder operating time is
Stuck spool in priority
within specificaNO valve (main pump).
tion.
Engine: Running
Refer to Operational PerformYES
To A
ance Test section.
Engine: Running
Check if pressure
YES at port A4 in pilot
shut-off valve is
within specification.
Faulty pilot shut-off
valve.
Engine: Running
NO
Pilot shut-off lever:
Check if pressure at
ON
port P in pilot
Specification:
shut-off valve is
3.7+0.503 Mpa
YES within specification.
Stuck check valve or
(38+53 kgf/cm2)
priority valve in charg Engine: Running
YES ing block, faulty pilot
Pilot shut-off lever:
pump or clogged pilot
ON
Disassemble,
filter.
Specification:
+0.5
clean
and
adjust
3.7 03 Mpa
pilot relief valve.
(38+53 kgf/cm2)
NO Check if trouble
occurs.
End
Engine: Running
NO
YES
Operate accelerator pedal.
NO Check if engine
speed changes.
Engine: Running
NO
T5-6-42
TROUBLESHOOTING / Troubleshooting B
YES
Engine: Running
Refer to Operational Performance Test section.
YES
NO
Faulty MC.
Check if pressure at
port ST in main pump
regulator is 2 MPa (20
kg/cm2) or more.
Accelerator pedal:
Fully depressed
Front attachment:
Operated
Faulty main relief
valve.
NO
YES
B
YES
End.
Disassemble and
clean main pump
regulator.
NO Check if front attachment operation is
normal.
NO
T5-6-43
To B
TROUBLESHOOTING / Troubleshooting B
F-3 Certain front attachment is slow / weak.
YES
Check if bucket opYES eration is worse only
during combined
operation of lift arm
raise and bucket.
YES
NO
Check if overload
relief valve pressure
is normal.
Refer to Operational
Performance Test
section.
Check if secondary
pilot pressure in pilot
circuit which trouble
occurs is normal.
Clogged or stuck
bucket flow rate control valve (check, orifice, spool).
NO
Engine: Running
Secondary pilot pressure: Refer to operational Performance
Test section.
Faulty pilot valve.
NO
In case of lift arm, restriction valve may be
stuck.
T5-6-44
TROUBLESHOOTING / Troubleshooting B
F-4 Front attachment moves with lever in neutral.
YES
NO
T5-6-45
TROUBLESHOOTING / Troubleshooting B
F-5 Front attachment drifts remarkably.
YES
Normal.
NO
NO
Engine: Running
T5-6-46
T4GB-05-04-001
TROUBLESHOOTING / Troubleshooting B
NO
YES
YES
T5-6-47
TROUBLESHOOTING / Troubleshooting B
F-6 Bucket is slow during combined operation.
YES
NO
NO
YES
T5-6-48
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-49
TROUBLESHOOTING / Troubleshooting B
F-7 Work mode is not effective.
T5-6-50
TROUBLESHOOTING / Troubleshooting B
F-8 Lift arm height kickout is not operated.
Connect terminal #2 of
harness end connector YES
in electromagnet at lift
arm raise side to vehicle frame.
Raise and lower lift
arm.
YES
While plate is located
in front of proximity
switch, check if there is
continuity.
Or while plate is away
from proximity switch,
check if there is disNO
continuity.
Disconnect connector
in electromagnet at lift
arm raise side in pilot
valve. Ground terminal #1 of harness end
connector to vehicle
frame. Check if voltage is 24 V.
Engine: Running
If one is YES, go to NO.
Faulty electromagnet
at lift arm raise side.
YES
NO
Engine: Running
Faulty fuse or faulty
harness between fuse
box B and electromagnet at lift arm
raise side.
NO
#2
1
T5-6-51
TROUBLESHOOTING / Troubleshooting B
F-9 Lift arm float is not operated.
YES
YES
Disconnect connector in electromagnet
at lift arm lower side
in pilot valve.
Connect terminal #2
of harness end connector to vehicle
frame.
Check for continuity.
Connect terminal #1 of
harness end connector
in electromagnet at lift
arm lower side to vehicle frame.
Check if voltage is 24 V.
Engine: Running
NO
NO
Engine: Running
#1
Faulty electromagnet
at lift arm lower side.
T5-6-52
TROUBLESHOOTING / Troubleshooting B
F-10 Bucket auto leveler is not operated.
Disconnect connector in
electromagnet at bucket
tilt side in pilot valve.
Ground terminal #1 of
harness end connector
to vehicle frame.
Check if voltage is 24 V.
Connect terminal #2
of harness end connector in electromagnet at bucket tilt
side to vehicle frame.
Operate bucket.
While bar is located
YES in front of proximity
switch, check if there
is continuity.
Or while bar is away
from proximity
switch, check if there
is discontinuity.
Engine: Running
If one is YES, go to
NO.
YES
NO
Faulty electromagnet
at bucket tilt side.
YES
NO
Engine: Running
Faulty fuse or faulty
harness between fuse
box B and electromagnet at bucket tilt
side.
NO
#2
1
T5-6-53
TROUBLESHOOTING / Troubleshooting B
F-11 Lift arm auto leveler is not operated. (Optional)
YES
Check if success is
displayed on angle
sensor learning status
of MC monitor item by
using Dr. ZX.
YES
To B
NO
Engine: Running
Lift arm auto leveler
switch: ON (2 used)
To A
NO
MC
Connector B
MC
Connector D
#B3
#1
#2
3
1
#1
#B20
T183-05-04-021
T5-6-54
#2
#3
#10
T183-05-04-009
TROUBLESHOOTING / Troubleshooting B
YES
NO
Connect terminal #2 of
harness end of connector in lift arm auto
leveler switch to vehicle frame.
Disconnect connector
MC-B in MC.
Connect terminal #B20
(upward) or B3 (downward) of harness end
to vehicle frame.
Check for continuity.
NO
YES
To C
Disconnect connector
MC-D in MC.
Check for continuity
YES between terminal
#D10 of harness end
of connector and terminal #2 of harness
end of connector in lift
arm angle sensor.
NO
YES
YES
Key switch: ON
NO
NO
Connect connector in
lift arm solenoid valve
in pilot valve.
YES Connect terminal #2 of
connector to vehicle
frame.
Turn lift arm raise lever
to detent position.
Check if lever is held.
YES
NO
To C
Engine: Running
NO
T5-6-55
TROUBLESHOOTING / Troubleshooting B
F-12 Lift arm auto leveler stop position cannot
be set. (Optional)
T5-6-56
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-57
TROUBLESHOOTING / Troubleshooting B
F-13 Ride control is not effective.
Disconnect connector
in ride control switch.
YES Check for continuity
between terminals #6
and #7 of switch end.
YES
Faulty MC.
NO
NO
YES
YES
Key switch: ON
NO
Normal.
To B
NO
To A
NO
Connector MC-C
Connector MC-A
C10
C1
4
10
#A23
C23
#7
#6
#A7
C31
#C21
T183-05-04-008
T5-6-58
TROUBLESHOOTING / Troubleshooting B
YES
Faulty TCU.
NO
YES
NO
NO
NO
Between terminals
#A23 (#A7) of connector MC-A in MC and #1
(#2) in ride control
proportional solenoid
valve
YES
Proportional Solenoid
Valve Connector
#1
NO
NO
#2
T5-6-59
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Machine does not travel forward/ reverse.
Machine can travel only when the following con-
Forward/Reverse Lever: F or R
Parking Brake Switch: OFF
axles (front, rear) may be faulty. Check for abnormal sound at each part.
NO
Engine: Running
Refer to the Operational Performance
Test section.
YES
Faulty forward/reverse
switch or forward/reverse
lever, or faulty harness.
YES
Engine: Running
T5-6-60
To A
TROUBLESHOOTING / Troubleshooting B
NO
YES
NO
NO
To B
Open circuit in harness in MC or between MC and monitor unit.
Between terminal
#B25 of connector
MC-B in MC and
terminal #A17 of
monitor unit connector 1-A in the monitor
unit
Faulty parking brake
pressure sensor.
NO
Engine: Running
Parking brake switch:
OFF
YES
Engine: Running
Parking brake switch:
OFF
A
To C
Monitor parking
brake signal output
of monitor unit monitor item on Dr. ZX.
Check if ON is displayed by using outline characters on a
colored background.
Engine: Running
Parking brake switch:
OFF
NO
YES
NO
Engine: Running
Parking brake switch:
OFF
T5-6-61
TROUBLESHOOTING / Troubleshooting B
T-2 Machine does not travel forward or reverse.
Replace transmission
control valve with norYES mal one.
Check if machine operation becomes normal.
Faulty transmission.
NO
Faulty TCU.
NO
YES
Check if machine can
travel forward/reverse by
NO using travel forward
lever.
Engine: Running
NO
T5-6-62
Faulty forward/reverse
switch or open circuit in
harness.
Faulty forward/reverse
lever or open circuit in
harness.
TROUBLESHOOTING / Troubleshooting B
T-3 Machine moves with lever in neutral.
YES
Monitor selected travel
speed gear of TCU
YES monitor item on Dr.
ZX.
Check if item except N
is displayed.
NO
Travel: Forward
Forward/reverse lever:
Neutral
Turn forward/reverse
switch ON.
Check if machine
moves.
Travel: Forward
Faulty forward/reverse
lever.
Faulty TCU.
NO
YES
Replace transmission
control valve with norNO mal one. Check if machine operation becomes normal.
Faulty transmission.
NO
Faulty TCU.
YES
T5-6-63
TROUBLESHOOTING / Troubleshooting B
T-4 Even if travel speed is turned up or down,
travel speed gear is not changed.
NO
YES
Refer to Troubleshooting
A.
YES
Disconnect connector
in shift switch.
Check if voltage at
NO terminal #7 of harness
end of connector is 24
V.
Key switch: ON
Engine: Running
NO
Refer to Troubleshooting
A.
YES
Connector TCU
#7
#63
#65
T4GB-05-05-001
T5-6-64
TROUBLESHOOTING / Troubleshooting B
Connect connector in
shift switch.
Set travel speed to
fourth gear. Disconnect
connector in TCU.
Check for continuity
between terminals #63
and #65 of harness
end of connector.
Key switch: OFF
YES
Faulty TCU.
NO
T5-6-65
TROUBLESHOOTING / Troubleshooting B
T-5 Even if up-shift switch is pushed, travel
speed gear is not turned up.
YES
Monitor USS switch of
TCU monitor item on
Dr. ZX.
Turn up-shift switch
ON. Check if ON is displayed on screen.
NO
Key switch: ON
Refer to Troubleshooting
A.
YES
Disconnect connector
in up-shift/down-shift
switch.
Check if voltage at
NO terminal #2 of harness
end of connector is 24
V.
Key switch: ON
NO
Refer to Troubleshooting
A.
YES
TCU Connector
Up-Shift/Down-Shift
Switch Connector
3
#29
#2
T4GB-05-05-001
T5-6-66
TROUBLESHOOTING / Troubleshooting B
Connect connector in
up-shift/down-shift
switch.
Disconnect connector
in TCU. Turn up-shift
switch ON.
Check for continuity
between terminal #29
of harness end of
connector and vehicle
frame.
YES
Faulty TCU.
NO
Faulty up-shift/down-shift
switch or open circuit in
harness.
T5-6-67
TROUBLESHOOTING / Troubleshooting B
T-6 Even if down-shift switch is pushed, travel
speed gear is not turned down.
YES
NO
YES
Disconnect connector
in up-shift/down-shift
switch.
Check if voltage at
NO terminal #2 or #1 of
each harness end of
connector is 24 V.
Key switch: ON
TCU Connector
Down-Shift Connector
#2
NO
Refer to Troubleshooting
A.
YES
Up-Shift/Down-Shift
Switch Connector
Refer to Troubleshooting
A.
#1
#22
T4GB-05-05-001
T5-6-68
TROUBLESHOOTING / Troubleshooting B
Connect connector in
up-shift/down-shift
switch.
Disconnect connector
in TCU.
Turn down-shift side in
up-shift/down-shift
switch and down-shift
switch ON alternately.
Check for continuity
between terminal #22
of harness end of
connector and vehicle
frame.
YES
Faulty TCU.
NO
T5-6-69
TROUBLESHOOTING / Troubleshooting B
T-7 Even if hold switch is pushed, travel speed
gear is not fixed.
YES
NO
Refer to Troubleshooting
A.
YES
Disconnect connector
in hold switch.
Check if voltage at
NO terminal #1 of harness
end of connector is 24
V.
Engine: Running
Key switch: ON
NO
Refer to Troubleshooting
A.
YES
TCU Connector
#1
#66
T4GB-05-05-001
T5-6-70
TROUBLESHOOTING / Troubleshooting B
Connect connector in
hold switch.
Disconnect connector
in TCU.
Turn hold switch ON.
Check for continuity
between terminal #66
of harness end of
connector and vehicle
frame.
YES
Faulty TCU.
NO
T5-6-71
TROUBLESHOOTING / Troubleshooting B
T-8 Travel mode is not shifted.
NO
Engine: Running
YES
Refer to Troubleshooting
A.
Disconnect connector
in travel mode selector
switch.
Check if voltages at
terminals #2, #3, #4
NO and #5 of harness end
of connector are 1V,
2V, 3V and 4V respectively.
YES
Normal.
NO
Key switch: ON
Refer to Troubleshooting
A.
YES
#4
#B28
#5
#B31 #B30
#B29
T4GB-05-05-002
T5-6-72
TROUBLESHOOTING / Troubleshooting B
Connect connector in
travel mode selector
switch.
Disconnect monitor
unit connector 1-B in
monitor unit.
Check if voltages at
terminals #B28, #B29,
#B30 and #B31 of
harness end of connector are 4V, 3V, 2V
and 1V respectively.
YES
Key switch: ON
T5-6-73
TROUBLESHOOTING / Troubleshooting B
T-9 Clutch cut-off is not operated.
NO
Execute troubleshooting
of each controller by
using Dr. ZX. Check if
any fault codes are dis Engine: Running
YES
Refer to Troubleshooting
A.
Disconnect connector
in clutch cut-off position
switch.
Check if voltages at
terminals #2, #3, #4
NO and #5 of harness end
of connector are 1V,
2V, 3V and 4V respectively.
YES
Normal.
NO
Key switch: ON
Refer to Troubleshooting
A.
YES
#4
#3
#B28
#5
#B31 #B30
#B29
T4GB-05-05-002
T5-6-74
TROUBLESHOOTING / Troubleshooting B
Connect connector in
clutch cut-off position
switch.
Disconnect monitor
unit connector 1-B in
monitor unit.
Check if voltages at
terminals #B28, #B29,
#B30 and #B31 of
harness end of connector are 4V, 3V, 2V
and 1V respectively.
YES
Key switch: ON
T5-6-75
TROUBLESHOOTING / Troubleshooting B
BRAKE SYSTEM TROUBLESHOOTING
B-1 Parking brake is not released.
Check the wiring connections first.
NO
NO
To A
Engine: Running
Engine: Running
Specification: 11.8 to 14.7
MPa (120 to 150 kgf/cm2)
NO
NO
Refer to Troubleshooting
C.
Engine: Running
End.
YES
#A2
#3
#3
T183-05-04-013
#18
T183-05-04-003
T5-6-76
T183-05-04-003
TROUBLESHOOTING / Troubleshooting B
Remove parking
brake relay 1.
Check if voltages between terminals #1,
#3 of harness end
and vehicle frame are
24 V.
Disconnect connector
in parking brake
switch.
Measure current at
YES connector of switch
end.
Check if all questions
are Yes.
Discontinuity between
terminals #6 and #7 with
switch in neutral
Discontinuity between
terminals #6 and #7 with
switch OFF
Continuity between terminals #3 and #8 with
switch OFF
Engine: Running
YES
NO
To B
Faulty alternator or
faulty harness.
NO
Key switch: ON
Faulty fuse or faulty
harness.
NO
NO
NO
To C
YES
10
#8 #7
Disconnect parking
brake relay 2.
NO Check for continuity
between terminal #2 of
harness end and vehicle frame.
#6
T5-6-77
TROUBLESHOOTING / Troubleshooting B
Check if voltages at
terminal #3 of harness
end of parking brake
relay 2 and vehicle
frame, at terminal #8
of parking brake
switch and vehicle
frame are 24 V respectively.
NO
End.
NO
Disassemble, clean
and adjust parking
brake.
Check if parking brake
becomes normal.
NO
YES
Engine: Running
#1
NO
To D
Engine: Running
YES
YES
T5-6-78
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-79
TROUBLESHOOTING / Troubleshooting B
B-2 Parking brake is not locked.
NO
Replace parking brake
relay 2 with other general
YES relay.
Check if parking brake is
operated properly.
Engine: Running
Parking brake switch: ON
Monitor parking brake
pressure of MC monitor item on Dr. ZX.
Check if pressure is
within specification.
Disconnect connector in
parking brake switch.
Turn parking brake
switch ON.
Check for continuity
between terminals #7
and #6 of switch end.
NO
YES
YES End.
Replace parking brake
pressure sensor with
YES normal one.
Check if parking brake
indicator lights.
Engine: Running
Parking brake switch: ON
Specification: 11.8 to 14.7
(120 to 150 kgf/cm2)
NO
Engine: Running
10
#2
1
#6
T5-6-80
Refer to Troubleshooting
NO C.
NO
#7
YES
TROUBLESHOOTING / Troubleshooting B
Disconnect connector in
parking brake solenoid
valve.
Check if voltage between
terminals #1 and #2 of
harness end is 24 V.
Engine: Running
Parking brake switch: ON
YES
NO
T5-6-81
TROUBLESHOOTING / Troubleshooting B
B-3 Service brake efficiency is bad or low.
NO
NO
Check if pressures at
ports BR1 and BR2 in
brake valve are within
specification.
Engine: Running
Brake pedal: Fully depressed
Specification: 4.18 0.85
2
YES
MPa (43 9 kgf/cm )
YES
End.
T5-6-82
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-83
TROUBLESHOOTING / Troubleshooting B
STEERING SYSTEM TROUBLESHOOTING
H-1 Steering cylinder operation is slow or does
not move.
NO
YES
NO
To A
Clogging in steering
valve pilot circuit.
YES
YES
To B
NO
Engine: Running
Refer to the Operational
Performance Test section.
NO
T5-6-84
To C
TROUBLESHOOTING / Troubleshooting B
YES
YES
Engine: Running
NO
Disassemble, clean
and adjust pilot relief
valve.
Check if steering handle is operated properly.
NO
YES
End.
YES
NO
End.
Disassemble, clean
and adjust steering
valve.
Check if valve is operated properly.
End.
YES
End.
T5-6-85
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-86
TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
O-1 Air conditioner malfunction
The air conditioner has a self-diagnosis function.
The self-diagnosis functions to:
1) Display Fault Codes
2) Change Displayed Fault Codes
3) Delete Fault Code
4) End Fault Code Display
Temperature
Control Switch
LCD
M178-01-017
Fault
Code
E11
E12
E13
E14
Abnormal coolant
temperature sensor
E15
E16
E21
E22
Abnormal damper
E43
E44
E51
Abnormal refrigerant
Cause
Open circuit in air circulation
sensor
Shorted circuit in air circulation
sensor
Open circuit in fresh air sensor
Shorted circuit in fresh air sensor
Open circuit in coolant temperature sensor
Shorted circuit in coolant temperature sensor
Open circuit in air vent sensor
Shorted circuit in air vent sensor
Abnormal air vent damper
Abnormal air mix damper
Abnormal high/low refrigerant
pressure
T5-6-87
Symptom
Value Y (air flow-in temperature) in response to the set-temperature is fixed.
TROUBLESHOOTING / Troubleshooting B
Change Displayed Fault Code
1. When displaying more than one fault code, push
either upper or bottom side of the temperature
control switch. The following fault code is displayed.
NOTE: Each time the displayed fault code is
changed, the buzzer sounds. In case only
one fault code exists, the displayed fault
code remains unchanged.
Temperature
Control Switch
LCD
LCD
M178-01-017
Circulation
Air Switch
M178-01-017
Fan Switch
T5-6-88
M178-01-017
TROUBLESHOOTING / Troubleshooting B
Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machines air conditioning system.
(Serial
File No.
Checked by:
No.
)
Operation Type
Manual
Semi-Auto
Full-Auto
Delivery Date
Year
Month
(2) When
Date
Year
Month
Day
Operating Hour (
h)
Time
Morning
Daytime
Evening
Night
Frequency
Every Day
Once a Week
Once a Month
Times per
(3) Where
Job Site Address
State
County
Town
Access Road Condition
Paved
Not Paved (Gravel
Sand
Soil)
(4) How (Operating Conditions)
Weather
Fine
Cloudy
Rain
Snow
Atmospheric Temperature
Very Hot
Hot
Cold
Very Cold
Operating Conditions
Parking
Traveling
Working
Temperature Control
Paint blanks equal to red indicators. / Fill in set-temperature
when full-auto operation
A/C
ON
OFF
Air Induction
Re-Circulation
Fresh Air Circulation
Control
AUTO
ON
OFF
Not Available
Panel
Fill following items when operated in manual mode or when manual control type unit is
used.
Vent Position
Front
Front / Rear
Foot
Front / Rear and Foot
Fan
First
Second
Third
Fourth
Fifth
Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
<Check Result>
Symptom
Not turned ON
(1) Is problem reproducible ?
Not turned OFF
Reproducible
Others
Not reproducible
Uncontrollable air temperature
(2) Pressure (To be measured at gauge maniSymptom
No cool air
fold)
No warm air
Low Pressure
Others
High Pressure
Uncontrollable air volume
(3) Which parts have been replaced ?
Symptom
Air flows in Hi mode only
1
No air flows
Small air volume
2
Others
Uncontrollable vent hole
Before replacing the control amplifier, be sure
Symptom
Vent hole isnt selected
to check that the connectors are correctly conOthers
nected while repeatedly disconnecting and reAbnormal panel indication
connecting connectors.
Faulty
Indi- Vent Hole
cator
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo
Hi)
Temperature Control
Symptom
Stays OFF
Stays ON
Blinks
Others
T5-6-89
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Refrigerant pressure
in both high and
low-pressure sides is
low.
Insufficient
Cooling
Power
Refrigerant pressure
in low-pressure side
is high.
Refrigerant pressure in
high-pressure side is low.
Refrigerant pressure
in high-pressure side
is high.
Frost forms.
T5-6-90
TROUBLESHOOTING / Troubleshooting B
Gas leaks from pipe joints and/or parts.
Refill refrigerant.
Readjust or replace.
Replace.
Repair.
Excessive refrigerant.
T5-6-91
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Case connection.
Louver resonance.
Fan contacts case, or foreign matter enters case.
Noise
Abnormal smell.
T5-6-92
TROUBLESHOOTING / Troubleshooting B
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.
Replace if loud.
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 drive belt.
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.
T5-6-93
TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor does not rotate.
Inoperable
cooling
system.
Check for oil and refrigerant leaks from parts other than
compressor and pipe joints by using gas detector.
Check for oil and refrigerant leaks from compressor (no
leaks from parts other than compressor) by using gas
detector.
(Refer to NOTE 1,
2 on page T5-6-97.)
Stain on exterior.
Others
T5-6-94
TROUBLESHOOTING / Troubleshooting B
Seized clutch.
Replace.
Replace.
Oil and refrigerant leaks from front housing, and/or cylinder block joint.
Normal leaks from hoses.
Replace.
Charge
refrigerant.
No leaks (normal).
Excessive oil.
T5-6-95
TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor rotation is abnormally draggy.
Overheating
is susceptible
to occur.
Trouble other than compressor.
Abnormal
noise
T5-6-96
TROUBLESHOOTING / Troubleshooting B
Replace.
Saggy belt.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise.
Replace.
Loose screws.
NOTE:
1. Do not quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose surface may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high-pressure side and low-pressure side is 0.5 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will disappear within about 10 seconds.
T5-6-97
TROUBLESHOOTING / Troubleshooting B
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. Add compressor oil
Oil amount: 160 cm3 (0.17 qt)
2. Charge air conditioner with refrigerant
Purging
Charge air conditioner with refrigerant
Warm-up operation
Inspection
T5-6-98
TROUBLESHOOTING / Troubleshooting B
CHARGE
AIR
REFRIGERANT
CONDITIONER
WITH
Necessity of Purging
Make 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.
Air
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.
Hydrochloric acid
corrodes metals if
moisture exists.
Hydrochloric Acid
W115-02-10-002
Metal Corrosion
Plugged Refrigerant
Flow
W115-02-10-003
Low Cooling
Efficiency
T5-6-99
TROUBLESHOOTING / Troubleshooting B
Purging Procedure
Gauge Manifold
Adapter
Low Pressure
Valve
Low Pressure
Charge Hose
High Pressure
Valve
High Pressure
Charge Hose
Center Pressure
Charge Hose
Vacuum Pump
(Parts
W115-02-10-005
Low Pressure
Side
S
Compressor
D
High Pressure
Side
T142-02-05-018
Fully Open
Fully Open
In Operation
W115-02-10-005
T5-6-100
TROUBLESHOOTING / Troubleshooting B
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again.
Close
Close
In Operation
W115-02-10-005
Refrigerant
Container
W115-02-10-007
Loosen
Open
W115-02-10-007
T5-6-101
TROUBLESHOOTING / Troubleshooting B
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, purge air
from the charge hose, as shown in
step 10. Charge the low pressure
side hose first.
6. Fully tighten the charge hose connection to the
gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
reading reaches 98 kPa (1 kgf/cm2, 14 psi).
NOTE: Use warm water of 40 C (104 F) or less to
warm the refrigerant container to aid in
charging operation.
High
Pressure
Gauge
Tighten
Open
Open
W115-02-10-007
W115-02-10-008
T5-6-102
TROUBLESHOOTING / Troubleshooting B
8. Confirm that the high pressure and low pressure
valves in the gauge manifold and the refrigerant
container valve are closed.
Start the engine and operate the air conditioner.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
Open
Open
W115-02-10-007
Close
T5-6-103
Close
W115-02-10-007
TROUBLESHOOTING / Troubleshooting B
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.
Observe the sight glass of the receiver tank and
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
Sight Glass
Receiver Tank
W115-02-10-009
T5-6-104
TROUBLESHOOTING / Troubleshooting B
Relation between Refrigerant Quantity and Refrigerant
Flow in Sight Glass:
Refrigerant
Quantity
(approx. 1 mm after)
Adequate
W115-02-10-016
Overcharged
W115-02-10-017
Bubbles are seen continuously after the air conditioner is turned ON.
Not Enough
W115-02-10-018
W115-02-10-019
115-02-10-021
Milk white:
Refrigerant flow shows thin milk white
as oil and refrigerant are separated.
CAUTION: Wait until the high-pressure-side
pressure drops to less than 980 kPa (10
kgf/cm2, 142 psi) before attempting to disconnect the high-pressure-side charge hose.
Otherwise, refrigerant and compressor oil
may spout.
13. After checking refrigerant quantity, disconnect the
low-pressure-side charge hose first. 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.
T5-6-105
TROUBLESHOOTING / Troubleshooting B
Warm-up Operation
After charting the air conditioner, carry out warm-up
operation five minute in order to lubricate system
with compressor oil.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
Inspection
After warm-up operation, carry out gas leak check
and performance check.
CAUTION: Refrigerant
will
produce
poisonous material if exposed to heat of 1000
C (1800 F) or more. Never bring refrigerant
close to a fire.
1. Check the air conditioner for gas leaks by 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.
Check each component for abnormalities.
Carry out ON-OFF check of the compressor
clutch.
Check compressor fan belt tension.
Check coolant level in the radiator.
Operate the air conditioner and check the
performance.
Leak Tester
W115-02-10-013
Retighten Line
Connection
W115-02-10-014
T5-6-106
TROUBLESHOOTING / Troubleshooting B
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-belts for wear. Replace if necessary.
4. Off-Season Maintenance
During off-season, operate the idler pulley and
compressor at least once a month for a short time
in order to check for any abnormal sounds.
Do not remove the compressor belts during
off-season. Operate the compressor occasionally
at slow speed for 5 to 10 minutes with the belt
slightly loosened in order to lubricate the machine
parts.
T5-6-107
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-108
TROUBLESHOOTING / 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 used on this machine are identical.
Therefore, by using this switch-check method, faulty
part /component, and/or harness can be easily found.
(Main Pump)
T4GB-05-06-010
T5-6-109
T4GB-01-02-011
TROUBLESHOOTING / Troubleshooting B
Applicability of Switch-Check Method
Fault Code
Trouble
11204-3
Abnormal Pump Delivery Pressure Sensor
High Voltage
11204-4
Abnormal Pump Delivery Pressure Sensor
Low Voltage
11209-3
Abnormal Implement Pressure Sensor High
Voltage
11209-4
Abnormal Implement Pressure Sensor Low
Voltage
11313-3
Abnormal Parking Brake Pressure Sensor
High Voltage
11313-4
Abnormal Parking Brake Pressure Sensor
Low Voltage
13314-3
Service Brake Pressure Switch High Voltage
13314-4
Service Brake Pressure Switch Low Voltage
T5-7-110
Applicability
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
TROUBLESHOOTING / Troubleshooting B
BLEEDING AIR FROM BRAKE (AXLE)
IMPORTANT: If air is contained in the brake, brake
efficiency is low so that the serious
accident may occur. When the brake
pipe is installed/ removed or hydraulic oil is replaced, release any
pressure in the brake. Until hydraulic oil (0.5 L) comes out from each
wheel (4 places) after bubbles stops,
continue to release any pressure.
1
1
T4GB-05-04-004
T4GB-05-04-005
T5-6-111
T4GB-05-04-006
TROUBLESHOOTING / Troubleshooting B
ONE PART OF DATA, DAILY REPORT
DATA, DISTRIBUTION DATA, TOTAL
OPERATING HOURS AND ALARM IS
NOT RECORDED
The required signal for data may not be sent to
ICF. As each signal is used for some data, check
the corresponding signal system according to the
table below.
Daily Report Data
Data
Input Signal
Date
Fuel level
10
11
12
13
14
Intake-air temperature
15
Fuel temperature
16
17
T5-6-112
TROUBLESHOOTING / Troubleshooting B
Monitor unit
Alternator
ECM
TCU
MC
MC
MC
MC
MC
Monitor unit
MC
ECM
ECM
Monitor unit
Alternator
Alternator
ECM
Inspected Position
-
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.
T5-6-113
TROUBLESHOOTING / Troubleshooting B
Input Signal
Replace ICF
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #33, #34 of connector monitor-2 in monitor unit
3 Fuel used amount
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
4 Machine hour meter
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #33, #34 of connector monitor-2 in monitor unit
5 Engine operating hours
Check terminal #8 of connector ICF-C in ICF, terminal L
in alternator
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
6 Travel operating distance
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #25, #26 of connector in TCU
7 Manual gear shifting operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
8 Automatic gear shifting operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
9 L mode operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
10 N mode operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
11 P mode operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
12 Radiator coolant temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #33, #34 of connector monitor-2 in monitor unit
13 Hydraulic oil temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
14 Intake-air temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
15 Fuel temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
16 Torque converter oil temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #33, #34 of connector monitor-2 in monitor unit
17 Engine operating hours distribution
Check terminal #8 of connector ICF-C in ICF, terminal L
in alternator
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.
1
2
Date
Fuel level
T5-6-114
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-115
TROUBLESHOOTING / Troubleshooting B
Distribution Data
Data
Input Signal
Hydraulic oil temperature - Intake-air tem- Distribution of temperature that intake-air temperature is
perature distribution
taken from hydraulic oil temperature
Torque converter oil temperature - Intake-air Distribution of temperature that intake-air temperature is
temperature distribution
taken from torque converter oil temperature
10
Radiator coolant temperature / Intake-air Distribution of coolant temperature and intake-air temtemperature
perature
11
Hydraulic oil temperature / Intake-air tem- Distribution of hydraulic oil temperature and intake-air
perature
temperature
12
Torque converter oil temperature / Intake-air Distribution of torque converter oil temperature and intemperature
take-air temperature
13
Travel speed gear distribution during manual Distribution of travel speed gear during manual gear
gear shifting
shifting
14
Travel speed gear distribution during auto- Distribution of travel speed gear during automatic gear
matic gear shifting
shifting
15
T5-6-116
for all controllers, the monitor display and the machine operation are
normal) and the required data is not
recorded in ICX, execute this inspection.
TROUBLESHOOTING / Troubleshooting B
MC
Monitor unit
MC
Monitor unit
ECM
MC
ECM
Monitor unit
ECM
MC
ECM
Inspected Position
Communication line between ECM and
ICF (CAN line)
Communication line between MC and ICF
(CAN line)
Communication line between TCU and ICF
(CAN line)
Communication line between monitor unit
and ICF (CAN line)
Communication line between MC and ICF
(CAN line)
Communication line between monitor unit
and ICF (CAN line)
Communication line between monitor unit
and ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between monitor
unit and ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between monitor
unit and ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between monitor
unit and ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between TCU and
ICF (CAN line)
Communication line between MC and ICF
(CAN line)
T5-6-117
TROUBLESHOOTING / Troubleshooting B
Distribution Data
Input Signal
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#18, #37 of connector in ECM
2
Pump load distribution
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#4, #15 of connector MC-C in MC
3
Travel load distribution
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#25, #26 of connector in TCU
4
Radiator coolant temperature distri- Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
bution
#33, #34 of connector monitor-2 in monitor unit
5
Hydraulic oil temperature distribution Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#4, #15 of connector MC-C in MC
6
Torque converter oil temperature dis- Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
tribution
#33, #34 of connector monitor-2 in monitor unit
7
Radiator coolant temperature In- Check terminal #8 of connector ICF-C in ICF, terminals #33,
take-air temperature distribution
#34 of connector monitor-2 in monitor unit
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
8
Hydraulic oil temperature - Intake-air Check terminals #C5, #C11 of connector ICF-C in ICF, termitemperature distribution
nals #4, #15 of connector MC-C in MC
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
9
Torque converter oil temperature - Check terminal #8 of connector ICF-C in ICF, terminals #33,
Intake-air temperature distribution
#34 of connector monitor-2 in monitor unit
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
10 Radiator coolant temperature / In- Check terminal #8 of connector ICF-C in ICF, terminals #33,
take-air temperature
#34 of connector monitor-2 in monitor unit
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
11 Hydraulic oil temperature /Intake-air Check terminals #C5, #C11 of connector ICF-C in ICF, termitemperature
nals #4, #15 of connector MC-C in MC
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
12 Torque converter oil temperature / Check terminal #8 of connector ICF-C in ICF, terminals #33,
Intake-air temperature
#34 of connector monitor-2 in monitor unit
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
13 Travel speed gear distribution during Check terminals #C5, #C11 of connector ICF-C in ICF, termimanual gear shifting
nals #4, #15 of connector MC-C in MC
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #25, #26 of connector in TCU
14 Travel speed gear distribution during Check terminals #C5, #C11 of connector ICF-C in ICF, termiautomatic gear shifting
nals #4, #15 of connector MC-C in MC
15 Engine load rate
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#18, #37 of connector in ECM
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.
1
Data
Fuel temperature distribution
T5-6-118
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-119
TROUBLESHOOTING / Troubleshooting B
Total Operating Hours Data
Data
Input Signal
1
2
Traveling distance
Automatic gear shifting operating Total automatic gear shifting operating hours
hours
T5-6-120
TROUBLESHOOTING / Troubleshooting B
Alternator
Alternator
ECM
TCU
MC
MC
MC
Inspected Position
Communication line between monitor
unit and ICF (CAN line)
Wiring between alternator and ICF
Communication line between ECM
and ICF (CAN line)
Communication line between TCU and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
T5-6-121
TROUBLESHOOTING / Troubleshooting B
Total Operating Hours Data
1
2
3
4
5
Data
Hour meter (ICF)
Hour meter (monitor
unit)
Engine operating hours
Input Signal
Replace ICF
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #33, #34
connector monitor-2 in monitor unit
Check terminal #8 of connector ICF-C in ICF, terminal L in alternator
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37
connector in ECM
Traveling distance
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #25, #26
connector in TCU
Manual gear shifting op- Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
erating hours
connector MC-C in MC
Automatic gear shifting Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
operating hours
connector MC-C in MC
7 L mode operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
connector MC-C in MC
8 N mode operating hours Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
connector MC-C in MC
9 P mode operating hours Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
connector MC-C in MC
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.
T5-6-122
of
of
of
of
of
of
of
of
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-6-123
TROUBLESHOOTING / Troubleshooting B
Alarm Data
Data
Input Signal
Overheat alarm
10
Emergency
steering
operation
alarm
Steering oil pressure alarm
11
12
13
14
T5-6-124
TROUBLESHOOTING / Troubleshooting B
Overheat switch
ECM
Monitor unit
Monitor unit
Alternator
Monitor unit
Monitor unit
Monitor unit
Monitor unit
Monitor unit
Monitor unit
Monitor unit
Monitor unit
Monitor unit
Monitor unit
Monitor unit
Inspected Position
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.
T5-6-125
TROUBLESHOOTING / Troubleshooting B
Alarm Data
Data
Input Signal
Check terminals #C5, #C11 of connector ICF-C in ICF,
1
terminals #33, #34 of connector monitor-2 in monitor unit
Engine warning alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
2
terminals #33, #34 of connector monitor-2 in monitor unit
Engine oil pressure alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
3
terminals #33, #34 of connector monitor-2 in monitor unit
Alternator indicator alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
4
terminals #33, #34 of connector monitor-2 in monitor unit
Air cleaner restriction alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
5
terminals #33, #34 of connector monitor-2 in monitor unit
Water separator alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
6
terminals #33, #34 of connector monitor-2 in monitor unit
Service brake oil level alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
7
terminals #33, #34 of connector monitor-2 in monitor unit
Service brake oil pressure alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
8
terminals #33, #34 of connector monitor-2 in monitor unit
Emergency steering operation alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
9
terminals #33, #34 of connector monitor-2 in monitor unit
Steering oil pressure alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
10
terminals #33, #34 of connector monitor-2 in monitor unit
Transmission oil temperature alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
11
terminals #33, #34 of connector monitor-2 in monitor unit
Hydraulic oil temperature alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
12
terminals #33, #34 of connector monitor-2 in monitor unit
Transmission filter restriction alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
13
terminals #33, #34 of connector monitor-2 in monitor unit
Transmission malfunction alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
14
terminals #33, #34 of connector monitor-2 in monitor unit
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.
Overheat alarm
T5-6-126
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.
YES (OK)
(2)
(1)
NO (NOT OK)
Key switch: ON
(3)
Use the service mode in monitor and the diagnosing system / controller diagnosing
system in Dr. ZX.
Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.
Harness End
Connector
Harness
T6L4-05-03-001
T5-7-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Check the wiring connections first.
YES
NO
YES
Conduct troubleshooting of
each indicator, which does not
light.
A
Faulty monitor unit.
NO
T183-05-04-013
T5-7-2
To A
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-7-3
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BUZZER IN MONITOR
Check the wiring connections first.
NOTE: * Terminals L in the alternator are water-resistant type connectors so that it is not
practical to measure voltage at these terminals. Measure voltage at terminal R in
safety relay. Check for continuity between
terminal R in safety relay and terminal L in
the alternator first.
YES
When engine starts,
buzzer continues to
sound.
YES
NO
Overheated engine.
NO
Normal.
Check if engine
-1
speed is 900 min
(rpm) or faster.
NO
Check if alternator inYES dicator lights.
YES
Conduct troubleshooting
of lighted indicator.
T5-7-4
TROUBLESHOOTING / Troubleshooting C
E
S
T183-05-04-013
Less than 12 V
or 35 V or higher
Between 12 V
and 35 V
T5-7-5
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF
PERATURE GAUGE
COOLANT
TEM-
YES
NO
YES
YES
Key switch: ON
NO
T5-7-6
TROUBLESHOOTING / Troubleshooting C
YES
NO
YES
Resistance (k)
7.60.76
4.00.35
2.70.22
0.920.07
0.560.04
0.420.03
0.280.01
#3
T5-7-7
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF TRANSMISSION OIL
TEMPERATURE GAUGE
Check the wiring connections first.
YES
NO
YES
YES
T5-7-8
NO
TROUBLESHOOTING / Troubleshooting C
YES
NO
T4GB-05-07-006
YES
Resistance (k)
7.60.76
4.00.35
2.70.22
0.920.07
0.560.04
0.420.03
0.280.01
T5-7-9
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
Check the wiring connections first.
YES
NO
YES
YES
T5-7-10
NO
TROUBLESHOOTING / Troubleshooting C
Fuel Gauge
Upper Limit
1/2
YES
T4GB-05-07-007
NO
Fuel Sensor
Float
Upper Limit (FULL)
YES
14 mm
1/2
NOTE: 1 mm = 0.03937 in
Float Position
Upper Limit (FULL)
1/2
Warning Level
Lower Limit (EMPTY)
Fuel Sensor
8
1
T183-05-04-013
T5-7-11
Resistance ()
10+0-4
385
773
90+10-0
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF TURN SIGNAL INDICATORS (LEFT AND RIGHT)
Check the wiring connections first.
If the turn signal indicators (left and right) do not
blink, the flasher relay may be faulty.
YES
YES
Replace turn signal relay
(right) (AR8) with turn signal
relay (left) (BR7).
NO Check if symptom is
switched.
NO
YES
T5-7-12
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HAZARD LIGHT INDICATOR
The hazard light indicator lights when the signal of
turn signal relay in left and right enters into the
hazard light switch. Therefore, although both turn
signal indicator light or blink and if the hazard light
indicator does not light, the harness between turn
signal relay and monitor unit may be faulty or the
monitor unit may be faulty. If the turn signal indicator at one side does not light or blink, refer to
troubleshooting that harness between turn signal
relay and hazard light switch may be faulty or the
turn signals (left and right) may be faulty in order
to conduct the remedy.
Check the wiring connections first.
T5-7-13
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HIGH BEAM INDICATOR
Check the wiring connections first.
Although dimmer
switch is turned to
HIGH beam position,
high beam indicator
does not light.
Although dimmer
switch is not in HIGH
beam position, high
beam indicator lights.
YES
NO
Disconnect connector of
head light switch.
Check if voltage at terminal
#2 of harness end connector is 0 V.
NO
YES
YES
NO
Disconnect connector
2-B in monitor unit.
Check if high beam indicator goes out.
T5-7-14
TROUBLESHOOTING / Troubleshooting C
YES
YES
NO
YES
NO
Monitor Unit
Connector 2-B
22
T4GB-05-05-002
T5-7-15
T183-05-04-003
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF WORKING LIGHT INDICATOR
Check if the working light switch and head light
switch are in the ON position.
NO
NO
YES
YES
YES
NO
Check if working light
lights.
Shorted circuit in harness
between working light relay 1
(AR8) and monitor unit.
NO
T5-7-16
TROUBLESHOOTING / Troubleshooting C
YES
NO
NO
Disconnect connector of
working light switch.
Check if indicator goes out.
NO
T183-05-04-003
T4GB-05-05-002
T5-7-17
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FORWARD/REVERSE
SWITCH INDICATOR
CAUTION: Turn the forward/reverse lever
and the forward/reverse switch to neutral and
turn the forward/reverse selector switch to
the ON position. If not, the indicator does not
light and the machine cannot be operated by
the forward/reverse switch.
YES
NO
YES
Disconnect connector
TCU.
Check if voltage at termiNO nal #30 of harness end
connector is 24 V.
Forward/reverse
selector switch: ON
NO
Open circuit in harness between terminal #34 of connector 1-B in monitor unit and
terminal #5 of connector
TCU, or faulty TCU.
Faulty connection of TCU
and connector, or faulty TCU.
Connect the disconnected
connector.
Disconnect connector of forward/reverse selector switch.
Check if voltage at terminal
#7 of harness end connector
is 24 V.
Faulty forward/reverse selector switch, or shorted circuit in harness between terminals #2 and #4 of connector.
YES
Turn forward/reverse
lever to Forward or
Reverse.
Check if machine
moves and indicator
goes out.
YES
NO
Disconnect connector
TCU.
NO Check if indicator goes
out.
T5-7-18
TROUBLESHOOTING / Troubleshooting C
YES
YES
Faulty forward/reverse
selector switch.
NO
NO
Connector TCU
5
30
Monitor Unit
Connector 1-B
T4GB-05-05-002
34
7
T4GB-05-05-001
T5-7-19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF MAINTENANCE INDICATOR
The maintenance indicator lights when the hour
meter reaches the set replacement interval for
lubrication system and filter. (Refer to the operation manual.) The maintenance indicator lighting
is controlled in the logic circuit of monitor unit. If
the maintenance indicator lights during the time
when the maintenance indicator must go out, the
monitor unit may be faulty. If the maintenance indicator does not light during the time when the
maintenance indicator must light, the light or the
monitor unit may be faulty.
T5-7-20
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PREHEAT INDICATOR
The preheat system operates only when coolant
temperature is below the specification. (Refer to
the SYSTEM / Electrical Circuit group.)
YES
Preheat indicator
lights although preheat system does
not operate
(coolant temperature is more than
specification).
YES
NO
Faulty ECM.
YES
NO
Preheat indicator
does not light although preheat
system operates
(coolant temperature is lower than
specification).
Key switch: ON
YES
Disconnect connector A in ECM.
Connect terminal
#11 of harness end
connector to vehiNO
cle frame.
Check if preheat
indicator lights.
Key switch: ON
NO
Faulty ECM.
Connect terminal
#24 of connector
1-B in monitor unit
to vehicle frame.
Check if preheat
indicator lights.
YES
Open circuit in
harness between
ECM and monitor
controller.
Faulty monitor unit.
Without disconnect- NO
ing connector, connect connector to
vehicle frame by
using a clip from the
rear of connector.
Monitor Unit
Connector 1-B
ECM
Connector A
#11
Faulty monitor
controller.
Faulty coolant
temperature sensor
YES
Disconnect connector of coolant
temperature sensor.
Short harness end
connector.
Check if indicator
lights.
Shorted circuit in
harness between
ECM and monitor
unit.
#24
T4GB-05-05-002
T1GR-05-04-002
T5-7-21
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF TRANSMISSION OIL
TEMPERATURE
Check the wiring connections first.
Disconnect connector
of transmission oil
temperature sensor.
Connect terminal of
YES harness end to vehicle
frame.
Check if indicator
lights.
YES
Key switch: ON
NO
Check if indicator
lights when key
switch is turned to
ON position.
Key switch: ON
Without disconnecting
connector, connect connector to vehicle frame by
using a clip from the rear
of connector.
Key switch: ON
NO
YES
YES
NO
T5-7-22
NO
TROUBLESHOOTING / Troubleshooting C
YES
Monitor Unit
Connector 2-A
#5
T183-05-04-013
T5-7-23
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HYDRAULIC
TEMPERATURE INDICATOR
OIL
T5-7-24
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-7-25
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION
OF
WARNING INDICATOR
TRANSMISSION
YES
Disconnect connector
TCU.
YES Connect terminal #52 of
harness end connector
to vehicle frame.
Check if indicator lights.
Although transmission is abnormal,
indicator does not
light.
NO
Key switch: ON
Without disconnecting connector, connect to vehicle
frame by using a clip from
the rear of connector.
NO
YES
YES
NO
Disconnect connector
1-A in monitor unit.
Check if indicator goes
out.
NO
T5-7-26
TROUBLESHOOTING / Troubleshooting C
Faulty TCU.
YES
Faulty TCU.
Connector TCU
T183-05-04-013
#15
T4GB-05-05-001
T5-7-27
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR
Check the wiring connections first.
YES
Check if indicator
lights when key
switch is turned to
ON position.
NO
Key switch: ON
NO
YES
Disassemble and
visually inspect.
Verify that air filter
is not moist.
Key switch: ON
YES
NO
T5-7-28
NO
Disconnect connector
1-A in monitor unit.
Check for continuity
between terminal #9 of
harness end connector
and air filter restriction
switch.
TROUBLESHOOTING / Troubleshooting C
YES
NO
Monitor Unit
Connector 1-A
#9
T5-7-29
T183-05-04-013
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR
Although the fault code is not displayed in ECM
and if the trouble occurs, conduct this remedy.
NOTE: After the engine stops in 1 to 2 minutes,
pressure may remain inside. When the engine re-starts under this condition, the indicator may not light.
Disconnect connector
A in ECM.
Connect terminal #17
of harness end conYES nector to vehicle frame.
Check if indicator
lights.
Indicator does not
light although engine oil pressure is
low.
Key switch: ON
Check if indicator
lights when key
switch is turned to
ON position.
YES
Key switch: ON
Engine: Stopped
NO
YES
YES
NO
T5-7-30
TROUBLESHOOTING / Troubleshooting C
Faulty ECM.
YES
Monitor Unit
Connector 1-A
T183-05-04-013
ECM
Connector A
T5-7-31
#17
T1GR-05-04-002
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERHEAT INDICATOR
Check the wiring connections first.
YES
Disconnect connector
of overheat switch.
Connect terminal of
YES
harness end to vehicle
frame.
Check if indicator
lights.
Indicator does not
light although engine
overheats.
Key switch: ON
Check if indicator
lights when key
switch is turned to
ON position.
NO
Key switch: ON
Without disconnecting
connector, connect
connector to vehicle
frame by using a clip
from the rear of connector.
Key switch: ON
NO
YES
YES
NO
T5-7-32
NO
TROUBLESHOOTING / Troubleshooting C
Overheat Switch
Coolant Temperature
Operation
Lower than 1073 C
OFF
(2256F)
1073 C (2256 F) or
ON
higher
YES
NO
#7
T5-7-33
T183-05-04-013
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE WARNING
INDICATOR
Although the fault code is not displayed in ECM and if
the trouble occurs, conduct this remedy.
Although engine is
abnormal, indicator
does not light.
Although engine is
not abnormal, indicator lights.
YES
NO
Faulty ECM.
Disconnect
connector 2-B
in monitor unit.
Connect terminal #21 of
monitor end to
vehicle frame.
Check if indicator lights.
YES
Open circuit in
harness between
ECM and monitor
unit.
Faulty monitor unit.
NO
NO
Faulty monitor
unit, or burnt indicator light.
YES
Faulty ECM.
YES
Key switch: ON
Engine: Stopped
NO
Disconnect connector
2-B in monitor unit.
Check if indicator goes
out.
Shorted circuit in
harness between
ECM and monitor
unit.
ECM
Connector A
#6
#21
T1GR-05-04-002
T4GB-05-05-002
T5-7-34
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF STOP INDICATOR
When the following troubles occur, the stop indicator
lights in order to announce the trouble to the operator, stop the machine and repair the machine.
Although the machine is repaired and if the stop indicator does not go out, other indicator on monitor
must light. Refer to the pages corresponding to the
indicator in this group or conduct the remedy according to Troubleshooting A.
Although there is no trouble and if the stop indicator
does not go out, the logic circuit in monitor unit may
be faulty.
(When the abnormal value is detected, the stop indicator lights;)
Low engine oil pressure
Overheat of the engine (high temperature of engine coolant)
Low level of service brake oil (low level of hydraulic oil tank)
Low service oil pressure
High temperature of transmission oil
Low steering oil pressure
High temperature of hydraulic oil
T5-7-35
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF SERVICE INDICATOR
When the following troubles occur, the service indicator lights in order to announce the trouble to the
operator, stop the machine and maintain the machine.
Although the machine is maintained and if the service indicator does not go out, other indicator on
monitor must light. Refer to the pages corresponding to the indicator in this group or conduct the
remedy according to Troubleshooting A.
Although there is no trouble and if the service indicator does not go out, the logic circuit in monitor unit
may be faulty.
(When the abnormal value is detected, the service indicator lights;)
Faulty generation of the alternator
Clogged air cleaner
Emergency steering operation
Lighting the engine warning indicator
Lighting the transmission warning indicator
Lighting the maintenance indicator
High temperature of axle oil
T5-7-36
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-7-37
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PARKING BRAKE INDICATOR
Although the fault code is not displayed in MC and
if the trouble occurs, conduct this remedy.
YES
Disconnect connector B
in MC. Check if indicator
goes out.
YES
Disconnect connector
1-A in monitor unit.
NO Check if indicator goes
out.
NO
YES
Disconnect connector B
in MC.
YES Connect harness end
connector to vehicle
frame.
Check if indicator lights.
Key switch: ON
NO
Key switch: ON
Engine: Stopped
MC
Connector
T183-05-04-013
#25
#17
T183-05-04-021
T5-7-38
TROUBLESHOOTING / Troubleshooting C
Faulty MC.
Faulty MC.
YES
T5-7-39
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF CLEARANCE LIGHT
INDICATOR
If the light is OFF and the clearance light and indicator light, the light switch may be faulty or the
harness between light switch and clearance light
or monitor unit may be shorted.
Check the wiring connections first.
YES
Indicator does not light.
Light switchON
Disconnect connector
1-B in monitor unit.
Check if voltage at terminal #21 of harness
end connector is 24 V.
To A
YES
NO
#21
T4GB-05-05-002
T5-7-40
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BRAKE LOW OIL
PRESSURE INDICATOR
When this trouble occurs, the fault code corresponding to the service brake pressure switch in
monitor unit must be displayed. Refer to Troubleshooting A and conduct the remedy for this
trouble.
Although the fault cold is not displayed and if the
trouble occurs, the monitor unit may be faulty.
Service Brake Pressure Switch
Pressure
Voltage
Operation
10 Mpa (82 kgf/cm2)
1.32 V or higher
OFF
or higher
Less than 8 Mpa
Less than 1.15 V
ON
(102 kgf/cm2)
T5-7-41
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BRAKE LOW OIL
LEVEL INDICATOR
Check the wiring connections first.
YES
Disconnect plug of
YES hydraulic oil level
switch. Check if indicator lights.
Although hydraulic
oil is low, indicator
does not light.
Key switch: ON
NO
Key switch: ON
NO
YES
Although hydraulic
oil is enough, indicator lights.
Disconnect connector of
hydraulic oil level switch.
When terminal of harness end is shorted,
check if indicator goes
out.
Key switch: ON
YES
NO
T5-7-42
NO
Disconnect connector
1-A in monitor unit.
Check if indicator
lights.
TROUBLESHOOTING / Troubleshooting C
YES
Monitor Unit
Connector 1-A
#13
T5-7-43
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION
OF
EMERGENCY
STEERING INDICATOR (Optional)
After checking if the fault code is not displayed on
Troubleshooting by Dr. ZX, conduct this remedy.
Connect connector of
check switch.
Disconnect connector
1-A in monitor unit.
YES Connect terminal #14 of
harness end connector
to vehicle frame.
When check switch is
turned ON, check for
continuity.
YES
NO
NO
YES
NO
YES
Key switch: ON
Although engine
starts, inspection of
emergency steering
pump unit is not
automatically operated.
To A
Disconnect connector
1-A in monitor unit.
Check if pump unit
stops.
YES
Key switch: ON
NO
Disconnect connector
2-A in monitor unit.
Check if pump unit
stops.
NO
T5-7-44
To C
TROUBLESHOOTING / Troubleshooting C
YES
YES
Replace emergency
steering relay with
horn relay.
Check if horn
sounds.
Disconnect connector
2-A in monitor unit.
Connect terminal #11 of
harness end to vehicle
frame.
Check if pump unit is
operated.
Key switch: ON
YES
NO
Faulty connector of
emergency steering
relay.
YES
Terminals #3 and #5 of
YES emergency steering relay are shorted. Check if
pump unit is operated.
NO
Key switch: ON
NO
YES
Faulty emergency
steering relay.
Replace emergency
steering relay with
horn relay.
Check if pump unit
stops.
Key switch: ON
Shorted circuit in
wiring and power
circuit between
emergency steering
relay and emergency steering
pump unit, or faulty
emergency steering
pump unit.
NO
Connector (Harness end of connector viewed from the open end side)
Emergency Steering Check
Switch Connector
#4
NO
Monitor Unit
Connector 1-A
Connector 2-A
Emergency Steering
Relay Connector
#2
#2
#1
#11
4
10
#5
#2
#14
T5-7-45
T183-05-04-013
#3
T183-05-04-003
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF LOW STEERING OIL
PRESSURE INDICATOR (Optional)
When this trouble occurs, the fault code corresponding to the emergency steering pressure
switch in monitor unit must be displayed. Refer to
Troubleshooting A and conduct the remedy.
Although the fault cold is not displayed and if the
trouble occurs, the monitor unit may be faulty.
T5-7-46
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-7-47
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF DISCHARGE WARNING INDICATOR
Check the wiring connections first.
NOTE: *Terminals L in the alternator are water-resistant type connectors so that it is not
practical to measure voltage at these terminals. Measure voltage at terminal R in
safety relay. Check for continuity between
terminal R in safety relay and terminal L in
the alternator first.
Between 12 V
and 35 V
Between 12 Check voltage at terV and 35 V minal #2 of connector
2-A in monitor unit.
When engine starts,
alternator indicator
does not go out.
Measure voltage at
terminal L in *alternator.
Engine: Running
Less than 12 V or
35 V or higher
Engine: Running
Less than 12 V or
35 V or higher
Between 12 V
and 35 V
YES
Check voltage at
terminal L in
*alternator.
Engine: Running
NO
Key switch: ON
NO
T5-7-48
Less than 12 V or
35 V or higher
TROUBLESHOOTING / Troubleshooting C
Connector (Harness end of connector viewed from the
open end side)
Monitor Unit
Connector 2-A
Safety Relay
Connector A
#2
E
S
T183-05-04-013
Check voltage at
terminal #2 of
connector 2-A in
monitor unit.
Between 12 V
and 35 V
Less than 12 V or
Engine: Running 35 V or higher
T5-7-49
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF MONITOR DISPLAY
The data on monitor display is not displayed by
the signal directly input from the sensors except
one part. The signal data which inputs to other
controllers from the sensors once is input to the
monitor unit by using the CAN communication
and is proceeded in the logic circuit of monitor unit.
Therefore, check if the CAN communication is
normal first and check if the sensors corresponding to the trouble are normal.
Description
Data on liquid
crystal display
Data on data
display
Cause of Trouble
Neutral indicator
Forward/reverse indicator
Driving mode indicator
Hold indicator
Speedometer
Automatic mode indicator
Clutch cut-off indicator
Ride control indicator
Model
Displayed on service mode
when starting only
Clock (24 hours)
Fuel consumption amount
Average fuel consumption amount
Odometer
Displayed on service mode
when starting only
Engine speed
Displayed on service mode
when starting only
Hydraulic
oil Displayed on service mode
temperature
when starting only
Fault code
Displayed on service mode
when starting only
Transmission oil Displayed on service mode
temperature
when starting only
Other data
Displayed on normal mode
when starting only
Remainder time that hydraulic oil can be used
Remainder time that hydraulic oil filter can be
used
Remainder time that transmission oil can be
used
Remainder time that transmission oil filter can be
used
Remainder time that engine oil can be used
Remainder time that engine oil filter can be used
Remainder time that fuel filter can be used
Hour meter
Coolant temperature
T5-7-50
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF RIDE CONTROL INDICATOR
Check the wiring connections first.
YES
Disconnect connector
1-A in monitor unit.
YES Connect terminal #10 of
harness end to vehicle
frame.
Check for continuity.
When ride control
switch is turned ON,
indicator does not
light.
NO
YES
NO
Disconnect connector of
ride control switch.
Connect terminal #7 of
harness end to vehicle
frame.
Check if indicator lights.
NO
YES
NO
Disconnect connector
1-A in monitor unit.
Check if indicator goes
out.
NO
10
YES
Shorted circuit in
harness between
ride control switch
and monitor unit.
Monitor Unit
Connector 1-A
10
#7
T183-05-04-013
T5-7-51
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE COOLANT
TEMPERATURE DISPLAY
This trouble on coolant temperature operation and
data on monitor display is displayed according to
the signal from the same coolant temperature
sensors. Therefore, when this trouble occurs, the
coolant temperature operation must be faulty.
Refer to the remedy for Malfunction Coolant Temperature Operation in this group and remedy this
trouble first. Although the coolant temperature
operation is not faulty and if this trouble occurs,
the monitor unit is faulty.
T5-7-52
Code
R
L
Or
Color
Red
Blue
Orange
Code
W
G
Lg
Y
Br
Gr
Yellow
Brown
Gray
B
P
V
Color
White
Green
Light
green
Black
Pink
Violet
T5-8-1
T5-8-2
Right
Wrong
T107-07-06-001
Right
Rust
Wrong
(Deformation)
Wrong
(Separation)
T107-07-06-002
Tester Probe
FOR
DISCONNECTING
Pull and Separate Type
T107-04-05-004
IMPORTANT: Before pulling and separating, release the lock of connector in the
solenoid valve by using a pair of
pincers.
T107-04-05-002
T107-04-05-003
T4GB-05-06-003
T5-8-3
T4GB-05-06-001
T4GB-05-06-002
T4GB-05-06-007
T5-8-4
T5-8-5
T5-8-6
(Fuse Box B)
10
20
30
40
19
29
39
18
17
16
15
4
3
14
13
12
11
28
27
26
25
24
23
22
21
38
37
36
35
34
33
32
31
M178-07-034
T5-8-7
M178-07-034
Replacement
1. Check if the negative cable is removed from either battery box from left and right of the machine.
2. Open the engine cover on left side of the machine with the front attachment side forward.
3. Remove bolts (M10) (2 used) from the L type
cover. Remove the cover. There are fusible links
(65A) (2 used).
4. Open the black box. There are fusible links (50A)
(2 used) (100A in total).
5. Pull out and replace the fusible link.
6. Install the negative cable to the battery.
T4GB-05-06-008
T5-8-8
Ground to vehicle
frame.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace
the battery.
4. Start the engine. Check voltage between the
battery positive terminal and the vehicle frame
(ground).
Normal Voltage: 26 to 28 V
T4GB-05-06-004
T5-8-9
Battery Positive
Terminal
T4GB-05-06-006
T5-8-10
T5-8-11
Connect to
the vehicle
frame.
Connect to
the vehicle
frame.
Short-circuit
between the
harness and
the vehicle
frame.
T107-07-05-003
T5-8-12
First short-circuit
A
B
C
a
b
c
Second short-circuit
T107-07-05-004
a
b
c
T107-07-05-005
T5-8-13
AND
CURRENT
MEASURE-
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 Probe (Negative) of Tester:
To ground to the vehicle frame
Red Probe (Positive) of Tester:
To touch the location to be measured
Engine
Power Source
Circuit
Key Switch
Location to be Measured
Specification
OFF
OFF
OFF
OFF
OFF
OFF
10 to 12.5 V
10 to 12.5 V
20 to 25 V
20 to 25 V
20 to 25 V
6 mA
START
START
20 to 25 V
20 to 25 V
START
START
START
START
START
START
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
Fast Speed
ON
26 to 30 V
Fast Speed
ON
Fast Speed
Fast Speed
ON
ON
ONOFF
ONOFF
ONOFF
ONOFF
26 to 30 V
13 to 30 V
26 to 30 V
26 to 30 V
ON
20 to 25 V
Stopped
Stopped
Stopped
Stopped
Stopped
Stopped
Preheat Circuit
Started
Started
Starting Circuit
Started
Started
Started
Started
Started
Started
Charging Circuit
26 to 30 V
13 to 30 V
13 to 30 V
Surge Voltage
Prevention Circuit
Idle Speed
Idle Speed
Idle Speed
Idle Speed
Accessory Circuit
Stopped
T5-8-14
8
Fuse Box A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
48
MC
592
TCU
Load Damp
Relay
GPS
464
Neutral Relay
594
76
ICX
1 3 54 2
1 3 54 2
33
Monitor
Unit
17
67
119
233
16
Radio
Fuse Box B
60
56
283
284
233
24
Glow Relay
ECM
119
117
114
120
118
115
Glow Plug
Fuel
Injection
Solenoid
Valve
18
Coolant
Temperature
Sensor
3
Battery Relay
13
Starter Relay 1
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Battery
Fusible Link
Fuse (100A)
10
15
11
14
Starter Motor
12
T4GB-05-06-009
T5-8-15
Signal or
Ground
Power
Power
Source
Source
1
Two Polarities
Key switch: ON
Tester black probe (negative):
T107-07-05-006
Evaluation:
If the measured voltage is within 50.5 V, the circuit
up to terminal of 5V power source is normal.
IMPORTANT: Altough terminal #1 is the teminal of
power source on the illustlation, all
the terminals are not terminals of
power source. Before measurement,
check the electrical circuit diagram
for the connector to be measured.
Power
Source Signal Ground
1
2
3
Three Polarities
Power
Source
Two Polarities
T107-07-05-007
Signal or
Ground
2
Key switch: ON
Tester black probe:
Ground terminal
(terminal #2 or #3)
Tester red probe:
Terminal of 5V power source
Evaluation:
If the measured voltage is within 50.5 V, the
circuits up to terminal of 5V power source and
ground terminal are normal.
Three Polarities
T5-8-16
Power
Source
1
T107-07-05-008
Signal
2
Ground
3
T107-07-05-009
Two Polarities
Power
Source
Signal
Connect
T107-07-05-010
Three Polarities
Power
Source Signal Ground
1
Connect
T107-07-05-011
T5-8-17
T5-8-18
MEMO
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MODEL:
PUBLICATION NO.:
YOUR NAME:
DATE:
FAX:
PAGE NO.:
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REPLY: