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93209-00770
SECTION AND GROUP SECTION 4 OPERATIONAL

PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
SHOP MANUAL Group 5 Component Test
Group 6 Adjustments
(Troubleshooting)
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner
All information, illustrations and

specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
(Blank)
INTRODUCTION
To The Reader
This manual is written for an experienced technician to
provide technical information needed to maintain and
repair this machine.
 Be sure to thoroughly read this manual for correct

product information and service procedures.
Additional References
Please refer to the other materials (operation and
maintenance manual, parts catalog, engine technical
material, Kawasaki shop materials, etc.) in addition to this
manual.
Manual Composition
Our shop manuals consist of the Technical Manual, the  Information included in the Workshop Manual:
Workshop Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for machine pre-delivery removal / installation and assembly / disassembly
and delivery, operation and activation of all devices procedures.
and systems, operational performance tests, and
troubleshooting procedures.  Information included in the Engine Manual:
Technical information needed for machine pre-delivery
and delivery and maintenance and repair of the machine,
operation and activation of all devices and systems,
troubleshooting and assembly / disassembly procedures.
Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual (Disassembly & Reassembly)
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group
IN-01
INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential dCAUTION:
for personal injury of machine damage. Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate
fNOTE:
Indicates supplementary technical information.
lifting techniques and equipment when lifting heavy
parts.
Units Used
SI Units (International System of Units) are used in this Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
manual. MKSA (Meter, Kilogram, Second, Ampere) system
units and English units are also indicated in parentheses A table for conversion from SI units to other system units
just behind SI units. is shown below for reference purposes.
Quantity To Convert From Into Multiply By

Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3 yd3 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm2 10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min-1 rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
fNOTE: The numerical value in this manual might be
different from the above-mentioned table.
IN-02
Symbol and Abbreviation
Symbol / Name Explanation

Abbreviation
S/M Shop Manual Shop Manual
T/C Torque Converter Torque Converter
T/M Transmission Transmission
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
DCU Dozing Control Unit DCU is the central control for the diesel exhaust fluid dosing
system and handles the dosing activity, tank level sensing
and tank temperature sensing.
VGS Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged
VGT Variable Geometry Turbo system to supercharge the exhaust energy while running
the engine at slow idle speed. VGS optimizes the turbine
rotation, improves the performance at slow-speed torque
and the acceleration, reduces fuel consumption, and reduces
particulate matter (PM) by adjusting the nozzle opening of
turbine housing.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
HVAC Heating, Ventilation, and Air Conditioning
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
ATT Attachment Front attachment, such as bucket
SY-1
(Blank)
SY-2
SAFETY
Recognize Safety Information
 These are the SAFETY ALERT SYMBOLS.
 When you see these symbols on your machine or in this

manual, be alert to the potential for personal injury.
 Follow recommended precautions and safe operating
practices.
SA-688
Understand Signal Words

 On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
 DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.
 WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
 CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
 DANGER or WARNING safety signs signs are located
near specific hazards. General precautions are listed on
CAUTION safety signs.
 Some safety signs do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
 CAUTION also calls attention to safety messages in this

manual.
 To avoid confusing machine protection with personal SA-1223

safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.
 f NOTE indicates an additional explanation for an

element of information.
SA-1
SAFETY
Follow Safety Instructions
 Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
 Learn how to operate the machine and its controls correctly
and safely.
 Allow only trained, qualified, authorized personnel to
operate the machine.
 Keep your machine in proper working condition. SA-003
 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused
by unauthorized modifications will void KCM Warranty
Policy.
 Never attempt to modify or disassemble the inlet/exhaust
parts and the muffler filter. Avoid giving shocks on the
muffler filter by striking elements with other objects or
dropping the elements. Failure to do so may affect the
exhaust gas purifying device, possibly damaging it or
lowering its performance.
 Do not use attachments and/or optional parts or
equipment not authorized by KCM. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
KCM Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.
SA-2
SAFETY
Prepare for Emergencies
 Be prepared if a fire starts or if an accident occurs.
 Keep a first aid kit and fire extinguisher on hand.

 Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
 To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
 Establish emergency procedure guidelines to cope with
fires and accidents.
 Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your SA-437
telephone.
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
SA-438
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
 Avoid wearing loose clothing, jewelry, or other items that

can catch on control levers or other parts of the machine.
 Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones while
operating the machine.
SA-3
SAFETY
Protect Against Noise
 Prolonged exposure to loud noise can cause impairment or
loss of hearing.
 Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
SA-434
Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
 In the walk-around inspection, be sure to cover all points

described in the “Inspect Machine Daily Before Starting”
section in the operator’s manual.
SA-435
SA-4
SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not mess up around the operator's seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
accelerator pedal, brake pedals, control lever lock switch
or control levers, which may result in serious injury or
death.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
 Keep all flammable objects and/or explosives away from
the machine.
 After using the ashtray, always cover it to extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
 Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact
with the accelerator or brake pedals during operation,
resulting in serious injury or death.
SA-5
SAFETY
Use Handrails and Steps

 Falling is one of the major causes of personal injury.
 When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
 Do not use any controls as handholds.

 Never jump on or off the machine. Never mount or
dismount a moving machine.
 Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
 Never get on and off the machine with tools in your
hands.
SA-439
Never Ride Attachment

 Never allow anyone to ride attachment or the load. This is
an extremely dangerous practice.
Adjust Operator’s Seat

 A poorly adjusted seat for either the operator or the
work at hand may quickly fatigue the operator leading to
misoperations.
 The seat should be adjusted whenever changing the

operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror SA-462
is broken, immediately replace it with a new one.
SA-6
SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open / close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the control lever lock switch to the lock ( ) position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.
 Before leaving the machine, be sure to first lower the front

attachment to the ground and then move the control
lever lock switch to the lock ( ) position. Turn the key
switch OFF to stop the engine.
 Before leaving the machine, close all windows, doors, and
access covers and lock them up.
Fasten Your Seat Belt

 If the machine should overturn, the operator may become
injured and / or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
 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. SA-237
 We recommend that the seat belt be replaced every four
years regardless of its apparent condition.
SA-7
SAFETY
Move and Operate Machine Safely
 Bystanders can be run over.
 Take extra care not to run over bystanders. Confirm the

location of bystanders before moving, or operating the
machine.
 Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
 Use a signal person when moving, or operating the
machine in congested areas. Coordinate hand signals
before starting the machine.
 Use appropriate illumination. Check that all lights are SA-398
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
 Ensure the cab door, windows, doors and covers are
securely locked.
 Check the mirrors and the monitor in the CAB for
problems.
If there is any problem, replace the problem part(s) or
clean the mirror, camera and the monitor.
Refer to Rear View Monitor section on the cleaning of the
camera and the monitor.
Handle Starting Aids Safely

Starting fluid:
 Starting fluid is highly flammable.
 Keep all sparks and flame away when using it.

 Keep starting fluid well away from batteries and cables.
 Remove container from machine if engine does not need
starting fluid.
 To prevent accidental discharge when storing a
pressurized container, keep the cap on the container, and
store it in a cool, well-protected location.
 Do not incinerate or puncture a starting fluid container.
SA-293
SA-8
SAFETY
Operate Only from Operator’s Seat
 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
 Start the engine only when seated in the operator's seat.

 NEVER start the engine while standing on the tire or on
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-431
Jump Starting
 Battery gas can explode, resulting in serious injury.
 If the engine must be jump started, be sure to follow the

instructions shown in the “OPERATING ENGINE” chapter in
the operator’s manual.
 The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
 Never use a frozen battery.
 Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
SA-9
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. SA-447
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
SA-10
SAFETY
Equipment of Head Guard, ROPS, FOPS
In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)
Any modification of the ROPS structure will modify its
performances and its certification will be lost.
ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure
SA-521
Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.
SA-481
SA-11
SAFETY
Keep Riders Off Machine
 Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
 Only the operator should be on the machine. Keep riders

off.
 Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-427
Drive Safely
 Beware of the possibility of slipping and / or turning over
the machine when driving on a slope.
 When driving on level ground, hold the bucket at mark

(A) 300 mm (12 in) above the ground as illustrated.
 Avoid traveling over any obstacles.
 Drive the machine slowly when driving on rough terrain.
 Avoid quick direction changes. Failure to do so may cause
the machine to turn over.
 If the engine stops while driving, the steering function
becomes inoperative. Immediately stop the machine by
applying the brake to prevent personal accident.
SA-448
SA-12
SAFETY
Drive Machine Safely (Work Site)
 Before driving the machine, always confirm that the
steering wheel / and forward / reverse lever (switch)
direction corresponds to the direction you wish to drive.
 Be sure to detour around any obstructions.
 Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
SA-449
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 200 to 300 mm
(approximately 8 to 12 in) (A) above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a slope

may cause the machine to skid or overturn. If the direction
must be changed, move the machine to level ground, then,
change the direction to ensure safe operation.
SA-450
WRONG
SA-451
SA-13
SAFETY
Drive Safely with Bucket Loaded
 If the machine is incorrectly operated while driving with the
bucket loaded, turning over of the machine may result. Be
sure to follow all the instructions indicated below.
 When driving the machine on a job site with the bucket

loaded, hold the bucket as low as possible to keep the
machine balanced and to have good visibility.
 Do not exceed the rated load capacity. Always operate
the machine within the rated load capacity.
 Avoid fast starts, stops, and quick turns. Failure to do so
may result in personal injury and / or death.
 Avoid rapid drive direction changes which could possibly SA-400
cause personal injury and / or death.
Drive on Snow Safely

 Beware of the possibility of slipping or turning over the
machine when driving on frozen snow surfaces.
 The machine may slip more easily than expected on

frozen snow surfaces even if the inclination is small.
Reduce speed when driving. Avoid fast starts, stops and
quick turns.
 Road shoulder and / or set-up utilities covered with snow
are difficult to locate. Be sure where they are before
removing snow.
SA-452
 Be sure to use tire chains when driving on snow.
 Avoid applying the brake for quick stops on snow. If a
quick stop is required, lower the bucket to the ground.
SA-14
SAFETY
Travel on Public Roads Safely
 This machine is not allowed to drive on public roads with
the bucket loaded.
 Be sure to empty the bucket.

 Hold the bucket at mark (A) 300 mm (12 in) above the
road surface as illustrated.
SA-453
Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
 Select level ground when possible to park machine.
 Do not park the machine on a grade.
 Lower the bucket to the ground.
 Put the forward / reverse lever (switch) in neutral, and pull
up the parking brake switch (lever) in the ON (parking
brake) position. SA-457
 Run the engine at low idle speed without load for 5
minutes to cool down the engine.
 Stop the engine and remove the key from the key switch.
 Turn the control lever lock switch to the lock ( ) position.
 Block both tires and lower the bucket to the ground.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.
SA-458
SA-15
SAFETY
Avoid Accidents from Backing Up and Turning
 Make sure no one is working under or close to the machine
before backing up or turning the machine to avoid personal
injury and / or death by being run over or entangled in the
machine.
 Keep all personnel away from the machine by sounding

the horn and / or using hand signals. Use extra care to be
sure no one is in from the articulation area before turning
the machine.
 Keep windows, mirrors, and lights in good condition.
 Reduce travel speed when dust, heavy rain, fog, etc.,
reduce the visibility.
 In case good visibility is not obtained, use a signal person SA-383
to guide you.
SA-312
SA-16
SAFETY
Avoid Positioning Bucket or Attachment Over
Anyone
 Never allow the bucket or attachment to pass over co-
workers and / or the dump truck operator’s cab. Falling soil
from the bucket or contact with bucket or attachment may
cause serious personal accidents and / or damage to the
machine.
 Avoid carrying the bucket or attachment over the co-

workers to ensure safe operation.
SA-518
Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS
PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE
MACHINE IS PREDICTED, SECURELY HOLD THE STEERING
WHEEL TO PREVENT YOUR BODY FROM BEING THROWN
OUT OF THE MACHINE.
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
SA-463
FASTEN YOUR SEAT BELT
 The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
 Be extra careful before operating on a grade.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the
machine.
 Reduce operating speeds to avoid tipping or slipping.
 Avoid changing direction when traveling on grades.
 NEVER attempt to travel across a grade steeper than 5
degrees if crossing the grade is unavoidable.
 Reduce swing speed as necessary when swinging loads.
 Be careful when working on frozen ground.
 Temperature increases will cause the ground to become

soft and make ground travel unstable.
SA-17
SAFETY
Never Undercut a High Bank
 The edges could collapse or a land slide could occur causing
SA-519
Dig with Caution

 Accidental severing of underground cables or gas lines may
cause an explosion and / or fire, possibly resulting in serious
injury or death.
 Before digging, check the location of cables, gas lines, and

water lines.
 Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
 If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
SA-396
 Contact your local “diggers hot line” if available in your
area , and / or the utility companies directly.
Have them mark all underground utilities.
Perform Truck Loading Safely

 Do not operate the machine involuntarily. Unexpected
machine movement may cause personal injury and / or
death.
 Do not lower the bucket with the lift arm control lever
in the FLOAT position. The bucket may free fall, possibly
causing personal injury and / or death.
 Always select a level surface for truck loading.
SA-397
SA-18
SAFETY
Avoid Power Lines
Serious injury or death can result from contact with electric
lines.
Never move any part of the machine or load closer to any

electric line than 3 m (10 ft) plus twice the line insulator
length.
SA-455
Precautions for Operation

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

obstacles with the bucket or arm during operation.
Precautions for Lightning

 The machine is vulnerable to lightning strikes.
 In the event of an electrical storm, immediately stop

operation, and lower the bucket to the ground. Evacuate
to a safe place far away from the machine.
 After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only after
repairing them.
SA-19
SAFETY
Object Handling
CRANING OPERATION USING THE MACHINE IS NOT
ALLOWED.
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
Never attach a sling or chain to the bucket teeth or to the

attachment (fork or grapple for example). They may come
off, causing the load to fall.
SA-132
Protect Against Flying Debris

 If flying debris hit eyes or any other part of the body, serious
injury may result.
 Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.
 Keep bystanders away from the working area before
striking any object.
SA-432
SA-20
SAFETY
Park Machine Safely
To avoid accidents:
 Park the machine on a firm, level surface.
 Lower bucket to the ground.
 Put the forward / reverse lever (switch) in neutral, and
turn the parking brake switch (lever) ON (parking brake)
position.
 Run the engine at low idle speed without load for 5
minutes.
 Turn key switch to OFF to stop engine.
 Remove the key from the key switch.
SA-456
 Turn the control lever lock switch to the lock ( ) position.
 Close windows, roof vent, and cab door.
 Lock all access doors and compartments.
Store Attachments Safely

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 Securely store attachments and implements to prevent

falling. Keep children and bystanders away from storage
areas.
SA-034
SA-21
SAFETY
Transport Safely
 Take care that the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
 Observe the related regulations and rules for safe

transportation.
 Select an appropriate truck or trailer for the machine to Less than 15 °
be transported.
 Be sure to use a signal person.
SA-454
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight.
3. Use the low speed gear.
4. Never steer the machine while being on the ramp. If the
traveling direction must be changed while being on the
ramp, unload the machine from the ramp, reposition the
machine on the ground, then try loading again.
5. After loading, install the lock bar to securely hold the
articulation mechanism.
6. Wedge the front and rear of tires. Securely hold the
machine to the truck or trailer deck with wire ropes.
Be sure to further follow the details described in the

TRANSPORTING chapter.
SA-22
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
 Do not refuel the machine while smoking or when near

open flame or sparks.
 Always stop the engine before refueling the machine.
 Fill the fuel tank outdoors.
 All fuels, most lubricants, and some coolants are flammable.

SA-018
 Store flammable fluids well away from fire hazards.
 Do not incinerate or puncture pressurized containers.
 Do not store oily rags; they can ignite and burn
spontaneously.
 Securely tighten the fuel and oil filler caps.
SA-019
SA-23
SAFETY
Practice Safe Maintenance
To avoid accidents:
 Understand service procedures before starting work.
 Keep the work area clean and dry.
 Do not spray water or steam inside cab.
 Never lubricate or service the machine while it is moving.
 Keep hands, feet and clothing away from power-driven
parts.
Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Run the engine at low idle speed without load for 5
SA-028
minutes.
4. Turn the key switch to OFF to stop engine.
5. Relieve the pressure in the hydraulic system by moving
the control levers several times.
6. Remove the key from the key switch.
7. Attach a “Do Not Operate” tag on the control lever.
8. Turn the control lever lock switch to the lock ( ) position.
9. Lock bar connects the front and rear frames.
10. Allow the engine to cool.
 If a maintenance procedure must be performed with the SA-312

engine running, do not leave machine unattended.
 Never work under a machine raised by the lift arm.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter of this manual.
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (-) before making
adjustments to electrical systems or before performing
SA-134
welding on the machine.
SA-527
SA-24
SAFETY
 Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
 Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid,
or window washer fluid may catch fire.
SA-037
Warn Others of Service Work

 Unexpected machine movement can cause serious injury.
 Before performing any work on the machine, attach a “Do

Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
Support Machine Properly

 Never attempt to work on the machine without securing
the machine first.
 Always lower the attachment to the ground before you

work on the machine.
 If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
SA-527
SA-25
SAFETY
Stay Clear of Moving Parts
 Entanglement in moving parts can cause serious injury.
 To prevent accidents, care should be taken to ensure that

hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
SA-026
Support Maintenance Properly

 Explosive separation of a tire and rim parts can cause
 Do not attempt to mount a tire unless you have the

proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
 Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
 When inflating tires, use a chip-on chuck and extension
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
if available.
 Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
 Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and
SA-249
may result in tire explosion.
SA-26
SAFETY
Prevent Parts from Flying
 Travel reduction gears are under pressure.
 As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
 GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
SA-344
Prevent Burns
Hot spraying fluids:
 After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
 Avoid possible injury from hot spraying water. DO NOT

remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to SA-039
release all pressure before removing the cap.
Hot fluids and surfaces:
 Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
 Wait for the oil and components to cool before starting

any maintenance or inspection work.
SA-225
SA-27
SAFETY
Replace Rubber Hoses Periodically
 Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
 Periodically replace the rubber hoses. (See the page of

“Periodic replacement of parts” in the operator’s manual.)
 Failure to periodically replace rubber hoses may cause a fire,

fluid injection into skin, or the front attachment to fall on a
person nearby, which may result in severe burns, gangrene, SA-019
or otherwise serious injury or death.
Avoid High-Pressure Fluids

 Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
 Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
SA-031
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours, or
gangrene may result.
SA-292
SA-044
SA-28
SAFETY
Prevent Fires
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to fires.
 Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
 Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
 Do not bend or strike high-pressure lines.
 Never install bent or damaged lines, pipes, or hoses.
 Replace fuel hoses and hydraulic hoses periodically even
SA-019
if there is no abnormality in their external appearance.
Check for Shorts:

 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
 Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.
SA-29
SAFETY
Clean up Flammables:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammables immediately. Check and clean high
temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammables away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammables such as
dead leaves from entering. However, flammables which
have passed through the wire screen may cause fires.
Check and clean the machine every day and immediately
remove accumulated flammables.
Check Key Switch:

 If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at low idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
 If any abnormalities are found, be sure to repair them
before operating the machine.
Check Heat Shields:

 Damaged or missing heat shields may lead to fires.
 Damaged or missing heat shields must be repaired or
replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as mufflers may cause fire. Always close the engine cover
while operating the machine.
SA-30
SAFETY
Evacuating in Case of Fire
 If a fire breaks out, evacuate the machine in the following
way:
 Stop the engine by turning the key switch to the OFF

position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 In an emergency, if the cab door can not be opened,
break the front or rear window panes with the emergency
evacuation hammer to escape from the cab. Refer to the
explanation pages on the Emergency Evacuation Method. SA-393
SS-1510
Beware of Exhaust Fumes

 Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
 If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
 PM (Particle Matter) combustion may generate white
smoke during muffler filter regeneration. Do not attempt
to do muffler filter manual regeneration in a badly
ventilated indoors. SA-016
Precautions for Welding and Grinding

 Welding may generate gas and / or small fires.
 Be sure to perform welding in a well ventilated and

prepared area. Store flammable objects in a safe place
before starting welding.
 Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
 Grinding on the machine may create fire hazards. Store

flammable objects in a safe place before starting grinding.
 After finishing welding and grinding, recheck that there are

SA-818
no abnormalities such as the area surrounding the welded
area still smoldering.
SA-31
SAFETY
Avoid Heating Near Pressurized Fluid Lines
 Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
 Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
 Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc..
Avoid Applying Heat to Lines Containing SA-030

Flammable Fluids
 Do not weld or flame cut pipes or tubes that contain
flammable fluids.
 Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
Precautions for Handling Accumulator and Gas

Damper
High-pressure nitrogen gas is sealed in the accumulator and
the gas damper. Inappropriate handling may cause explosion,
possibly resulting in serious injury or death.
Strictly comply with the following items:

 Do not disassemble the unit.
 Keep the units away from open flames and fire.
 Do not bore a hole, do not cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing the unit, sealed gas must be released.
Consult your nearest authorized dealer.
SA-32
SAFETY
Remove Paint Before Welding or Heating
 Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
 Avoid potentially toxic fumes and dust.

 Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
 Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
Beware of Asbestos and Silicon Dust and Other

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer.
Inhalation of silicon dust and other contamination may
cause sickness.
 Depending on the work site conditions, the risk

of inhaling asbestos fiber, silicon dust or other
contamination may exist. Spray water to prevent asbestos
fibers, silicon dust or other contamination from becoming
airborne. Do not use compressed air.
 When operating the machine in a work site where SA-029
asbestos fibers, silicon dust or other contamination
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contamination.
 Keep bystanders out of the work site during operation.
 Asbestos might be present in imitation parts. Use only
genuine KCM/Hitachi Parts.
SA-33
SAFETY
Prevent Battery Explosions
 Battery gas can explode.
 Keep sparks, lighted matches, and flame away from the

top of battery.
 Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
 Do not charge a frozen battery; it may explode. Warm the
battery to 16 °C (60 °F) first.
 Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the
battery may result.
 Loose terminals may produce sparks. Securely tighten all
SA-032
terminals.
 Connect terminals to the correct electrical poles. Failure
to do so may cause damage to the electrical parts or fire.
 Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into eyes,
possibly resulting in blindness.
 Be sure to wear eye protection when checking electrolyte
specific gravity.
Service Air Conditioning System Safely

 If spilled onto skin, refrigerant may cause a cold contact
burn.
 Refer to the instructions described on the container for

proper use when handling the refrigerant.
 Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
 Never touch the refrigerant.
SA-405
SA-34
SAFETY
Handle Chemical Products Safely
 Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.
 A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
 Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and use recommended equipment.
SA-309
 See your authorized dealer for MSDS’s (available only in
English) on chemical products used with your machine.
Dispose of Waste Properly

 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with KCM equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
 Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.
 Do not pour waste onto the ground, down a drain, or into
any water source.
 Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to SA-226
recover and recycle used air conditioning refrigerants.
 Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
SA-35
SAFETY
Notes for Muffler Filter
Muffler Filter
The muffler filter removes particle matters (PM) in
the exhaust gas. The muffler filter traps PM, and it is
automatically regenerated by burning PM when the set
amount of PM is accumulated in the filter. Follow the
instructions below to prevent the muffler filter from being
damaged.
dWARNING: Exhaust gas from the muffler filter, muffler

and exhaust piping becomes hot during and right
after engine running and filter regeneration (burning
PM). Keep away from the direction of the exhaust
piping and its vicinity during the filter regeneration.
Be careful not to let your skin contact with any hot gas
from the exhaust piping. It may cause severe burns.
Do not directly touch water coming out of the muffler filter.

The water is mildly-acidic by oxidation catalyst mounted
in the muffler filter. If filter water spills on your skin,
immediately flush it out with clean water.
Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.
SA-36
SAFETY
Precaution for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which is
situated at the back of the driver's seat. There is a possibility
that a medical device, including an implantable device
such as a cardiac pacemaker, would be affected and would
malfunction by the electrical waves emitted from the
communication terminal equipment.
Any person affixed with a medical device such as the above

should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.662 inches) apart at MNEC-01-046
all times. If such condition cannot be met, please contact our
company's nearest dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.
Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipment:
Model A Model B
E-GSM900 0.573 W/Kg 0.12 W/Kg
(914.8 MHz) (897.6 MHz)
DCS-1800 0.130 W/Kg 0.06 W/Kg
(1710.2 MHz) (1748.0 MHz)
WCDMA Band I 0.271 W/Kg 0.05 W/Kg
(1950.0 MHz) (1950.0 MHz)
WCDMA Band VIII - 0.10 W/Kg
(892.6 MHz)
fNOTE: Please contact to your authorized representative

if you want to know which terminal type A or B is installed.
* This data was measured by having each type of

communication terminal equipment, such as the
communication terminal equipment used with this machine,
and a human body set apart by 3 cm (1.18 inches).
* SAR is a measure of the amount of radio frequency energy
absorbed by the body when using a wireless application such
as a mobile phone.
In Japan: * Under the Japanese Radio Act and other relevant

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).
In EU Member nation: * Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).
SA-37
SAFETY
 Never attempt to disassemble, repair, modify or displace the
communication terminal, antennas or cables. Failure to do
so may result in damage and/or fire to the base machine or
to the communication terminal. (When required to remove
or install the communication terminal, consult your nearest
authorized dealer.)
 Do not pinch or forcibly pull cables, cords or connectors.

Failure to do so may cause short circuit or broken circuit
that may result in damage and/or fire to the base machine
or to the communication terminal.
SA-38
SAFETY
Before Returning the Machine to the Customer
 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced.
SA-435
SA-39
SAFETY
(Blank)
SA-40
SECTION 4
OPERATIONAL PERFORMANCE TEST

CONTENTS
Operational Performance Tests....................................... T4-1-1
Preparation for Performance Tests................................ T4-1-2
Group 2 Standard
Operational Performance Standard Table.................. T4-2-1
Main Pump P-Q Diagram................................................T4-2-10
Sensor Activating Range.................................................T4-2-12
Group 3 Engine Test
Engine Speed........................................................................ T4-3-1
Lubricant Consumption.................................................... T4-3-3
Travel Speed.......................................................................... T4-4-1
Service Brake Function Check......................................... T4-4-4
Service Brake Wear Amount............................................. T4-4-6
Parking Brake Function Check........................................ T4-4-7
Bucket Stopper and Bell Crank Stopper
Clearance........................................................................... T4-4-8
Hydraulic Cylinder Cycle Time.......................................T4-4-10
Dig Function Drift Check.................................................T4-4-12
Bucket Levelness................................................................T4-4-13
Control Lever Operating Force......................................T4-4-14
Control Lever Stroke.........................................................T4-4-16
Group 5 Component Test
Primary Pilot Pressure (Including Brake Circuit)....... T4-5-1
Secondary Pilot Pressure................................................... T4-5-4
Main Pump Delivery Pressure......................................... T4-5-6
Main Relief Set Pressure.................................................... T4-5-8
Steering Relief Pressure...................................................T4-5-12
Overload Relief Valve Set Pressure..............................T4-5-14
Main Pump Flow Rate Measurement.........................T4-5-16
Service Brake Pressure (Front and Rear) ...................T4-5-24
Parking Brake Pressure.....................................................T4-5-26
Brake Accumulator Pressure .........................................T4-5-28
Brake Warning Pressure (Pressure-Decreasing)......T4-5-30
Brake Warning Pressure (Pressure-Increasing)........T4-5-32
Transmission Clutch Pressure........................................T4-5-34
Torque Converter Pressure (Inlet)................................T4-5-36
Group 6 Adjustment
Transmission Learning....................................................... T4-6-1
Lift Arm Angle Sensor Learning...................................... T4-6-5
Digging Position Adjustment.......................................... T4-6-7
80Z6 Trbl
(Blank)
80Z6 Trbl
SECTION 4 OPERATIONAL PERFORMANCE TEST
Operational Performance Tests

Use operational performance test procedure to The machine performance does not always deteriorate
quantitatively check all system and functions on the as the working hours increase. However, the machine
machine. performance is normally considered to reduce in
proportion to the increase of the operation hours.
Purpose of Performance Tests Accordingly, restoring the machine performance by
repair, adjustment, or replacement shall consider the
1. To comprehensively evaluate each operational
number of the machine’s working hours.
function by comparing the performance test data
with the standard values.
Definition of “Performance Standard”
2. According to the evaluation results, repair, adjust, or
1. Operation speed values and dimensions of the new
replace parts or components as necessary to restore
machine.
the machine’s performance to the desired standard.
2. Operational performance of new components
3. To economically operate the machine under
adjusted to specifications. Allowable errors will be
optimal conditions.
indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, and hydraulic cylinders.
2. Hydraulic component unit test is to check the
operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evaluate
the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
Preparation for Performance Tests

Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on, before
starting to test.
TEST AREA and TOOL

1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 200 m (656 ft 2 in), and to make
the steering operate.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
4. Prepare the measuring instruments and tools. Use
MPDr. if possible.
PRECAUTIONS
1. Before starting to test, agree upon the signals to be
employed for communication among coworkers.
Once the test is started, be sure to communicate
with each other using these signals, and to follow
them without fail.
2. Operate the machine carefully and always give first
priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance to
obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test data
obtained can be produced repeatedly. Use mean
values of measurements if necessary.
T4-1-2
Group 2 Standard
Operational Performance Standard Table The following switch positions shall be selected and the
hydraulic oil temperature shall be maintained as indicated
The standard Performance values are listed in the table below as the preconditions of performance tests unless
below. otherwise instructed in each performance test procedure:
Refer to the Group T4-3 to T4-5 for performance test  Accelerator Pedal: Full Stroke
procedures.  Power Mode Switch: ON
Values indicated in parentheses are reference values.  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
Performance Test Designation Unit Performance Remarks Reference

Standard Page
Engine Speed min-1 Power mode switch: OFF T4-3-1
Slow Idle Speed (without load) 800±25 Value indicated on MPDr.
Fast Idle Speed (without load) 2280±30 Value indicated on MPDr.
Fast Idle Speed (with torque 1920±50 Second- speed forward,
converter stalled) Value indicated on MPDr.
Fast Idle Speed (with torque 1660±50 Third- speed forward, Value
converter stalled and relieved) indicated on MPDr.
Engine Speed min-1 Power mode switch: ON T4-3-1
Slow Idle Speed (without load) 800±25 Value indicated on MPDr.
Fast Idle Speed (without load) 2320±30 Value indicated on MPDr.
Fast Idle Speed (with torque 2110±50 Second- speed forward,
converter stalled) Value indicated on MPDr.
Fast Idle Speed (with torque 1820±50 Third- speed forward, Value
converter stalled and relieved) indicated on MPDr.
Valve Clearance (In, Ex) mm (in) In: 0.254 (0.010) With the engine cold Refer to
Ex: 0.508 (0.020) Engine Manual
Lubricant Consumption (Rated mL/h 50 or less Hour meter: 2000 hours T4-3-4
output) or less
T4-2-1
Group 2 Standard

Standard Page
Travel Speed km/h (mph) Power mode switch: OFF T4-4-1
First Speed (Forward/Reverse) 6.4±0.6/6.8±0.7 Value indicated on MPDr.
(4.0±0.3/4.2±0.4)
Second Speed (Forward/Reverse) 11.0±1.1/11.5±1.1 Value indicated on MPDr.
(6.8±0.6/7.1±0.6)
Third Speed (Forward/Reverse) 16.4±1.6/25.0±2.5 Value indicated on MPDr.
(10.0±0.9/15.5±1.5)
Fourth Speed (Forward) 23.6±2.4 (14.7±1.4) Value indicated on MPDr.
Fifth Speed (Forward) 37.1±3.6 (23.0±2.2)
Travel Speed km/h (mph) Power mode switch: ON T4-4-1
First Speed (Forward/Reverse) 6.4±0.6/6.8±0.7 Value indicated on MPDr.
(3.9±0.3/4.2±0.4)
Second Speed (Forward/Reverse) 11.6±1.2/12.2±1.2 Value indicated on MPDr.
(7.2±0.7/7.6±0.7)
Third Speed (Forward/Reverse) 17.4±1.7/27.1±2.7 Value indicated on MPDr.
(10.8±1.0/16.8±1.7)
Fourth Speed (Forward) 25.9±2.6 (16.1±1.6) Value indicated on MPDr.
Fifth Speed (Forward) 37.1±3.7 (23.1±2.3)
Service Brake Function Check m (ft) 12 (39) or less Vehicle speed: 35±3 km/h T4-4-4
(21.7±1.8 mph)
Service Brake Wear Amount mm (in) T4-4-6
CLUCH Disc (Out Put Side) -
CLUCH Disc (Piston In Put Side) - Allowable limit: 3.5 (0.14)
Parking Brake Function Check mm/5 min 0 T4-4-7
Parking Brake Wear Amount mm -
Brake Disc 2.2 (0.1) Allowable limit: 1.9 (0.07)
Brake Pad 6.0 (0.2) Allowable limit: 4.5 (0.18)
Bucket Stopper Clearance mm 0 T4-4-8
Bell Crank Stopper Clearance mm 2 (0.1) T4-4-8
Front Pin Wear Amount mm - Allowable limit: -1.0 (-0.03) -
Front Bushing Wear Amount mm - Allowable limit: -1.5 (-0.05) -
Clearance Between Front Pin and mm 0.3 (0.01) -
Bushing
T4-2-2
Group 2 Standard

Standard Page
Hydraulic Cylinder Cycle Time sec Power mode switch: OFF T4-4-10
Lift Arm Raise 5.6±0.3
Lift Arm Lower (Float) 2.9±0.4
Bucket Dump 1.6±0.3
Steering 2.5±0.4
Hydraulic Cylinder Cycle Time sec Power mode switch: ON T4-4-10
Lift Arm Raise 5.0±0.3
Lift Arm Lower (Float) 2.9±0.4
Bucket Dump 1.5±0.3
Steering 2.5±0.4
Dig Function Drift Check mm (in)/15 min T4-4-12
Lift Arm Cylinder 15 or less (0.6)
Bucket Cylinder 10 or less (0.4)
Bucket Bottom 75 or less (3)
Bucket Levelness mm 14 or less (0.6) T4-4-13
T4-2-3
Group 2 Standard

Standard Page
Control Lever Operating Force N (kgf ) Two-lever T4-4-14
Lift Arm Raise 10 (1.0) or less
Lift Arm Raise (Detent) 16 (1.6) or less
Lift Arm Raise (Detent Release) 36 (3.6) or less
Lift Arm Lower 10 (1.0) or less
Lift Arm Lower (Float) 16 (1.6) or less
Lift Arm Lower (Float Release) 36 (3.6) or less
Bucket Control Lever Tilt 11 (1.1) or less
Bucket Control Lever Tilt (Detent) 16 (1.6) or less
Bucket Control Lever Tilt (Detent 36 (3.6) or less
Release)
Bucket Control Lever Dump 16 (1.6) or less
Steering 16 (1.6) or less
Forward/Reverse Lever 12+3-2 (1.2+0.3-0.2)
Accelerator Pedal 40±2 (4.0±0.2)
Brake Pedal (Right) 323±32 (32.9±3.3)
Inching Pedal (Left) 278±28 (28.3±2.9)
T4-2-4
Group 2 Standard

Standard Page
Control Lever Operating Force N (kgf ) MF (Joystick type) lever T4-4-14
Lift Arm Raise 20 (2.0) or less
Lift Arm Raise (Detent) 40 (4.0) or less
Lift Arm Raise (Detent Release) 50 (5.0) or less
Lift Arm Lower 20 (2.0) or less
Lift Arm Lower (Float) 40 (4.0) or less
Lift Arm Lower (Float Release) 50 (5.0) or less
Bucket Control Lever Tilt 20 (2.0) or less
Bucket Control Lever Tilt (Detent) 40 (4.0) or less
Bucket Control Lever Tilt (Detent 50 (5.0) or less
Release)
Bucket Control Lever Dump 30 (3.0) or less
Steering 16 (1.6) or less
Forward/Reverse Lever 12+3-2 (1.2+0.3-0.2)
Accelerator Pedal 40±2 (4.0±0.2)
Brake Pedal (Right) 323±32 (32.9±3.3)
Inching Pedal (Left) 278±28 (28.3±2.9)
fNOTE: MF: Multi-Function
T4-2-5
Group 2 Standard

Standard Page
Control Lever Stroke mm (in) Two-lever T4-4-16
Lift Arm Raise 42±5 (1.7±0.2)
Lift Arm Raise (Detent) 65±5 (2.6±0.2)
Lift Arm Lower 32±5 (1.3±0.2)
Lift Arm Lower (Float) 55±5 (2.2±0.2)
Bucket Control Lever Tilt 42±5 (1.7±0.2)
Bucket Control Lever Tilt (Detent) 65±5 (2.6±0.2)
Bucket Control Lever Dump 55±5 (2.2±0.2)
Steering Wheel Rotation (Right 4.0 to 4.5 (0.2)
Max. to Left Max.)
Forward/Reverse Lever 50±5 (2.0±0.2)
Steering Wheel Play 5 to 15 (0.2 to 0.6)
Brake Pedal Play 7 to 16 (0.3 to 0.6)
Control Lever Stroke mm (in) MF (Joystick type) lever T4-4-16
Lift Arm Raise 58±10 (2.3±0.4)
Lift Arm Raise (Detent) 79±10 (3.1±0.4)
Lift Arm Lower 58±10 (2.3±0.4)
Lift Arm Lower (Float) 79±10 (3.1±0.4)
Bucket Control Lever Tilt 58±10 (2.3±0.4)
Bucket Control Lever Tilt (Detent) 79±10 (3.1±0.4)
Bucket Control Lever Dump 79±10 (3.1±0.4)
Steering Wheel Rotation (Right 4.0 to 4.5 (0.2)
Max. to Left Max.)
Forward/Reverse Lever 50±5 (2.0±0.2)
Steering Wheel Play 5 to 15 (0.2±0.6)
Brake Pedal Play 4 to 13 (0.2±0.5)
fNOTE: MF: Multi-Function
T4-2-6
Group 2 Standard

Standard Page
Pedal Depressing Angle deg. (without play) T4-4-16
Accelerator Pedal 18±1
Brake Pedal (Right) 17.2±1.5
Inching Pedal (Left) 15.1±1.5
Electrolyte Density (Specification at 1.26 Allowable limit: 1.16 -
20 °C)
Tire Inflation kPa (kgf/cm2) -
Bias Tire 375 (3.8)
Radial Tire 300 (3.0)
T4-2-7
Group 2 Standard

Standard Page
Primary Pilot Pressure MPa (kgf/cm2) 4.8±0.3 (48±3) T4-5-1
Secondary Pilot Pressure MPa (kgf/cm2) 3.7+0.5-0.3 (38+5-3) T4-5-4
Main Pump Delivery Pressure MPa (kgf/cm2) 2.0+1.0-0.5 (20+10-5) In neutral, Value indicated T4-5-6
on MPDr.
Main Relief Set Pressure MPa (kgf/cm2) T4-5-8
Relief Operation of Lift Arm 27.4 -0 (280 -0)
+1.9 +19
Value indicated on MPDr.
Relief Operation of Bucket 27.4+1.9-0 (280+19-0) Value indicated on MPDr.
Steering Relief Pressure MPa (kgf/cm2) 27.4+1.9-0 (280+19-0) Value indicated on MPDr. T4-5-12
Overload Relief Pressure MPa (kgf/cm2) Reference values at 50 L/ T4-5-14
min
Lift Arm Raise 34.3+1.0-0 (350+10-0)
Bucket 30.4+1.0-0 (310+10-0)
Main Pump Flow Rate Measurement L/min - Refer to T4-2-10, 11 T4-5-16
Service Brake Pressure (Front/Rear) MPa (kgf/cm2) 6.6±0.6 (67±6) at brake pedal (right) T4-5-24
Parking Brake Pressure MPa (kgf/cm2) 10.8 to 17.0 (110 T4-5-26
to 173)
Brake Accumulator Pressure MPa (kgf/cm2) T4-5-28
Service Brake 16±1.0 (163±10)
Parking Brake 16±1.0 (163±10)
Brake Warning Pressure (Pressure- MPa (kgf/cm2) 8±0.5 (82±5) T4-5-30
Decreasing)
Brake Warning Pressure (Pressure- MPa (kgf/cm2) 10±0.5 (102±5) T4-5-32
Increasing)
Transmission Clutch Pressure MPa (kgf/cm2) 1.6 to 1.8 (16 to 18) T4-5-34
Torque Converter Pressure MPa (kgf/cm2) T4-5-36
Inlet Pressure 0.9 to 1.2 (9 to 12)
Outlet Pressure 0.45 to 0.7 (4.5 to
7.0)
T4-2-8
Group 2 Standard
(Blank)
T4-2-9
Group 2 Standard
Main Pump P-Q Diagram

 P-Q Control (Torque Control) Points on P-Q Line
(Reference: Measured at Test Stand)
Delivery Pressure Flow Rate
 Rated Pump Speed: 2200 min-1 (rpm)
MPa (kgf/cm2) L/min
 Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
A 4.9 (50) 275±3
f NOTE: Refer to T4-5-16. B 19.6 (200) 275±5
C 24.5 (250) 243±6
D 27.4 (280) 213±6
L/min A B
MPa (kgf/cm2) P
T4GB-04-02-001
T4-2-10
Group 2 Standard
 P-Q Control by Pump Control Pilot Pressure Signal

(Reference: Measured at Test Stand)
 Rated Pump Speed: 2200 min-1 (rpm) Points on P-Q Line
 Hydraulic Oil Temperature: 50±5 °C (122±9 °F) Pump Control Pressure Flow Rate
MPa (kgf/cm2) L/min
f NOTE: Refer to T4-5-18.
A 0.39+0.1 −0.2 (4+1 −2) 275±3
B 1.25±0.05 (12.7±0.5) 70±2
C 1.96+0.02 −0 (20+0.2 −0) 40±2
Q
L/min
A
MPa (kgf/cm2) Pi1-Pi2
T4GB-04-02-002
T4-2-11
Group 2 Standard
Sensor Activating Range
1. Checking Method
 Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
 Unless specified:
Engine Speed Power Mode

Switch
Fast Idle Speed ON
• Monitor each sensor by using MPDr.
2. Sensor Activating Range

Item Operation Specification
Pump Delivery Pressure Neutral 1.5 to 3.0 MPa (15 to 30 kgf/cm2)
Relieved 27.4 to 29.3 MPa (279 to 299 kgf/cm2)
Main Relief Pressure Neutral 1.5 to 3.0 MPa (15 to 30 kgf/cm2)
Control Lever: Relieved 27.4 to 29.3 MPa (279 to 299 kgf/cm2)
Parking Brake Pressure Parking Brake Switch: ON 0 to 0.1 MPa (0 to 1 kgf/cm2)
Parking Brake Switch: OFF 10.8 to 17.0 MPa (110 to 173 kgf/cm2)
Service Brake Pressure Brake Pedal: Neutral 0 to 0.05 MPa (0 to 0.5 kgf/cm2)
Brake Pedal: Fully Depressed 6.6±0.6 MPa (67±6 kgf/cm2)
T4-2-12
Group 3 Engine Test
Engine Speed
Summary:
1. Measure the engine speed by using the monitor
unit or MPDr.
2. Measure the engine speeds in each mode.
fNOTE: If the engine speed is not adjusted correctly, all

other performance data will be unreliable. Consequently,
measure the engine speed before performing all other
tests in order to check that the engine speed meets
specification.
Preparation:
1. Select the service menu of monitor (In case of
MPDr., install MPDr. first).
2. Warm up the machine until coolant temperature
reaches 50 °C (122 °F) or more, hydraulic oil
temperature is 50±5 °C (122±9 °F), and transmission
oil temperature is 85±5 °C (185±41 °F).
T4-3-1
Group 3 Engine Test
Measurement:
1. Measure the items as shown in the table below.
2. When measuring, set the switch and test condition
as shown in the table below in response to the
engine speed to be measured.
Forward/Reverse Accelerator Pedal Parking Brake Switch Power Mode Switch

Lever, Shift Switch
Slow Idle Speed N No depression ON ON/OFF
(with no load)
Fast Idle Speed Second speed/third Full stroke ON ON/OFF
(with no load) speed forward
Fast Idle Speed Second speed Full stroke OFF ON/OFF
(with torque converter forward
stalled)
Fast Idle Speed Third speed forward Full stroke OFF ON/OFF
(with torque converter
stalled and relieved)
Declutch Position Brake Pedal Control Lever

Switch (Bucket)
Slow Idle Speed OFF - Transporting
(with no load) position, No control
lever operation
Fast Idle Speed OFF Full stroke Transporting
(with no load) position, No control
lever operation
(with torque converter position, No control
stalled) lever operation
(with torque converter position, Bucket is
stalled and relieved) tilted and relieved.
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-3-2
Group 3 Engine Test
Lubricant Consumption
Measuring Method
1. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
2. Record read-out A (unit: hour) of the hour meter.
3. Replenish the lubricant up to the high-level gauge.
4. Operate the machine for at least 100 hours or until
the oil level lowers to the low-level gauge.
IMPORTANT: Keep the machine-leaving time in step
1 above.
5. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
6. Record read-out B (unit: hour) of the hour meter.
7. Replenish the lubricant up to the high-level gauge
while measuring the oil-replenishing volume C.
fNOTE: When measuring, use a high-precision

measuring cylinder or the like.
8. Determine lubricant consumption from the
following equation: Oil replenishing volume (C)
[mL] / Operating hours (B-A) [hr]
Evaluation:
T4-3-3
Group 3 Engine Test
(Blank)
T4-3-4
Travel Speed
Summary:
1. Measure the time required for the machine to travel
a 50 m (164 ft) test track and check the performance
of the travel drive system (torque converter to
transmission).
Preparation:
1. Adjust air pressure of the tires evenly in advance.
(Refer to Operational Performance Standard.)
2. Provide a flat, solid test track 50 m (164 ft) in length,
with extra length of 70 m (229 ft) on both ends
for machine acceleration and deceleration. (For a
measurement at fourth speed, a 300 m (984 ft)
acceleration zone is needed.) c b c
d e
3. Empty the bucket and hold the lift arm with it T4GB-04-04-001
floated 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 in) above the
ground. a- 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 c- Acceleration/Deceleration
in) Zone
4. Maintain the hydraulic oil temperature at 50±5 b- Test Track d- End
°C (122±9 °F). Warm the axle oil satisfactorily by e- Start
repeating travel operation and brake operation.
Make a warm up operation so that the indicators of
the coolant temperature monitor and the torque
converter oil temperature monitor should rise
above the horizontal position.
T4-4-1
Measurement:
dCAUTION: Do not perform measurement in

reverse travel to avoid accident.
1. Measure in each mode (first speed to fifth speed).
2. Select the switches as follows.
Shift Switch Parking Brake Accelerator Pedal Power Mode

Switch Switch
First Speed First Speed OFF Full Stroke ON/OFF
Second Speed Second Speed OFF Full Stroke ON/OFF
Third Speed Third Speed OFF Full Stroke ON/OFF
Fourth Speed Fourth Speed OFF Full Stroke ON/OFF
Fifth Speed Fifth Speed OFF Full Stroke ON/OFF
3. Set the forward/reverse lever to the F (forward)

position. Start traveling the machine in the
acceleration zone with the accelerator pedal
depressed to the stroke end.
4. Measure the travel speed (sec) of each travel mode.
5. Repeat the measurement three times and calculate
the mean values.
6. Convert the measurement value to be expressed in
km/h.
Measurement value (seconds) = S (sec)
Converted value (hourly speed) = A (km/h)
A = (50×3600)/(S×1000)
Evaluation:
Remedy:
T4-4-2
(Blank)
T4-4-3
Service Brake Function Check

Summary:
1. Check the performance of the service brake.
2. The braking capability of the brake is an item of
safety control. Be sure to conduct the performance
test.
Preparation:
1. Adjust air pressure of the tires evenly in advance.
(Refer to Operational Performance Standard.)
2. On a paved dry road, prepare a 150 m (492
ft) straight travel course (a 100 m (328 ft) of
acceleration zone and a 50 m (164 ft) of test track)
and set the brake starting point.
3. Empty the bucket and hold the lift arm with it a
ground. b
c d T4GB-04-04-002
4. Maintain the hydraulic oil temperature at 50±5
°C (122±9 °F). Warm the axle oil satisfactorily by
repeating travel operation and brake operation. a- 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 c- Stopping Point
Make a warm up operation so that the indicators of in) d- Brake Starting Point
b- Stopping Distance
converter oil temperature monitor should rise
T4-4-4
Measurement:
dCAUTION: Do not perform measurement in

reverse travel to avoid accident.
1. Measure in high-speed mode.
2. Select the switches as follows.
Shift Switch Parking Brake Accelerator Pedal Power Mode Declutch Position
Switch Switch Switch
Fifth Speed OFF Full Stroke ON OFF
3. Set the forward/reverse lever to the F (forward)

position. Start traveling the machine in the
acceleration zone with the accelerator pedal
depressed to the stroke end and travel at 35 km/h
(22 mph).
4. Release the accelerator pedal and step on the right
service brake pedal at the brake starting point.
Completely stop the machine.
5. Measure the distance from the brake starting point
to the point where the front tire is contacting.
the mean values. Add traveling distance 0.97 m (3 ft
2 in) to the mean value. This is stopping distance.
Evaluation:
Remedy:
T4-4-5
Service Brake Wear Amount 1, 2
Summary:
1. Check the wear amount of the brake disc at the
service brake of the axle by using thickness gauge
(3) (ST 8077).
Preparation:
1. Clean around inspection plug (1) of the axle (2
places at both sides). Remove inspection plugs (1)
and O-rings (2).
2. After the measurement, install inspection plugs (1)
and new O-rings (2).
m : 50 N·m (5 kgf·m) TNEJ-04-04-002
Measurement: 3
1. Operate the service brake by stepping on the brake
pedal.
2. Insert thickness gauge (3) into the inspection port.
Measure dimension (A) between clutch discs (4) at
the output side.
Evaluation:
1. When dimension (A) between clutch discs (4) at the
output side is 3.5 mm (0.14 in) or less, clutch disc
(5) inside the piston side is worn in excess of the
maximum allowable limit of use.
TNEJ-04-04-003
2. In the method above, in case the wear amount is
beyond the maximum allowable limit of use or in
case the service brake portion has been assembled, 4 A 4
refer to Operational Performance Standard in T4-2.
5 TNEJ-03-09-004
1- Inspection Plug 5- Clutch Disc (Piston Input

2- O-Ring Side)
3- Thickness Gauge (ST 8077)
4- Clutch Disc (Output Side)
T4-4-6
Parking Brake Function Check

Summary:
1. Measure the parking brake function on a specified
slope.
2. The braking capability of the brake is an item of
safety control. Be sure to conduct the performance
test.
Preparation:
1. Measure on a pavement surface with a gradient of
20 % (11.31°).
2. Empty the bucket and hold the bucket with it
ground.
3. Maintain the hydraulic oil temperature at 50±5
a
°C (122±9 °F). Warm the axle oil satisfactorily by
repeating travel operation and brake operation.
Make a warm up operation so that the indicators of b
converter oil temperature monitor should rise T4GB-04-04-003
a- 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 b- 20 %(11.31°)
in)
Measurement:
1. Climb the slope and set the parking brake switch to
the ON position.
2. Stop the engine.
3. After the body has stopped, put a mark (white line)
on the tire and the road surface respectively.
4. After five minutes have passed, measure the
amount of movement between white lines of tire
and road surface.
the mean values.
Evaluation:
T4-4-7
Bucket Stopper and Bell Crank Stopper

Clearance
Summary:
1. Measure wear and deformation conditions of the
bucket stopper (dump side and tilt side) and the
clearance between bell crank stopper and cross
tube.
Preparation:
1. Stop the vehicle on a plane road surface and
operate the parking brake.
a
Measurement: b
 Bucket Dump Stopper (a)
1. Raise the lift arm to the highest lifting position and
stop the engine.
2. Dump the bucket slowly with the engine stopped
until the bucket contacts dump stopper (a). At
this time, measure strokes (A and B) of the bucket
cylinder and the lift arm and dump angle (C) of the
bucket. In addition, measure the clearance between
bell crank stopper (b) and the cross tube.
3. At the same time, measure the contact condition of
bucket dump stopper (a) (left and right).
 Bucket Tilt Stopper (c)
1. Raise the lift arm until lift arm cylinder stroke (E)
T4GB-04-04-008
becomes the length of the specified.
2. Set the engine at idling speed and make tilting a- Bucket Dump Stopper b- Bell Crank Stopper
operation until the bucket calmly contacts bucket
tilt stopper (c).
3. At this time, measure strokes (D and E) of the bucket
cylinder and the lift arm cylinder and tilt angle (F) of
the bucket. In addition, measure height (G) from the
ground to the bucket lowest portion. c
4. At the same time, measure the contact condition of
bucket tilt stopper (c) (left and right).
T4GB-04-04-010
c- Bucket Tilt Stopper
T4-4-8
Evaluation:
1. Bucket Dump Stopper 2. Bucket Tilt Stopper
 Cylinder Strokes A and B  Cylinder Strokes D and E
Model Bucket Cylinder Lift Arm Model Bucket Cylinder Lift Arm
Cylinder Cylinder
A (mm) (in) B (mm) (in) D (mm) (in) E (mm) (in)
80Z6 362±1.5 1120±2 80Z6 690 (27.2) 360 (14.2)
(14.2±0.06) (44±0.08)
 Bucket Tilt Angle (F)
 Bucket Dump Angle C Model F (deg.)
Model C (deg.) 80Z6 50
80Z6 50±2
 Height from Ground to Bucket Lowest Portion (G)
 Clearance between Bell Crank Stopper and Cross Model G (mm) (in)
Tube
80Z6 450 (17.7)
Model Clearance between Bell Crank
Stopper and Cross Tube (mm)  Clearance between Bucket Dump Stopper and Lift
(in) Arm
80Z6 Standard 0 Model Clearance at Longitudinal and
Limit 2.0 (0.08) Unsymmetrical Lateral Clearance
Contact (mm) of a Stopper
 Clearance between Bucket Dump Stopper and Lift (in) (mm) (in)
Arm 80Z6 Standard 0 0
Model Clearance at Longitudinal and Limit 0.5 (0.02) 1.0 (0.04)
Unsymmetrical Lateral Clearance
Contact (mm) of a Stopper Clearance at Unsymmetrical Contact
(in) (mm) (in)
80Z6 Standard 0 0 c
a b
Limit 0.5 (0.02) 1.0 (0.04)
Longitudinal and Lateral Clearance of a Stopper
Clearance at Unsymmetrical Contact
c
a b
c
T4GB-04-04-009
a b
Longitudinal and Lateral Clearance of a Stopper a- Left c- Clearance Limit
b- Right
c
a b
T4GB-04-04-009 fNOTE: Standard dimensions indicate those of a new
tire (Standard) at the designated air pressure.
a- Left c- Clearance Limit
b- Right
T4-4-9
Hydraulic Cylinder Cycle Time Lift Arm Cylinder:

(Raising)
Summary:
1. Measure the operating time of cylinders for
the lift arm, bucket, and steering and check the
performance of the cylinder drive system (main
pump to each cylinder).
2. The bucket should be empty.
T4GB-04-04-016
Preparation:
1. Measurement is made for the following positions.
(Lowering)
 Measurement of Lift Arm Cylinder (Raising)
Fully tilt the bucket and lower the lift arm.
 Measurement of Lift Arm Cylinder (Lowering)
Lower the lift arm until the bucket bottom surface
touches the ground horizontally.
 Measurement of Bucket Cylinder
Lift the lift arm to the highest position.
 Measurement of Steering Cylinder
Empty the bucket and take the driving position. T487-04-03-005
2. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Bucket Cylinder:
d CAUTION: Select ground filled with sand or
something so that the bucket contacts the ground
with buffer.
T487-04-03-006
Driving Position
a
M4GB-04-001
a- 0.4 to 0.5 m (1 ft 4in to 1 ft 8

in)
T4-4-10
Measurement:
1. Select the pedal, switches, and forward/reverse
lever as follows.
Accelerator Pedal Parking Brake Forward/ Power Mode

Switch Reverse Lever Switch
Lift Arm (Raising) Full stroke (engine: fast idle speed) ON N ON/OFF
Lift Arm (Lowering) Neutral (engine: slow idle speed) ON N ON/OFF
Bucket Full stroke (engine: fast idle speed) ON N ON/OFF
Steering Full stroke (engine: fast idle speed) OFF N ON/OFF
dCAUTION: Prevent personal injury. Always make

sure that the area is clear and that coworkers
are out of the steering area before starting the
measurement.
2. Measure the cylinder cycle times as follows:
(Cylinder full stroke includes cylinder cushioning
zone.)
 Measurement of Lift Arm Cylinder (Raising)
Operate the lift arm control lever to the stroke end.
Measure the time of movement of the lift arm from
the lowest position to the highest position.
 Measurement of Lift Arm Cylinder (Lowering)
Lower the bucket onto the ground in the horizontal
position and lift the lift arm to the highest position.
Keep the lift arm control lever at the a float position.
Measure the time of movement of the bucket
reaching the ground.
 Measurement of Bucket Cylinder
Operate the bucket control lever to the stroke end.
Measure the time of movement of the bucket from
the full tilt position to the full dump position.
 Measurement of Steering Cylinder
Operate the steering wheel to the stroke end.
Measure the time of movement of the steering
wheel from the right to the left stroke end and from
the left to the right stroke end.
the mean values.
Evaluation:
Remedy:
T4-4-11
Dig Function Drift Check

Summary:
1. Measure dig function drift, which can be caused by
oil leakage in lift arm cylinder, bucket cylinder, and
the control valve, with the bucket loaded.
2. Measure in the standard front condition (standard
bucket).
3. In case measurement is made immediately after the
cylinder replacement, bleed air from the cylinder
before measurement by operating the cylinders
slowly to the stroke end several times.
Preparation:
1. Load the bucket with either soil or a weight
equivalent to the weight standard 5580 kg (12400
lb).
1
dCAUTION: Never allow any personnel to be
under the bucket.
2. In the front position, extend the lift arm to the
maximum reach and hold the bucket at an angle of
about 5 degrees declined forward from full tilting.
(122±9 °F).
2
Measurement: a
1. Stop the engine.
2. In 15 minutes after the engine has been stopped,
measure the change in position of lift arm cylinder
(2) (b), bucket cylinder (1) (b), and bottom of the
bucket (a). T4GB-04-04-014
b=A-B 1- Bucket Cylinder 2- Lift Arm Cylinder

3. Repeat the measurement three times and calculate a- Dig Function Drift Amount
the mean values.
c
Evaluation:
Remedy:
Refer to Troubleshooting B. B
A
TNEJ-04-04-001
c- Mark
T4-4-12
Bucket Levelness
Summary:
1. Check left and right inclinations of the bucket.
Preparation:
1. Place the unloaded machine on a horizontal bed
on the ground. (In case a bed is not available, place
it on a horizontal flat concrete on the ground. Deal
with the measurement values as guide lines.)
2. Adjust the tire air pressure to the designated value.
3. Lower the bucket onto the ground in the horizontal
position.
1
Measurement:
dCAUTION: Never put hands, feet, and measuring

instruments under the bucket.
T4GB-04-04-011
1. Float the bucket bottom slightly above the bed.

2. Measure the vertical distance from the bed and the
bottom surface of cutting edge (1) on the left and
right ends, and confirm the difference.
the mean values.
Evaluation:
T4-4-13
Control Lever Operating Force

Summary:
1. Measure a play and operating condition of each
control lever, pedal, and steering wheel, and
measure operating force of them.
2. Measure maximum operating force of each control
lever, pedal, and steering wheel. Travel Position
3. Measure the lever stroke along the control lever

operation from the grip center of each control lever.
Measure at 150 mm (6 in) from the pedal support of
each pedal.
Preparation:
1. Empty the bucket and hold the litt arm with it
floated 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 in) above the a
ground.
M4GB-04-001
(122±9 °F). a- 0.4 to 0.5 m (1 ft 4 in to 1 ft 8
in)
T4-4-14
Measurement:
1. Measure for each control lever, pedal, and steering
wheel.
2. Select the pedal, switches, and forward/reverse
lever as follows.
Accelerator Pedal Parking Brake Forward/

Switch Reverse Lever
Neutral (engine: ON N
slow idle speed)
dCAUTION: Prevent personal injury. Always make

sure that the area is clear and that coworkers
are out of the steering area before starting the TNED-04-04-001
measurement.
1
3. Attach a spring balance scale (tension type) onto
each of the lift arm, bucket, and forward/reverse
lever. Measure the maximum operating force by
operating them to the stroke end.
4. In case of the pedals, attach a spring balance
scale (compression type) or a load cell onto them.
Measure the operating force when they are stepped
slightly.
5. In case of the steering wheel, attach a spring
balance scale (tension type) onto knob (1). Measure
the maximum operating force when it is moved. MNEC-01-036
3 2
the mean values. 1- Knob 3- Brake Pedal
2- Accelerator Pedal
Evaluation:
T4-4-15
Control Lever Stroke

Summary:
1. Measure a play and operating condition of each
control lever, pedal, and steering wheel, and
measure the stroke.
2. Measure at the grip tip of each control lever.
Measure at the pedal top of each pedal.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both side
lever strokes.
Preparation:
(122±9 °F).
Measurement:
1. Measure as follows.
 Measurement of Control Lever
 Lower the bucket bottom onto the ground.
 Stop the engine.
 Measure each lever stroke from neutral to the stroke
end of each control lever of lift arm, bucket, and
forward/reverse at the grip top center.
 Measurement of Pedal
 Lower the bucket bottom onto the ground.
 Stop the engine.
 Measure the stroke from neutral to the stroke end of
the pedal at the pedal top.
 Measurement of Steering Wheel
 Start the engine. (Slow idle)
 Float the bucket slightly above the ground.
 Measure the number of times of rotation required
for movement of the steering wheel from the right
to the left stroke end and from the left to the right
stroke end.
2. Measure the chord length from neutral to the stroke
end.
the mean values.
Evaluation:
T4-4-16
Primary Pilot Pressure (Including Brake

Circuit)
dCAUTION: If air is mixed in the brake system,

the brake function is reduced and serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines and
replacing hydraulic oil. (Refer to Troubleshooting
1
B.)
IMPORTANT: Primary pilot pressure circuit delivers
pressure oil from pilot pump (1) to the brake
circuit when pressure in service brake accumulator
(4) decreases, and accumulates pressure in service
brake accumulator (4). Therefore, the brake
circuit pressure (15.5 MPa, 158 kgf/cm2 or higher)
is higher than the pilot circuit pressure. Use a
pressure gauge capable of measuring 15.5 MPa
(158 kgf/cm2) or higher.
Preparation:
4 2
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil TNED-04-05-001
tank and bleed air. 3
3. Disconnect hose (3) from the pilot filter (2) inlet or

outlet port. Install the adapter (13/16-16UNF), a
nipple, a pressure gauge, and a coupling between
pilot filter (2) and hose (3).
j : 22 mm, 24 mm, 27 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
(122±9 °F).
T1F3-04-05-001
T4-5-1
Measurement:
1. Select the following conditions:
Accelerator Power Mode Parking Forward/

Pedal Switch Brake Reverse
Switch Lever
Full stroke ON ON N
2. Read pressures on the pressure gauge with no load.

the mean values.
fNOTE: When pressure in the service brake accumulator

decreases during measurement of primary pilot pressure,
the measured value increases to 15.5 MPa (158 kgf/cm2)
for several seconds.
Evaluation:
T4-5-2
Primary Pilot Pressure Adjustment Procedure
Adjustment: 1
1. Remove plug (1) from the relief valve.
j : 36 mm A A
2. Remove shim (2) from the relief valve.

3. Install the estimated number of shims (2).
fNOTE: Total thickness of shim (2) should be 1.5 mm or

less.
4. Install shim (2) to the relief valve. Tighten plug (1).
m : 98.0±9.8 (10±1.0 kgf·m)

5. After adjustment, check the set pressure.
fNOTE: Standard Change in Pressure (Reference)

Shim (2) Change in Pressure
Thickness kPa (kgf/cm2)
mm
0.2 61.8 (0.63)
0.5 154.5 (1.57)
TNED-03-07-008
Section A-A
TNED-03-07-018
T4-5-3
Secondary Pilot Pressure

Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Measure pressure between pilot valve and control
valve. Disconnect pilot hose (1) from the circuit to
be measured. Install a tee and a pressure gauge.
j : 17 mm, 19 mm, 22 mm
(122±9 °F).
Measurement: 1
TNEJ-04-05-001

Pedal Switch Brake Reverse
Switch Lever
Full stroke ON ON N
2. Measure pilot pressure by using a pressure gauge

with the lift arm and bucket control levers operated
to full stroke.
the mean values.
Evaluation:
Remedy:
T4-5-4
(Blank)
T4-5-5
Main Pump Delivery Pressure

Preparation:
1. Stop the engine. ST 6941

tank and bleed air.
3. Remove the plug (G1/4) from delivery pressure
check port (1) on the main pump. Install the adapter
(ST 6069), the hose (ST 6943), and the pressure
gauge (ST 6941).
l : 6 mm
(122±9 °F). 1
ST 6069
ST 6943
Measurement:
T4GB-04-05-008
Accelerator Power Mode Parking Forward/ 1- Pump 1 Delivery Pressure
Pedal Switch Brake Switch Reverse Check Port
Lever
Full stroke ON ON N
2. Measure pressure with the control levers in neutral

without load.
the mean values.
Evaluation:
Remedy:
T4-5-6
(Blank)
T4-5-7
Main Relief Set Pressure

Summary:
1. Measure the main relief valve set pressure at the ST 6941
delivery port in main pump.
Preparation:
1. Stop the engine.
tank and bleed air.
gauge (ST 6941).
l : 6 mm 1
4. Start the engine. Confirm that no oil leakage is ST 6069

ST 6943
T4GB-04-05-008
(122±9 °F).
1- Pump 1 Delivery Pressure
Check Port
T4-5-8
Measurement:
Pedal Switch Brake Switch Reverse
Lever
Full stroke ON ON N
2. Operate the bucket or lift arm control levers slowly,

operate each cylinder to the stroke end, and relieve
each function.
the mean values.
Evaluation:
T4-5-9
Main Relief Valve Pressure Adjustment Procedure

1. While holding lock nut (1), remove nut (3).
j : 17 mm
2. While holding screw (2), loosen lock nut (1).
j : 17 mm
3. Turn adjusting screw (2) in order to adjust the relief
pressure to the specification.
3
4. While holding screw (2), tighten lock nut (1).
m : 19.5 N·m (2 kgf/cm2)

1 2
5. While holding lock nut (1), tighten nut (3). T4GB-04-05-010
6. Check the relief set pressures.

Adjusting Screw (2) 1/4 1/2 3/4 1
Turns 2
Change in MPa 2.79 5.59 8.36 11.2
Pressure (kgf/cm2) (28.5) (57) (85.2) (114)
a b
T105-06-05-002
a- Pressure Increase b- Pressure Decrease
T4-5-10
(Blank)
T4-5-11
Steering Relief Pressure

Summary:
1. Measure the steering relief valve set pressure at the ST 6941
main pump delivery port and check performance of
the steering relief valve.
Preparation:
1. Stop the engine.
tank and bleed air.
gauge (ST 6941).
1
l : 6 mm ST 6069
ST 6943
observed at the pressure gauge connection. T4GB-04-05-008

1- Pump 1 Delivery Pressure
(122±9 °F).
Check Port
Measurement:
Lever
Full stroke ON ON N
2. Install the articulation lock bar. Slowly operate the

steering wheel and relieve the steering.
the mean values.
Evaluation:
T4-5-12
Steering Relief Valve (4) Pressure Adjustment

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

T4GB-04-05-012
5. While holding lock nut (1), tighten nut (3).
3 1
j : 37 N·m (3.8 kgf·m)
6. Check the relief set pressures.

Turns
Change in MPa 3.8 7.5 11.3 15.0
Pressure (kgf/cm2) (39) (77) (115) (153)
2
T4GB-04-05-013
a b
T105-06-05-002
a- Pressure Increase b- Pressure Decrease
T4-5-13
Overload Relief Valve Set Pressure

Summary:
1. The circuit pressure must be increased by applying
an external force while blocking the return circuit
from the control valve. This measuring method
is hazardous and the results obtained with this 5. Maintain the hydraulic oil temperature at 50±5 °C
method are unreliable. (122±9 °F).
2. The oil flow rate used to set the overload relief
pressure is far less than that used to set the main Measurement:
relief pressure. Therefore, measuring the overload
pressure in the main circuit by increasing the main
relief set pressure more than the overload valve Accelerator Power Mode Parking Forward/
set-pressure is not a proper method. In addition, Pedal Switch Brake Switch Reverse
main relief valve may be designed to leak a small Lever
quantity of oil before relieving. In this case, its pre- Full stroke ON ON N
leaking start pressure must be increased more than
the overload relief valve set pressure. However, the
pre-leaking start pressure is not always increased 2. Slowly operate the bucket or lift arm control lever,
more than the overload relief valve set-pressure as operate each cylinder to the stroke end, and relieve
the adjustable upper limit of the main relief valve each function.
set-pressure is provided. Accordingly, the overload
3. Read pressures on the pressure gauge at this time.
relief valve assembly should be removed from the
machine and checked on a specified test stand at 4. Repeat the measurement three times and calculate
a correct oil flow rate. Some overload relief valves the mean values.
come in contact with the control valve body to
block the oil passage. When this type of overload ST 6941
relief valve is checked, the control valve body must
be precisely finished as the test unit. Provide one
control valve other than that on the machine as a
test kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload relief
valve. And, assume that the overload relief valve
is functioning correctly if the obtained main relief
pressure is within the specified value range.
1
Preparation:
1. Stop the engine. ST 6069
ST 6943
2. Push the air bleed valve on top of the hydraulic oil T4GB-04-05-008
tank and bleed air.
3. Remove the plug (G1/4) from delivery pressure 1- Pump 1 Delivery Pressure
check port (1) on the main pump. Install the adapter Check Port
gauge (ST 6941).
l : 6 mm
T4-5-14
Evaluation:
Performance of the overload relief valves are normal
if the measured main relief pressures are within the 1
specified value range.
2
Overload Relief Valve Pressure Adjustment
Procedure
fNOTE: In principle, adjust the overload relief valve TNED-04-05-003

pressure on a test stand.
1- Lock Nut 2- Adjusting Screw

Loosen lock nut (1) and adjust pressure by using
adjusting screw (2).
1. Loosen lock nut (1).
j : 22 mm
2. Turn adjusting screw (2) in order to adjust the
pressure.
l : 6 mm 1 2
3. Tighten lock nut (1).
j : 22 mm
a b
4. After adjustment, check the set pressure.

Turns W107-02-05-129
Change in MPa 5.2 10.6 15.9 21.1
Pressure (kgf/cm ) (54)
2
(108) (162) (216) a- Pressure Increase b- Pressure Decrease
T4-5-15
Main Pump Flow Rate Measurement

 P-Q Control (Torque Control)
Summary:
Main pump performance is checked by measuring the 6. Remove the vacuum pump. Loosen plug (12) on top
pump flow rate by using a hydraulic tester installed of the pump casing. Bleed air from the casing until
at the main pump delivery port to be measured. Use oil only comes out.
MPDr. and a pressure gauge at the same time.
IMPORTANT: This measurement procedure is a j : 41 mm
simple method. The measured data will be lower 7. Fully open the loading valve of hydraulic tester (5).
by approx. 5 % than the accurately measured
value. In order to measure accurately, disconnect 8. Start the engine. Confirm that no oil leakage
the return circuit from the control valve and is observed at the pressure gauge connection.
connect it to the hydraulic oil tank. Connect MPDr. and select the monitoring function.
Preparation: Measurement:
1. Stop the engine. Push the air bleed valve on top the 1. Maintain the hydraulic oil temperature at 50±5 °C
hydraulic oil tank and bleed air. Connect a vacuum (122±9 °F).
pump to the oil filler port. 2. Measure the maximum flow rate.
fNOTE: Operate the vacuum pump while connecting the 3. Select the following conditions:
pump flow rate test line.
2. Disconnect delivery hose (7) from the main pump. Pedal Switch Brake Switch Reverse
Connect test hose (3) to the main pump delivery Lever
port.
Full stroke ON ON N
j : 41 mm
3. Install test hose (3) to hydraulic tester (5) by using 4. Slowly restrict the loading valve of hydraulic tester
adapter (4). Install adapter (6) and delivery hose (7) (5) while relieving pressure in the bucket tilt circuit.
to hydraulic tester (5). Measure the flow rates and engine speeds at each
pressure point specified in the P-Q curve. (Refer to
j : 41 mm T4-2-10.)
4. Install a pressure gauge to the main pump to be 5. Repeat the measurement three times and calculate
measured. (Refer to Main Relief Set Pressure.) the mean values.
l : 6 mm
5. Disconnect the hose (14) from regulator port ST
(13). Install the plug (G1/4) to the removed hose (14)
and the regulator port ST (13).
j : 17 mm
T4-5-16
Evaluation:
1. Convert the measured flow rates to those at the
specified engine speed by using the following
formula:
Qc = Ns×Q/Ne
Qc : Converted Flow Rate

Q : Measured Flow Rate
Ns : Specified Engine Speed: 2200 min-1
Ne : Measured Engine Speed:
Values indicated on MPDr.
2. Standard Flow Rate
3 4 5 6 7
TNED-04-05-005
12
TNED-04-05-004
14 13
3- Test Hose (1-7/16-12UN) 5- Hydraulic Tester (ST 6299) 7- Delivery Hose 13- Port ST
4- Adapter 1-7/16-12UN×G1-1/2 6- Adapter 1-7/16-12UN×G1-1/2 12- Plug 14- Hose
T4-5-17
 Pilot Characteristics
Summary:
Main pump performance is checked by measuring the 7. Remove the vacuum pump. Loosen plug (12) on top
pump flow rate by using hydraulic tester (5) installed of the pump casing. Bleed air from the casing until
at the main pump delivery port to be measured. Use oil only comes out.
MPDr. and pressure gauge (18) at the same time.
IMPORTANT: This measurement procedure is a j : 41 mm
simple method. The measured data will be lower 8. Fully open the loading valve of hydraulic tester (5).
by approx. 5 % than the accurately measured
value. In order to measure accurately, disconnect 9. Start the engine. Confirm that no oil leakage is
the return circuit from the control valve and observed at the pressure gauge connection.
connect it to the hydraulic oil tank.
Preparation:
1. While referring to steps 1 to step 3 on T4-5-16,
install hydraulic tester (5) to the main pump to be
measured.
2. Disconnect the hose from regulator port Pi1 (21).
Install the plug (G1/4) to the removed hose.
j : 19 mm
3. Connect regulator port Pi2 (8) and port VQ (2) to the
hydraulic oil tank.
j : 19 mm
4. Install adapters (15) (3 used) to pressure reducing
valve (16). Remove plug (23) from manifold valve
(1). Install adapter (13) and hose (14). Connect hose
(14) to port P1 of pressure reducing valve (16).
l : 8 mm
j : 19 mm
5. Install tee (17) to port P2 of pressure reducing valve
(16). Connect pressure gauge (18) and hose (9) to
tee (17). Connect hose (9) to the regulator (c).
j : 19 mm
6. Connect hose (19) and tee (20) to port T of pressure
reducing valve (16). Disconnect hose (10) from
return pipe (22). Install tee (20) to return pipe (22).
Connect hoses (10, 19) to tee (20).
j : 22 mm, 27 mm
T4-5-18
3 4 5 6 7
TNED-04-05-005
21
8 12
23 1
2
TNED-04-05-007
22
Pressure Reducing Valve Port Position
16
T 10
P1 P2
18 20
19
15
T
c P2 P1 b
TNED-04-05-006
9 17 15 16 15 14 13
b- To Manifold Valve c- To Regulator Port Pi1 (21)
1- Manifold Valve 7- Delivery Hose 14- Hose G3/8 19- Hose G3/8
2- Port VQ 8- Port Pi2 15- Adapter G3/8 20- Tee G3/8×G1/2×G1/2
3- Test Hose (1-7/16-12UN) 9- Hose G1/4 16- Pressure Reducing Valve 21- Port Pi1
4- Adapter 1-7/16-12UN×G1-1/2 10- Hose G1/2 (4325439) 22- Return Pipe
5- Hydraulic Tester (ST 6299) 12- Plug (Regulator) 17- Tee G3/8×G1/4×G1/4 23- Plug G3/8
6- Adapter 1-7/16-12UN×G1-1/2 13- Adapter G3/8 18- Pressure Gauge (ST 6931)
T4-5-19
Measurement:
(122±9 °F).
2. Measure pump flow rate in response to the external
command pilot pressure.
Lever
Full stroke ON ON N
4. Adjust the pressure reducing valve set pressure to

each pressure point specified along the main pump
P-Q curve. (Pilot Characteristics) (Refer to T4-2-11.)
Measure the flow rates and engine speeds at the
pressure points specified in the P-Q curve.
the mean values.
Evaluation:
1. Convert the measured flow rates to those at the
specified engine speed by using the following
formula:
Qc = Ns×Q/Ne
Qc : Converted Flow Rate
Q : Measured Flow Rate
Ns : Specified Engine Speed: 2200 min-1
Ne : Measured Engine Speed:
Values indicated on MPDr.
2. Standard Flow Rate
T4-5-20
3 4 5 6 7
TNED-04-05-005
21
8 12
23 1
2
TNED-04-05-007
22
Pressure Reducing Valve Port Position
16
T 10
P1 P2
18 20
19
15
T
c P2 P1 b
TNED-04-05-006
9 17 15 16 15 14 13
b- To Manifold Valve c- To Regulator Port Pi1 (21)
1- Manifold Valve 7- Delivery Hose 14- Hose G3/8 19- Hose G3/8
2- Port VQ 8- Port Pi2 15- Adapter G3/8 20- Tee G3/8×G1/2×G1/2
3- Test Hose (1-7/16-12UN) 9- Hose G1/4 16- Pressure Reducing Valve 21- Port Pi1
4- Adapter 1-7/16-12UN×G1-1/2 10- Hose G1/2 (4325439) 22- Return Pipe
5- Hydraulic Tester (ST 6299) 12- Plug (Regulator) 17- Tee G3/8×G1/4×G1/4 23- Plug G3/8
6- Adapter 1-7/16-12UN×G1-1/2 13- Adapter G3/8 18- Pressure Gauge (ST 6931)
T4-5-21
Regulator Adjustment
6 5 1
7
8
4
9 10
TNED-03-01-025
1- Lock Nut (For Minimum Flow 3- Lock Nut (For Maximum Flow 5- Lock Nut (For Pilot Pressure 8- Adjusting Screw (For P-Q
Rate) Rate) Characteristic) Control)
2- Adjusting Screw (For Minimum 4- Adjusting Screw (For 6- Adjusting Screw (For Pilot 9- Lock Nut (For P-Q Control)
Flow Rate) Maximum Flow Rate) Pressure Characteristic) 10- Adjusting Screw (For P-Q
7- Lock Nut (For P-Q Control) Control)
Adjustment Item Adjustment Procedure Remarks

1. Maximum Flow Rate Loosen lock nut (3) and turn adjusting Do not turn it more than 2 turns.
Q screw (4). Do not increase the maximum flow
Rotating adjusting screw (4) 1/4 a turn rate. In other words, do not turn the
clockwise decreases the flow rate by adjusting screw counterclockwise.
12.58 cm3/rev. Securely tighten lock nut (3) after
j : 22 mm adjustment.
m : 20 N·m (2 kgf·m)
P
TDAA-04-05-004
T4-5-22
Adjustment Item Adjustment Procedure Remarks

2. Pilot Pressure Characteristics Loosen lock nut (1) and turn adjusting Do not turn adjusting screw (2) more
Q screw (2). than one turn.
Rotating adjusting screw (2) 1/4 turn Securely tighten lock nut (1) after
clockwise decreases the flow rate by adjustment.
9.22 cm3/rev.
j : 17 mm
m : 20 N·m (2 kgf·m)
Pi
TNED-04-5-008
Q
3. P-Q Control (Torque Adjustment) Loosen lock nut (7) and turn adjusting Do not turn it more than 1 turn.
screw (8). Rotate the adjusting screws watching
Rotating the adjusting screw 1/4 a turn the engine performance.
clockwise increases the flow rate by Securely tighten lock nut (7) after
15.5 cm3/rev. adjustment.
j : 30 mm
m : 30 N·m (3 kgf·m)
Pd
TDAA-04-05-006
4. P-Q Control (Torque Adjustment) Loosen lock nut (9) and turn adjusting Do not turn it more than 1 turn.
screw (10). Rotate the adjusting screws watching
Rotating the adjusting screw 1/4 a turn the engine performance.
clockwise increases the flow rate by 4.2 Securely tighten lock nut (9) after
cm3/rev. adjustment.
Pd
j : 13 mm
m : 10 N·m (1 kgf·m)
TDAA-04-05-007
T4-5-23
Service Brake Pressure (Front and Rear)

B.)
Summary:
1. Measure the pressure at the outlet port of brake
valve (5) when brake pedal (2) is depressed.
Preparation:
dCAUTION: Set blocks (1) onto the front and rear

tires in order not to move the machine. Keep away
from the machine.
T4GB-04-05-017
1. Stop the engine.
1
tank and bleed air. 2
3. Depress brake pedal (2) at least 50 strokes in order
to decrease the accumulated pressure left in the
brake circuit.
4. Install a pressure gauge to the front and rear wheel
brake circuits.
 Front wheel brake circuit pressure: Disconnect hose
(3) from brake valve (5). Install the tee (9/16-18UNF)
and a pressure gauge between brake valve (5) and
hose (3).
j : 22 mm
 Rear wheel brake circuit pressure: Disconnect hose 5
(4) from brake valve (5). Install the tee (9/16-18UNF)
and a pressure gauge between brake valve (5) and
hose (4).
j : 22 mm
observed at the pressure gauge connection. 4
6. Maintain the hydraulic oil temperature at 50±5 °C 3
(122±9 °F). TNEJ-04-05-002
T4-5-24
Measurement:
Lever
Full stroke ON ON N
2. Measure the pressure when fully depressing the

brake pedal at left side to the floor.
the mean values.
Evaluation:
Remedy:
Normally, the front and rear wheel brake pressures
become equal. If not, malfunction of the brake valve
and dirt caught in the valve are suspected.
T4-5-25
Parking Brake Pressure

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

from the machine.
1. Stop the engine.
tank and bleed air.
3. Disconnect brake hose (2) from the parking brake
side. Install a pressure gauge to the removed hose.
j : 19 mm T4GB-04-05-017
IMPORTANT: When the parking brake disc is dirty 1

with hydraulic oil, the parking brake function is
reduced. Clean hydraulic oil off the parking brake 2
disc.
(122±9 °F).
M4GB-06-004
T4-5-26
Measurement:
Accelerator Pedal Brake Pedal Forward/Reverse
Lever
Neutral Full stroke N
2. Release the parking brake and measure the pressure

at this time.
the mean values.
Evaluation:
Remedy:
T4-5-27
Brake Accumulator Pressure

B.)
Summary:
1. Measure the accumulated brake pressure at the
accumulator output port. The accumulated brake
pressure varies according to operation of the brake.
Record the maximum value.
Preparation:

T4GB-04-05-017
from the machine. 1

1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil a
tank and bleed air.
3. Depress the brake pedal at least 50 strokes in
order to decrease the accumulated pressure left in
accumulator (5) of the brake circuit.
4. Disconnect hoses (3, 4) from brake charge valve (2).
Install the tee (7/16-20UNF) and a pressure gauge
between brake charge valve (2) and hoses (3, 4).
j : 19 mm 2

3
5
(122±9 °F).
TNED-04-05-009
a- To Brake Valve
T4-5-28
Measurement:
Lever
Full stroke ON ON N
2. Measure the maximum pressure when depressing

the brake pedal slowly several times.
the mean values.
Evaluation:
Remedy:
T4-5-29
Brake Warning Pressure (Pressure-

Decreasing)

B.)
Summary:
1. Measure the pressure at the accumulator output
port when the buzzer sounds while decreasing the
accumulated brake pressure.
Preparation:

T4GB-04-05-017
from the machine. 1

1. Stop the engine.
tank and bleed air.
j : 19 mm 2

3
5
(122±9 °F).
TNED-04-05-009
a- To Brake Valve
T4-5-30
Measurement:
Forward/Reverse Lever Parking Brake Switch
N ON
2. Stop the engine. Set the key switch to the ON

position.
3. Depress the brake pedal several times. Measure the
pressure when the buzzer sounds.
the mean values.
Evaluation:
Remedy:
T4-5-31
Brake Warning Pressure (Pressure-

Increasing)

B.)
Summary:
1. Measure the pressure at the accumulator output
port when the buzzer stops sounding while
increasing the accumulated brake pressure.
Preparation:

T4GB-04-05-017
from the machine. 1

1. Stop the engine.
tank and bleed air.
j : 19 mm 2

3
5
(122±9 °F).
TNED-04-05-009
a- To Brake Valve
T4-5-32
Measurement:
Forward/Reverse Lever Parking Brake Switch
N ON
2. Stop the engine. Set the key switch to the ON

position.
3. Depress the brake pedal several times. Sound the
buzzer.
4. Start the engine. Measure the pressure when the
buzzer stops sounding. Notice that it is difficult to
read the gauge as the pressure increases rapidly.
the mean values.
Evaluation:
Remedy:
T4-5-33
Transmission Clutch Pressure

Summary:
1. Measure each operating pressure of the
transmission clutch at each check port of the
transmission control valve.
Preparation:
1. Stop the engine.
2. Remove the plug from the check port. Install a hose,
an adapter, and a pressure gauge.
l : 5 mm
m : 6 N·m (0.6 kgf/cm2)
fNOTE: Although the pressure can be measured by using

one pressure gauge, all pressures can be measured by
using six pressure gauges at the same time.
4. Maintain the torque converter oil temperature at 80
to 95 °C (176 to 203 °F).
Measurement:

from the machine.
T4GB-04-05-017
1
Accelerator Brake Pedal Power Mode Declutch Parking Brake
Pedal Switch Position Switch Switch
Full stroke Full stroke ON OFF OFF
2. Operate the forward/reverse lever and the shift

switch. Measure each clutch pressure. (As for the
combination of clutch pack, refer to the following
page.)
the mean values.
Evaluation:
T4-5-34
1 4
2 5
3 6
T4GB-04-05-021
1- Second Speed 4- High-Speed Forward

2- Low-Speed Forward 5- Reverse
3- Third Speed 6- First Speed
Transmission Clutch Pack Combination

Directional Control Clutch Pack Speed Control Clutch Pack
Selected Low-Speed High-Speed Reverse (5) First Speed (6) Second Speed Third Speed (3)
Speed Shift Forward (2) Forward (4) (1)
First Speed  
Forward (F1)
Second Speed  
Forward (F2)
Third Speed  
Forward (F3)
Fourth Speed  
Forward (F4)
Fifth Speed  
Forward (F5)
First Speed  
Reverse (R1)
Second Speed  
Reverse (R2)
Third Speed  
Reverse (R3)
fNOTE: The operating pressure is applied to the clutch

with the mark  when setting the forward/reverse lever
and the shift switch to each selected speed shift.
T4-5-35
Torque Converter Pressure (Inlet)

Summary:
1. Measure the inlet pressure of torque converter
pressure at the check port of torque converter
housing.
Preparation:
1. Stop the engine.
2. Remove plug (3) from the check port of
transmission control valve (2). Install a hose, an
adapter, and a pressure gauge to the open part.
l : 5 mm
m : 6 N·m (0.6 kgf/cm2)

4. Maintain the torque converter oil temperature at 80
to 95 °C (176 to 203 °F).
Measurement:

from the machine. T4GB-04-05-017
1. Select the following conditions: 1
Accelerator Brake Pedal Power Mode Declutch Parking Brake
Pedal Switch Position Switch Switch
Full stroke Full stroke ON OFF OFF
2. Set the forward/reverse lever to F (Forward) and the

shift switch to 5 (Fifth Speed). Measure the pressure.
the mean values.
Evaluation:
T4-5-36
T4GB-04-05-021
2- Transmission Control Valve
3- Plug
T4-5-37
(Blank)
T4-5-38
Group 6 Adjustment
Transmission Learning
IMPORTANT: When transmission or transmission
control valve has been repaired/replaced, and TCU
has been replaced, perform transmission learning.
Preparation:
1. When the key switch is in the OFF position, connect
MPDr. to MPDr. connector (1) at the body end (relay
box).
2. Start the engine.
3. Select the Service Menu screen on the monitor and
transmission oil temperature (2) appears. (Refer to
T5-2.)
4. Stall the transmission with the following machine
conditions.
Condition:
A TNDB-01-02-029
 Declutch Position Switch: OFF
 Travel Mode: Manual Mode
 Shift Switch: 5th
 Parking Brake Switch: OFF Detail A 1
 Brake Pedal: Depressed (Fully)
 Accelerator Pedal: Depressed (Fully)
 Forward/Reverse Lever: Forward Position
5. Depress the accelerator pedal and raise

transmission oil temperature (2) up to 110 ºC (230
ºF).
6. When transmission oil temperature (2) is 110 ºC (230
ºF), stop transmission stalling with the following
machine conditions.
Deactivation Condition:
 Accelerator Pedal: Not Depressed
 Forward/Reverse Lever: Neutral Position
 Parking Brake Switch: ON TNDB-01-02-005
 Brake Pedal: Not Depressed
TNDB-04-06-011
T4-6-1
Group 6 Adjustment
MPDr. Operation:
1
A
IMPORTANT: Do not operate control levers and other
switches when learning is performed.
1. Start MPDr. Select Functions, Machine Body, Main

Setting, Constant Change, Calibration Value Setting,
and Transmission Calibration in sequence. Then, the
Transmission Calibration screen appears. (Figure A)
2. When transmission oil temperature (3) is 110 ºC, 2
select Start (1) from the pull-down menu on the
Transmission Calibration screen and click Set (2).
3. The message on the inquity is displayed on the
Transmission Calibration screen on MPDr.. Click Yes
(4) (Figure B). TNDB-04-06-013
4. The learning starts and Progress (C1 to C6) of

learning is displayed on the monitor. (Figure C)
TNDB-04-06-011
3
B
4 TNDB-04-06-014
TNDB-04-06-004
3
T4-6-2
Group 6 Adjustment
5. When the learning is completed, the Learning End D

screen appears on the monitor. (Figure D)
6. The message "Writing process in controller is
complete" is displayed on the Transmission
Calibration screen on MPDr. Click OK (5). (Figure E)
7. Set the key switch to the OFF position, and finish
the learning.
fNOTE: When the machine is in deactivation condition

while learning, the learning is stopped on the way. At
this time, the message on the error is displayed on the T4GB-04-06-006
Transmission Calibration screen on MPDr. Perform the
learning again. (Figure F)
E
5 TNDB-04-06-015
TNDB-04-06-016
T4-6-3
Group 6 Adjustment
(Blank)
T4-6-4
Group 6 Adjustment
Lift Arm Angle Sensor Learning

IMPORTANT: When lift arm angle sensor has been 1
replaced, perform lift arm angle sensor learning.
Preparation:
1. Connect MPDr. (Refer to Transmission Learning.)
3. Set front control lever lock switch (1) to UNLOCK
Position (3).
4. Raise lift arms to the highest level by lift arm raise
operation.
5. Set front control lever lock switch (1) to LOCK
Position (2). MNEC-01-041
6. Set the key switch to the OFF position.
2 1
MNEC-01-015
2- LOCK 3- UNLOCK
T4-6-5
Group 6 Adjustment
MPDr. Operation:
1
A
IMPORTANT: When lift arm angle sensor has been
replaced, perform lift arm angle sensor learning.
1. Set the key switch to the ON position.

and Arm Angle Sensor Calibration in sequence.
Then, the Arm Angle Sensor Calibration screen 2
appears. (Figure A)
3. Select Start (1) from the pull-down menu on the
Arm Angle Sensor Calibration screen and click Set
(2).
IMPORTANT: The learning can not be performed TNDB-04-06-017
when the value of lift arm angle sensor is out of
range from 3.3 V to 4.3 V.
B
4. When the learning is completed correctly, the
buzzer sounds. The message "Writing process in
controller is complete" is displayed on the Arm
Angle Sensor Calibration screen on MPDr. Click OK
(3). (Figure B)
5. Set the key switch to the OFF position, and finish
the learning.
fNOTE: In case the learning is stopped on the way, the

message on the error is displayed on the Angle Sensor
Calibration screen on MPDr. Perform the learning again.
(Figure C)
TNDB-04-06-018
3
TNDB-04-06-019
T4-6-6
Group 6 Adjustment
Digging Position Adjustment

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

system, perform the digging position adjustment after
performing the lift arm angle sensor learning.
Preparation:
1. Connect MPDr. (Refer to Transmission Learning.)
MNEC-01-041
3. Set front control lever lock switch (1) to UNLOCK
Position (3). 1
2
4. Lower the lift arms and set the bucket on the
ground horizontally.
5. Set front control lever lock switch (1) to LOCK
Position (2).
6. Set the key switch to the OFF Position.
MNEC-01-015
2- LOCK 3- UNLOCK
T4-6-7
Group 6 Adjustment
MPDr. Operation:
1
A
1. Set the key switch to the ON position.
and Digging Position Calibration in sequence. Then,
the Digging Position Calibration screen appears.
(Figure A)
3. Select Start (1) from the pull-down menu on the
2
Digging Position Calibration screen and click Set (2).
4. When the learning is completed correctly, the
message "Writing process in controller is complete"
is displayed on the screen on MPDr. Click ON (3).
(Figure B)
TNDB-04-06-020
5. Set the key switch to the OFF position and finish the
learning. B
fNOTE: Digging position adjustment can be set at the

position lower than horizontal lift arm position.
3 TNDB-04-06-021
T4-6-8
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Group 5 Troubleshooting A
Introduction............................................................................T5-1-1 Troubleshooting A (Base Machine Diagnosis
Diagnosis Procedure........................................................... T5-1-2 By Using Fault Codes) Procedure.............................. T5-5-1
Electric System Inspection................................................ T5-1-5 MC Fault Code List............................................................... T5-5-3
Precautions for Inspection and Maintenance............ T5-1-6 Column Display Controller Fault Code List...............T5-5-15
Instructions for Disconnecting Connectors............... T5-1-8 Air Conditioner Controller Fault Code List................T5-5-18
Fuse Inspection...................................................................T5-1-10 ECM FAULT CODE CONTRAST LIST...............................T5-5-19
Fusible Link Inspection....................................................T5-1-13 TCU Fault Code List...........................................................T5-5-35
Battery Voltage Check......................................................T5-1-14 MC Fault Codes 111000 to 111002..............................T5-5-55
Alternator Check................................................................T5-1-15 MC Fault Code 111003.....................................................T5-5-56
Continuity Check...............................................................T5-1-16 MC Fault Codes 111006, 111007, 111011.................T5-5-59
Voltage and Current Measurement.............................T5-1-18 CAN1 Harness Check........................................................T5-5-60
Check by False Signal.......................................................T5-1-25 MC Fault Codes 111014, 111025..................................T5-5-64
Test Harness.........................................................................T5-1-26 MC Fault Code 111100.....................................................T5-5-65
MC Fault Code 111103, 111106, 111107...................T5-5-66
Group 2 Monitor MC Fault Codes 111205...................................................T5-5-67
Outline..................................................................................... T5-2-1 MC Fault Codes 111200, 111203..................................T5-5-68
Operating Procedures of Service Menu....................... T5-2-3 MC Fault Codes 111217, 111312..................................T5-5-69
Coolant Temperature Gauge and Transmission Oil MC Fault Codes 111204, 111206..................................T5-5-70
Temperature Gauge...................................................... T5-2-7 MC Fault Code 111208.....................................................T5-5-71
Fuel Gauge............................................................................. T5-2-8 MC Fault Codes 111311, 111313..................................T5-5-72
Group 3 e-Service MC Fault Code 111411.....................................................T5-5-73
Outline..................................................................................... T5-3-1 MC Fault Code 111412.....................................................T5-5-74
List of Operation Data........................................................ T5-3-2 MC Fault Code 111413.....................................................T5-5-75
Snapshot Data....................................................................... T5-3-6 MC Fault Code 111422.....................................................T5-5-76
Communication System.................................................... T5-3-7 MC Fault Code 111901.....................................................T5-5-77
MC Fault Codes 120003, 120004..................................T5-5-78
Group 4 Component Layout MC Fault Codes 120014...................................................T5-5-79
Main Component (Overview).......................................... T5-4-1 Column Display Controller Fault Code 115001.......T5-5-81
Main Component................................................................. T5-4-2 Column Display Controller Fault Code 115011.......T5-5-82
Main Component (Travel System)................................. T5-4-3 Column Display Controller (Information)
Electrical System (Overview)........................................... T5-4-5 Fault Codes 120500 to120503, 120505................T5-5-83
Electrical System (Cab)....................................................... T5-4-6 Column Display Controller Fault Codes
Engine and Fan Pump......................................................T5-4-14 120506, 120507, 120510 to 120512,
Pump Device.......................................................................T5-4-15 120515, 120516, 120518............................................T5-5-84
Control Valve.......................................................................T5-4-15
Fan Valve (Option).............................................................T5-4-16 Group 6 Troubleshooting B
Drive Unit..............................................................................T5-4-17 Troubleshooting B (Machine Diagnosis by Using
Front Axle..............................................................................T5-4-17 Trouble Symptom) Procedure.................................... T5-6-1
Manifold Valve.....................................................................T5-4-18 Relationship between Machine Trouble Symptoms
Parking Brake Solenoid Valve Block............................T5-4-18 and Related Parts............................................................ T5-6-3
Brake Charge Valve............................................................T5-4-18 Correlation between Trouble Symptoms and Part
Steering Valve, Secondary Steering Failures.............................................................................T5-6-24
Valve (Option)................................................................T5-4-19 Engine System Troubleshooting..................................T5-6-47
Secondary Steering Pump (Option)............................T5-4-19 All Actuator System Troubleshooting.........................T5-6-53
Ride Control Valve (Option)............................................T5-4-20 Front Attachment System Troubleshooting.............T5-6-59
80Z6 Trbl
Steering System Troubleshooting...............................T5-6-69
Travel System Troubleshooting....................................T5-6-73
Brake System Troubleshooting.....................................T5-6-83
Other System Troubleshooting.....................................T5-6-87
Exchange Inspection..................................................... T5-6-101
Air Bleeding Procedures for Brake (Axle)................ T5-6-103
Outline..................................................................................... T5-7-1
Functions of Main Parts..................................................... T5-7-6
Troubleshooting.................................................................T5-7-11
Air Conditioner Controller Fault Code List................T5-7-12
Air Conditioner Controller Fault Codes
E11 to E22........................................................................T5-7-13
Air Conditioner Controller Fault Codes
E43 to E92........................................................................T5-7-14
Work after Replacing Components.............................T5-7-36
Refill Compressor Oil........................................................T5-7-37
Charge Air Conditioner with Refrigerant..................T5-7-38
Hose and Pipe Tightening Torque................................T5-7-46
80Z6 Trbl
Introduction
Refer to the inspection and troubleshooting procedures
after any machine trouble has occurred. The inspection
and troubleshooting procedures are presented in an
orderly fashion in this section to quickly find the cause of
the machine trouble and solution.
The troubleshooting section in this manual consists of

seven groups; Diagnosing Procedure, Monitor, e-Service,
Component Layout, Troubleshooting A (Base Machine
Diagnosis by Using Fault Codes), Troubleshooting B
(Machine Diagnosis by Using Troubleshooting Symptom),
and Air Conditioner.
 Diagnosing Procedure  Troubleshooting A (Base Machine Diagnosis by Using

This group explains procedures of troubleshooting Fault Codes)
and precautions and/or information for the electrical Refer to these procedures if any fault codes are
system inspection. displayed when each controller is diagnosed by
using MPDr. (or the the service menu of monitor).
Example: Fuse Inspection IMPORTANT: The information controller receives
and retains a record of the electrical signal system
 Monitor malfunction of each controller in the form of
This group contains the display screen of monitor fault codes by using the CAN communication. In
and the operating procedures of service menu. addition, the self-diagnosing function records the
electrical signal system malfunction in the form of
 e-Service fault codes
This group contains as follows. Download data from
the information controller and upload. Procedures Example: Fault Code 111000-2: Abnormal EEPROM
when starting communication, when installing
the communication controller and when replacing  Troubleshooting B (Machine Diagnosis by Using
the information controller. Explanation for the Troubleshooting Symptom)
communication system. Refer to troubleshooting B for diagnosis by using
trouble symptom.
 Component Layout Refer to these procedures when no fault codes are
displayed after diagnosing the machine by using
MPDr. (or the service menu of monitor).
Example: Even if accelerator pedal is operated,

engine speed does not change.
 Air Conditioner
This group contains system of the air conditioner,
troubleshooting, and procedures for charging air
conditioner with refrigerant.
T5-1-1
Diagnosis Procedure
These six basic steps are essential for efficient
troubleshooting:
1. Study the system

 Study the machine's technical manuals.
 Know the system and how it works, and what the
construction, functions and specifications of the
system components are.
(Construction and functions)
2. Ask the operator
Before inspecting, get the full story of malfunctions
T107-07-01-001
from the operator below.
 Operating condition: How is the machine being
used? (Find out if the machine is being operated
correctly.)
 Trouble identification: When was the trouble noticed,
and what types of work the machine doing at that
time?
 Trouble symptom: What are the details of the
trouble? Did the trouble slowly get worse, or did it
appear suddenly for the first time?
 Trouble history: Did the machine have any other
troubles previously? If so, which parts were repaired
before?
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine's daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the
T4GB-05-01-002
batteries, as troubles in the electrical system such as
low battery voltage, loose connections and blown
fuses will result in malfunction of the controllers,
causing total operational failure of the machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result, wasting
time. Check for blown fuses before troubleshooting.
Even if a fuse looks normal by visual inspection, a
fine crack is difficult to find.
Always use a circuit tester when checking the fuses.
4. Operate the machine yourself
Reproduce the trouble on the machine and make
sure the actual phenomenon.
If the trouble cannot be confirmed, stop the engine
and obtain further details of the malfunction
from the operator. Also, check for any incomplete
connections of the wire harnesses corresponding to
the trouble.
T4GB-05-01-003
T5-1-2
5. Perform troubleshooting
dCAUTION: Do not disconnect wire harnesses or

hydraulic lines while the engine is running. The
machine may malfunction or pressurized oil may
spout, possibly resulting in personal injury. Stop
the engine before disconnecting wire harnesses or
hydraulic lines.
Perform diagnosis by connecting MPDr. to the machine
or by using the service menu of monitor.
In case any fault code has been displayed by diagnosis
by using MPDr. (the service menu of monitor),
check the cause of the trouble by referring to
Troubleshooting A in this section. In case any fault
code has been displayed by diagnosis by using MPDr.
(the service menu of monitor), write the fault code.
TNED-05-01-001
Delete the fault code once and retry self-diagnosis
again. If the fault code is displayed again, check the
cause of the trouble by referring to Troubleshooting
A in this section. After the machine trouble has been
corrected, the fault code (displayed by the service
menu of monitor) will be deleted. Therefore, in case
the problems which are not easily re-predicable are
encountered, check the fault code by using MPDr..
In case the fault code is not displayed, check
operating condition of each component by referring
to Troubleshooting B in this section and by using the
monitoring function of MPDr. (the service menu of
monitor).
f NOTE: Note that the fault codes displayed do not
necessarily indicate machine trouble. The controller
stores even temporary electrical malfunctions, such as
a drop in battery output voltage or disconnection of the
switches, sensors, etc., for inspections. For this reason,
the "RETRIAL" is required to erase the accumulated fault
codes from the controller memory and to confirm if any
fault codes are indicated after the "RETRIAL".
T5-1-3
6. Trace possible causes

Before reaching a conclusion, check the most
suspect causes again.
Try to identify the actual cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T4GB-05-01-006
T5-1-4
Electric System Inspection

The precautions and information for the electrical system
inspection are explained here. The electrical system
inspection contains as follows.
 Precautions for Inspection and Maintenance

 Instructions for Disconnecting Connectors
 Fuse Inspection
 Fusible Link Inspection
 Battery Voltage Check
 Alternator Check
 Continuity Check
 Voltage and Current Measurement
 Check by False Signal
 Test Harness
T5-1-5
Precautions for Inspection and Maintenance

1. Disconnect the power source.
Disconnect the wire harness from the negative
terminal side in battery first when taking wire
harnesses and connectors off for repair or
replacement work. Failure to do so can result in
damage to the wire harnesses, fuses and fusible
links and, in some cases, cause fire due to short
circuiting. In addition, even when the key switch
is turned OFF, the controller may be operated for
a specified time. Therefore, disconnect the wire
harness from the negative terminal side in battery
after setting the key switch to the OFF position and
waiting one minute or more.
2. Color coding of wire harnesses.
As for the color codes of wire harnesses in the
electrical system, refer to the table. In cases on the
design sheet where two colors are indicated for one
wire, the left initial stands for base color, while the
right initial stands for marking color.
Code R W L G Y B
Color Red White Blue Green Yellow Black
Code Or Lg Br p Gr V
Color Orange Light Brown Pink Gray Violet
green
fNOTE:
 Code BW indicates a black base wire with white fine-
line marking.
 Initials "O" and "Or" both stand for the color orange.
 Wires with longitudinal stripes printed on them are
not color coded. Do not confuse them with color
coded wires.
T5-1-6
3. Precautions for connecting and disconnecting

terminal connectors.
 When disconnecting the wire harnesses, grasp
them by their connectors. Do not pull on the wire
itself. Release the lock first before attempting to
separate connectors, if a lock is provided. (Refer to
Instructions for Disconnecting Connector on T5-1-8.)
 The water-resistant connectors keep water out.
If water enters them, water will not easily drain TDAA-05-08-002
from them. When checking the water-resistant
connectors, take extra care not to allow water to
enter the connectors. In case water should enter the
connectors, reconnect only after the connectors are 1
thoroughly dried.
 Before connecting the terminal connectors, check 2
that no terminals are bent (3) or coming off (4). In
addition, as most connectors are made of brass, 3
check that no terminals are rusting (2).
 When connecting terminal connectors provided with
a lock, insert them together until the lock "clicks." 4
 Pull the wire harness near the connector in order to TDAA-05-08-003
check if it is correctly connected.
1- Correct 3- Bent
2- Rusting 4- Coming Off
4. Precaution for using a circuit tester.

 Before using a circuit tester, refer to the instructions
in the circuit tester manual. Then, set the circuit TDAA-05-08-004
tester to meet the object to be measured, voltage
range and current polarity.
 Before starting the connector test, always check the
connector terminal numbers, referring to the circuit
diagram. When the connector size is very small, and
the standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or a pin
around the probe to make the test easier.
 When checking the connector by using a circuit
tester, insert a tester probe from the wire harness
end of connector in order not to damage the
terminal inside connector.
T5-1-7
Instructions for Disconnecting Connectors
 Push Lock, Pull, and Separate Type

 Push the lock, and pull connector.
 Connectors will not be easily separated even if the
lock is pushed while being pulled.
 The lock is located on female side connector (wire
harness end side).
T107-04-05-002
 Raise Lock, Pull, and Separate Type
T107-04-05-003
T4GB-05-06-003
 Pull and Separate Type

IMPORTANT: Before pulling and separating, unlock
the connector in the solenoid valve by using a pair
of pincers.
T107-04-05-004
T5-1-8
 Remove the Bolt, Pull, and Separate Type

l : 4 mm
TNEE-05-01-001
 Unlock, Move the Lever, Pull, and Separate Type

f NOTE: Securely unlock with one hand and slowly pull
the lever with the other hand. Then, the connector will be
separated.
T4GB-05-06-001
T4GB-05-06-002
 Rotate Lock, Pull, and Separate Type

f NOTE: Pick up the wire harness end connector with
fingers and rotate it counterclockwise while pushing the
projection part. Then, the connector will be separated.
T4GB-05-06-007
T5-1-9
Fuse Inspection
Cracks in a fuse are so fine that it is very difficult or
impossible to find by visual inspection. Use a circuit tester
fNOTE: Check the glow plug relay circuit fuse with
the key switch set in the ON position and follow the
in order to correctly inspect fuse continuity. Use a circuit procedure in step 3.
tester in order to correctly inspect fuse continuity by
following the instructions described below.
1. Set the key switch to the ON position. When the

key switch is in the ON position, current from key
switch terminal M turns the battery relay ON so that
electric power is supplied to all circuits except the
glow plug relay circuit. (Refer to the circuit diagram.) e d e
2. Remove the fuse box cover. Set a circuit tester.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of circuit tester to
the body. Touch the terminals located (e) of fuse
box one-by-one with the positive probe of circuit
tester. When normal continuity of a fuse is intact,
the circuit tester will indicate 20 to 25 V (battery
voltage).
M178-07-034
d- Terminals connected to the e- Terminals connected to loads

power source (accessories)
a, b
b
a
10 20
9 19
8 18
7 17
6 16
5 15
4 14
3 13
2 12
1 11
c
MNEC-01-047
a- Fuse Box A c- Relay Box M178-07-034

b- Fuse Box B
T5-1-10
Fuse Box A (a)
Fuse No. Capacity Connected to

1 5A Back Buzzer Relay, Backup Buzzer
2 5A Brake Light Relay, Brake Light (RH), Brake Light (LH), Brake Light Switch, Turn Signal Lever, Turn
Signal Light Relay (RH) (Power), Turn Signal Light Relay (LH) (Power)
3 10A Head Light Relay, Head Light (LH), Head Light (RH)
4 10A Light Switch, Dimmer Switch, Work Light Switch
5 (15A) Auxiliary 1
6 10A Horn Relay, Horn, Horn Switch
7 10A Flasher Relay, Hazard Light Switch, Turn Signal Light Relay (RH), Turn Signal Light Relay (LH), Turn
Signal Light (Hazard Light) (RH), Turn Signal Light (Hazard Light) (LH)
8 10A Load Dump 2 Relay, Load Dump 1 Relay, MC (Power), GSM (Option) (Power), GPS (Option) (Power),
Column Display Controller (Backup Power), Information Controller (Power)
9 10A TCU (Power)
10 30A ECM Main Relay, Fuel Pump Relay, Fuel Pump
11 10A Parking Brake Switch, Hazard Light Switch, Work Light Switch, Control Lever Lock Switch, Power
Mode Switch, Fan Reverse Rotation Switch (Option), Ride Control Switch (Option), Secondary
Steering Check Switch (Option), First Speed Fixed Switch, Tail Light (RH), Tail Light (LH), Clearance
Light (RH), Clearance Light (LH)
12 (20A) Auxiliary 2 (Rear View Monitor, Rear Camera)
13 10A Battery Relay, ECM Main Relay (Power), Fuel Pump Relay (Power), ECM, Column Display Controller,
Buzzer in Column Display Controller, Information Controller, Declutch Position Switch, Speed Shift
Retard Mode Switch, MC, GSM (Option), GPS (Option), Back Buzzer Relay (Power), Air Conditioner
Controller (Air Conditioner), Fresh/Re-Circulated Air Damper Servo Motor (Air Conditioner),
Compressor Relay (Air Conditioner) (Power), Blower Motor Relay (Air Conditioner) (Power),
Condenser Relay (Air Conditioner)
14 10A TCU (Power), Parking Brake Relay 1, Parking Brake Relay 2 (Power), Parking Brake Switch, DIAG, Hold
Switch, DSS (Down Shift Switch), Forward/Reverse Lever, Shift Switch
15 10A MC (Solenoid Valve Power)
16 5A Coil (Bucket Tilt Side), Bucket Leveler Relay, Bucket Proximity Switch, Coil (Lift Arm Raise Side),
Kickout Relay, Lift Arm Proximity Switch, Coil (Lift Arm Lower Side), Pilot Shut-Off Relay, Control
Lever Lock Switch, Pilot Shut-Off Solenoid Valve, Quick Coupler Switch (Option)
17 20A Work Light (Rear) Relay, Rear Work Light (RH), Rear Work Light (LH)
18 5A Parking Brake Solenoid Valve, Parking Brake Relay 2
19 10A High-Beam Relay, Head Light/High-Beam (RH), Head Light/High-Beam (LH)
20 5A Secondary Steering Pump Relay (Option), Secondary Steering Motor (Option)
T5-1-11
Fuse Box B (b)
Fuse No. Capacity Connected to

1 5A Radio (Backup Power)
2 10A Cigar Lighter
3 15A Wiper Motor (F), Wiper Relay (F) 2, Wiper Relay (F) 1, Washer Relay (F), Washer Motor (F), Wiper/
Washer Switch (F)
4 20A Work Light (Front) Relay, Front Work Light (Right) (Cab), Front Work Light (Left) (Cab)
5 10A Wiper Motor (R), Wiper Relay (R), Washer Relay (R), Washer Motor (R), Wiper/Washer Switch (R)
6 10A Compressor Relay (Air Conditioner), Compressor (Air Conditioner),
7 15A External Power (12 V) (Option)
8 20A Seat Heater (Option)
9 10A Beacon Light Switch (Option), Beacon Light (Option)
10 20A Blower Motor Relay (Air Conditioner), Blower Motor (Air Conditioner), Power Transistor
11 5A Cab Light, Radio
12 10A High/Low Pressure Switch (Air Conditioner), Condenser Relay (Air Conditioner), Condenser Relay
(HI) (Air Conditioner), Electric Fan (Air Conditioner)
13 (10A) Auxiliary 3
14 (10A) Auxiliary 4
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
T5-1-12
Fusible Link Inspection 3 2 1
Inspection
1. Visually inspect fusible links (2, 3).
Replacement
1. Disconnect the negative cable from the battery.
2. Pull out fusible links (2, 3). Replace fusible links (2,
3).
3. Connect the negative cable to the battery.
MNEC-01-503
T111-04-05-015
1- Battery Relay 3- Fusible Link (65 A) (2 Used)

2- Fusible Link (140 A) (2 Used)
T5-1-13
Battery Voltage Check

1. Turn the key switch OFF. Check voltage between the
battery positive terminal and the body (ground).
Normal Voltage: 24 V
fNOTE: If voltage is abnormal, recharge or replace the

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

system.
TNEE-05-01-002
T5-1-14
Alternator Check
Generally, if the alternator has generated electricity,
alternator indicator (1) will disappear. If alternator
indicator (1) is displayed while the engine is running, the
alternator might be defective.
How to Check Alternator

1. Set the key switch to the ON position. Confirm that
alternator indicator (1) is displayed.
2. Measure voltage between terminals B and E of the
alternator. If the measured voltage is around 24 V,
the alternator circuit can be considered normal. If 1 MNDB-01-008
the measured voltage is low, a shortage in battery
capacity or looseness of the wire connectors
of alternator circuit might be the cause of the
malfunction. When voltage is 0 V, the wiring
between fuse box and alternator might be loose or
disconnected. Also, the alternator cannot generate
electricity if the ground line is disconnected.
3. Next, start the engine and measure voltage
generated while the alternator rotates. As described
above, measure voltage between terminals B and E
on the alternator side. B
If voltage is around 28 V, the alternator is operating
normally. If the rated voltage is not being generated
(around 24 V), there is some trouble with the
alternator or the regulator.
T157-07-06-003
T5-1-15
Continuity Check
IMPORTANT: Before continuity check, set the key
switch to the OFF position. A a
 Single-line continuity check

Disconnect both end connectors of the wire harness and
check continuity between both ends:
 ∞ Ω = Discontinuity
 0 Ω = Continuity
A a
 When the one end connector is far apart from the
other, connect one end of connector (A) to the body by
using a clip. Then, check continuity of the wire harness
through the body as illustrated.
 ∞ Ω = Discontinuity
 0 Ω = Continuity
A a
 Single-line short-circuit check
Disconnect both end connectors of the wire harness and
check continuity between one end connector of the wire
harness and the body:
 0 Ω = Short-circuit is present.
 ∞ Ω = No short-circuit is present.
T107-07-05-003
 Multi-line continuity check

Disconnect both end connectors of the wire harness,
and short-circuit two terminals, (A) and (B), at one end
connector, as illustrated. Then, check continuity between
terminals (a) and (b) at the other connector. A a
B b
If the ohm-meter reading is ∞ Ω, either line (A) - (a), C c
or (B) - (b) is in discontinuity. To find out which line is
discontinued, conduct the single line continuity check
on both lines individually, or, after changing the short-
circuit terminals from (A) - (B) to (A) - (C), check continuity
once more between terminals (a) and (c). By conducting
the multi-line continuity check twice, it is possible to find
out which line is discontinued. With terminals (A) and (C) T107-07-05-004
short-circuited, check continuity between terminals (a)
and (c).
 0 Ω = Line (B) - (b) has discontinuity.
 ∞ Ω = Line (A) - (a) has discontinuity.
A a
B b
 Multi-line short-circuit check C c
Disconnect both end connectors of the wire harness, and
check continuity between terminals (A) and (B) or (C).
 0 Ω = Short-circuit exists between the lines.
 ∞ Ω = No short-circuit exists between the lines.
T107-07-05-005
T5-1-16
(Blank)
T5-1-17
Voltage and Current Measurement

Turn key switch ON so that the specified voltage (current)
is supplied to the location to be measured. Judge if the
circuit is normal by evaluating whether the measured
voltage (current) matches the specification.
24-Volt Circuit
Start checking the circuit in order up to the location to
be measured from either power source or actuator side.
Thereby, the faulty location in the circuit will be found.
 Black (negative) probe terminal of circuit tester: To
ground to the body
 Red (Positive) probe terminal of circuit tester: To
touch the location to be measured
Engine Key Switch Location to be Measured Specification

Electric Power Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery (Switch) 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link A (65A) 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current *1 20 mA or less
Preheating Circuit
Stopped ON or START Between (11) and Ground: Key Switch (M) 20 to 25 V
Stopped ON or START Between (7) and Ground: Intake Air Heater Relay *2 20 to 25 V
Charging Circuit
Fast Speed ON Between (9) and Ground: Alternator (B)/Generating Voltage 26 to 30 V
Fast Speed ON Between (8) and Ground: Battery Relay (Switch) 26 to 30 V
Fast Speed ON Between (17) and Ground: Fusible Link (140 A)/Generating Voltage 26 to 30 V
Fast Speed ON Between (14) and Ground: Column Display Controller (#2-28) 13 to 30 V
Surge Voltage
Prevention Circuit
Idle Speed ON Between (9) and Ground: Alternator (B) 26 to 30 V
Idle Speed ON Between (10) and Ground: Load Dump 1 Relay 26 to 30 V
Idle Speed ON Between (6) and Ground: Battery Relay (Coil) 26 to 30 V
*1 Before measurement, disconnect the negative cable from the battery.
*2 The preheating circuit is operated for the preheating time according to the coolant temperature.
T5-1-18
h(8)
f
10
5
m
c
k
8 4 3 2 1 2-17
17 i
m
a
6 d
11
9
b 14
2-28
1-21
J2-50
J2-40
J2-42
E
TNEJ-05-01-001
e j
7
E- Ground
a- Battery d- Battery Relay g- Key Switch j- ECM

b- Alternator e- Intake Air Heater h- Fuse Box A k- Fusible Link (140 A)
c- Fusible Link A (65A) f- Load Dump 1 Relay i- Column Display Controller m- To Battery Relay
T5-1-19

Accessory Circuit
Stopped ON Between (12) and Ground: Key Switch (ACC) 20 to 25 V
Stopped ON Between (13) and Ground: Radio 20 to 25 V
Stopped ON Between (5) and Ground: Fusible Link A (65A) 20 to 25 V
T5-1-20
a d
5
c
12
n(1) 13 p
E
TNEJ-05-01-002
E- Ground
a- Battery d- Battery Relay h- Fuse Box B

c- Fusible Link A (65A) g- Key Switch p- Radio
T5-1-21

Starting Circuit
Started START Between (6) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (8) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (14) and Ground: Starter (#30) 20 to 25 V
Started START Between (15) and Ground: Starter (#50) 20 to 25 V
Started START Between (16) and Ground: Starter Relay 1 (B) 20 to 25 V
Started START Between (17) and Ground: Key Switch (ST) 20 to 25 V
Started START Between (18) and Ground: Neutral Relay 20 to 25 V
Started START Between (19) and Ground: Fuse Box A (#10) 20 to 25 V
Started START Between (20) and Ground: ECM(J3-4) 20 to 25 V
Started START Between (21) and Ground: ECM Main Relay (Switch) 20 to 25 V
Started START Between (22) and Ground: ECM Main Relay (Coil) 20 to 25 V
Neutral Engine Start
Circuit *
Stopped ON Between (11) and Ground: Key Switch 20 to 25 V
Stopped ON Between (23) and Ground: Fuse Box A (#14) 20 to 25 V
Stopped ON Between (24) and Ground: TCU(#67) 20 to 25 V
Stopped ON Between (25) and Ground: Neutral Relay (Coil) 0V
Stopped ON Between (18) and Ground: Neutral Relay (Switch) 20 to 25 V
* Before measurement, set the forward/ reverse lever to the neutral position.
T5-1-22
8 4
6 d
t u
23
67
h(14)
24
g 11 t
17
r 18
E
14
t 19 h(10) 21 s 20 j
25
b
15
22
16 c
E
TNEJ-05-01-003
E- Ground
b- Starter g Key Switch r- Neutral Relay u- TCU

c- Starter Relay 1 h- Fuse Box A s- ECM Main Relay
d- Battery Relay j- ECM t- Forward/Reverse Lever
T5-1-23
5-Volt Circuit
 Voltage between terminal #1 and the body Two Polarities
Disconnect the connector with the key switch OFF.
Measure voltage between terminal #1 of the body 1 2
harness end connector and the body (ground).
 Key Switch: ON
ground to the body
 Red (Positive) probe terminal of circuit tester: To
terminal #1
Evaluation: If the measuring voltage is within 5 ± 0.5 volts, T107-07-05-006

the circuit up to terminal #1 is normal.
Three Polarities
1 2 3
T107-07-05-007
 Voltage between terminal #1 and the ground terminal

Turn OFF the key switch, and disconnect the sensor Two Polarities
connector. Measure the voltage between terminal #1
1 2
(5 V power supply) of the body harness end connector
and the ground terminal (terminal #2 for two-polarities
or terminal #3 for three-polarities connector) under the
following conditions.
 Key Switch: ON
ground terminal (Terminal #2 or #3)
 Red (Positive) probe terminal of circuit tester: To T107-07-05-008
terminal #1
Evaluation: If the measuring voltage is within 5 ± 0.5

volts, the circuit up to terminal #1 or the ground terminal Three Polarities
(terminal #2 or #3) is normal.
1 2 3
T107-07-05-009
T5-1-24
Check by False Signal

Two Polarities
Turn the key switch OFF. Disconnect the sensor connector.
1 2
Turn the key switch ON. Connect terminal #1 (power
source) of the body harness end connector to terminal #2
(signal). (Power voltage is used as a false signal.)
Check this state by using the monitor function of MPDr.
When the maximum value is displayed, MC and the circuit
up to the body harness end connector are normal. If "ON"
is displayed, the pressure switch circuits are normal.
IMPORTANT: Do not connect terminal #1 or #2 T107-07-05-010

to terminal #3 or to the body (ground) when
checking a three-polarity connector.
Three Polarities
f NOTE: Some kinds of sensors can be monitored by the
1 2 3
service menu of the monitor.
T107-07-05-011
T5-1-25
Test Harness Parts Number 4283594 (ST 7126)
Install a test harness between connectors. Check the

circuit condition depending on whether the test harness
lamp lights or extinguishes during operation.
 Parts Number 4283594 (ST 7126)

Use in order to check a single-line (discontinuity and/or
voltage).
T107-07-05-012
 During Operation: Light is ON.
Parts Number (ST 7226)
4
 Parts Number (ST 7226) 3 50
Use in order to check the solenoid valve unit circuits.
150 50 50
1 2 2 1
 When the corresponding control lever or switch is
operated: Light is ON. T107-07-06-015
Connect a test harness to the wire harness end connector

of pressure sensor. Check the state of pressure sensor
circuit.
 ST 6701 for high-pressure sensor
 ST 6703 for low-pressure sensor
TDAA-05-06-003
T5-1-26
Connecting Procedure of Test Harness
fNOTE: The connecting procedures of test harness of

pump delivery pressure sensor (1) are explained.
1. Disconnect a connector of pump delivery pressure
sensor (1).
TNED-05-01-003
1
2. Connect the male end connector of test harness

(3) (ST 6701) to wire harness end connector (4) of
pump delivery pressure sensor (1).
3. Connect dummy sensor (2) equivalent to #4436271
to the female end connector of test harness (3) (ST
6701).
2 3 TDAA-05-06-002
2 3 4
TDAA-05-06-003
T5-1-27
(Blank)
T5-1-28
Group 2 Monitor
Outline
Basic Screen
Monitor Panel
1 2 3 4 5 6 7
40 8
39 9
38 10
11
37
12
36
35 13
34
14
15
33
16
32
31 30 MNDB-01-034
29 28 27 26 25 24 23 22 21 20 19 18 17
1- Left Turn Signal Light Indicator 14- (Unused) 25- Monitor Display Selection 36- (Unused)
2- High Beam Indicator 15- Secondary Steering Indicator Switch (Down) 37- Hydraulic Oil Temperature
3- Work Light Indicator (Option) 26- Forward/Reverse Selector Indicator
4- Right Turn Signal Light 16- Low Steering Oil Pressure Switch Indicator (Option) 38- Transmission Warning
Indicator Indicator (Option) 27- Monitor Display Indicator
5- (Unused) 17- Seat Belt Indicator 28- Fan Reverse Rotation Indicator 39- Transmission Oil Temperature
6- (Unused) 18- Discharge Warning Indicator (Option) Indicator
7- Service Indicator 19- Fuel Gauge 29- Engine Warning Indicator 40- Transmission Oil Temperature
8- Maintenance Indicator 20- Power Mode Indicator 30- Overheat Indicator Gauge
9- Parking Brake Indicator 21- Monitor Display Selection 31- Coolant Temperature Gauge
10- Clearance Light Indicator Switch 32- Engine Oil Low Pressure
11- Control Lever Lock Indicator 22- (Unused) Indicator
12- (Unused) 23- Monitor Display Selection 33- Air Filter Restriction Indicator
13- Brake Oil Low Pressure Switch (Up) 34- (Unused)
Indicator 24- Preheat Indicator 35- (Unused)
f NOTE: Refer to the separated volume, Operator’s

Manual for details of the monitor panel.
T5-2-1
Group 2 Monitor
Monitor Display
1
1- Monitor Display
2- Monitor Display Mode Switch
3- Monitor Display Selection Switch (Up)
4- Monitor Display Selection Switch (Down)
5- Speedometer
6- Machin Information Display
7- Hold Indicator
8- Forward/Reverse and Shift Position Indicator MNDB-01-008
4 3 2
9- Ride Control Indicator
10- ECO Indicator 8 9 10 5
Vehicle Information Display (6)

12- Engine Speed Display
13- Coolant Temperature Display
14- Transmission Oil Temperature Display
15- Hydraulic Oil Temperature Display
16- Fuel Consumption Display
17- (Unused)
18- Hour Meter Display
19- Average Fuel Consumption Display MNDB-01-033
7 6
20- Odometer Display
21- Fault Code Display
19 20 21 22
22- (Unused)
18
17
16
MNDB-01-033
15 14 13 12
T5-2-2
Group 2 Monitor
Operating Procedures of Service Menu

IMPORTANT: The service menu is provided only for
maintenance activity. Do not explain this function
to your customers.
The following items can be displayed on the monitor
without using MPDr..
 Clock (time, 24-hour) *

 Hour Meter *
 Odometer *
 INFO (Information) *
 Engine Speed
 Coolant Temperature
 Transmission Oil Temperature
 Hydraulic Oil Temperature
 Fault Code
 Fuel Consumption
 Average Fuel Consumption
f NOTE: The normal menu with the mark * is displayed
on Service Menu.
f NOTE: Refer to the separated volume, Operator’s
Manual for details of operation for the normal menu
with the mark *.
T5-2-3
Group 2 Monitor
How to display service menu

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

Current Engine Speed (5) is displayed. (Figure A) When 1 2 3 4
pushing monitor display selection switch (3) once on
this screen, Coolant Temperature is displayed.
Coolant Temperature A
Current Engine Coolant Temperature (6) is displayed.

(Figure B) When pushing monitor display selection
switch (3) once on this screen, Transmission Oil
Temperature is displayed.
Transmission Oil Temperature 5

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

Current Hydraulic Oil Temperature (8) is displayed. C
(Figure D) When pushing monitor display selection
switch (3) once on this screen, Fault Code is displayed.
7
D
TNDB-05-02-005
8
T5-2-4
Group 2 Monitor
Fault Code
1. Current fault code (5) can be displayed. (Figure E)
2. When some Fault Codes (5) exist and whenever
pushing monitor display selection switch (2), other
fault codes are displayed.
3. When pushing monitor display selection switch (3)
once on this screen, Fuel Consumption is displayed.
f NOTE: When the trouble of Fault Code (5) on the screen

is solved, '-----' (bar) is displayed.
f NOTE: When Fault Code (5) does not exist, ERROR (6) is
displayed. In this case, '-----' (bar) is displayed. MNDB-01-008
f NOTE: The fault code of air conditioner controller is 2 3 4

displayed on the LCD panel of air conditioner controller.
(Refer to T5-7.)
5 6
E
Fuel Consumption/Average Fuel Consumption
1. Current Fuel Consumption (7) is displayed. (Figure F)
once on this screen, Average Fuel Consumption (8)
up to the present is displayed. (Figure G) TNDB-05-02-006
3. Whenever pushing monitor display selection switch

(4) on this screen, Unit is changed (l/hgal/h). 7
F
once on this screen, Clock is displayed. (Figure H)
TNDB-05-02-007
8
G
TNDB-05-02-008
TNDB-05-02-009
T5-2-5
Group 2 Monitor
List of Service Menu Display
Display Order Item Unit Data

1 Clock (time, 24-hour) * h, min -
2 Hour Meter * h -
3 Odometer * km (mile) -
4 INFO (Information) * - -
5 Engine Speed min-1 Input signal from ECM
6 Coolant Temperature ºC Input signal from ECM
7 Transmission Oil Temperature ºC Input signal from TCU
8 Hydraulic Oil Temperature ºC Input signal from MC
9 Fault Code ERROR -
10 Fuel Consumption l/h (gal/h) -
11 Average Fuel Consumption l/h (gal/h) -
f NOTE: The normal menu with the mark * is displayed

on Service Menu.
T5-2-6
Group 2 Monitor
Coolant Temperature Gauge and

Transmission Oil Temperature Gauge
Coolant Temperature Gauge No. Coolant Temperature (ºC)

A 25
E B 40
D
C 95
D 105
E (120)
C
A
TNED-05-02-003
f NOTE: When the coolant temperature reaches the (D)

zone or more, the maintenance indictor on the monitor
panel is ON and the buzzer sounds.
Transmission Oil Temperature Gauge No. Coolant Temperature (ºC)

A 25
E B 50
D C 80
D 120
E (125)
A
TNDB-05-02-010
f NOTE: When the transmission oil temperature reaches

the (D) zone, the maintenance indictor on the monitor
panel is ON.
T5-2-7
Group 2 Monitor
Fuel Gauge
Fuel Gauge No. Fuel Level (%) Fuel Sensor (Ω)

A 100 (FULL) 100-4
A
B 50 32.9
C 12 77±3
D 0 (EMPTY) 90+100
a
C
D
TNDB-05-02-011
f NOTE: When the fuel gauge reaches the (C) zone,

indictor (a) on the monitor panel is ON.
T5-2-8
Group 3 e-Service
Outline
Controller saves the input signals from various sensors
and switches of the machine as data. Various input signals
are recorded as Operation Data and Snapshot Data in
monitor controller.
The recorded data is downloaded to the personal

computer and is uploaded to the center server via
LAN, so that the data can be used as “e-Service”. The
machine equipped with the communication terminal
(option) sends the data to the center server by using the
communication terminal. (As for the communication
system, refer to T5-3-7.)
T5-3-1
Group 3 e-Service
List of Operation Data

List of Daily Report Data
Item Details
Date Date of daily report data.
Time Last time when the engine is operated during a day.
Fuel Level The value of the final remained fuel during a day. (Value is recorded by fuel
sensor data from monitor controller.)
Fuel Usage Amount The value of fuel used during a day. (Value is calculated and recorded by
accumulated fuel usage amount from ECM.)
Machine Hour Meter Hour meter cumulative hours. (Hours are recorded by hour meter from monitor
controller.)
Machine Travel Distance Travel distance during a day.
Engine Power Mode OFF Total hours of power mode (OFF) with engine running during a day. (Hours are
Operating Hours recorded by power mode switch information from MC.)
Hours Power Mode ON Hours Total hours of power mode (ON) with engine running during a day. (Hours are
recorded by power mode switch information from MC.)
Travel AUTO 1 Mode Total operating hours of travel mode (AUTO 1 mode) during a day. (Hours are
Operating Traveling Hours recorded by travel mode switch information from MC.)
Hours AUTO 2 Mode Total operating hours of travel mode (AUTO 2 mode) during a day. (Hours are
Traveling Hours recorded by travel mode switch information from MC.)
Manual Mode Total operating hours of travel mode (Manual mode) during a day. (Hours are
Traveling Hours recorded by travel mode switch information from MC.)
T5-3-2
Group 3 e-Service
Item Details
Engine Operating Hour Distribution Engine operating hour distribution during a day. (Engine ON state is recorded
Data when engine is running for more than 5 minutes at each range of engine
operating hour distribution.)
Latitude Signal from GPS antenna.
Longitude Signal from GPS antenna.
fNOTE: The daily operation in this table is equivalent

to the hours between 0:00 and 23:59:59 counted by the
monitor controller built-in clock. In case the engine is
kept operated beyond 0:00, such data are recorded as
those for the following day.
T5-3-3
Group 3 e-Service
List of Frequency Distribution Data
Item Details
Pump Load Frequency distribution of main pump delivery pressure
Radiator Coolant Temperature (79 °C Total hours when coolant temperature is less than 80 °C during a day.
or less)
Radiator Coolant Temperature (80 to Total hours when coolant temperature is 80 °C or more and less than 94 °C
93 °C) during a day.
Radiator Coolant Temperature (94 to Total hours when coolant temperature is 94 °C or more and less than 105 °C
104 °C) during a day.
Radiator Coolant Temperature (105 °C Total hours when coolant temperature is 105 °C or more during a day.
or more)
Hydraulic Oil Temperature (49 °C or Total hours when hydraulic oil temperature is less than 50 °C during a day.
less)
Hydraulic Oil Temperature (50 to 89 Total hours when hydraulic oil temperature is 50 °C or more and less than 90 °C
°C) during a day.
Hydraulic Oil Temperature (90 to 99 Total hours when hydraulic oil temperature is 90 °C or more and less than 100 °C
°C) during a day.
Hydraulic Oil Temperature (100 °C or Total hours when hydraulic oil temperature is 100 °C or more during a day.
more)
Torque Converter Oil Temperature (49 Total hours when torque converter oil temperature is less than 50 °C during a
°C or less) day.
Torque Converter Oil Temperature (50 Total hours when torque converter oil temperature is 50 °C or more and less than
to 89 °C) 90 °C during a day.
Torque Converter Oil Temperature (90 Total hours when torque converter oil temperature is 90 °C or more and less than
to 109 °C) 110 °C during a day.
Torque Converter Oil Temperature Total hours when torque converter oil temperature is 110 °C or more during a
(110 °C or more) day.
T5-3-4
Group 3 e-Service
List of Total Operating Hours
Item Details
Hour Meter End Hour meter’s value accumulated in machine’s monitor
Travel Distance Odometer’s value accumulated in machine’s monitor
Engine Power Mode OFF Total engine operating hours selecting power mode (OFF)
Operating Hours
Hours Power Mode ON Hours Total engine operating hours selecting power mode (ON)
Travel AUTO 1 Mode Total operating hours of travel mode (AUTO 1 mode)
Operating Traveling Hours
Hour AUTO 2 Mode Total operating hours of travel mode (AUTO 2 mode)
Traveling Hours
Manual Mode Total operating hours of travel mode (Manual mode)
Traveling Hours
MC Communication Error Time Total hours of MC communication error
ECM Communication Time Out Time Total hours of ECM communication time out
T5-3-5
Group 3 e-Service
Snapshot Data
Item Details
Serial No. - Machine serial no.
Snapshot Model 1 Difference of large-sized crawler, middle-sized crawler, wheeled excavator, and
wheel loader
Model 2 Detail difference on model 1
DTC Code Fault code and frequency of occurrence
Priority -
Hour Meter Machine’s hour meter at a time when trouble occurred
Occurrence: Year Year at a time when trouble occurred
Occurrence: Date Date at a time when trouble occurred
Occurrence: Time Time at a time when trouble occurred
SA -
SPN Version 001: Version 1
010: Version 2
011: Version 3
100: Version 4
111: Missing version
fNOTE: The data on machine body system including

MC are downloaded as for Snapshot Data Download
(Hitachi). The data on engine system including ECM are
downloaded as for Snapshot Data Download (Isuzu).
T5-3-6
Group 3 e-Service
Communication System
The communication system is used for maintenance of
the machine, “e-Service” by transmitting various data of
the machine regularly via the communication terminal.
fNOTE: Depending on the circumstances of the machine

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

terminal, GPS antenna and communication antenna.
The functions of each equipment are:
 Communication Terminal:
Receives the data from monitor controller and GPS
antenna, and sends the data to the communication
antenna.
 GPS Antenna:
Receives location information of the machine.
 Communication Antenna:
Communicates the data.
T5-3-7
Group 3 e-Service
(Blank)
T5-3-8
Main Component (Overview)
7
6
5
8
10
11
12
13
14 TNEJ-01-02-001
1- Bucket 4- Front Combination Light 7- Rain Cap/Pre-Cleaner (Option) 11- Steering Cylinder (2 Used)
2- Bell Crank (Lever) (Headlight, Turn Signal Light, 8- Rear Work Light (2 Used) 12- Lift Arm Cylinder (2 Used)
3- Bucket Cylinder Clearance Light, Hazard Light) 9- Rear Combination Light (Turn 13- Lift Arm
(2 Used) Signal Light, Hazard Light, Tail 14- Bucket Link
5- Front Work Light (2 Used) Light, Brake Light) (2 Used)
6- Cab 10- Battery (2 Used)
T5-4-1
Main Component
1 2 3 4 5 6 7 8
9
10
19
18
17
16
15 14 TNEJ-01-02-002
13 12 11
1- Radiator Assembly (Refer to 7- Manifold Valve (Refer to T5- 12- Ride Control Valve (Option) 17- Engine and Fan Pump (Refer to
T5-4-4.) 4-18.) (Refer to T5-4-20.) T5-4-14.)
2- Muffler 8- Brake Charge Valve (Refer to 13- Ride Control Accumulator 18- Fuel Tank
3- Air Cleaner T5-4-18.) (Option) 19- Fan Motor
4- Hydraulic Oil Tank 9- Brake Valve 14- Steering Pilot Valve
5- Pilot Valve 10- Steering Valve 15- Pilot Filter
6- Parking Brake Solenoid Valve 11- Control Valve (Refer to T5-4- 16- Service Brake Accumulator (2
Block (Refer to T5-4-18.) 15.) Used)
T5-4-2
Main Component (Travel System)
1 2 3 4 5
9
8
TNEJ-01-02-003
7
6
1- Front Axle (Refer to T5-4-17.) 4- Drive Unit (Refer to T5-4-17.) 7- Rear Propeller Shaft
2- Steering Accumulator (2 Used) 5- Rear Axle 8- Front Propeller Shaft
3- Pump Device (Refer to T5-4- 6- Torque Converter Cooler 9- Steering Cylinder (2 Used)
15.) Check Valve
T5-4-3
Radiator Assembly
3 4 5
TNEJ-01-02-004
a- Front Side of Machine
1- Coolant Reservoir 3- Inter Cooler 5- Radiator

2- Oil Cooler 4- Torque Converter Cooler
T5-4-4
Electrical System (Overview)
6
5
3 4
10
9
7 TNEJ-01-02-005
1- Engine and Fan Pump (Refer to 3- Electrical System (Cab) (Refer 7- Electrical System (Components 8- Electrical System (Around Fuel
T5-4-14.) to T5-4-6.) Related with Relays) (Refer to Tank and Radiator Assembly)
2- Electrical System (Around 4- Horn (2 Used) T5-4-11.) (Refer to T5-4-13.)
Hydraulic Oil Tank) (Refer to 5- Lift Arm Proximity Switch 9- Battery (2 Used)
T5-4-12.) 6- Bucket Proximity Switch 10- Back Buzzer (Option)
T5-4-5
Electrical System (Cab)
1 13 2 14 3
12
4
11
6 TNED-01-02-029
10
7
TNEJ-01-02-013
1- Radio 6- Components Related with 9- Brake Pedal 13- GPS Antenna (Option)
2- Upper Switch Panel (Option) Controllers and Relays (Refer 10- Brake Pedal (Option) 14- Communication Antenna
3- Speaker to T5-4-7.) 11- Front Wiper Motor (Option)
4- Rear Wiper Motor 7- Accelerator Pedal Sensor 12- Components Related with
5- Components Related with (Accelerator Pedal) Monitor and Switches (Refer
Right Console (Refer to T5-4-8.) 8- Brake Light Switch to T5-4-9.)
T5-4-6
Controller and Relays
3 View A
36 35
40
A
TNDB-01-02-032
30 38 39
TNDB-01-02-029
29
28
5
32
12 11 10 9 8
17 16 15 14 13
6
34
37 22 21 20 19 18
27 26 25 24 23
33
TNEJ-01-02-006
1 4 TNDB-01-02-030
1- TCU 13- Work Light (Front) Relay (AR6) 23- Neutral Relay (BR6) 34- Air Conditioner Condenser
2- Flasher Relay 14- Work Light (Rear) Relay (AR7) 24- Left Turn Signal Light Relay (High Pressure) Relay
3- Air Conditioner Controller 15- Right Turn Signal Light Relay (BR7) 35- Front Wiper (1) Relay (WR1)
4- MC (Main Controller) (AR8) 25- Front Washer Relay (BR8) 36- Front Wiper (2) Relay (WR2)
5- ECM Main Relay 16- Horn Relay (AR9) 26- Rear Wiper Relay (BR9) 37- GSM
6- Air Conditioner Condenser 17- Secondary Steering Relay 27- Rear Washer Relay (BR10) 38- Back Buzzer Relay
Relay (AR10) (Option) 28- Fuse Box B 39- Load Dump Relay 2
8- Fuel Pump Relay (AR1) 18- Parking Brake Relay 1 (BR1) 29- Fuse Box A 40- ICF (Information Controller)
9- Head Light Relay (Right) (AR2) 19- Parking Brake Relay 2 (BR2) 30- MPDr. Connector
10- High-Beam Relay (AR3) 20- Pilot Shut-Off Relay (BR3) 32- Relay Box A (RBA)
11- Bucket Leveler Relay (AR4) 21- Brake Light Relay (BR4) 33- Relay Box B (RBB)
12- Kickout Relay (AR5) 22- Load Dump Relay 1 (BR5)
T5-4-7
Right Console
Detail #2(1), #3 (2)
Fingertip Control Lever Type 21
*3(2)
5
*3(2) 6 7 8
10 11 22
*2(1) 12
*1(3) *2(1)
23
20
13
14
15
16
17 TNEJ-01-02-014
TNEJ-01-02-016
Multi-Function Joystick Lever Type Detail #24
21
23 3
5 24
6 7 8
10 11
12
24
25
26
13
14
15
16 TNEJ-01-02-017
17 TNEJ-01-02-015
1- *Bucket Control Lever 10- Fan Reverse Rotation Switch 14- Lift Arm Auto Leveler (Raise) 22- Horn Switch
2- *Lift Arm Control Lever (Option) Switch (Option) 23- Quick Power Switch
3- *Attachment Control Lever 11- Back Buzzer Switch (Option) 15- Lift Arm Auto Leveler (Lower) 24- Multi-Function Joystick Lever
(Option) 12- Hydraulic Coupler Switch Switch (Option) 25- Hold Switch
5- Control Lever Lock Switch (Option) 16- First Speed Fixed Switch 26- Horn Switch
6- Auxiliary 13- Secondary Steering Operation 17- Ride Control Switch (Option)
7- Auxiliary Check Switch (Option) 20- Hold Switch
8- Power Mode Switch 21- DSS (Down Shift Switch)
fNOTE: * The layout of each control lever may depend

on the machine specification.
T5-4-8
Monitor and Switches
TNED-01-02-029
2 3 4 5 6 7 8 9
10
11
12
1
MNDB-01-002 13 MNDB-01-003
1- Front/Rear Wiper Switch 5- Forward/Reverse Lever/Shift 7- Turn Signal Lever/Light 11- Declutch Position Switch
2- Hazard Light Switch Switch Switch/Dimmer Switch 12- Automatic Speed Shift Retard
3- Work Light Switch 6- Monitor Panel (Refer to T5- 8- Key Switch Switch
4- Parking Brake Switch 4-10.) 9- Travel Mode Switch 13- Cigar Lighter
10- (Unused)
T5-4-9
Monitor Panel
1 2 3 4 5 6 7
40 8
39 9
38 10
11
37
12
36
35 13
34
14
15
33
16
32
31 30 MNDB-01-034
29 28 27 26 25 24 23 22 21 20 19 18 17
1- Left Turn Signal Light Indicator 14- (Unused) 25- Monitor Display Selection 36- (Unused)
2- High-Beam Indicator 15- Secondary Steering Indicator Switch (Down) 37- Hydraulic Oil Temperature
3- Work Light Indicator (Option) 26- Forward/Reverse Selector Indicator
4- Right Turn Signal Light 16- Low Steering Oil Pressure Switch Indicator (Option) 38- Transmission Warning
Indicator Indicator (Option) 27- Monitor Display Indicator
5- (Unused) 17- Seat Belt Indicator 28- Fan Reverse Rotation Indicator 39- Transmission Oil Temperature
6- (Unused) 18- Alternator Indicator (Option) Indicator
7- Service Indicator 19- Fuel Gauge 29- Engine Warning Indicator 40- Transmission Oil Temperature
8- Maintenance Indicator 20- Power Mode Indicator 30- Overheat Indicator Gauge
9- Parking Brake Indicator 21- Monitor Display Selection 31- Coolant Temperature Gauge
10- Clearance Light Indicator Switch 32- Engine Oil Low Pressure
11- Control Lever Lock Indicator 22- (Unused) Indicator
12- (Unused) 23- Monitor Display Selection 33- Air Filter Restriction Indicator
13- Brake Oil Low Pressure Switch (Up) 34- (Unused)
Indicator 24- Preheat Indicator 35- (Unused)
T5-4-10
Electrical System (Components Related with

Relays)
5 4 3 2 1
TNEE-01-02-006
1- Battery Relay 4- Starter Relay 1

2- Fusible Link (140 A) (2 Used) 5- Intake Air Heater Relay
3- Fusible Link (65 A) (2 Used)
T5-4-11
Electrical System (Around Hydraulic Oil Tank)
2 3
1
TNEJ-01-02-007
8 7 6 5 4
1- Hydraulic Oil Tank 4- Fuel Pre-Filter (Option) 7- Hydraulic Oil Temperature 8- Secondary Steering Pump
2- Air Filter Restriction Switch 5- Washer Fluid Tank Sensor (Option) (Refer to T5-4-19.)
3- Air Cleaner 6- Fuel Pump
T5-4-12
Electrical System (Around Fuel Tank and

Radiator Assembly)
 Without Fan Valve  With Fan Valve (Option) Attached
3 2 1 TNEJ-01-02-008 3 2 1 TNEJ-01-02-009
1- Fuel Level Sensor 3- Fan Pump Delivery Pressure 4- Fan Speed Control Solenoid 6- Fan Valve (Option) (Refer to
2- Fuel Tank Sensor Valve T5-4-16.)
5- Fan Motor
T5-4-13
Engine and Fan Pump

1 2
3 4
5
A
15
6
8
12 11
View A
10 13
14
T4GD-01-02-009
1- Common Rail Pressure Sensor 5- Crankcase Pressure Sensor 10- Engine Oil Filter 15- Fuel Main Filter
2- Boost Pressure/Boost 6- Engine Oil Pressure Switch 11- Alternator
Temperature Sensor 7- Cam Angle Sensor 12- Starter Motor
3- Coolant Temperature Sensor 8- ECM 13- Supply Pump
4- Injector 9- Crank Speed Sensor 14- Fan Pump
T5-4-14
Pump Device
1
T4GB-01-02-009
5 4
Control Valve
11
10
T4GB-01-02-027
1- Main Pump 6- Main Relief Valve (Steering) 9- Overload Relief Valve (Bucket: 11- Main Relief Valve (Front
2- Regulator 7- Overload Relief Valve (Lift Arm: Rod Side) Attachment)
3- Priority Valve Bottom Side) 10- Make-Up Valve (Lift Arm: Rod
4- Pump Delivery Pressure Sensor 8- Overload Relief Valve (Bucket: Side)
5- Pilot Pump Bottom Side)
T5-4-15
Fan Valve (Option)
1
5
2 TNEE-01-02-031
1- Fan Speed Control Solenoid 2- Fan Reverse Rotation Control 3- Fan Control Valve 5- Fan Pump Delivery Pressure
Valve Solenoid Valve 4- Fan Reverse Rotation Spool Sensor
T5-4-16
Drive Unit
1 View A
6
2
12 7
5
11 8
4
10 9
14
T4GB-01-02-026
Front Axle
15
TNEJ-01-02-010
1- Breather 6- Torque Converter Input Speed 9- Proportional Solenoid Valve Y3 12- Proportional Solenoid Valve Y6
2- Transmission Control Valve Sensor (For 1st Speed Clutch) (For 2nd Speed Clutch)
3- Transmission Oil Filter 7- Proportional Solenoid Valve 10- Proportional Solenoid Valve Y4 14- Parking Brake
4- Torque Converter Output Y1 (For Fast-Speed Forward (For 3rd Speed Clutch) 15- Pressure Sensor (Brake
Speed Sensor Clutch) 11- Proportional Solenoid Valve Secondary Pressure)
5- Transmission Intermediate 8- Proportional Solenoid Valve Y2 Y5 (For Slow-Speed Forward
Shaft Sensor (For Reverse Clutch) Clutch)
T5-4-17
Manifold Valve Brake Charge Valve
3 4
5
2
1
TNED-01-02-021
TNED-01-02-013
Parking Brake Solenoid Valve Block
8 9
TNEE-01-02-013
1- Pilot Accumulator (Steering) 4- Pressure Sensor (Primary Pilot 6- Pressure Sensor (Brake Primary 8- Pressure Sensor (Parking
2- Torque Control Solenoid Valve Pressure) Pressure) Brake)
3- Control Lever Lock Solenoid 5- Pilot Accumulator (Front 7- Parking Brake Solenoid Valve 9- Parking Brake Accumulator
Valve Attachment)
T5-4-18
Steering Valve, Secondary Steering

Valve (Option)
1 2 3
5 4
TNEE-01-02-014
Secondary Steering Pump (Option)
9 8 7
TNED-01-02-019
1- Overload Relief Valve 4- Secondary Steering Pump 6- Steering Pressure Switch

2- Steering Valve Delivery Pressure Sensor (Option)
3- Overload Relief Valve (Option) 7- Electric Motor
5- Secondary Steering Valve 8- Gear Pump
(Option) 9- Relief Valve
T5-4-19
Ride Control Valve (Option)
2 3 4
TNDB-01-02-040
(Pilot Hose Mounting Part)
5
c
TNEJ-01-02-012
a- Front Side of Machine b- Front Frame c- Rear Frame
1- Overload Relief Valve 3- Ride Control Solenoid Valve 5- Pressure Sensor (Lift Arm
2- Ride Control Valve 4- Ride Control Accumulator Raise) (Option)
T5-4-20
Troubleshooting A (Base Machine Diagnosis

By Using Fault Codes) Procedure
Refer to troubleshooting A procedure in case any fault fNOTE: The engine controller (ECM) judges the engine
codes are displayed after diagnosing by using MPDr. or malfunction. After the engine is repaired, select Fault
the service menu of the monitor. Code Clear on Engine Setting. Then, delete the fault code
of engine controller (ECM) on Troubleshooting. (Refer to
 Diagnosis Procedure TROUBLESHOOTING / Monitor.)
 The diagnosis procedures for the displayed fault
codes are explained in this group.
 In case more than one fault code are displayed at the
same time, MC may be faulty or the power/ground
of the sensor system may be faulty.
 When the MC fault code is displayed with other fault
code, replace MC.
 When fault code 111003-3 (Abnormal Sensor
Voltage) is displayed with other fault code, diagnose
for fault code 111003-3 first.
 In case more than one fault code other than those
described above are displayed at the same time,
diagnose for each fault code.
 It may be required that the machine is operated or
the test harness is connected at inspection.
Check the items of preparation and perform
inspection according to the procedures when
diagnosing.
fNOTE: All connector images in this section are viewed

from the open end side of wire harness end.
1
2
T6L4-05-03-001
1- Wire Harness End Connector 2- Wire Harness
T5-5-1
Contents of Diagnosis
Fault Code
Preparation
Tools for a diagnosis and contents

needing inspection beforehand are
explained.
How to Read Table

Fault Code Trouble Inspection Evaluation Cause
Method
(A) (B) (C) (D) (E)
(F) (G) (H)
 A: Fault code
 B: Trouble details
 C, F: Inspection method for trouble cause
 D, G: Evaluation specification of check results
 E, H: Trouble cause for the fault code
Procedure:
1. Check an applicable line depending on displayed fault cord (A).
2. After checking or measuring on Inspection Method (C), refer to Evaluation
(D) and judge the results.
3. In case the results are satisfied with Evaluation (D), the trouble cause
becomes Cause (E).
In case the results are not satisfied with Evaluation (D), go to the next
procedure, Inspection Method (F).
Circuit Diagram of Test Harness
A connection point of the test harness and a point to check are explained.
(Only Pressure Sensor System Troubleshooting)
T5-5-2
MPDr. Fault Code Reference Table
Fault Code MPDr. Message Category Reference 1 Reference 2
111000-2 Abnormal EEPROM MC T5-5-9 T5-5-61
111001-2 Abnormal RAM MC T5-5-9 T5-5-61
111002-2 Abnormal A/D Converter MC T5-5-9 T5-5-61
111003-3 Abnormal Sensor Voltage MC T5-5-9 T5-5-62
111006-2 (MC) EC Communication Error MC T5-5-10 T5-5-65
111007-2 (MC) IC Communication Error 1 MC T5-5-10 T5-5-65
111011-2 (MC) Transmission Controller Communication Error MC T5-5-10 T5-5-65
111014-2 (MC) Air Conditioner Controller Communication Error MC T5-5-10 T5-5-70
111025-2 (MC) Column Monitor Communication Error MC T5-5-10 T5-5-70
111100-2 Abnormal Engine Speed MC T5-5-11 T5-5-71
111103-3 Accelerator Pedal Circuit High Input MC T5-5-11 T5-5-72
111103-4 Accelerator Pedal Circuit Low Input MC T5-5-11 T5-5-72
111106-3 Abnormal Accelerator Pedal 2 Circuit High Input MC T5-5-11 T5-5-72
111106-4 Abnormal Accelerator Pedal 2 Circuit Low Input MC T5-5-11 T5-5-72
111107-2 Accelerator Pedal Sensor Correlation Diagnosis MC T5-5-11 T5-5-72
111200-3 Lift Arm Raise Pilot Pressure Sensor Circuit High Input MC T5-5-13 T5-5-74
111200-4 Lift Arm Raise Pilot Pressure Sensor Circuit Low Input MC T5-5-13 T5-5-74
111204-3 Pump Delivery Pressure Sensor Circuit High Input MC T5-5-12 T5-5-76
111204-4 Pump Delivery Pressure Sensor Circuit Low Input MC T5-5-12 T5-5-76
111205-3 Lift Arm Angle Sensor Circuit High Input MC T5-5-19 T5-5-73
111205-4 Lift Arm Angle Sensor Circuit Low Input MC T5-5-19 T5-5-73
T5-5-3
MPDr. Fault Code Reference Table (Continued)
111206-3 Hyd. Fan Circut Pressure Sensor Circuit High Input MC T5-5-12 T5-5-76
111206-4 Hyd. Fan Circut Pressure Sensor Circuit Low Input MC T5-5-12 T5-5-76
Emergency Steering Check Pressure Sensor Circuit High
111208-3 MC T5-5-12 T5-5-77
Input
Emergency Steering Check Pressure Sensor Circuit Low
111208-4 MC T5-5-12 T5-5-77
Input
111217-3 Pilot Pressure Sensor Circuit High Input MC T5-5-14 T5-5-75
111217-4 Pilot Pressure Sensor Circuit Low Input MC T5-5-14 T5-5-75
111311-3 Service Brake Primary Pressure Sensor Circuit High Input MC T5-5-14 T5-5-78
111311-4 Service Brake Primary Pressure Sensor Circuit Low Input MC T5-5-14 T5-5-78
Service Brake Secondary Pressure Sensor Circuit High
111312-3 MC T5-5-15 T5-5-75
Input
Service Brake Secondary Pressure Sensor Circuit Low
111312-4 MC T5-5-15 T5-5-75
Input
111313-3 Parking Brake Pressure Sensor Circuit High Input MC T5-5-15 T5-5-78
111313-4 Parking Brake Pressure Sensor Circuit Low Input MC T5-5-15 T5-5-78
T5-5-4
111411-2 Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB MC T5-5-16 T5-5-79
Hydraulic Fan Reverse Rotation P/S Valve FB High
111411-3 MC T5-5-16 T5-5-79
Current
111411-4 Fan Reverse Rotation P/S Valve FB Low Current MC T5-5-16 T5-5-79
111412-2 Hyd. Fan P/S Valve Abnormal FB MC T5-5-17 T5-5-80
111412-3 Hyd. Fan P/S Valve FB High Current MC T5-5-17 T5-5-80
111412-4 Hyd. Fan P/S Valve FB Low Current MC T5-5-17 T5-5-80
111413-2 Pump Swash Angle P/S Valve Abnormal FB MC T5-5-17 T5-5-81
111413-3 Pump Swash Angle P/S Valve FB High Current MC T5-5-17 T5-5-81
111413-4 Pump Swash Angle P/S Valve FB Low Current MC T5-5-17 T5-5-81
111422-2 Ride Control (Bottom) P/S Valve Abnormal FB MC T5-5-17 T5-5-82
111422-3 Ride Control (Bottom) P/S Valve FB High Current MC T5-5-17 T5-5-82
111422-4 Ride control Solenoid Valve FB Low Current MC T5-5-17 T5-5-82
111720-2 Lift arm angle sensor is Uncalibrated MC T5-5-18 -
111721-2 Digging position is Uncalibrated. MC T5-5-18 -
111901-3 Hyd. Oil Temp Sensor Circuit High Input MC T5-5-19 T5-5-83
111901-4 Hyd. Oil Temp Sensor Circuit Low Input MC T5-5-19 T5-5-83
T5-5-5

Communication
114100-2 Communication Terminal: Abnormal EEPROM T5-5-24 -
Terminal
Communication
114101-2 Communication Terminal: Abnormal IB/OB Queue T5-5-24 -
Terminal
Communication
114102-2 Communication Terminal: Abnormal Local Loop Back T5-5-24 -
Terminal
Communication
114103-2 Communication Terminal: No Satellite Found T5-5-24 -
Terminal
Communication
114104-2 Communication Terminal: Remote Loop Back Error 1 T5-5-24 -
Terminal
Communication
114105-2 Communication Terminal: Remote Loop Back Error 2 T5-5-24 -
Terminal
Communication Terminal: Transmission/Receiving Communication
114106-2 T5-5-24 -
Data Unmatched Terminal
T5-5-6
115001-2 Abnormal REG input H level Column Display T5-5-21 T5-5-87
115003-2 Abnormal EEPROM Column Display T5-5-21 -
115011-3 Open circuit in fuel level sensor Column Display T5-5-21 T5-5-88
115011-4 Shorted circuit in fuel level sensor Column Display T5-5-21 T5-5-88
115018-2 24 V Output Error Column Display T5-5-21 -
120003-2 Emergency Steering Operation Alarm MC T5-5-20 T5-5-84
120004-2 Emergency Steering Operating Pressure Error MC T5-5-20 T5-5-84
120014-2 Overrun Alarm MC T5-5-20 T5-5-85
T5-5-7
120500-2 Overheat Alarm Column Display T5-5-22 T5-5-89
120501-2 Engine Warning Alarm Column Display T5-5-22 T5-5-89
120502-2 Engine Oil Pressure Alarm Column Display T5-5-22 T5-5-89
120503-2 Air Cleaner Restriction Alarm Column Display T5-5-22 T5-5-89
120505-2 Brake Pressure Alarm Column Display T5-5-22 T5-5-89
120506-2 Steering Oil Pressure Alarm Column Display T5-5-22 T5-5-90
120507-2 Transmission Error Alarm Column Display T5-5-22 T5-5-90
120510-2 Transmission Oil Temperature Column Display T5-5-23 T5-5-90
120511-2 Fuel Filter Restriction Alarm Column Display T5-5-23 T5-5-90
120512-2 Emergency Steering Alarm (Lighting) Column Display T5-5-23 T5-5-90
120515-2 Engine Alarm Column Display T5-5-23 T5-5-90
120516-2 Hydraulic Oil Temperature Alarm Column Display T5-5-23 T5-5-90
120518-2 Emergency Steering Alarm (Blinking) Column Display T5-5-22 T5-5-90
fNOTE:
 Refer to page T5-5-25 for the ECM fault code list.
 Refer to page T5-5-41 for the TCU fault code list.
 Refer to Group 7 Air Conditioner for the air conditioner controller fault code list.
T5-5-8
MC Fault Code List
Controller Hardware Failure

Fault Code Trouble Cause Symptoms in Machine Remedy
Operation When Trouble
Occurs.
111000-2 Abnormal EEPROM Faulty MC - Replace MC.
111001-2 Abnormal RAM Faulty MC - Replace MC.
111002-2 Abnormal A/D Faulty MC - Replace MC.
Converter
111003-3 Abnormal Sensor Faulty MC Although the accelerator Check the sensor connected
Voltage Faulty sensor pedal is operated, the engine to MC.
Faulty harness speed does not change. Check the harness.
Replace MC.
T5-5-9
CAN Data Reception Failure

Fault Code Trouble Cause Symptoms in Machine Operation Remedy
When Trouble Occurs.
111006-2 (MC) EC Faulty harness Even if accelerator pedal is operated, Check the wire
Communication Error engine speed does not change. harness.
111007-2 (MC) IC Faulty information The information for e-Service cannot Check the CAN1
Communication Error controller be collected. harness.
1 Faulty CAN1 Replace
harness information
controller.
111011-2 (MC) Transmission Faulty TCU The automatic speed shift cannot be Check the wire
Controller Faulty harness performed. harness.
Communication Error Replace TCU
111014-2 (MC) Air Conditioner Faulty air The air conditioner is not effective. Check the CAN1
Controller conditioner harness.
Communication Error controller Replace the
Faulty CAN1 air conditioner
harness controller.
111025-2 (MC) Column Monitor Faulty column The alarms and meters on column Check the CAN1
Communication Error display controller display cannot be displayed correctly. harness.
Faulty CAN1 Replace column
harness display controller.
T5-5-10
Engine Failure
Operation When Trouble
Occurs.
111100-2 Abnormal Engine Engine speed: 4000 The machine operation Check the wire harness.
Speed min-1 or more. speed is slow. (During Check the crank speed
Or engine speed speed sensing, the torque is sensor.
(ECM): 500 min-1 or decreased.) Replace the cam angle
less. sensor.
And engine speed
(TCU): 500 min-1 or
more.
111103-3 Accelerator Pedal Voltage: more than The engine speed is fixed to Check the wire harness.
Circuit High Input 4.74 V 1000 min-1. Replace the accelerator
pedal.
111103-4 Accelerator Pedal Voltage: less than The engine speed is fixed to Check the wire harness.
Circuit Low Input 0.25 V 1000 min-1. Replace the accelerator
pedal.
111106-3 Abnormal Voltage: more than The engine speed is fixed to Check the wire harness.
Accelerator Pedal 2 4.74 V 1000 min-1. Replace the accelerator
Circuit High Input pedal.
111106-4 Abnormal Voltage: less than The engine speed is fixed to Check the wire harness.
Accelerator Pedal 2 0.25 V 1000 min-1. Replace the accelerator
Circuit Low Input pedal.
111107-2 Accelerator Pedal Voltage difference The engine speed is fixed to Check the wire harness.
Sensor Correlation between accelerator 1000 min-1. Replace the accelerator
Diagnosis pedal sensor end pedal.
#1 and #2 is 0.5 V or
more.
T5-5-11
Pump Failure
111204-3 Pump Delivery Voltage: 4.75 V Traction force is lack during Check the wire harness.
Pressure Sensor or more digging operation. Replace the pump delivery
Circuit High Input pressure sensor.
111204-4 Pump Delivery Voltage: less Traction force is lack during Check the wire harness.
Pressure Sensor than 0.25 V digging operation. Replace the pump delivery
Circuit Low Input pressure sensor.
111206-3 Hyd. Fan Circut Voltage: 4.75 V Fan rotation direction (in normal / Check the wire harness.
Pressure Sensor or more reverse) cannot change manually Replace the fan pump
Circuit High Input and automatically. delivery pressure sensor.
111206-4 Hyd. Fan Circut Voltage: less Fan rotation direction (in normal / Check the wire harness.
Pressure Sensor than 0.25 V reverse) cannot change manually Replace the fan pump
Circuit Low Input and automatically. delivery pressure sensor.
111208-3 Emergency Steering Voltage: 4.75 V The initial automatic check for Check the wire harness.
Check Pressure or more secondary steering operation Replace the secondary
Sensor Circuit High cannot be performed. (When the steering pump delivery
Input engine starts) pressure sensor.
Secondary steering indicator of
monitor blinks.
111208-4 Emergency Steering Voltage: less The initial automatic check for Check the wire harness.
Check Pressure than 0.25 V secondary steering operation Replace the secondary
Sensor Circuit Low cannot be performed. (When the steering pump delivery
Input engine starts) pressure sensor.
monitor blinks.
T5-5-12
Pilot Failure
111200-3 Lift Arm Raise Pilot Voltage: 4.75 V Ride control is not activated. Check the wire harness.
Pressure Sensor or more Replace the pressure sensor
Circuit High Input (lift arm raise).
111200-4 Lift Arm Raise Pilot Voltage: less Ride control is not activated. Check the wire harness.
Pressure Sensor than 0.25 V Replace the pressure sensor
Circuit Low Input (lift arm raise).
T5-5-13

111217-3 Pilot Pressure Voltage: 4.75 V Front attachment control lever Check the wire harness.
Sensor Circuit High or more lock indicator of monitor is always Replace the pressure sensor
Input OFF. (primary pilot pressure).
111217-4 Pilot Pressure Voltage: less Front attachment control lever Check the wire harness.
Sensor Circuit Low than 0.25 V lock indicator of monitor is always Replace the pressure sensor
Input OFF. (primary pilot pressure).
111311-3 Service Brake Voltage: 4.75 V The low brake oil pressure Check the wire harness.
Primary Pressure or more indicator is always ON. Replace the pressure sensor
Sensor Circuit High Although the service brake is (brake primary pressure).
Input applied, the brake oil pressure
gauge points at the minimum
value, zero.
111311-4 Service Brake Voltage: less The low brake oil pressure Check the wire harness.
Primary Pressure than 0.25 V indicator is always ON. Replace the pressure sensor
Sensor Circuit Low Although the service brake is (brake primary pressure).
Input applied, the brake oil pressure
gauge points at the minimum
value, zero.
T5-5-14

111312-3 Service Brake Voltage: 4.75 V The declutch control becomes Check the wire harness.
Secondary Pressure or more ineffective. The declutch is Replace the pressure sensor
Sensor Circuit High impossible. The speed shift does (brake secondary pressure).
Input not automatically downshift to
first speed with the travel mode
set in AUTO 1 mode.
111312-4 Service Brake Voltage: less The declutch control becomes Check the wire harness.
Secondary Pressure than 0.25 V ineffective. The declutch is Replace the pressure sensor
Sensor Circuit Low impossible. The speed shift does (brake secondary pressure).
Input not automatically downshift to
first speed with the travel mode
set in AUTO 1 mode.
111313-3 Parking Brake Voltage: 4.75 V Although the parking brake Check the wire harness.
Pressure Sensor or more is applied, the parking brake Replace the pressure sensor
Circuit High Input indicator is not ON. (The parking (parking brake).
brake signal is forcibly fixed to the
Release side.)
111313-4 Parking Brake Voltage: less Although the parking brake Check the wire harness.
Pressure Sensor than 0.25 V is applied, the parking brake Replace the pressure sensor
Circuit Low Input indicator is not ON. (The parking (parking brake).
brake signal is forcibly fixed to the
Release side.)
T5-5-15
Proportional Solenoid Valve Failure

111411-2 Hydraulic Fan Reverse Solenoid valve The fan reverse rotation control Check the wire
Rotation P/S Valve output: 140 mA becomes ineffective. harness.
Abnormal FB or more, feedback Fan rotation direction (in normal /
current: More reverse) cannot change manually and
than 920 mA or automatically.
less than 70 mA;
both are detected.
111411-3 Hydraulic Fan Reverse Current: more Fan rotation direction is fixed in Check the wire
Rotation P/S Valve FB than 920 mA reverse. harness.
High Current
111411-4 Fan Reverse Rotation Current: less than Fan rotation direction (in normal / Check the wire
P/S Valve FB Low 70 mA reverse) cannot change manually and harness.
Current automatically.
T5-5-16

111412-2 Hyd. Fan P/S Valve Solenoid valve The fan speed is fixed to the Check the wire
Abnormal FB output: 140 mA maximum. harness.
or more, feedback
current: More
than 920 mA or
less than 70 mA;
both are detected.
111412-3 Hyd. Fan P/S Valve FB Current: more The fan speed is fixed to the Check the wire
High Current than 920 mA minimum. harness.
111412-4 Hyd. Fan P/S Valve FB Current: less than The fan speed is fixed to the Check the wire
Low Current 70 mA maximum. harness.
111413-2 Pump Swash Angle P/S Solenoid valve Machine overall operation is slow. Check the wire
Valve Abnormal FB output: 140 mA harness.
or more, feedback
current: More
than 920 mA or
less than 70 mA;
both are detected.
111413-3 Pump Swash Angle P/S Current: more The engine stalls is remarkable at high Check the wire
Valve FB High Current than 920 mA loaded. In addition, the engine lug- harness.
down is remarkable.
111413-4 Pump Swash Angle P/S Current: less than Machine overall operation is slow. Check the wire
Valve FB Low Current 70 mA harness.
111422-2 Ride Control (Bottom) Solenoid valve The ride control becomes ineffective. Check the wire
P/S Valve Abnormal FB output: 140 mA harness.
or more, feedback
current: More
than 920 mA or
less than 70 mA;
both are detected.
111422-3 Ride Control (Bottom) Current: more The ride control is always activated. Check the wire
P/S Valve FB High than 920 mA harness.
Current
111422-4 Ride control Solenoid Current: less than The ride control is always activated. Check the wire
Valve FB Low Current 70 mA harness.
T5-5-17
Learning Failure
111720-2 Lift arm angle sensor is The lift arm angle Dual lift arm auto leveler cannot be Perform lift arm
Uncalibrated. sensor calibration set. angle sensor
is not performed. calibration.
Or, it fails.
111721-2 Digging position is The digging Dual lift arm auto leveler cannot be Perform digging
Uncalibrated. position set. (The machine with ride control Position calibration.
calibration is not attached.)
performed. Or, it
fails.
T5-5-18
Other Failures
111901-3 Hyd. Oil Temp Sensor Voltage: more When hydraulic oil temperature is Check the wire
Circuit High Input than 4.35 V less than 0 °C, the auto-warming up harness.
control is not effective.
The fan speed is always fixed to the
maximum. The fan reverse rotation
control is not activated.
111901-4 Hyd. Oil Temp Sensor Voltage: less than When hydraulic oil temperature is Check the wire
Circuit Low Input 0.1 V less than 0 °C, the auto-warming up harness.
control is not effective.
The fan speed is always fixed to the
maximum. The fan reverse rotation
control is not activated.
111205-3 Lift Arm Angle Sensor Voltage: 4.75 V or Dual lift arm auto leveler operation is Check the wire
Circuit High Input more not effective. harness.
Replace the lift arm
angle sensor.
111205-4 Lift Arm Angle Sensor Voltage: less than Dual lift arm auto leveler operation is Check the wire
Circuit Low Input 0.25 V not effective. harness.
Replace the lift arm
angle sensor.
T5-5-19

120003-2 Emergency Steering Secondary The alarm is displayed on the monitor. -
Activated Steering Pump is (It is displayed during operation.)
activated.
120004-2 Emergency Steering Secondary The alarm is displayed on the monitor. Check the wire
Activated Pressure steering pump harness.
Alarm delivery pressure Replace the
does not increase secondary steering
up to the pump delivery
specified value. pressure sensor.
(When the engine
starts)
120014-2 Overrun Alarm The vehicle speed The buzzer sounds. Check the wire
is beyond the harness.
upper limit. Replace the vehicle
speed sensor.
T5-5-20
Column Display Controller Fault Code List

Operation When
Trouble Occurs.
115001-2 Abnormal REG Input Alternator generating The alternator Check the wire
H level voltage: 33.5 V or more indicator is ON. harness.
Check the battery.
Check the alternator.
115003-2 Abnormal EEPROM Faulty column display - Replace the column
controller. display controller.
115011-3 Fuel Level sensor 131±5 Ω or less The fuel gauge Check the wire
Circuit High Input continues for 5 (pointer) points to E. harness.
seconds. Replace the fuel level
sensor.
115011-4 Fuel Level Sensor 4±2 Ω or less The fuel gauge Check the wire
Circuit Low Input continues for 5 (pointer) points to E. harness.
seconds. Replace the fuel level
sensor.
115018-2 Abnormal 24 V Output Faulty column display - Check the wire
controller. harness.
Replace the column
display controller.
T5-5-21
Fault Code Trouble Cause Remedy

120500-2 Overheat Alarm Coolant temperature is high while Check the wire harness.
the engine runs. Replace the overheat switch.
120501-2 Engine Error Faulty engine system Refer to ECM fault code list.
120502-2 Engine Oil Pressure Engine oil pressure decreases. Check the wire harness.
Alarm Replace the engine oil pressure switch.
120503-2 Air Cleaner Clogged air cleaner. Check the wire harness.
Restriction Alarm Replace the air cleaner restriction switch.
120505-2 Brake Pressure Brake oil pressure decreases. Check the wire harness.
Alarm Replace the pressure sensor (brake primary
pressure).
120506-2 Steering Oil Faulty steering pressure switch Check the wire harness.
Pressure Alarm (Option) Replace the steering pressure switch.
120507-2 T/M Malfunction Faulty transmission system Refer to TCU fault code list.
T5-5-22
Fault Code Trouble Cause Remedy

120510-2 Transmission Oil Transmission oil temperature is Check the wire harness.
Temperature high while the engine runs. Replace the torque converter oil temperature
sensor.
120511-2 Fuel Filter Supply pump inlet pressure Check the wire harness.
Restriction Alarm decreases. Replace the fuel filter.
120512-2 Emergency Steering Faulty secondary steering system Check the wire harness.
Alarm (Lighting) (OPT) Replace the secondary steering pump delivery
pressure sensor.
120515-2 Engine Alarm Faulty engine system Refer to Engine Troubleshooting Manual.
120516-2 Hydraulic Oil Hydraulic Oil Temperature is high Check the wire harness.
Temperature Alarm while the engine runs. Replace the hydraulic oil temperature.
120518-2 Emergency Steering Faulty secondary steering pump Check the wire harness.
Alarm (Blinking) (OPT) Replace the secondary steering operation
check switch (OPT).
T5-5-23
Communication Terminal Fault Code List
Fault Code Trouble or MPDr. Message Cause Remedy

114100-2 Communication Terminal: The internal memory of satellite Replace the controller (satellite
Abnormal EEPROM communication terminal (option) communication terminal).
is abnormal.
114101-2 Communication Terminal: The internal memory of satellite Replace the controller (satellite
Abnormal IB/OB Queue communication terminal (option) communication terminal).
is abnormal.
114102-2 Communication Terminal: Abnormality is detected on Check the communication
Abnormal Local Loop Back communication test with the antenna for satellite.
satellite.
114103-2 Communication Terminal: No Satellite can not be caught. Check the communication
Satellite Found antenna for satellite.
114104-2 Communication Terminal: Remote Abnormality is detected on Replace the controller (satellite
Loop Back Error 1 communication test with the communication terminal).
satellite and base station.
114105-2 Communication Terminal: Remote Abnormality is detected on Replace the controller (satellite
Loop Back Error 2 communication test with the communication terminal).
satellite and base station.
114106-2 Communication Terminal: Transmission/receiving data with Replace the controller (satellite
Transmission/Receiving Data the satellite is unmatched. communication terminal).
Unmatched
Air Conditioner Controller Fault Code List
fNOTE: Refer to Group 7 Air Conditioner.
T5-5-24
ECM FAULT CODE CONTRAST LIST
Fault Code Trouble (Cause) Fault Code Lighting Indicator

(MP.Dr.) (INSITE)
84-2 Wheel-Based Vehicle Speed-Data 241 Service Indicator
Erratic, Intermittent, or Incorrect. The
ECM lost the vehicle speed signal.
84-10 Wheel-Based Vehicle Speed Sensor 242 Service Indicator
Circuit tampering has been detected-
Abnormal Rate of Change. Signal
indicates an intermittent connection or
VSS tampering.
91-0 Accelerator Pedal or Lever Position 148 Engine Warning Indicator
Sensor 1-Data Valid but Above Normal
Operational Range-Most Severe Level.
A frequency of more than 1500 Hz has
been detected at the frequency throttle
input to the ECM.
91-1 Accelerator Pedal or Lever Position 1 147 Engine Warning Indicator
Sensor Circuit Frequency-Data Valid
but Below Normal Operational Range-
Most Severe Level. A frequency of less
than 100 Hz has been detected at the
frequency throttle input to the ECM.
Sensor 1 Circuit-Voltage Above Normal,
or Shorted to High Source. High voltage
detected at accelerator pedal position
circuit.
Sensor 1 Circuit-Voltage Below Normal,
or Shorted to Low Source. Low voltage
detected at accelerator pedal position
signal circuit.
91-19 SAE J1939 Multiplexed Accelerator 287 Service Indicator
Pedal or Lever Sensor System-Received
Network Data In Error. The OEM vehicle
electronic control unit (VECU) detected
a fault with its accelerator pedal.
93-2 Auxiliary Alternate Torque Validation 528 Service Indicator
Switch-Data Erratic, Intermittent, or
Incorrect.
T5-5-25

(MP.Dr.) (INSITE)
97-3 Water in Fuel Indicator Sensor Circuit- 428 Service Indicator
Voltage Above Normal, or Shorted to
High Source. High voltage detected at
the water in fuel circuit.
97-4 Water in Fuel Indicator Sensor Circuit- 429 Service Indicator
Voltage Below Normal, or Shorted to
Low Source. Low voltage detected at
the water in fuel circuit.
97-15 Water in Fuel Indicator-Data Valid but 418 Service Indicator (Blinking)
Above Normal Operational Range-Least
Severe Level. Water has been detected
in the fuel filter.
100-1 Engine Oil Rifle Pressure-Data Valid 415 Engine Warning Indicator
Most Severe Level. Oil pressure signal
indicates oil pressure below the engine
protection critical limit.
100-2 Engine Oil Rifle Pressure-Data Erratic, 435 Service Indicator
Intermittent, or Incorrect. An error in
the engine oil pressure switch signal
was detected by the ECM.
100-3 Engine Oil Rifle Pressure 1 Sensor 135 Service Indicator
Circuit-Voltage Above Normal, or
Shorted to High Source. High signal
voltage detected at the engine oil
pressure circuit.
100-4 Engine Oil Rifle Pressure 1 Sensor 141 Service Indicator
Circuit-Voltage Below Normal, or
Shorted to Low Source. Low signal
voltage detected at engine oil pressure
circuit.
T5-5-26

(MP.Dr.) (INSITE)
100-18 Engine Oil Rifle Pressure-Data Valid 143 Service Indicator
Moderately Severe Level.
102-2 Intake Manifold 1 Pressure-Data Erratic, 2973 Service Indicator
Intermittent, or Incorrect. The ECM has
detected an intake manifold pressure
signal that is too high or low for current
engine operating conditions.
102-3 Intake Manifold 1 Pressure Sensor 122 Service Indicator
voltage detected at the intake manifold
pressure circuit.
102-4 Intake Manifold 1 Pressure Sensor 123 Service Indicator
voltage or open circuit detected at the
intake manifold pressure circuit.
102-16 Intake Manifold 1 Pressure-Data 124 Service Indicator
Valid but Above Normal Operational
Range-Moderately Severe Level. Intake
manifold pressure has exceeded the
maximum limit for the given engine
rating.
103-10 Turbocharger 1 Speed-Abnormal Rate 2345 Service Indicator
of Change. The turbocharger speed
sensor has detected an erroneous
speed value.
103-16 Turbocharger 1 Speed-Data Valid 595 Service Indicator
but Above Normal Operational
Range-Moderately Severe Level. High
turbocharger speed has been detected.
103-18 Turbocharger 1 Speed-Data Valid 687 Service Indicator
but Below Normal Operational
Range-Moderately Severe Level. Low
turbocharger speed detected by the
ECM.
T5-5-27

(MP.Dr.) (INSITE)
105-0 Intake Manifold 1 Temperature-Data 155 Engine Warning Indicator
Range-Most Severe Level. Intake
manifold air temperature signal
indicates intake manifold air
temperature above engine protection
critical limit.
105-3 Intake Manifold 1 Temperature Sensor 153 Service Indicator
voltage detected at intake manifold air
temperature circuit.
105-4 Intake Manifold 1 Temperature Sensor 154 Service Indicator
voltage detected at intake manifold air
105-16 Intake Manifold 1 Temperature-Data 488 Service Indicator
Range-Moderately Severe Level.
Intake manifold air temperature
signal indicates intake manifold air
temperature is above the engine
protection warning limit.
108-3 Barometric Pressure Sensor Circuit- 221 Service Indicator
Voltage Above Normal, or Shorted
to High Source. High signal voltage
detected at barometric pressure circuit.
108-4 Barometric Pressure Sensor Circuit- 222 Service Indicator
Voltage Below Normal, or Shorted
to Low Source. Low signal voltage
detected at barometric pressure circuit.
110-0 Engine Coolant Temperature-Data Valid 151 Engine Warning Indicator
but Above Normal Operational Range-
Most Severe Level. Engine coolant
temperature signal indicates engine
coolant temperature above engine
protection critical limit.
T5-5-28

(MP.Dr.) (INSITE)
110-2 Engine Coolant Temperature-Data 334 Service Indicator
engine coolant temperature reading
is not changing with engine operating
conditions.
110-3 Engine Coolant Temperature 1 Sensor 144 Service Indicator
voltage or open circuit detected at
engine coolant temperature circuit.
110-4 Engine Coolant Temperature 1 Sensor 145 Service Indicator
voltage detected at engine coolant
110-16 Engine Coolant Temperature-Data 146 Service Indicator
Range-Moderately Severe Level. Engine
coolant temperature signal indicates
engine coolant temperature is above
engine protection warning limit.
111-1 Coolant Level-Data Valid but Below 235 Engine Warning Indicator
Normal Operational Range-Most
Severe Level. Low engine coolant level
detected.
111-3 Coolant Level Sensor 1 Circuit-Voltage 195 Service Indicator
Above Normal, or Shorted to High
Source. High signal voltage detected at
engine coolant level circuit.
111-4 Coolant Level Sensor 1 Circuit-Voltage 196 Service Indicator
Below Normal, or Shorted to Low
Source. Low signal voltage detected at
engine coolant level circuit.
T5-5-29

(MP.Dr.) (INSITE)
111-18 Coolant Level-Data Valid but Below 197 Service Indicator
Normal Operational Range-Moderately
Severe Level. Low coolant level has
been detected.
157-0 Injector Metering Rail 1 Pressure-Data 449 Engine Warning Indicator
Range-Most Severe Level.
157-1 Injector Metering Rail 1 Pressure-Data 2249 Service Indicator
Valid but Below Normal Operational
Range-Most Severe Level. The ECM has
detected that fuel pressure is lower
than commanded pressure.
ECM has detected that the fuel pressure
signal is not changing.
157-3 Injector Metering Rail 1 Pressure 451 Service Indicator
Sensor Circuit-Voltage Above Normal,
or Shorted to High Source. High
signal voltage detected at the rail fuel
pressure sensor circuit.
157-4 Injector Metering Rail 1 Pressure 452 Service Indicator
Sensor Circuit-Voltage Below Normal,
or Shorted to Low Source. Low signal
voltage detected at the rail fuel
pressure sensor circuit.
Range-Moderately Severe Level. The
ECM has detected that fuel pressure is
higher than commanded pressure.
T5-5-30

(MP.Dr.) (INSITE)
Valid but Below Normal Operational
Range-Moderately Severe Level. The
ECM has detected that fuel pressure is
lower than commanded pressure.
168-16 Battery 1 Voltage-Data Valid but Above 442 Service Indicator
Severe Level. ECM supply voltage is
above the maximum system voltage
level.
168-18 Battery 1 Voltage-Data Valid but Below 441 Service Indicator
Severe Level. ECM supply voltage is
below the minimum system voltage
level.
190-0 Engine Crankshaft Speed/Position-Data 234 Engine Warning Indicator
Range-Most Severe Level. Engine speed
signal indicates engine speed above
engine protection limit.
190-2 Engine Crankshaft Speed/Position-Data 689 Service Indicator
Erratic, Intermittent, or Incorrect. Loss of
signal from crankshaft sensor.
190-2 Engine Crankshaft Speed/Position- 2321 Service Indicator
Data Erratic, Intermittent, or Incorrect.
Crankshaft engine speed sensor
intermittent synchronization.
251-2 Real Time Clock Power Interrupt-Data 319 Service Indicator (Blinking)
Erratic, Intermittent, or Incorrect. Real
Time Clock lost power.
T5-5-31

(MP.Dr.) (INSITE)
441-3 Auxiliary Temperature Sensor Input 293 Service Indicator
1 Circuit-Voltage Above Normal, or
OEM auxiliary temperature circuit.
441-4 Auxiliary Temperature Sensor Input 294 Service Indicator
1 Circuit-Voltage Below Normal, or
voltage detected at the OEM auxiliary
441-14 Auxiliary Temperature Sensor Input 292 Engine Warning Indicator
1-Special Instructions.
558-2 Accelerator Pedal or Lever Idle 431 Service Indicator
Validation Switch-Data Erratic,
Intermittent, or Incorrect. Voltage
detected simultaneously on both
idle validation and off-idle validation
switches.
558-13 Accelerator Pedal or Lever Idle 432 Engine Warning Indicator
Validation Circuit-Out of Calibration.
Voltage at idle validation on-idle
and off-idle circuit does not match
accelerator pedal position.
611-2 Auxiliary Intermediate (PTO) Speed 523 Service Indicator
Switch Validation-Data Erratic,
Intermittent, or Incorrect.
611-31 Electronic Control Module data lost- 757 Service Indicator
Condition Exists. Severe loss of data
from the ECM.
612-2 Engine Magnetic Crankshaft Speed/ 115 Engine Warning Indicator
Position lost both of two signals-Data
ECM has detected that the primary
engine speed sensor and the backup
engine speed sensor signals are
reversed.
T5-5-32

(MP.Dr.) (INSITE)
625-2 OEM Datalink Cannot Transmit-Data 1633 Service Indicator
Erratic, Intermittent, or Incorrect.
Communications within the OEM
datalink network is intermittent.
627-2 Power Supply Lost With Ignition On- 1117 None
Supply voltage to the ECM fell below 6.2
volts momentarily, or the ECM was not
allowed to power down correctly (retain
battery voltage for 30 seconds after key
OFF).
627-12 Injector Power Supply-Bad Intelligent 351 Service Indicator
Device or Component. The ECM
measured injector boost voltage is low.
629-12 Engine Control Module Critical Internal 111 Engine Warning Indicator
Failure-Bad Intelligent Device or
Component. Error internal to the ECM
related to memory hardware failures or
internal ECM voltage supply circuits.
629-12 Engine Control Module Warning 343 Service Indicator
internal hardware failure-Bad Intelligent
Device or Component. Internal ECM
failure.
630-13 Electronic Calibration Code 342 Engine Warning Indicator
Incompatibilty-Out of Calibration. An
incompatible calibration has been
detected in the ECM.
633-31 Electronic Fuel Injection Control Valve 2311 Service Indicator
Circuit-Condition Exists. Fuel pump
actuator circuit resistance too high or
too low.
T5-5-33

(MP.Dr.) (INSITE)
639-9 SAE J1939 Multiplexing PGN Timeout 285 Service Indicator
Error-Abnormal Update Rate. The
ECM expected information from a
multiplexed device but did not receive
it soon enough or did not receive it at
all.
639-13 SAE J1939 Multiplexing Configuration 286 Service Indicator
Error-Out of Calibration. The ECM
expected information from a
multiplexed device but only received a
portion of the necessary information.
640-14 Auxiliary Commanded Dual Output 599 Engine Warning Indicator
Shutdown-Special Instructions.
644-2 External Speed Command Input 237 Service Indicator
(Multiple Unit Synchronization)-Data
Erratic, Intermittent, or Incorrect.
Communication between multiple
engines may be intermittent.
647-3 Fan Control Circuit-Voltage Above 2377 Service Indicator
Normal, or Shorted to High Source.
Open circuit or high voltage detected at
the fan control circuit.
647-4 Fan Control Circuit-Voltage Below 245 Service Indicator
Normal, or Shorted to Low Source.
Low signal voltage detected at the fan
control circuit when commanded on.
T5-5-34

(MP.Dr.) (INSITE)
651-5 Injector Solenoid Driver Cylinder 1 322 Service Indicator
Circuit-Current Below Normal, or Open
Circuit. High resistance detected on
injector Number 1 circuit or no current
detected at Number 1 Injector driver or
return pin when the voltage supply at
the harness is on.
detected at Number 2 injector driver or
the harness is on.
the harness is on.
the harness is on.
the harness is on.
T5-5-35

(MP.Dr.) (INSITE)
the harness is on.
677-3 Starter Relay Driver Circuit-Voltage 584 Service Indicator
Source. Open circuit or high voltage
detected at starter lockout circuit.
677-4 Starter Relay Driver Circuit-Voltage 585 Service Indicator
Source. Low voltage detected at starter
lockout circuit.
697-3 Auxiliary PWM Driver 1 Circuit-Voltage 2557 Service Indicator
Source. High signal voltage detected at
the analog torque circuit.
697-4 Auxiliary PWM Driver 1 Circuit-Voltage 2558 Service Indicator
Source. Low signal voltage detected at
the analog torque circuit.
702-3 Auxiliary Input/Output 2 Circuit- 527 Service Indicator
Voltage Above Normal, or Shorted to
High Source. High signal voltage or
open circuit has been detected at the
auxiliary input/output 2 circuit.
703-3 Auxiliary Input/Output 3 Circuit-Voltage 529 Service Indicator
Source. Low signal voltage has been
detected at the auxiliary input/output
2 circuit.
723-2 Engine Camshaft Speed / Position 778 Service Indicator
Sensor-Data Erratic, Intermittent, or
Incorrect. The ECM has detected an
error in the camshaft position sensor
signal.
T5-5-36

(MP.Dr.) (INSITE)
723-2 Engine Camshaft Speed / Position 2322 None
Sensor-Data Erratic, Intermittent, or
Incorrect. Camshaft engine speed
sensor intermittent synchronization.
723-7 Engine Speed / Position Camshaft and 731 Service Indicator
Crankshaft Misalignment-Mechanical
System Not Responding Properly
or Out of Adjustment. Mechanical
misalignment between the crankshaft
and camshaft engine speed sensors.
723-11 Auxiliary Equipment Sensor Input 779 Service Indicator
3-Root Cause Not Known.
729-3 Intake Air Heater 1 Circuit-Voltage 2555 Service Indicator
Source. High voltage detected at the
intake air heater signal circuit.
729-4 Intake Air Heater 1 Circuit-Voltage 2556 Service Indicator
Source. Low voltage detected at the
intake air heater signal circuit.
974-3 Remote Accelerator Pedal or Lever 133 Engine Warning Indicator
Position Sensor 1 Circuit-Voltage Above
Normal, or Shorted to High Source. High
voltage detected at remote accelerator
pedal position circuit.
974-4 Remote Accelerator Pedal or Lever 134 Engine Warning Indicator
Position Sensor 1 Circuit-Voltage Below
Normal, or Shorted to Low Source. Low
voltage detected at remote accelerator
pedal position signal circuit.
974-19 SAE J1939 Multiplexing Remote 288 Engine Warning Indicator
Accelerator Pedal or Lever Position
Sensor Circuit-Received Network Data
In Error. The OEM vehicle electronic
control unit (VECU) detected a fault
with the remote accelerator.
T5-5-37

(MP.Dr.) (INSITE)
1075-3 Electric Lift Pump for Engine Fuel 2265 Service Indicator
Supply Circuit-Voltage Above Normal,
or Shorted to High Source. High voltage
or open detected at the fuel lift pump
signal circuit.
1075-4 Electric Lift Pump for Engine Fuel 2266 Service Indicator
Supply Circuit-Voltage Below Normal,
or Shorted to Low Source. Low signal
voltage detected at the fuel lift pump
circuit.
1172-3 Turbocharger 1 Compressor Inlet 691 Service Indicator
Temperature Circuit-Voltage Above
Normal, or Shorted to High Source. High
signal voltage detected at turbocharger
compressor inlet air temperature circuit.
1172-4 Turbocharger 1 Compressor Inlet 692 Service Indicator
Temperature Circuit-Voltage Below
signal voltage detected at turbocharger
compressor inlet air tempera
1347-3 Fuel Pump Pressurizing Assembly 272 Service Indicator
1 Circuit-Voltage Above Normal, or
fuel pump actuator circuit.
1 Circuit-Voltage Below Normal, or
voltage detected at the fuel pump
actuator circuit.
1-Mechanical System Not Responding
Properly or Out of Adjustment.
T5-5-38

(MP.Dr.) (INSITE)
1377-2 Multiple Unit Synchronization Switch- 497 Service Indicator
1388-3 Auxiliary Pressure Sensor Input 1 297 Service Indicator
voltage detected at the OEM pressure
circuit.
1388-4 Auxiliary Pressure Sensor Input 1 298 Service Indicator
OEM pressure circuit.
1388-14 Auxiliary Pressure Sensor Input 296 Engine Warning Indicator
1-Special Instructions.
2789-15 Turbocharger Turbine Inlet Temperature 2346 None
(Calculated)-Data Valid but Above
Normal Operational Range-Least
Severe Level. Turbocharger turbine inlet
temperature has exceeded the engine
protection limit.
2789-15 Turbocharger Compressor Outlet 2347 None
Temperature (Calculated)-Data Valid but
Above Normal Operational Range-Least
Severe Level.
3509-3 Sensor Supply 1 Circuit-Voltage Above 386 Service Indicator
High voltage detected at sensor supply
number 1 circuit.
3509-4 Sensor Supply 1 Circuit-Voltage Below 352 Service Indicator
Low voltage detected at sensor supply
number 1 circuit.
High voltage detected at sensor supply
number 2 circuit.
T5-5-39

(MP.Dr.) (INSITE)
3510-4 Sensor Supply 2 Circuit-Voltage Below187 Service Indicator
voltage detected at the sensor supply
number 2 circuit.
High voltage detected at +5 volt sensor
supply circuit to the accelerator pedal
position sensor.
Low voltage detected at +5 volt sensor
supply circuit to the accelerator pedal
position sensor.
voltage detected on the +5 volt sensor
supply circuit to the engine speed
sensor.
T5-5-40
TCU Fault Code List
Fault Code Trouble Cause Behavior of TCU Repair Procedure

5000-12 Signal Error in Broken wire harness between Fixed to neutral. Check the wire harness
Shift Switch shift switch and TCU. between TCU and shift
Shorted circuit in power switch.
circuit or grounding to the Check the combination signal
body because of faulty wire at each speed shift in the shift
harness. switch.
Faulty forward/reverse switch.
5010-12 Signal Error Broken wire harness between Fixed to neutral. Check the wire harness
in Forward/ forward/reverse lever and between TCU and forward/
Reverse Lever TCU. reverse lever.
Shorted circuit in power Check the combination signal
circuit or grounding to the of each position at F-N-R
body because of faulty wire speed shift in the forward/
harness. reverse lever.
Faulty forward/reverse lever.
5040-12 Signal Error Broken wire harness between Fixed to neutral. Check the wire harness
in Forward/ forward/reverse switch and between TCU and forward/
Reverse Switch TCU. reverse switch.
Shorted circuit in power Check the combination signal
circuit or grounding to the of each position at F-N-R
body because of faulty wire speed shift in the forward/
harness. reverse switch.
Faulty forward/reverse switch.
5110-3 Transmission Shorted circuit in power - Check the wire harness
Oil Temperature circuit because of faulty wire between TCU and sensor.
Sensor High harness. Check the connectors.
Voltage No connection to TCU Check the sensor.
harness.
Faulty temperature sensor.
Shorted circuit in power
circuit by the connector pin
or broken connector pin.
5110-4 Transmission Grounding to body because - Check the wire harness
Oil Temperature of faulty wire harness. between TCU and sensor.
Sensor Low Faulty temperature sensor. Check the connectors.
Voltage Grounding to body by the Check the sensor.
connector pin.
T5-5-41

5140-3 Torque Shorted circuit in power Connect the clutch Check the wire harness
Converter Input circuit because of faulty wire according to the backup between TCU and sensor.
Speed Sensor harness. program. Check the connectors.
High Voltage No connection to TCU wire Shock when shifting Check the rotation sensor.
Feedback. harness. travel speed may (1050 Ω at 20 °C (68 °F))
voltage to TCU: Faulty rotation sensor. become strong.
7.00 V or more. Shorted circuit in power
circuit by the connector
pin or faulty connection of
connector pin.
5140-4 Torque Grounding to body because Connect the clutch Check the wire harness
Converter Input of faulty wire harness. according to the backup between TCU and sensor.
Speed Sensor Faulty rotation sensor. program. Check the connectors.
Low Voltage Shock when shifting Check the rotation sensor.
Feedback. travel speed may (1050 Ω at 20 °C (68 °F))
voltage to TCU: become strong.
0.45 V or less.
5120-3 Torque Shorted circuit in power - Check the wire harness
Converter Oil circuit because of faulty wire between TCU and sensor.
Temperature harness. Check the connectors.
Sensor High No connection to TCU wire Check the sensor.
Voltage harness.
Faulty temperature sensor.
Shorted circuit in power
circuit by the connector pin
or broken connector pin.
5120-4 Torque Grounding to body because - Check the wire harness
Converter Oil of faulty wire harness. between TCU and sensor.
Temperature Faulty temperature sensor. Check the connectors.
Sensor Low Grounding to body by the Check the sensor.
Voltage connector pin.
T5-5-42

5140-12 Torque Faulty contact because of Connect the clutch Check the wire harness
Converter Input faulty wire harness or faulty according to the backup between TCU and sensor.
Speed Sensor connector. program. Check the connectors.
Signal Error Faulty rotation sensor. Shock when shifting Check the rotation sensor.
Feedback. travel speed may (1050 Ω at 20 °C (68 °F))
voltage to TCU: become strong.
Uncertain value.
5150-3 Torque Shorted circuit in power Connect the clutch Check the wire harness
Converter circuit because of faulty wire according to the backup between TCU and sensor.
Output Speed harness. program. Check the connectors.
Sensor High No connection to TCU wire Shock when shifting Check the rotation sensor.
Voltage harness. travel speed may (1050 Ω at 20 °C (68 °F))
Feedback. Faulty rotation sensor. become strong.
voltage to TCU: Shorted circuit in power If the vehicle speed
7.00 V or more. circuit by the connector sensor is abnormal,
pin or faulty connection of return the forward/
connector pin. reverse lever to neutral
and operate it again.
Then, machine can
travel only at first or
second speed.
5150-4 Torque Grounding to body because Connect the clutch Check the wire harness
Converter of faulty wire harness. according to the backup between TCU and sensor.
Output Speed Faulty rotation sensor. program. Check the connectors.
Sensor Low Shock when shifting Check the rotation sensor.
Voltage travel speed may (1050 Ω at 20 °C (68 °F))
Feedback. become strong.
voltage to TCU: If the vehicle speed
0.45 V or less. sensor is abnormal,
return the forward/
reverse lever to neutral
Then, machine can
second speed.
T5-5-43

5150-12 Torque Faulty shorted circuit because Connect the clutch Check the wire harness
Converter of faulty wire harness or according to the backup between TCU and sensor.
Output Speed faulty connector. program. Check the connectors.
Sensor Signal Faulty rotation sensor. Shock when shifting Check the rotation sensor.
Error. travel speed may (1050 Ω at 20 °C (68 °F))
Feedback become strong.
voltage to TCU: If the vehicle speed
Uncertain value. sensor is abnormal,
return the forward/
reverse lever to neutral
Then, machine can
second speed.
5160-3 Transmission Shorted circuit in power Connect the clutch Check the wire harness
Intermediate circuit because of faulty wire according to the backup between TCU and sensor.
Shaft Speed harness. program. Check the connectors.
Sensor High No connection to TCU wire Shock when shifting Check the rotation sensor.
Voltage harness. travel speed may (1050 Ω at 20 °C (68 °F))
Feedback. Faulty rotation sensor. become strong.
voltage to TCU: Shorted circuit in power
7.00 V or more. circuit by the connector
connector pin.
5160-4 Transmission Grounding to body because Connect the clutch Check the wire harness
Intermediate of faulty wire harness. according to the backup between TCU and sensor.
Shaft Speed Faulty rotation sensor. program. Check the connectors.
Sensor Low Shock when shifting Check the rotation sensor.
Voltage travel speed may (1050 Ω at 20 °C (68 °F))
voltage to TCU:
0.45 V or less.
5160-12 Transmission Faulty shorted circuit because Connect the clutch Check the wire harness
Intermediate of faulty wire harness or according to the backup between TCU and sensor.
Shaft Speed faulty connector. program. Check the connectors.
Sensor Signal Faulty rotation sensor. Shock when shifting Check the rotation sensor.
Error travel speed may (1050 Ω at 20 °C (68 °F))
voltage to TCU:
Uncertain value.
T5-5-44

5170-3 Vehicle Speed Shorted circuit in power Vehicle speed cannot Check the wire harness
Sensor High circuit because of faulty wire be detected. Automatic between TCU and sensor.
Voltage harness. speed shift is not Check the connectors.
Feedback. No connection to TCU wire performed. (Speed shift Check the rotation sensor.
voltage to TCU: harness. is fixed to first speed or (1050 Ω at 20 °C (68 °F))
12.5 V or more. Faulty rotation sensor. second speed during
Shorted circuit in power automatic speed shift.)
circuit by the connector
connector pin.
5170-4 Vehicle Speed Grounding to body because Vehicle speed cannot Check the wire harness
Sensor Low of faulty wire harness. be detected. Automatic between TCU and sensor.
Voltage Faulty vehicle speed sensor. speed shift is not Check the connectors.
Feedback. performed. (Speed shift Check the vehicle speed
voltage to TCU: is fixed to first speed or sensor. (1050 Ω at 20 °C (68
1.00 V or less. second speed during °F))
automatic speed shift.)
5170-12 Vehicle Speed Faulty shorted circuit because Vehicle speed cannot Check the wire harness
Sensor Signal of faulty wire harness or be detected. Automatic between TCU and sensor.
Error faulty connector. speed shift is not Check the connectors.
Feedback. Faulty vehicle speed sensor. performed. (Speed shift Check the vehicle speed
voltage to TCU: Sensor gap dimension error. is fixed to first speed or sensor. (1050 Ω at 20 °C (68
Uncertain value. second speed during °F))
automatic speed shift.) Check the sensor gap.
5180-2 Vehicle Speed Faulty vehicle speed sensor. Vehicle speed cannot Check the vehicle speed
Sensor Pulse Sensor gap dimension error. be detected. Automatic sensor. (1050 Ω at 20 °C (68
Output Error speed shift is not °F))
performed. (Speed shift Check the sensor gap.
is fixed to first speed or Check the wire harness
second speed during between TCU and sensor.
automatic speed shift.)
T5-5-45

5480-3 Abnormal First Shorted circuit in power Turn TCU to neutral. Check the wire harness
Speed Clutch circuit because of faulty wire After returning the between TCU and
Proportional harness or faulty connector. forward/reverse lever transmission control valve.
Solenoid Valve Faulty proportional solenoid to neutral, operate it Check the connector between
High Voltage valve. again. Then, machine TCU and transmission control
can travel only at first orvalve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal wire
to neutral. harness in transmission
control valve.
5480-4 Abnormal First Grounding to body because Turn TCU to neutral. Check the wire harness
Speed Clutch of faulty wire harness or After returning the between TCU and
Proportional faulty connector. forward/reverse lever transmission control valve.
Solenoid Valve Faulty shorted circuit to other to neutral, operate it Check the connector between
Low Voltage proportional solenoid valve again. Then, machine TCU and transmission control
output circuit in TCU because can travel only at first or valve.
of faulty wire harness or second speed. Check resistance in the
faulty connector. If other proportional proportional solenoid valve.
Faulty proportional solenoid solenoid valve is (19 Ω at 20 °C (68 °F))
valve. abnormal, TCU is fixed Check the internal wire
control valve.
5480-5 Open Circuit Faulty contact of wire Turn TCU to neutral. Check the wire harness
in First harness, connector, and TCU. After returning the between TCU and
Speed Clutch Faulty proportional solenoid forward/reverse lever transmission control valve.
Proportional valve. to neutral, operate it Check the connector between
Solenoid Valve again. Then, machine TCU and transmission control
can travel only at first or valve.
control valve.
T5-5-46

5490-3 Abnormal Shorted circuit in power Turn TCU to neutral. Check the wire harness
Second circuit because of faulty wire After returning the between TCU and
Speed Clutch harness or faulty connector. forward/reverse lever transmission control valve.
Proportional Faulty proportional solenoid to neutral, operate it Check the connector between
Solenoid Valve valve. again. Then, machine TCU and transmission control
High Voltage can travel only at first or valve.
control valve.
5490-4 Abnormal Grounding to body because Turn TCU to neutral. Check the wire harness
Second of faulty wire harness or After returning the between TCU and
Speed Clutch faulty connector. forward/reverse lever transmission control valve.
Proportional Shorted circuit to other to neutral, operate it Check the connector between
Solenoid Valve proportional solenoid valve again. Then, machine TCU and transmission control
Low Voltage output circuit in TCU. can travel only at first or valve.
Faulty proportional solenoid second speed. Check resistance in the
valve. If other proportional proportional solenoid valve.
control valve.
in Second harness, connector, and TCU. After returning the between TCU and
control valve.
T5-5-47

5500-3 Abnormal Third Shorted circuit in power Turn TCU to neutral. Check the wire harness
Speed Clutch circuit because of faulty wire After returning the between TCU and
valve.
can travel only at first or
control valve.
5500-4 Abnormal Third Grounding to body because Turn TCU to neutral. Check the wire harness
Speed Clutch of faulty wire harness or After returning the between TCU and
control valve.
in Third harness, connector, and TCU. After returning the between TCU and
control valve.
T5-5-48

5510-3 High-Speed Shorted circuit in power Turn TCU to neutral. Check the wire harness
Forward Clutch circuit because of faulty wire After returning the between TCU and
control valve.
5510-4 High-Speed Grounding to body because Turn TCU to neutral. Check the wire harness
Forward Clutch of faulty wire harness or After returning the between TCU and
control valve.
in High-Speed harness, connector, and TCU. After returning the between TCU and
Forward Clutch Faulty proportional solenoid forward/reverse lever transmission control valve.
control valve.
T5-5-49

5520-3 Low-Speed Shorted circuit in power Turn TCU to neutral. Check the wire harness
Forward Clutch circuit because of faulty wire After returning the between TCU and
valve.
can travel only at first or
control valve.
5520-4 Low-Speed Grounding to body because Turn TCU to neutral. Check the wire harness
Forward Clutch of faulty wire harness or After returning the between TCU and
Solenoid Valve Shorted circuit to other to neutral, operate it Check the connector between
control valve.
in Low-Speed harness, connector, and TCU. After returning the between TCU and
Forward Clutch Faulty proportional solenoid forward/reverse lever transmission control valve.
control valve.
T5-5-50

5530-3 Abnormal Shorted circuit in wire Turn TCU to neutral. Check the wire harness
Reverse Clutch harness or connector and After returning the between TCU and
Proportional power circuit. forward/reverse lever transmission control valve.
control valve.
5530-4 Abnormal Grounding to body because Turn TCU to neutral. Check the wire harness
Reverse Clutch of faulty wire harness or After returning the between TCU and
Solenoid Valve Shorted circuit to other to neutral, operate it Check the connector between
control valve.
5530-5 Open Circuit in Faulty contact of wire Turn TCU to neutral. Check the wire harness
Reverse Clutch harness, connector, and TCU. After returning the between TCU and
Proportional Faulty proportional solenoid forward/reverse lever transmission control valve.
Solenoid Valve valve. to neutral, operate it Check the connector between
again. Then, machine TCU and transmission control
control valve.
T5-5-51

5560-3 Abnormal Shorted circuit in power - Check the wire harness
Reverse Light circuit because of faulty wire between TCU and reverse
Relay Exciting harness. light relay.
Circuit High Faulty reverse light relay. Check the wire harness
Voltage Shorted circuit in power between reverse light relay
circuit by the connector pin. and TCU.
Check the wire harness in
reverse light relay.
5560-4 Abnormal Grounding to body because - Check the wire harness
Reverse Light of faulty wire harness. between TCU and reverse
Relay Exciting Faulty reverse light relay. light relay.
Circuit Low Grounding to body by the Check the wire harness
Voltage connector pin. between reverse light relay
and TCU.
Check the wire harness in
reverse light relay.
5560-5 Faulty Open Faulty connection of wire - Check the wire harness
Circuit in harness and TCU. between TCU and reverse
Reverse Light Faulty reverse light relay. light relay.
Relay Exciting Faulty contact of connector Check the wire harness
Circuit. and TCU. between reverse light relay
TCU detects and TCU.
wrong voltage Check the wire harness in
similar to reverse light relay.
voltage during
faulty open
circuit.
T5-5-52
fault Code Trouble Cause Behavior of TCU Repair Procedure

5570-3 TCU ADM3 Shorted circuit in wire - Check the wire harness
circuit detects harness to power circuit between TCU ADM3 and
wrong voltage because of faulty wire power circuit.
in power circuit harness. Check the connectors.
like shorted Shorted circuit in wire
circuit harness to power circuit
because of connector pin.
5570-4 TCU ADM3 Grounding to body because - Check the wire harness to
circuit detects of faulty wire harness. TCU ADM3 circuit.
wrong voltage Grounding connector pin to Check the connectors.
like grounding body.
to body
5570-5 TCU ADM3 Faulty contact between wire - Check the wire harness to
circuit detects harness or connector and TCU TCU ADM3 circuit.
wrong voltage ADM3 circuit. Check the connectors.
like open circuit
T5-5-53

5620-4 Abnormal Grounding to body because - Check the wire harness
Output Signal of faulty wire harness. between TCU and column
Circuit of Faulty column display display controller.
Transmission controller. Check the connector
Failure Low Grounding the connector pin between TCU and column
Voltage to body. display controller.
Faulty column display
controller.
5620-5 Open Circuit Faulty connection of wire - Check the wire harness
in Output harness and TCU. between TCU and column
Signal Circuit Faulty column display display controller.
of Transmission controller. Check the connector
Failure Faulty connection of between TCU and column
connector and TCU. display controller.
Faulty column display
controller.
5620-3 Abnormal Shorted circuit in power - Check the wire harness
Output Signal circuit because of faulty wire between TCU and column
Circuit of harness. display controller.
Transmission Faulty column display Check the connector
Failure High controller. between TCU and column
Voltage Shorted circuit in power display controller.
circuit by the connector pin. Faulty column display
controller.
T5-5-54

5660-2 First Speed Clutch First speed clutch pressure is Turn TCU to neutral. Check the first speed clutch
Slipping. low. After returning the pressure.
When operating the Main clutch pressure is low. forward/reverse lever to Check the main clutch
first speed clutch, if Faulty transmission neutral, operate it again. pressure.
the value calculated intermediate shaft speed Then, machine can Check the signal of
by the signal sensor. travel at first or second transmission intermediate
of transmission Faulty vehicle speed sensor. speed. shaft speed sensor.
intermediate shaft Faulty clutch. If other clutch is Check the signal of vehicle
speed sensor is abnormal, TCU is fixed speed sensor.
different from to neutral. Replace the clutch.
the actual value
of vehicle speed
sensor, TCU
determines that
the clutch slipping
occurs.
5665-2 Second Speed Second speed clutch pressure Turn TCU to neutral. Check the second speed
Clutch Slipping. is low. After returning the clutch pressure.
When operating Main clutch pressure is low. forward/reverse lever to Check the main clutch
the second speed Faulty transmission neutral, operate it again. pressure.
clutch, if the intermediate shaft speed Then, machine can Check the signal of
value calculated sensor. travel at first or second transmission intermediate
by the signal Faulty vehicle speed sensor. speed. shaft speed sensor.
of transmission Faulty clutch. If other clutch is Check the signal of vehicle
intermediate shaft abnormal, TCU is fixed speed sensor.
speed sensor is to neutral. Replace the clutch.
different from
the actual value
of vehicle speed
sensor, TCU
determines that
the clutch slipping
occurs.
5670-2 Third Speed Clutch Third speed clutch pressure Turn TCU to neutral. Check the third speed clutch
Slipping. is low. After returning the pressure.
When operating the Main clutch pressure is low. forward/reverse lever to Check the main clutch
third speed clutch, if Faulty transmission neutral, operate it again. pressure.
of transmission Faulty vehicle speed sensor. speed. shaft speed sensor.
intermediate shaft Faulty clutch. If other clutch is Check the signal of vehicle
speed sensor is abnormal, TCU is fixed speed sensor.
different from to neutral. Replace the clutch.
the actual value
of vehicle speed
sensor, TCU
determines that
the clutch slipping
occurs.
T5-5-55

5675-2 High-Speed High-speed forward clutch Turn TCU to neutral. Check the high-speed
Forward Clutch pressure is low. After returning the forward clutch pressure.
Slipping. Main clutch pressure is low. forward/reverse lever to Check the main clutch
When operating Faulty transmission neutral, operate it again. pressure.
the high-speed intermediate shaft speed Then, machine can Check the signal of
forward clutch, if sensor. travel at first or second transmission intermediate
the value calculated Faulty torque converter speed. shaft speed sensor.
by the signal output speed sensor. If other clutch is Check the signal of torque
of transmission Faulty clutch. abnormal, TCU is fixed converter output speed
intermediate to neutral. sensor.
shaft speed Replace the clutch.
sensor is different
from the actual
value of torque
converter output
speed sensor, TCU
determines that
the clutch slipping
occurs.
5680-2 Low-Speed Forward Low-speed forward clutch Turn TCU to neutral. Check the low-speed forward
Clutch Slipping. pressure is low. After returning the clutch pressure.
the low-speed Faulty transmission neutral, operate it again. pressure.
forward clutch, if intermediate shaft speed Then, machine can Check the signal of
the value calculated sensor. travel at first or second transmission intermediate
by the signal Faulty torque converter speed. shaft speed sensor.
of transmission output speed sensor. If other clutch is Check the signal of torque
intermediate Faulty clutch. abnormal, TCU is fixed converter output speed
shaft speed to neutral. sensor.
sensor is different Replace the clutch.
from the actual
value of torque
converter output
speed sensor, TCU
determines that
the clutch slipping
occurs.
5685-2 Reverse Clutch Reverse clutch pressure is Turn TCU to neutral. Check the reverse clutch
Slipping. low. After returning the pressure.
the reverse clutch, if Faulty transmission neutral, operate it again. pressure.
of transmission Faulty torque converter speed. shaft speed sensor.
intermediate output speed sensor. If other clutch is Check the signal of torque
shaft speed Faulty clutch. abnormal, TCU is fixed converter output speed
sensor is different to neutral. sensor.
from the actual Replace the clutch.
value of torque
converter output
speed sensor, TCU
determines that
the clutch slipping
occurs.
T5-5-56

5700-0 Overheating - - Machine cooling.
Transmission Check the transmission oil
Oil. level.
TCU detects Check the sensor.
higher oil
temperature
than allowable
value.
5730-0 Clogged Oil filter contamination. - Check the transmission oil
Transmission Oil Broken the wire harness filter.
Filter. and connector, or faulty Check the wire harness
TCU detects connection to power circuit between TCU and
pressure from the wire harness and transmission oil filter
difference connector. restriction switch.
beyond Faulty transmission oil filter Check the transmission
allowable restriction switch. oil filter restriction switch.
range. (resistance measurement)
5745-15 Overrunning. - - -
TCU detects
transmission
output speed
beyond the
specified value.
5755-15 Over- - TCU may be fixed to -
Transmission neutral.
Input Torque.
TCU detects
transmission
output torque
beyond the
specified value.
T5-5-57

5760-0 Overheat - - Machine cooling.
at Torque Check the transmission oil
Converter level.
Outlet. Check the sensor.
TCU detects
higher oil
temperature
than allowable
value.
5810-3 Sensor Power - - Check the wire harness and
Source High connector from terminal #3
Voltage. in TCU.
6 V or more at Check the power at terminal
terminal #3 (for #3 in TCU. (5 V)
5 V sensor) in Replace TCU.
TCU.
5810-4 Sensor Power - - Check the wire harness and
Source Low connector from terminal #3
Voltage. in TCU.
4 V or less at Check the power at terminal
terminal #3 (for #3 in TCU. (5 V)
5 V sensor) in Replace TCU.
TCU.
T5-5-58

5820-4 Power Source Measurement voltage at the Fixed to neutral. Check fuse #9 and fuse #14 in
Voltage power source is below 18 V. fuse box B.
Decrease Check the wire harness and
connector between fuse #9
and fuse #14 in fuse box B
and TCU.
5820-3 Power Source Measurement voltage at the Fixed to neutral. Check fuse #9 and fuse #14 in
Voltage power source is beyond 32.5 fuse box B.
Increase V. Check the wire harness and
connector between fuse #9
and fuse #14 in fuse box B
and TCU.
5830-2 Proportional Shorted circuit in wire Fixed to neutral. Check fuse #9 in fuse box B.
Solenoid Valve harness or connector and Check the wire harness
Power Source power circuit. between control valve
Error. Grounding the wire harness transmission control valve
While power and connector to body. and TCU.
from CPU in No power from fuse #9 in fuse Check the connector
TCU is supplied box B. between control valve
to terminals Faulty TCU. transmission control valve
#12 and #13, and TCU.
measuring Replace TCU.
CPU detects
low voltage, or
while power
from CPU in TCU
is not supplied
to terminals
#12 and #13,
measuring CPU
detects voltage.
T5-5-59

5890-2 Abnormal Faulty TCU. Fixed to neutral. Replace TCU.
EPROM
TCU cannot
make out the
memory
5900-13 Broken Failure in data save. Fixed to neutral. Replace TCU.
Program. Install new TCU or the used
Transmission one for other machine.
control is
disabled.
5910-13 Application - Fixed to neutral. Replace TCU.
Error.
Application is
defective.
5930-7 Learning Failure One of the learning values in Fixed to neutral. Check the clutch.
in Transmission transmission learning control
Learning program is beyond normal
Control range.
Program
5930-13 No Correcting Failure in data save to the - Execute transmission learning
Data of memory. control program.
Transmission New TCU. Re-install transmission
Learning learning control program.
Control
Program and
Declutch
Control Pressure
T5-5-60
MC Fault Codes 111000 to 111002
Fault Code Trouble Cause

111000-2 Abnormal EEPROM Faulty MC
111001-2 Abnormal RAM Faulty MC
111002-2 Abnormal A/D Converter Faulty MC
fNOTE: Even if the engine and the machine are operated

normally with the fault code displayed after retrial, the
machine can be operated as it is.
T5-5-61
MC Fault Code 111003

IMPORTANT: When fault code 111003-3 (Abnormal
Sensor Voltage) is displayed with other fault code,
diagnose on fault code 111003-3 first.
Fault Code Trouble Inspection Method Evaluation Cause

111003-3 Abnormal Sensor Disconnect connectors from Fault code 111003-3 is Faulty sensor
Voltage all sensors and accelerator not displayed.
pedal sensor. Retry the
troubleshooting by using MPDr.
Measure voltage between Voltage: less than 0.25 V Open circuit in wire
sensor harness end #1 and body. harness #1.
Check shorted circuit in harness 0Ω Shorted circuit in
between sensor harness end #1 wire harness #1 and
and #3. #3.
- Normal in above check. Faulty MC
2 3 4 5 6 7 8 9 10 11 12 13
TNDJ-05-05-001
1- MC 5- Pressure Sensor (Parking 8- Secondary Steering Pump 12- Fan Pump Delivery Pressure
2- Pump Delivery Pressure Sensor Brake) Delivery Pressure Sensor (OP) Sensor
3- Pressure Sensor (Primary Pilot 6- Pressure Sensor (Lift Arm 9- Steering Pressure Switch (OP) 13- Hydraulic Oil Temperature
Pressure) Raise) (OP) 10- Lift Arm Angle Sensor (OP) Sensor
4- Pressure Sensor (Brake Primary 7- Accelerator Pedal Sensor 11- Pressure Sensor (Brake
Pressure) Secondary Pressure)
T5-5-62
Connector (Harness end of connector viewed from the

open end side)
 Pressure Sensor (Lift Arm Raise) (Option)
 Pressure Sensor (Brake Secondary Pressure)
 Pressure Sensor (Primary Pilot Pressure)
 Steering Pressure Switch (Option)
T6LE-05-05-011
 Pump Delivery Pressure Sensor

 Fan Pump Delivery Pressure Sensor
 Secondary Steering Pump Delivery Pressure Sensor
(Option)
 Lift Arm Angle Sensor (Option)
 Pressure Sensor (Brake Primary Pressure)
T6LE-05-05-010
 Accelerator Pedal Sensor
TNDJ-05-05-011
T5-5-63
(Blank)
T5-5-64
MC Fault Codes 111006, 111007, 111011

Preparation
 Disconnect the connectors from each controller.
 Check the wiring connections first.
 Check the CAN1 harness between the controllers.
(Refer to CAN1 Harness Check on T5-5-60 to 62.)
Fault Code Trouble Inspection Method Cause

111006-2 (MC) EC Continuity check (open circuit) Open circuit in wire
Communication harness.
Error Discontinuity check (shorted Shorted circuit in
circuit) wire harness.
111007-2 (MC) IC Continuity check (open circuit) Open circuit in wire
Communication harness.
Error 1 Discontinuity check (shorted Shorted circuit in
circuit) wire harness.
111011-2 (MC) Transmission Continuity check (open circuit) Open circuit in wire
Controller harness.
Communication Discontinuity check (shorted Shorted circuit in
Error circuit) wire harness.
T5-5-65
CAN1 Harness Check

Preparation
 Before continuity check, set the key switch to the OFF position.
Evaluation
Continuity (0 Ω) Discontinuity (∞ Ω)
Continuity check Correct Discontinuity
(open circuit)
Discontinuity check Shorted circuit Correct
(shorted circuit)
Inspection CAN Harness MC ECM TCU Information Column Display A/C

Controller Controller
Continuity check High side #A28 #B46 #25 #C5 #2-B30 #8
between MC and Low side #A29 #B47 #26 #C11 #2-B29 #9
each controller
Discontinuity check High side #A28-#D1 #B46-#A1 #25-#1 #C5-#C14 #2-B30-#1-B28 #8-#26
between CAN #A28-#E1 #B46-#A2 #25-#2 #C5-#C15 - -
circuit and ground #A28-#E2 - - - - -
circuit in each #A28-#E5 - - - - -
controller #A28-#E6 - - - - -
Low side #A29-#D1 #B47-#A1 #26-#1 #C5-#C14 #2-B29-#1-B28 #9-#26
#A29-#E1 #B47-#A2 #26-#2 #C5-#C15 - -
#A29-#E2 - - - - -
#A29-#E5 - - - - -
#A29-#E6 - - - - -
T5-5-66
Inspection CAN Harness MC ECM TCU Information Column Display A/C

Controller Controller
Discontinuity High side #A28-#E3 #B46-#A3 #25-#23 #C5-#C1 #2-B30-#1-A1 #8-#17
check between #A28-#E4 #B46-#A4 #25-#68 #C5-#C2 - #8-#17
CAN circuit and #A28-#D2 - - - - -
power circuit in #A28-#D5 - - - - -
each controller #A28-#D6 - - - - -
Low side #A29-#E3 #B47-#A3 #26-#23 #C11-#C1 #2-B29-#1-A1 #9-#17
#A29-#E4 #B47-#A4 #26-#68 #C11-#C2 - #9-#17
#A29-#D2 - - - - -
#A29-#D5 - - - - -
#A29-#D6 - - - - -
Discontinuity High side #A28-#E10 #B46-#B39 #25-#45 #C5-#C7 #2-B30-#1-A2
check between
CAN circuit and
Low side #A29-#E10 #B47-#B39 #26-#45 #C11-#C7 #2-B29-#1-A2
key signal circuit
in each controller
Discontinuity - #A28-#A29 #B46-#B47 #25-#26 #C5-#C11 #2-B29-#2-B30 #8-#9
check between
CAN (High side)
circuit and CAN
(Low side) circuit
in each controller
T5-5-67
Connector (Wire harness end)

 MC-A Connector  TCU Connector
TNDJ-05-05-010
 MC-D Connector
TNDJ-05-05-006
 EC-E Connector
TNDB-05-05-003
 Column Display Controller 1-A Connector
TNDJ-05-05-008
TNDJ-05-05-007
 Column Display Controller 1-B Connector
 ECM-B(J2) Connector
TNDB-05-05-007
TNDJ-05-05-002
 ECM-A(J3) Connector
TNDJ-05-05-009
 A/C3 Connector
TNDJ-05-05-003
 Information Controller-C Connector
17
C2 C5
C1
C7 TNCC-05-05-004
26
T1V1-05-04-002
C15 C11
T5-5-68
(Blank)
T5-5-69
MC Fault Codes 111014, 111025

Preparation
 Disconnect the connectors from each controller.
 Check the CAN1 harness between the controllers.
(Refer to CAN1 Harness Check on T5-5-60 to 62.)
Fault Code Trouble Inspection Method Cause

111014-2 (MC) Air Conditioner Continuity check (open circuit) Open circuit in wire
Controller harness.
111025-2 (MC) Column Continuity check (open circuit) Open circuit in wire
Monitor harness.
T5-5-70

Preparation
 The actual engine speed which ECM sends by using
the CAN bus line is abnormal.
Diagnose ECM.
 The engine speed which TCU sends by using the CAN
bus line is abnormal. Diagnose TCU.
Fault Code Trouble Cause

111100-2 Abnormal Engine Speed Engine speed: 4000 min-1 or more. Or
engine speed (ECM): 500 min-1 or less and
engine speed (TCU): 500 min-1 or more.
T5-5-71
MC Fault Code 111103, 111106, 111107

Preparation

111103-3 Accelerator Pedal Circuit Measure resistance 0Ω Shorted circuit in wire
High Input between accelerator pedal harness #1 and #3.
sensor end #1 and #3.
- Normal in above Open circuit accelerator
check. pedal sensor.
111103-4 Accelerator Pedal Circuit Measure voltage between Voltage: less than Open circuit in wire
Low Input accelerator pedal sensor 0.25 V harness #1.
harness end #3 and body.
Measure voltage between Voltage: less than Open circuit in wire
accelerator pedal sensor 0.25 V harness #4.
harness end #3 and #4.
- Normal in above Faulty accelerator pedal.
check.
111106-3 Abnormal Accelerator Voltage: more than 4.74 V The engine speed Check the wire harness.
Pedal 2 Circuit High is fixed to 1000 Replace the accelerator
Input min-1. pedal.
111106-4 Abnormal Accelerator Voltage: less than 0.25 V The engine speed Check the wire harness.
Pedal 2 Circuit Low Input is fixed to 1000 Replace the accelerator
min-1. pedal.
111107-2 Accelerator pedal Sensor Voltage difference between The engine speed Check the wire harness.
correlation diagnosis accelerator pedal sensor is fixed to 1000 Replace the accelerator
end #1 and #2 is 0.5 V or min-1. pedal.
more.
Connector (Wire Harness end)

 Accelerator Pedal Sensor
TNDJ-05-05-011
T5-5-72
MC Fault Codes 111205

Preparation

111205-3 Lift Arm Angle Sensor Measure resistance 0Ω Shorted circuit in wire
Circuit High Input between lift arm angle harness #1 and #2.
sensor end #1 and #2.
- Normal in above Open circuit lift arm angle
check. sensor.
111205-4 Lift Arm Angle Sensor Measure voltage between Voltage: less than Open circuit in wire
Circuit Low Input lift arm angle sensor 0.25 V harness #1.
harness end #1 and body.
Measure voltage between Voltage: less than Open circuit in wire
lift arm angle sensor 0.25 V harness #3.
harness end #1 and #3.
- Normal in above Faulty lift arm angle
check. sensor.

 Lift Arm Angle Sensor (Option)
T6LE-05-05-010
T5-5-73

Preparation
 Connect the test harness (ST 6703) and dummy
sensor equivalent to #4436535.
 Before inspection, set the key switch to the ON
position.

111200-3 Lift Arm Raise Pilot Retry by using MPDr. Un-displayed fault Faulty sensor.
Pressure Sensor Circuit code
High Input Measure voltage between B Voltage: 4.75 V or Shorted circuit in wire
and body. more harness #1 and #2.
111200-4 Lift Arm Raise Pilot Retry by using MPDr. Un-displayed fault Faulty sensor.
Low Input Measure voltage between A Voltage: less than Open circuit in wire
and body. 0.25 V harness #1.
Measure voltage between A Voltage: less than Open circuit in wire
and C (GND). 0.25 V harness #3.
- Normal in above Open circuit in wire
check. harness #2.
C B A
TDAA-05-06-003
T5-5-74

Preparation
position.

111217-3 Pilot Pressure Sensor Retry by using MPDr. Un-displayed fault Faulty sensor.
Circuit High Input code
Measure voltage between B Voltage: 4.75 V or Shorted circuit in wire
111217-4 Pilot Pressure Sensor Retry by using MPDr. Un-displayed fault Faulty sensor.
Circuit Low Input code
Normal in above Open circuit in wire
check. harness #2.
111312-3 Service Brake Secondary Retry by using MPDr. Un-displayed fault Faulty sensor.
111312-4 Service Brake Secondary Retry by using MPDr. Un-displayed fault Faulty sensor.
check. harness #2.
C B A
TDAA-05-06-003
T5-5-75

Preparation
position.

111204-3 Pump Delivery Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
Sensor Circuit High Input code
111204-4 Pump Delivery Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
Sensor Circuit Low Input code
check. harness #2.
111206-3 Hyd. Fan Circuit Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
111206-4 Hyd. Fan Circuit Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
check. harness #2.
C B A
TDAA-05-06-003
T5-5-76

Preparation
position.

111208-3 Emergency Steering Retry by using MPDr. Un-displayed fault Faulty sensor.
Check Pressure Sensor code
Circuit High Input Measure voltage between B Voltage: 4.75 V or Shorted circuit in wire
111208-4 Emergency Steering Retry by using MPDr. Un-displayed fault Faulty sensor.
Check Pressure Sensor code
Circuit Low Input Measure voltage between A Voltage: less than Open circuit in wire
check. harness #2.
C B A
TDAA-05-06-003
T5-5-77

Preparation
position.

111311-3 Service Brake Primary Retry by using MPDr. Un-displayed fault Faulty sensor.
111311-4 Service Brake Primary Retry by using MPDr. Un-displayed fault Faulty sensor.
check. harness #2.
111313-3 Parking Brake Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
111313-4 Parking Brake Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
check. harness #2.
C B A
TDAA-05-06-003
T5-5-78

Preparation

111411-2 Hydraulic Fan Reverse Measure resistance 0/∞Ω Faulty solenoid valve.
Rotation P/S Valve between solenoid valve #1 (Normal value:
Abnormal FB and #2. 22±0.4 Ω)
Measure voltage between 0V Open circuit in wire
solenoid valve harness end harness #1.
#1 and body.
Oil Pressure Driving Fan 0 mA Open circuit in wire
Reverse P/S FB harness #2.
- Normal in above Shorted circuit in wire
check. harness #1 and #2.
111411-3 Hydraulic Fan Reverse Measure resistance 0Ω Faulty solenoid valve.
Rotation P/S Valve FB between solenoid valve #1 (Normal value:
High Current and #2. 22±0.4 Ω)
111411-4 Hydraulic Fan Reverse Measure resistance ∞Ω Faulty solenoid valve.
Rotation P/S Valve FB between solenoid valve #1 (Normal value:
Low Current and #2. 22±0.4 Ω)
#1 and body.
Reverse P/S FB harness #2.

 Solenoid Valve Connector
TNED-05-05-020
T5-5-79

Preparation

111412-2 Hyd. Fan P/S Valve Measure resistance 0/∞Ω Faulty solenoid valve.
Abnormal FB between solenoid valve #1 (Normal value:
and #2. 22.3±0.4 Ω)
#1 and body.
Control P/S FB harness #2.
111412-3 Hyd. Fan P/S Valve FB Measure resistance 0Ω Faulty solenoid valve.
High Current between solenoid valve #1 (Normal value:
and #2. 22.3±0.4 Ω)
111412-4 Hyd. Fan P/S Valve FB Measure resistance ∞Ω Faulty solenoid valve.
Low Current between solenoid valve #1 (Normal value:
and #2. 22.3±0.4 Ω)
#1 and body.
Control P/S FB harness #2.

TNED-05-05-020
T5-5-80

Preparation

111413-2 Pump Swash Angle P/S Measure resistance 0/∞Ω Faulty solenoid valve.
Valve Abnormal FB between solenoid valve #1 (Normal value:
and #2. 10.3±0.515 Ω)
#1 and body.
Monitor Pump Torque 0 mA Open circuit in wire
Control P/S Valve Output harness #2.
FB.
111413-3 Pump Swash Angle P/S Measure resistance 0Ω Faulty solenoid valve.
Valve FB High Current between solenoid valve #1 (Normal value:
and #2. 10.3±0.515 Ω)
111413-4 Pump Swash Angle P/S Measure resistance ∞Ω Faulty solenoid valve.
Valve FB Low Current between solenoid valve #1 (Normal value:
and #2. 10.3±0.515 Ω)
#1 and body.
Monitor Pump Torque 0 mA Open circuit in wire
Control P/S Valve Output harness #2.
FB.

T1V1-05-04-003
T5-5-81

Preparation

111422-2 Ride Control (Bottom) Measure resistance 0/∞Ω Faulty solenoid valve.
P/S Valve Abnormal FB between solenoid valve #1 (Normal voltage:
and #2. 23.2±0.4 Ω)
#1 and body.
Ride Control P/S FB 0 mA Open circuit in wire
harness #2.
111422-3 Ride Control (Bottom) Measure resistance 0Ω Faulty solenoid valve.
P/S Valve FB High between solenoid valve #1 (Normal voltage:
Current and #2. 23.2±0.4 Ω)
111422-4 Ride Control (Bottom) Measure resistance ∞Ω Faulty solenoid valve.
P/S Valve FB Low Current between solenoid valve #1 (Normal voltage:
and #2. 23.2±0.4 Ω)
#1 and body.
Ride Control P/S FB 0 mA Open circuit in wire
harness #2.

TNED-05-05-020
T5-5-82

Preparation

111901-4 Hyd. Oil Temp Sensor Measure resistance Refer to the table. Faulty sensor.
Circuit Low Input between sensor #1 and #2.
check. harness #1.
111901-3 Hyd. Oil Temp Sensor Measure resistance Refer to the table. Open circuit in wire
Circuit High Input between sensor #1 and #2. harness #2.
Measure voltage between 0V Faulty sensor.
sensor harness end #1 and
body.
check. harness #1.
Specification of Hydraulic Oil Temperature Sensor Connector (Wire harness end)

Hydraulic Oil Resistance (kΩ)  Hydraulic Oil Temperature Sensor
Temperature (°C)
-30 (24.5)
-20 15.04+1.29-1.20
TNED-05-05-021
-10 (9.16)
0 (5.74)
10 (3.70)
20 2.45+0.14-0.13
30 (1.66)
40 (1.15)
50 (0.811)
60 (0.584)
70 (0.428)
80 0.318±0.008
90 (0.240)
100 (0.1836)
110 0.1417±0.0018
120 (0.1108)
T5-5-83

120003-2 Emergency Steering Check secondary steering Correct Faulty wire harness.
Activated check switch (Option). Incorrect Faulty secondary
steering check switch.
120004-2 Emergency Steering Disconnect a connector Displayed fault code Faulty MC or shorted
Activated Pressure Alarm from the steering pressure circuit in wire harness.
switch. Retry by using Un-displayed fault Faulty steering
MPDr. code pressure switch.
T5-5-84
MC Fault Codes 120014

120014-2 Overrun Alarm Diagnose on fault codes - -
of TCU.
T5-5-85
(Blank)
T5-5-86
Column Display Controller Fault Code

115001

115001-2 Abnormal REG input H Measurement of voltage 13 to 33.5 V Faulty column display
level between column display controller.
controller harness end #2-
B28 and body
Measurement of voltage at 13 to 33.5 V Open circuit in wire
alternator terminal L harness.
- Normal in above Faulty alternator.
check

TNDJ-05-05-009
T5-5-87
Column Display Controller Fault Code

115011

115011-3 Fuel Level Sensor Circuit Measure resistance Refer to the table. Faulty sensor.
High Input between sensor #1 and #2.
sensor harness end #1 and harness #1.
body.
check. harness #2.
115011-4 Fuel Level Sensor Circuit Measure resistance Refer to the table. Faulty sensor.
Low Input between sensor #1 and #2.
Fuel Gauge No. Fuel Level (%) Fuel Sensor (Ω)

A 100 (FULL) 100-4
A B 50 33±5
C 0 (EMPTY) 90+100
C
TNED-05-05-008

 Fuel Sensor
TNED-05-05-022
T5-5-88
Column Display Controller (Information) Fault Codes 120500 to120503, 120505

120500-2 Overheat Alarm Diagnose on fault codes of - -
ECM. - -
120501-2 Engine Error Diagnose on fault codes of - -
ECM.
120502-2 Engine Oil Pressure Alarm Diagnose on fault codes of - -
ECM.
120503-2 Air Cleaner Restriction Disconnect a connector Displayed fault code Faulty column display
Alarm from air filter restriction controller or shorted
switch. Retry by using circuit in wire harness.
MPDr. Un-displayed fault Faulty air filter
code restriction switch.
120505-2 Brake Pressure Alarm Diagnose on fault codes - -
of MC. - -

TNDJ-05-05-008
TNDB-05-05-007
T5-5-89
Column Display Controller Fault Codes 120506, 120507, 120510 to 120512, 120515, 120516,
120518

120506-2 Steering Oil Pressure Alarm Diagnose on fault codes - -
of MC.
120507-2 T/M Malfunction Diagnose on fault codes of - -
HST controller.
120510-2 Transmission Oil Diagnose on fault codes - -
Temperature of MC.
120511-2 Fuel Filter Restriction Diagnose on fault codes of - -
Alarm ECM.
120512-2 Emergency Steering Alarm Diagnose on fault codes - -
(Lighting) of MC.
120515-2 Engine Alarm Diagnose on fault codes of - -
ECM.
120516-2 Hydraulic Oil Temperature Diagnose on fault codes - -
Alarm of MC.
120518-2 Emergency Steering Alarm Diagnose on fault codes - -
(Blinking) of MC.

TNDJ-05-05-008
TNDB-05-05-007
T5-5-90
Troubleshooting B (Machine Diagnosis by

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

from the open end side of wire harness end.
1
2
T6L4-05-03-001
1- Wire Harness End Connector 2- Wire Harness
T5-6-1
Contents of Diagnosis
Trouble Symptom
Preparation
Viewpoints for a diagnosis and contents

needing inspection beforehand are
explained.
How to Read Table

Inspection
Procedure Condition Evaluation Cause
Method
(A) (B) (C) (D) (E)
(F) (G) (H) (I) (J)
 A, F: Inspection order
 B, G: Inspection method for trouble cause
 C, H: Conditions for inspection
 D, I: Evaluation specification of check results
 E, J: Trouble cause for trouble symptom
Procedure:
1. Perform inspection according to Inspection Method (B) and Condition (C) of
Procedure (A).
2. In case the results are applied to Evaluation (D), the trouble cause is Cause (E).
In case the results are not applied to Evaluation (D), go to the next procedure,
Procedure (F).
T5-6-2
Relationship between Machine Trouble

Symptoms and Related Parts
This table indicates the relationship between machine
trouble symptoms and the potential problem parts, which
may cause trouble if failed, and the evaluation methods of
these components.
Parts MC (Main Controller) Accelerator Pedal (Accelerator Travel Mode Selector Switch
Pedal Sensor)
Item
Function Controls engine, pump, and valve Instructs target engine speed Shifts the travel mode into AUTO
operation. according to accelerator pedal 1, AUTO 2, and Manual modes.
depressing amount.
Symptoms Depending on trouble situations, MC holds engine speed in 1000 MC holds the travel mode in
in control control system malfunction may min-1. Manual mode.
system when differ. (The following symptoms
trouble occurs in machine operation indicates
that MC logic circuit has failed.)
Symptoms The engine speed is fixed to 1000 The engine speed is fixed to 1000 Open circuit: Travel mode is
in machine min-1. min-1. always Manual mode.
operation As pump displacement is held at Shorted circuit: Travel mode is
when trouble minimum, all actuator speeds are always AUTO 1/ AUTO 2 mode.
occurs slow.
Evaluation by 111000, 111001, 111002, 111003 111103 -
Fault Code
Evaluation by - MC: Demand Engine Speed MC: Travel Mode Selector Switch
Monitoring ECM: Actual Engine Speed
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-3
Parts Power Mode Switch Quick Power Switch Declutch Position Switch
Item
Function Turns power mode ON/OFF. Turns power mode ON/OFF. Activates or deactivates the
declutch control.
Symptoms Same as shown below. Same as shown below. Declutch control is not activated.
in control
system when
trouble occurs
Symptoms Power mode (ON/OFF) can not Functions of power mode switch Although declutch position
in machine change. become effective. switch is turned ON, the declutch
operation The power mode indicator on indicator on monitor is not ON.
when trouble monitor is not shifted.
occurs
Evaluation by - - -
Fault Code
Evaluation by MC: Power Mode Switch MC: Quick Power Switch MC: Clutch Cut OFF Position
Monitoring Switch
Evaluation - - -
by using Test
Harness
Note - When quick power mode control Brake Pedal Depressing Amount:
is effective. Two modes, Large and Small with
(Quick power mode is not the declutch position switch set
activated when travel is in neutral in the ON position
or the travel load is light.)
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-4
Parts Fan Reverse Rotation Switch Forward/Reverse Lever

(Option)
Item
Function Shifts fan reverse rotation control Shifts forward clutch solenoid
solenoid valve of fan valve. valve, and reverse clutch solenoid
valve of transmission.
Symptoms Same as shown below. TCU holds the travel in neutral.
in control
system when
trouble occurs
Symptoms Although fan reverse rotation Although forward/reverse lever
in machine switch is turned ON, cooling fan is operated, machine does not
operation does not rotate in reverse. travel forward/reverse.
when trouble The fan reverse rotation indicator The FNR indication on monitor is
occurs on monitor is not ON. (The not shifted.
indicator does not blink when
shifting.)
Evaluation by - TCU: 5010
Fault Code
Evaluation by - TCU: Forward/Reverse Lever (N)/
Monitoring (F)/(R)
Evaluation - -
by using Test
Harness
Note - -
Descriptions T2-2, 2-4 T2-2, T2-5
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-5
Parts Forward/Reverse Selector Switch Forward/Reverse Switch (Option)

(Option)
Item
Function Shifts forward/reverse lever Shifts forward clutch solenoid
and forward/reverse switch valve, and reverse clutch solenoid
operations. valve of transmission.
Symptoms TCU makes forward/reverse lever TCU makes forward/reverse lever
in control operation effective. operation effective.
system when
trouble occurs
Symptoms Functions of forward/reverse Functions of forward/reverse
in machine lever become effective. lever become effective.
operation
when trouble
occurs
Evaluation by - TCU: 5040
Fault Code
Evaluation by TCU: Forward/Reverse Selector TCU: Option Forward/Reverse
Monitoring Switch Switch (N)/(F)/(R)
Evaluation - -
by using Test
Harness
Note The operation is effective with When forward/reverse lever
forward/reverse lever and is operated, forward/reverse
forward/reverse switch set in the selector switch operation
neutral position. becomes ineffective. (forward/
reverse lever priority)
Descriptions T2-2, T2-5 T2-2, T2-5
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-6
Parts Shift Switch Downshift Switch (DSS) Hold Switch
Item
Function Shifts solenoid valves of Shifts speed shift solenoid valves Shifts speed shift solenoid valves
transmission control valve. of transmission and shifts down of transmission and holds the
the speed shift during automatic speed shift during automatic
speed shift. speed shift.
Symptoms When there are no output from Same as shown below. Same as shown below.
in control shift switch, TCU holds the speed
system when range in third speed with Manual
trouble occurs mode, and TCU controls the
speed range up to third speed
with AUTO 1/AUTO 2 mode.
Symptoms The speed shift is held in third The speed shift is not shifted The speed shift is not held
in machine speed with travel mode set in down although downshift although hold switch is turned
operation Manual mode. switch (DSS) is turned ON during ON during automatic speed shift.
when trouble The speed shift is automatically automatic speed shift. The hold indication on monitor is
occurs changed to third speed as max. The shift indication on monitor is not displayed.
speed in AUTO 1/AUTO 2 mode. not shifted.
Evaluation by - - -
Fault Code
Evaluation by TCU: Shift Switch TCU: DSS Switch TCU: Gear Hold Switch
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T2-2, T2-5 T2-2 T2-2
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-7
Parts Ride Control Switch
Item
Function Shifts ride control solenoid valve
and activates or deactivates the
ride control.
Symptoms Same as shown below.
in control
system when
trouble occurs
Symptoms Open circuit: Ride control switch
in machine is always OFF. Although ride
operation control switch is turned ON, the
when trouble ride control is not activated.
occurs Shorted circuit: Ride control
switch is always ON.
Evaluation by -
Fault Code
Evaluation by MC: Ride Control Switch
Monitoring
Evaluation -
by using Test
Harness
Note -
Descriptions T2-2, T2-4
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-8
Parts Parking Brake Switch Front Control Lever Lock Switch Pilot Shut-Off Solenoid Valve
Item
Function Shifts parking brake solenoid Shifts pilot shut-off solenoid Opens and closes the front pilot
valve. valve. circuit.
Symptoms Same as shown below. Same as shown below. Same as shown below.
in control
system when
trouble occurs
Symptoms Although the parking brake Open circuit: Front control lever When closed: The lift arm and
in machine switch is turned ON/OFF, the lock switch is always OFF. Pilot bucket are not operated. (Pilot
operation parking brake is not released/ shut-off solenoid valve is not pressure oil is not supplied to
when trouble applied with the engine running. shifted. The lift arm and bucket pilot valve.)
occurs are not operated although the When open: Pilot pressure oil is
control lever is operated with the always supplied to pilot valve.
front control lever lock switch set
in UNLOCK position.
Shorted circuit: Front control
lever lock switch is always ON.
Evaluation by - - -
Fault Code
Evaluation by Column Display Controller: MC: Pilot Primary Pressure -
Monitoring Parking Brake Signal Output
Evaluation - - -
by using Test
Harness
Note Although the parking brake is - -
turned OFF, the parking brake is
applied with the engine stopped.
Descriptions T2-2, T2-5 T2-4 T2-5
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-9
Parts Hydraulic Oil Temperature Sensor Torque Converter Oil

Temperature Sensor
Item
Function Monitors hydraulic oil Monitors torque converter oil
temperature. temperature.
Symptoms MC recognizes that hydraulic MC recognizes that torque
in control oil temperature is 120 °C when converter oil temperature is 120
system when open circuit occurs. (Hydraulic °C when open circuit occurs.
trouble occurs oil temperature: 120 °C is not
displayed on monitoring.)
Symptoms When hydraulic oil temperature is The color of transmission oil
in machine 0 °C or less when starting engine, temperature on monitor is red.
operation auto-warming up control is not The indicator is displayed.
when trouble operated.
occurs
Evaluation by 111901 111011
Fault Code
Evaluation by MC: Hydraulic Oil Temperature TCU: Torque Converter Oil
Monitoring Temperature
Evaluation - -
by using Test
Harness
Note - -
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-10
Parts Pump Delivery Pressure Sensor Fan Pump Delivery Pressure Secondary Steering Pump
Sensor Delivery Pressure Sensor (Option)
Item
Function Detects pump delivery pressure. Detects fan pump delivery Detects secondary steering pump
pressure. delivery pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symptoms occur. following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms Matching control while digging is Although fan reverse rotation When the engine starts, the
in machine not activated. switch (option) is operated, secondary steering pump is
operation fan rotation direction can not operated normally but Secondary
when trouble change. Steering Alarm is indicated. When
occurs the engine stops, the secondary
steering pump is not operated.
Evaluation by 111204 111260 111208
Fault Code
Evaluation by MC: Pump Delivery Pressure MC: Hydraulic Fan Circuit Pressure MC: Emergency Steering Pump
Monitoring Delivery Pressure
Evaluation - - -
by using Test
Harness
Note Possible to judge if sensor or wire Possible to judge if sensor or wire Possible to judge if sensor or wire
harness is faulty by switching harness is faulty by switching harness is faulty by switching
pressure sensor with other pressure sensor with other pressure sensor with other
delivery pressure sensor. delivery pressure sensor. delivery pressure sensor.
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-11
Parts Steering Pressure Switch (Option) Pressure Sensor (Parking Brake Pressure Sensor (Brake Primary
Pressure) Pressure)
Item
Function Detects steering circuit pressure. Detects parking brake pressure. Detects brake pressure.
Symptoms Same as shown below. When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms Secondary steering pump is Although the parking brake The low brake oil pressure
in machine operated when the wire harness is applied, the parking brake indicator is always ON.
operation is disconnected while traveling. indicator is not ON.
when trouble The low steering oil pressure The machine does not accelerate.
occurs indicator is always ON. (with the parking brake dragging)
Shorted circuit: The initial
automatic check for secondary
steering operation cannot be
performed. (When the engine
starts)
monitor blinks.
Evaluation by 120004, 120506 111313, 115015 111311
Fault Code
Evaluation by MC: Steering Pressure Switch MC: Parking Brake Pressure MC: Service Brake Primary
Monitoring Pressure
Evaluation - - -
by using Test
Harness
Note - Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor with by switching pressure sensor with
other pressure sensor. other pressure sensor.
Descriptions T2-2 T2-2, T2-4 T2-2, T2-4
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-12
Parts Pressure Sensor (Brake Secondary Lift Arm Angle Sensor (Option) Pressure Sensor (Lift Arm Raise)
Pressure) (Option)
Item
Function Detects front brake pressure. Detects operating angle of the Detects lift arm raise pilot
lift arm. pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symptoms occur. following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms The speed shift does not The lift arm auto leveler lower The ride control is not activated.
in machine automatically downshift to first kickout control is not activated.
operation speed with the travel mode set in The lift arm auto leveler height
when trouble AUTO 1 mode. kickout control is not activated.
occurs The declutch control is not
activated.
Evaluation by 111312 111205 111200
Fault Code
Evaluation by MC: Service Brake Secondary MC: Lift Arm Angle Sensor MC: Lift Arm Raise Pilot Pressure
Monitoring Pressure (For Clutch Cut Off )
Evaluation - - -
by using Test
Harness
Note - - Possible to judge if pressure
sensor is faulty or port is clogged
by switching pressure sensor with
other pressure sensor.
Descriptions T2-2 T2-2 T2-2, T2-4
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-13
Parts Pressure Sensor (Primary Pilot

Pressure)
Item
Function Detects primary pilot pressure.
Symptoms When output is 0 V or 5 V, the
in control following symptoms occur.
system when
trouble occurs
Symptoms Although front control lever lock
in machine solenoid valve is operated with
operation front control lever lock switch set
when trouble in the ON (Lock) position, front
occurs control lever lock indicator is not
ON.
Evaluation by 111217
Fault Code
Evaluation by MC: Pilot Primary Pressure
Monitoring
Evaluation -
by using Test
Harness
Note Possible to judge if pressure
sensor is faulty or port is clogged
by switching pressure sensor with
other pressure sensor.
Descriptions T2-2, T2-4
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-14
Parts Torque Converter Input Speed Torque Converter Output Speed Transmission Intermediate Shaft
Sensor Sensor Speed Sensor
Item
Function Detects torque converter input Detects torque converter output Detects transmission
shaft speed. shaft speed. intermediate shaft speed.
Symptoms When abnormality is detected, When abnormality is detected, When abnormality is detected,
in control the following symptoms occur. the following symptoms occur. the following symptoms occur.
system when
trouble occurs
Symptoms The speed change feeling The speed change feeling Nothing special.
in machine becomes bad extremely during becomes extremely bad during
operation automatic speed shift. automatic speed shift.
when trouble Engine speed may not increase Engine speed may not increase
occurs up to fast idle speed. up to fast idle speed.
Evaluation by TCU: 5140 TCU: 5150 TCU: 5160, 5560, 5565, 5670,
Fault Code 5675, 5680, 5685
Evaluation by TCU: Actual Engine Speed TCU: Torque Converter Output TCU: Transmission Output Speed
Monitoring Speed
Evaluation - - -
by using Test
Harness
Note Possible to judge if speed sensor Possible to judge if speed sensor Possible to judge if speed sensor
is faulty by switching pressure is faulty by switching pressure is faulty by switching pressure
sensor with other speed sensor. sensor with other speed sensor. sensor with other speed sensor.
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-15
Parts Vehicle Speed Sensor
Item
Function Detects transmission output
shaft speed.
Symptoms When abnormality is detected,
in control the following symptoms occur.
system when
trouble occurs
Symptoms The speed meter continues to
in machine display 0 km/h.
operation The overrun alarm control is not
when trouble effective.
occurs The ride control is not effective.
Evaluation by TCU: 5170
Fault Code
Evaluation by MC: Vehicle Speed Pulse
Monitoring
Evaluation -
by using Test
Harness
Note Possible to judge if speed sensor
is faulty by switching pressure
sensor with other speed sensor.
Descriptions T2-2
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-16
Parts Ride Control Solenoid Valve

(Option)
Item
Function Shifts spool in ride control valve.
in control
system when
trouble occurs
Symptoms High current: The ride control is
in machine always activated.
operation Low current: The ride control is
when trouble not effective.
occurs
Evaluation by 111422
Fault Code
Evaluation by MC: Ride Control P/S Output, Ride
Monitoring Control P/S Output FB
Evaluation Install light harness (ST 7226).
by using Test Check output signals from MC
Harness and wire harness condition.
Note -
Descriptions T2-2, 2-4
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-17
Parts Parking Brake Solenoid Valve Torque Control Solenoid Valve
Item
Function Applies and releases parking Supplies control pressure to main
brake by using pilot pressure oil. pump.
Symptoms Same as shown below. Same as shown below.
in control
system when
trouble occurs
Symptoms When closed: The parking brake High current: Pump torque of
in machine is not released. (Pilot pressure oil main pump is kept maximum.
operation is not supplied to parking brake.) The engine stalls or engine
when trouble When open: Parking brake is lug-down is remarkable at high
occurs not activated while running the loaded.
engine. (Pressure oil continues to Low current: Pump torque of
be supplied to the parking brake.) main pump is kept minimum and
machine movement becomes
slow.
Evaluation by - 111413
Fault Code
Evaluation by - MC: Pump Swash Angle P/S
Monitoring Output, Pump Swash Angle P/S
Output FB
Evaluation - -
by using Test
Harness
Note - -
Descriptions T2-2, 2-4 T2-2
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-18
Parts Fan Speed Control Solenoid Valve Fan Reverse Rotation Control
Solenoid Valve (Option)
Item
Function Control fan speed. Shifts fan reverse rotation spool
of fan valve.
in control
system when
trouble occurs
Symptoms High current: The fan speed is High current: The fan always
in machine fixed to the minimum. rotates in reverse.
operation Low current: The fan speed is Low current: The fan does not
when trouble fixed to the maximum. rotate in reverse.
occurs
Evaluation by 111412 111411
Fault Code
Evaluation by MC: Hyd Fan Speed Control P/S MC: Hyd Fan Reverses Rotation
Monitoring Output, Hyd Fan Speed Control P/S Output, Hyd Fan Reverses
P/S Output FB Rotation P/S Output FB
Evaluation - -
by using Test
Harness
Note - -
Descriptions T2-2, 2-4 T2-2, 2-4
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-19
Parts Forward/ Reverse Clutch Solenoid Speed Shift Solenoid Valves (Y3,
Valves (Y1, Y2, and Y5) Y4, and Y6)
Item
Function Shifts forward spool, and reverse Shifts spools in speed shift
spool of transmission control solenoid valves (Y3, Y4, and Y6) of
valve. transmission control valve.
in control
system when
trouble occurs
Symptoms Refer to TCU Fault Code List (T5-5) Refer to TCU Fault Code List (T5-5)
in machine
operation
when trouble
occurs
Evaluation by TCU: 5510, 5520, 5530, 5830 TCU: 5480, 5490, 5500, 5830
Fault Code
Evaluation by - -
Monitoring
Evaluation - -
by using Test
Harness
Note -
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-20
Parts Main Relief Valve (Front Overload Relief Valve

Attachment)
Item
Function Prevents pressure in main pump Prevents actuator circuit pressure
circuit from exceeding the set generated by external force from
pressure when a control lever is exceeding the set pressure with a
operated. control lever set in neutral.
in control
system when
trouble occurs
Symptoms If stuck in fully closed position, If stuck in fully closed position,
in machine hose of front attachment may be hose of front attachment may be
operation damaged. damaged by external force.
when trouble If stuck in fully open position, If stuck in fully open position,
occurs power is weak during digging power is weak during digging
operation. operation.
Evaluation by - -
Fault Code
Evaluation by - -
Monitoring
Evaluation - -
by using Test
Harness
Note - -
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-21
Parts Pump Control Valve
Item
Function Supplies pressure oil from the
main pump to the regulator of
pump device and increases/
decreases the pump delivery flow
rate.
in control
system when
trouble occurs
Symptoms Load is applied to the pump
in machine as the pump delivery flow rate
operation does not decrease with the front
when trouble attachment control lever set in
occurs neutral.
As pump torque increases,
acceleration is not smooth when
staring the vehicle. Vehicle speed
does not increase.
Evaluation by -
Fault Code
Evaluation by -
Monitoring
Evaluation -
by using Test
Harness
Note -
Descriptions T2-4
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-22
Parts Main Relief Valve (Steering) Ride Control Spool (Ride Control Fan Reversing Spool (Fan Valve)
Valve) (Option) (Option)
Item
Function Prevents pressure in main pump Is shifted by pilot pressure from Is shifted by pilot pressure
circuit from exceeding the set ride control solenoid valve. from fan reverse rotation
pressure when a steering wheel is Connects the accumulator to control solenoid valve in fan
operated. lift arm cylinder circuit and valve. Changes the fan rotation
increases/decreases the lift arm direction (in normal/reverse).
cylinder bottom pressure.
Symptoms Same as shown below. Same as shown below. Same as shown below.
in control
system when
trouble occurs
Symptoms If stuck in fully closed position, If stuck in neutral position, the If stuck in normal direction
in machine steering hose may be damaged. ride control is not activated. position, the fan always rotates in
operation If stuck in fully open position, If stuck in ride control operating normal direction.
when trouble turning force of steering wheel position, digging operation is not If stuck in reverse direction
occurs increases and steering operation smooth. position, the fan always rotates
becomes difficult. in reverse direction. Overheating
occurs easily.
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in F&S
S/M)
T5-6-23
Correlation between Trouble Symptoms and

Part Failures
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
The trouble symptoms in this table are described
provided that each trouble occurs independently. In
case more than one trouble occurs at the same time, find
out all faulty components while checking all suspected
components in each trouble symptom.
The marks / in this table indicate the influence to

trouble symptom.
: Related, required to check
: Related. However, in case this component fails, other
trouble symptom will be more noticeable so that this
component will not be the direct cause of the trouble
concerned.
T5-6-24
Engine System Troubleshooting
Trouble Symptom E-1 E-2 E-3

Starter does not rotate. Even if starter rotates, Engine starts with forward/
engine does not start. reverse lever set in the
Parts positions except N.
MC
ECM  
TCU 
Information Controller
Monitor
Column Display Controller
MPDr.
Key Switch   
Accelerator Pedal Sensor
Forward/Reverse Lever  (Neutral)  (Neutral)
Forward/Reverse Selector  
Switch (Option)
Forward/Reverse Switch  (Neutral)  (Neutral)
(Option)
Battery 
Battery Relay 
Fuse Box A  (#13, #14)  (#10)  (#14)
Fuse Box B
Neutral Relay  
Load Dump 2 Relay 
Starter Relay 1 
ECM Main Relay  
Fuel Pump Relay 
Starter 
Engine Unit 
Coolant Temperature Sensor
Glow Plug Relay
Glow Plug
Pump Delivery Pressure Sensor
Remark
: Check required : Related
T5-6-25
Trouble Symptom E-4 E-5

Power mode is not shifted Even if key switch is turned
when pushing power mode OFF, engine does not stop.
Parts switch.
MC  
ECM 
TCU
Information Controller 
Monitor 
Column Display Controller
MPDr. 
Key Switch 
Power Mode Switch 
Forward/Reverse Lever
Forward/Reverse Selector
Switch (Option)
Forward/Reverse Switch
(Option)
Battery
Battery Relay 
Fuse Box A
Fuse Box B
Neutral Relay
Load Dump 2 Relay 
Starter Relay 1
ECM Main Relay 
Fuel Pump Relay
Starter
Engine Unit
Glow Plug Relay
Glow Plug
Remark
T5-6-26
All Actuator System Troubleshooting
Trouble Symptom A-1 A-2

Actuator of only front Actuator speed of front
attachment do not work. attachment and steering are
Parts slow.
MC 
Battery
Fuse Box A  (#16)
Pilot Shut-Off Relay 
Control Lever Lock Switch 
Power Mode Switch 
Pilot Pump  
Brake Charge Valve 
Priority Valve (Brake)  
Pilot Relief Valve (Brake)
Manifold Valve 
Pilot Relief Valve  
Torque Control Solenoid Valve 
Pilot Shut-Off Solenoid Valve  
Pilot Valve  
Pressure Sensor (Primary Pilot  
Pressure)
Pressure Sensor (Lift Arm Raise) 
(OP)
Spool (Control Valve)  
Main Relief Valve (Front 
Attachment)
Cylinder
Main Pump 
Pump Delivery Pressure Sensor 
Priority Valve 
Pump Regulator 
Pilot Filter 
Remark
T5-6-27
Trouble Symptom A-3

Actuator of front attachment
does not stop even if a
Parts control lever is set to neutral.
MC
ECM
TCU
Monitor
Key Switch
Forward/Reverse Lever
Switch (Option)
Forward/Reverse Switch
(Option)
Pilot Shut-Off Relay
Control Lever Lock Switch 
Battery
Engine Unit
Crank Revolution Sensor
Cam Angle Sensor
Exhaust Temperature Sensor
Main Pump
Pilot Pump
Pump Regulator
Manifold Valve
Torque Control Solenoid Valve
Pilot Shut-Off Solenoid Valve
Pressure Sensor (Primary Pilot
Pressure)
Pilot Valve 
Control Valve 
Pilot Filter
Pilot Relief Valve
Hydraulic Oil Temperature
Sensor
Torque Converter Oil
Temperature Sensor
Pressure Sensor (Parking Brake)
Remark
T5-6-28
Trouble Symptom A-5 A-6

Fan speed does not change. Fan does not rotate in
reverse when pushing fan
Parts reverse rotation switch (OP).
MC  
ECM 
TCU
Monitor
MPDr. 
Key Switch
Power Mode Switch
Fan Reverse Rotation Switch 
(OP)
Battery
Fuse Box A
Fuse Box B
Fan Valve (OP)  
Fan Speed Control Solenoid 
Valve
Fan Reverse Rotation Control 
Solenoid Valve (OP)
Fan Control Valve (OP)  
Fan Motor  
Fan Pump  
Engine Unit
Crank Revolution Sensor
Cam Angle Sensor
Coolant Temperature Sensor 
Boost Temperature Sensor 
Fan Pump Delivery Pressure  
Sensor
Hydraulic Oil Temperature 
Sensor
Torque Converter Oil 
Temperature Sensor
Pressure Sensor (Parking Brake) 
Remark
T5-6-29
(Blank)
T5-6-30
Front Attachment System Troubleshooting
Trouble Symptom F-1 F-2

All front attachment Some cylinders are not
actuator power are weak. operated or speed are slow.
Parts
MC 
Battery
Fuse Box B
Pilot Shut-Off Relay
Control Lever Lock Switch
Power Mode Switch
Pilot Pump  
Priority Valve (Brake Charge 
Valve)
Pilot Relief Valve (Brake Charge 
Valve)
Pilot Relief Valve (Manifold 
Valve)
Torque Control Solenoid Valve 
(Manifold Valve)
(Manifold Valve)
Pilot Valve 
Pressure Sensor (Primary Pilot 
Pressure)
Bucket Flow Rate Control Valve
(Control Valve)
(OP)
Spool (Control Valve)  
Main Relief Valve (Front   (Overload)
Attachment)
Pump Control Valve (Control 
Valve)
Cylinder 
Main Pump 
Priority Valve (Main) 
Pump Regulator
Pilot Filter 
Remark
T5-6-31

Front attachment drifts Shock is large when
remarkably. stopping lift arm raise/lower
operation or bucket dump/
Parts tilt operation.
MC
Monitor
Lift Arm Angle Sensor (OP)
Pilot Pump
Brake Charge Valve
Manifold Valve
Pilot Valve  
Slow Return Valve  (Lift Arm, Bucket)
(OP)
Spool (Control Valve)  
Load Check Valve (Control 
Valve)
Cylinder 
Main Pump
Remark with the engine stopped
T5-6-32

Bucket auto leveler control is Lift arm float control is not
not activated. (Detent is not activated. (Detent is not
Parts held.) held.)
MC 
Monitor
Battery
Battery Relay
Fuse Box A  (#16)  (#16)
Lift Arm Angle Sensor (OP) 
Bucket Proximity Switch 
Pilot Pump
Brake Charge Valve
Manifold Valve
Pilot Valve  (Bucket)  (Lift Arm)
Spool (Control Valve)  (Bucket)  (Lift Arm)
Cylinder
Main Pump
Remark
T5-6-33
Trouble Symptom F-7 F-8 F-9

Lift arm auto leveler height Lift arm auto leveler lower Ride control is not activated
kickout control (OP) is not kickout control (OP) is not (OP).
Parts activated. activated.
MC   
TCU
MPDr.  (Lift Arm Angle Sensor  (Lift Arm Angle Sensor  (Setting: ON)
Learning) Learning)
Fuse Box A  (#16)  (#16)
Lift Arm Angle Sensor (OP)   
Vehicle Speed Sensor 
Ride Control Switch (OP) 
Pilot Pump
Brake Charge Valve
(Manifold Valve)
Pilot Valve  (Lift Arm)  (Lift Arm)
Lift Arm Raise Side Coil (Pilot 
Valve)
Lift Arm Lower Side Coil (Pilot 
Valve)
Pressure Sensor (Primary Pilot
Pressure)
(OP)
Ride Control Solenoid Valve 
(OP)
Spool (Control Valve)  (Lift Arm)  (Lift Arm)
Spool (Ride Control Valve) (OP) 
Cylinder  (Lift Arm)
Accumulator (Ride Control) (OP) 
Main Pump
Remark
T5-6-34
Steering System Troubleshooting
Trouble Symptom S-1 S-2 S-3

Steering operation is weak. Steering operation is slow. Shock of steering operation
is large.
Parts
MC 
Priority Valve (Brake Charge 
Valve)
Pilot Relief Valve (Brake Charge 
Valve)
Pilot Relief Valve (Manifold 
Valve)
Torque Control Solenoid Valve  
(Manifold Valve)
Pressure Sensor (Primary Pilot  
Pressure)
Steering Pilot Pump (Steering 
Wheel)
Steering Valve (Spool)  
Overload Relief Valve (Steering
Valve)
Steering Pressure Switch 
Steering Cylinder (Left, Right)  
Steering Accumulator 
Main Pump  
Steering Relief Valve (Priority  
Valve)
Priority Valve (Main)   
Pump Regulator 
Pilot Pump  
Pilot Filter 
Remark
T5-6-35
Trouble Symptom S-4

Secondary steering (option)
is not operated. (Check
automatic operation when
Parts the engine starts)
MC 
TCU
Monitor
MPDr.  (Setting: ON)
Battery
Fuse Box A  (#20)
Secondary Steering Relay (OP) 
Vehicle Speed Sensor 
Pilot Pump
Brake Charge Valve
Manifold Valve
Steering Pressure Switch (OP) 
Secondary Steering Pump 
Delivery Pressure Sensor (OP)
Steering Cylinder (Left, Right)
Steering Accumulator
Main Pump
Secondary Steering Motor (OP) 
Secondary Steering Pump (OP) 
Remark
T5-6-36
Travel System Troubleshooting
Trouble Symptom T-1 T-2 T-3

Although forward/reverse Although forward/reverse Declutch is not operated.
lever is operated, machine lever is set to neutral
does not travel forward/ position, machine travels.
Parts reverse.
MC 
TCU   
Monitor 
Battery
Fuse Box A  (#14)  (#14)  (#14)
Brake Pedal (Right) Switch
Brake Valve 
Forward/Reverse Lever  (Forward/Reverse)  (Neutral)  (Forward)
Forward/Reverse Switch  
(Option)
Forward/Reverse Selector  
Switch (Option)
Declutch Position Switch 
Drive Unit   
Transmission Control Valve   
Torque Converter Input Speed 
Sensor
Torque Converter Output Speed 
Sensor
Transmission Intermediate Shaft
Speed Sensor
Vehicle Speed Sensor 
Slow-Speed Forward Clutch   
Solenoid Valve (Y5)
Fast-Speed Forward Clutch   
Solenoid Valve (Y1)
Reverse Clutch Solenoid Valve  
(Y2)
Propeller Shaft 
Axle 
Pressure Sensor (Brake 
Secondary Pressure)
Pressure Sensor (Parking Brake) 
Remark Neutral Control Declutch Control
T5-6-37

Travel mode can not be Although shift switch is Although vehicle speed
shifted. operated, speed shift does changes, speed shift does
Parts not change. not change automatically.
MC  
TCU  
Monitor
Battery
Fuse Box A  (#14)
Travel Mode Selector Switch   (Manual Mode)  (AUTO 1/AUTO 2 Mode)
Shift Switch 
Drive Unit  
Transmission Control Valve  
Torque Converter Input Speed  
Sensor
Torque Converter Output Speed  
Sensor
Speed Sensor
Vehicle Speed Sensor  
Speed Shift Solenoid Valve (Y3,  
Y4, and Y6)
Pressure Sensor (Brake
Secondary Pressure)
Remark Manual Speed Shift Control Automatic Speed Shift Control
T5-6-38

Speed shift is not shifted Speed shift is not held when Speed shift retard control
down when pushing pushing hold switch. (Option) is not activated.
Parts downshift switch (DSS).
MC 
TCU   
Monitor
Key Switch  (ON)
Battery 
Fuse Box A  (#14)  (#14)
Fuse Box B
Travel Mode Selector 
Forward/Reverse Lever 
Forward/Reverse Switch 
(Option)
Forward/Reverse Selector 
Switch (Option)
Shift Switch
Downshift Switch (DSS) 
Hold Switch 
Shift Change Delay Mode 
Switch
Drive Unit   
Transmission Control Valve   
Torque Converter Input Speed  
Sensor
Torque Converter Output Speed  
Sensor
Speed Sensor
Vehicle Speed Sensor   
Speed Shift Solenoid Valve   
Transmission Oil Filter
Transmission Oil Filter
Restriction Switch
Pressure Sensor (Parking Brake)
Lift Arm Angle Sensor (OP) 
(OP)
Remark Effective wher travel mode Effective wher travel mode
selector is AUTO 1 mode or selector is AUTO 1 mode or
AUTO 2 mode. AUTO 2 mode.
T5-6-39
(Blank)
T5-6-40
Brake System Troubleshooting
Trouble Symptom B-1 B-2 B-3

Parking brake is not Parking brake is not applied. Service brake braking force
released. (When the engine becomes weak.
Parts runs)
MC  
Column Display Controller 
Key Switch  (ON)
Battery
Fuse Box A  (#14, #18)  (#14, #18)
Fuse Box B
Parking Brake Switch  (Released)  (Operated)
Parking Brake Relay 1  (OFF)  (ON)
Parking Brake Relay 2  (ON) 
Parking Brake Solenoid Valve  
Parking Brake  
Parking Brake Accumulator
Brake Charge Valve  
Pressure Sensor (Parking Brake)  
Pilot Relief Valve (Brake Charge  
Valve)
Pressure Sensor (Brake Primary 
Pressure)
Service Brake Accumulator 
Brake Valve 
Axle (Service Brake) 
Pressure Sensor (Brake 
Secondary Pressure)
Pilot Pump  
Pilot Filter  
Engine
Remark The parking brake can not be
released as the parking brake
release pressure is not supplied
with the engine stopped.
T5-6-41
(Blank)
T5-6-42
Other System Troubleshooting
Trouble Symptom O-1 O-2 O-3

Clearance light and tail light, Head light is not ON. Head light is not shifted to
are not ON. high beam.
Parts
MC
Column Display Controller  (Indicator)  (Indicator)  (Indicator)
Key Switch  (ON)  (ON)
Battery 
Fuse Box A  (#4, #11)  (#3, #4)  (#19, #4)
Fuse Box B
Light Switch   
Dimmer Switch  
Head Light Relay (Left) 
Head Light Relay (Right) 
High Beam Relay 
Head Light   (High Beam)
Clearance Light 
Tail Light 
License Plate Light (Option) 
Remark
T5-6-43

Hazard light is not operated. Turn signal light is not Horn does not sound.
operated.
Parts
MC
Column Display Controller  (Indicator)  (Indicator)
Key Switch  (ON)
Battery  
Fuse Box A  (#7)  (#2, #7)  (#6)
Fuse Box B
Hazard Light Switch 
Turn Signal Lever 
Horn Switch 
Flasher Relay  
Turn Signal Light Relay (Left)  
Turn Signal Light Relay (Right)  
Horn Relay 
Turn Signal Light (Hazard Light)  
Horn 
Remark
T5-6-44

Reverse light is not ON. Brake light is not ON. Work light does not light.
Reverse buzzer (Option) does
Parts not sound.
MC
TCU 
Column Display Controller  (Indicator)
Key Switch  (ON)  (ON)  (ON)
Battery
Fuse Box A  (#1, #13)  (#2)  (#4, #17)
Fuse Box B  (#4)
Forward/Reverse Lever  (R)
Switch (Option)
Forward/Reverse Switch  (R)
(Option)
Brake Light Switch (Brake Pedal) 
Light Switch 
Work Light Switch 
Reverse Buzzer Relay (OP) 
Brake Light Relay 
Work Light (Front) Relay 
Work Light (Rear) Relay 
Reverse Light 
Reverse Buzzer (OP) 
Brake Light 
Work Light 
Remark
T5-6-45

Wiper is not operated. Washer is not operated. Cab light is not ON.
Parts
MC
Column Display Controller 
Key Switch  (ON)  (ON)
Battery 
Fuse Box A
Fuse Box B  (#3, #5)*1  (#3, #5)*1  (#11)
Front Wiper/ Washer Switch  
Rear Wiper/ Washer Switch  
Cab Light Switch 
Rear Cab Light Switch 
Door Open/Close Switch (Cab) 
Front Wiper Relay 1 
Front Wiper Relay 2  (Fast Speed)
Rear Wiper Relay 
Front Washer Relay 
Rear Washer Relay 
Front Wiper Motor 
Rear Wiper Motor 
Front Washer Motor 
Rear Washer Motor 
Remark

f NOTE: *1) Fuse #3: Front Wiper, Fuse #5: Rear Wiper
T5-6-46
Engine System Troubleshooting

E-1 Starter does not rotate.
Preparation
 Check that the forward/reverse lever is in the neutral  In case the radio with the key switch set in the ACC
position. position and the horn with the key switch set in
 This trouble has nothing to do with the electronic the OFF position are operated normally, the wire
control system such as MC. harness between battery and key switch terminal B
 Check the wiring connections first. is considered normal.
Procedure Inspection Method Condition Evaluation Cause

1 Measure battery voltage and - The measured values Faulty battery
electrolyte density are not within the
normal values
(Normal value:
Voltage: 24 V or more,
Electrolyte density:
1.26 or more)
2 Switch the neutral relay with Set the key switch Starter: Rotating Faulty neutral relay
other general relay to START after
switching relays
3 Measure voltage between Key switch: START 0V Open circuit in wire harness
neutral relay harness end #1 between key switch and neutral
and #3 relay
4 Measure voltage at starter Key switch: START 0V Open circuit in wire harness
relay 1 harness end terminal S between starter cut relay and
starter relay 1
5 Measure voltage at battery Key switch: ON 0V Faulty battery relay
relay terminal A
6 Measure voltage at starter Key switch: START 0V Faulty starter relay 1
terminal #50
7 Check continuity between Key switch: START ∞Ω Faulty key switch
key switch #1 and #6
8 Monitor Forward/Reverse Forward/reverse OFF is displayed Faulty forward/reverse lever
Lever (N) lever: N
9 - - The check mentioned Faulty starter
above is normal
T5-6-47
E-2 Even if starter rotates, engine does not start.
Preparation
 Check that #10 fuse in fuse box A is not abnormal.  Check that the fuel filter is not clogged.
 Check the wiring connections first.  Check that the fuel pump is operated normally when
turning the key switch ON.

1 Measure voltage between Key switch: ON 0V Open circuit in wire harness
ECM main relay harness end between ECM main relay and
#B and the body. fuse #10 in fuse box A.
ECM main relay harness end between ECM main relay and
#C2 and the body. fuse #13 in fuse box A.
3 Switch fuel pump relay with Key switch: ON The engine starts Faulty fuel pump relay
other general relay
4 - - The check mentioned Faulty ECM or engine unit
above is normal

 ECM main Relay
TNDJ-05-06-001
T5-6-48
E-3 Engine starts with forward/reverse lever set in

the positions except N.
Preparation
 Even if the key switch is set to the START position
with the forward/reverse lever set in the positions
except N (neutral), the starter does not rotate.
 Check #14 fuse in fuse box A.
 Refer to SYSTEM/Electrical System/Neutral Engine
Start Circuit.
 Refer to SYSTEM/Hydraulic System.

1 Measure voltage at neutral Forward/reverse 0V Open circuit in wire harness
relay harness end #1 lever: F or R between forward/reverse lever
and neutral relay
2 Switch the neutral relay with Set the key switch Starter: Rotating Faulty neutral relay
other general relay to START after
switching relays
3 - - The check mentioned Find out cause of trouble by
above is normal tracing other trouble symptoms

 Neutral Relay
T183-05-04-003
T5-6-49
E-4 Power mode is not shifted when pushing

power mode switch.
Preparation

1 Monitor Power Mode Switch Power mode OFF is displayed Faulty power mode switch or
switch: ON open circuit in wire harness
between power mode switch
and MC
2 - - The check mentioned Faulty MC
above is normal
T5-6-50
E-5 Even if key switch is turned OFF, engine does

not stop.
Preparation 1
 Remove fusible link A (65A) (1) and stop the engine
as emergency procedures first.
 In case other trouble symptoms occur, perform
troubleshooting of these troubles first.
 If the fault code is not displayed, the key switch may
be faulty.
 Refer to SYSTEM/Electrical System.
MNEC-01-503
T5-6-51
(Blank)
T5-6-52
All Actuator System Troubleshooting

A-1 Actuator of only front attachment do not
work.
Preparation
 If the pilot system is faulty, the cause of trouble may  Refer to SYSTEM/Electrical System.
exist in the pilot shut-off circuit.  Check the wiring connections first.
 Check that #16 fuse in fuse box A is not abnormal.
 Pilot valves, travel motors, and/or control valve
spools are unlikely to be faulty at the same time.

1 Switch pilot shut-off relay Pilot shut-off lever: The symptom Faulty pilot shut-off relay
with other general relay UNLOCK position disappears
2 Monitor Pilot Primary Control lever lock Pressure is not Faulty control lever lock switch
Pressure switch: UNLOCK detected
position
3 Measure resistance between - 0/∞ Ω Faulty pilot shut-off solenoid
pilot shut-off solenoid valve valve
#1 and #2
4 Check continuity between Connect pilot ∞Ω Open circuit in wire harness
pilot shut-off relay harness shut-off solenoid between pilot shut-off solenoid
end #4 and body valve harness end valve and pilot shut-off relay
terminal #2 to
body
5 - - The check mentioned Faulty pilot valve
above is normal

 Pilot Shut-Off Relay
T183-05-04-003
T5-6-53
A-2 Actuator speed of front attachment and

steering are slow.
Specification Remark
(MPa)
Primary Pilot 4.5±0.8 Accelerator pedal:
Pressure Full stroke
Preparation
 The pump flow rate is minimized due to some  If actuator speed of only front attachment is slow, the
reasons. pilot system may be faulty (A-1) or the circuit after
 Check fuse of the torque control solenoid valve. the pilot valve may be faulty (F-2).
 Even if speed is satisfactory, in case power is weak,  If actuator speed of only steering is slow, the circuit
refer to the troubleshooting for faulty main relief after the steering valve may be faulty (S-3).
valve (F-1/S-1).  Refer to SYSTEM/Hydraulic System.

1 Monitor Lift Arm Raise Pilot Lift arm relief The measured Faulty pilot relief valve in
Pressure operation values are not within manifold valve
the normal values
(Normal value: 3.4 to
4.2 MPa)
2 Monitor Pilot Primary - The measured Clogged pilot filter
Pressure values are not within
the normal values
5.3 MPa)
3 Disassemble and inspect the - There is abnormality Faulty priority valve (brake)
priority valve (brake) (stuck spool)
4 Measure pressure at port LS Accelerator pedal: The measured Faulty priority valve (main)
of priority valve (main) Fully depressed values are not within (stuck spool)
without load the normal values
(Control lever: (Normal value: 1.2 to
Neutral) 2.6 MPa)
5 - - The check mentioned Faulty pump device
above is normal
T5-6-54
A-3 Actuator of front attachment does not stop

even if a control lever is set to neutral.
Preparation
 Stuck spool in the pilot valve or stuck main spool in
the control valve is suspected.

1 Set the control lever lock - Actuator stops Faulty pilot valve (stuck spool)
switch to LOCK position
2 - - The check mentioned Faulty control valve (stuck spool)
above is normal
T5-6-55
A-5 Fan speed does not change.
Preparation
 The sensors detect the conditions necessary to  Refer to SYSTEM/Control System/Fan Reverse
operate fan speed control. Therefore, if these sensors Rotation Control.
fails, fan speed control becomes ineffective.
 Accelerator pedal sensor, coolant temperature
sensor, boost temperature sensor, hydraulic
oil temperature sensor, torque converter oil
temperature sensor, and pressure sensor (refrigerant
pressure) are also engaged in the fan speed control.
However, if these sensors fail, other operating
functions will be also affected.

1 Monitor Target Hydraulic Fan Engine: Running Fan speed does not Faulty ECM, TCU, or MC
Speed change according
to accelerator pedal
depressing amount
2 Monitor Hydraulic Fan Circuit Engine: Running Fan pump delivery Faulty fan pump
Pressure pressure does not
change according
to accelerator pedal
depressing amount
3 Disassemble and inspect the - There is abnormality Faulty fan speed control
fan speed control solenoid solenoid valve
valve
4 Disassemble and inspect the - There is abnormality Faulty fan control valve
fan control valve
5 - - The check mentioned Faulty fan motor
above is normal
T5-6-56
A-6 Fan does not rotate in reverse when pushing

fan reverse rotation switch (Option).
Preparation
 Refer to SYSTEM/Control System/Fan Reverse
Rotation Control.

1 Monitor fan reverse rotation Parking brake is OFF is displayed Faulty fan reverse rotation
switch applied switch
Fan reverse
rotation switch:
ON
2 Measure resistance between - 0/∞ Ω (Normal value: Faulty fan reverse rotation
fan reverse rotation control 22 Ω) control solenoid valve
solenoid valve #1 and #2
3 Measure voltage between Key switch: ON 0V Open circuit in harness between
fan reverse rotation control fan reverse rotation control
solenoid valve harness end #1 solenoid valve and MC
and body
above is normal
T5-6-57
(Blank)
T5-6-58
Front Attachment System Troubleshooting

F-1 All front attachment actuator power are weak.
Main Relief Valve Specification Remark

Set Pressure (MPa)
Lift arm and 27.4+1.9−0
bucket relief
operation
Preparation
 If operating speeds are extremely slow, pump control
may be faulty. Faulty pilot system may also cause this
trouble.

1 Monitor Pump Delivery Lift arm relief The measured values Faulty main relief valve (Front
Pressure operation are not within the Attachment) (readjust)
normal values
T5-6-59
F-2 Some cylinders are not operated or speeds

are slow.
Overload Relief Specification Remark

Valve Set Pressure (MPa)
Lift Arm Raise 34.3+1.0−0
Bucket 30.4+1.0−0
Preparation
 When other actuator (brake) is operated normally,
the pilot pump (primary pilot pressure) is considered
to be normal.

1 Measure Pilot Secondary Refer to T4-5 The measured values Faulty pilot valve
Pressure are not within the
normal values
4.2 MPa)
2 Switch overload relief valves, - Symptom is reversed Faulty overload relief valve
of which the set pressure are
same
3 - - The check mentioned Stuck control valve spool, or
above is normal faulty cylinder (faulty seal kit)
T5-6-60
F-3 Front attachment drifts remarkably.

1 Set the control lever lock - The symptom Faulty pilot valve
switch to LOCK position disappears
2 Switch the overload relief - The symptom Faulty overload relief valve
valves (lift arm raise, bucket) disappears
3 Disassemble and inspect the - There is abnormality Faulty cylinder (seal kit)
cylinder
4 - - The check mentioned Scored control valve spool,
above is normal broken spring, or loose spool
end
T5-6-61
F-4 Shock is large when stopping lift arm

raise/lower operation or bucket dump/tilt
operation.
Preparation
 Check that control levers are not abnormal first.

1 Disassemble and inspect the - There is abnormality Faulty slow return valve
slow return valve
2 - - The check mentioned Stuck control valve spool, or
above is normal faulty cylinder (faulty seal kit)
T5-6-62
F-5 Bucket auto leveler control is not activated.

(Detent is not held.)
Preparation
 Refer to SYSTEM/Control System/Bucket Auto Leveler
Control.

pilot valve bucket tilt side coil between #16 fuse in fuse box A
harness end #081A and body and pilot valve bucket tilt side
coil
2 Check continuity between Bucket tilt detent Bucket proximity Faulty pilot valve bucket tilt side
pilot valve bucket tilt side coil control lever switch: ON: ∞ Ω coil
harness end #431 and body operation Bucket proximity
switch: OFF: 0 Ω
bucket leveler relay harness between bucket proximity
end #2 and body switch and bucket leveler relay
4 - - The check mentioned Faulty bucket proximity switch
above is normal

 Bucket Leveler Relay  Pilot Valve (Fingertip Control Lever Type)
#081A #431
T183-05-04-003 TNDJ-05-06-003
 Pilot Valve (Multi-Function Joystic Lever Type)
#431
#081A
T8UC-05-04-004
T5-6-63
F-6 Lift arm float control is not activated. (Detent

is not held.)
Preparation
 Refer to SYSTEM/Control System/Lift Arm Float
Control.

pilot valve lift arm lower side between #16 fuse in fuse box
coil harness end #081D and A and pilot valve lift arm lower
body side coil
2 Check continuity between Lift arm lower 0Ω Faulty ground in pilot valve lift
pilot valve lift arm lower side control lever arm lower side coil
coil harness end #G36B and operation
body
3 - - The check mentioned Faulty pilot valve lift arm lower
above is normal side coil

 Pilot Valve (Fingertip Control Lever Type)  Pilot Valve (Multi-Function Joystic Lever Type)
#081D #G36B
#G36B
#081D
TNDJ-05-06-003 T8UC-05-04-004
T5-6-64
F-7 Lift arm auto leveler height kickout control

(Option) is not activated.
Preparation
 Refer to SYSTEM/Control System/Lift Arm Auto  Check #16 fuse in fuse box A.
Leveler Height Kickout Control.  Check the wiring connections first.

pilot valve lift arm raise side between #16 fuse in fuse box A
coil harness end #081C and and pilot valve lift arm raise side
body coil
2 Check continuity between Lift arm raise, 0Ω Faulty ground in pilot valve lift
pilot valve lift arm raise side detent control arm raise side coil
coil harness end #535 and lever operation
body
3 Monitor Lift Arm Auto Leveler Lift arm auto OFF is displayed Faulty lift arm auto leveler
Switch (raise) leveler switch switch (raise)
(raise): ON
4 - - The check mentioned Faulty pilot valve lift arm raise

Dual Auto Leveler (Option) Dual Auto Leveler (Option)
#535
#081C #535
TNDJ-05-06-003 #081C T8UC-05-04-004
T5-6-65
F-8 Lift arm auto leveler lower kickout control

(Option) is not activated.
Preparation
 Refer to SYSTEM/Control System/Lift Arm Auto  Check the wiring connections first.
Leveler Lower Kickout Control.  Check #16 fuse in fuse box A.

pilot valve lift arm lower side between #16 fuse in fuse box
coil harness end #081D and A and pilot valve lift arm lower
body side coil
2 Check continuity between Lift arm lower, 0Ω Faulty ground in pilot valve lift
pilot valve lift arm lower side detent control arm lower side coil
coil harness end #536 and lever operation
body
3 Monitor Lift Arm Auto Leveler Lift arm auto OFF is displayed Faulty lift arm auto leveler
Switch (lower) leveler switch switch (lower)
(lower): ON
4 - - The check mentioned Faulty pilot valve lift arm lower

Dual Auto Leveler (Option) Dual Auto Leveler (Option)
#536
#081D #536 #081D
TNDJ-05-06-003 T8UC-05-04-004
T5-6-66
F-9 Ride control (Option) is not activated.
Preparation
 Check the ride control setting with the MPDr.  When other actuator (front attachment) is operated
first. The activating conditions for ride control are normally, the pilot pump (primary pilot pressure) is
different according to the settings. considered to be normal.
 Refer to SYSTEM/Control System/Ride Control.  Check the wiring connections first.

1 Monitor Ride Control Switch Ride control OFF is displayed Faulty ride control switch or
switch: ON open circuit in wire harness
between ride control switch and
MC
2 Measure resistance between - 0/∞ Ω (Normal value: Faulty ride control solenoid
ride control solenoid valve #1 22±0.4 Ω) valve
and #2
3 - - The check mentioned Stuck ride control valve spool or
above is normal faulty accumulator

TNED-05-05-020
T5-6-67
(Blank)
T5-6-68
Steering System Troubleshooting

S-1 Steering operation is weak.
Main Relief Valve Specification Remark

Set Pressure (MPa)
Steering relief 27.4+1.9−0
operation
Preparation
 If operating speeds are extremely slow, pump control
may be faulty. Faulty pilot system may also cause this
trouble.

1 Monitor Pump Delivery Steering relief The measured values Faulty steering relief valve
Pressure operation are not within the (readjust)
normal values

T5-6-69
S-2 Steering operation is slow.
Specification Remark
(seconds)
Steering cylinder 2.5±0.4 Accelerator pedal:
operation time Fully depressed
Power mode
switch: OFF
The bucket
should be empty
Preparation
 If speed of front attachment is also slow, the main
system may be faulty (A-2).
 Check that the steering wheel is not abnormal first.

1 Measure Steering Relief - The measured Faulty main relief valve
Pressure values are not within (steering)
the normal values
(Normal value: 27.4
to 29.3 MPa)
2 Disassemble and inspect the - There is abnormality Faulty priority valve
priority valve
3 - - The check mentioned Stuck steering valve spool or
above is normal faulty steering cylinder (faulty
seal kit)
T5-6-70
S-3 Shock of steering operation is large.
Preparation
 Check that the steering wheel is not abnormal first.  Set machine to carry position before checking gas
 The steering valve may be faulty. pressure in the accumulator.

1 Check gas pressure in the - There is abnormality Gas leakage of accumulator
accumulator
2 Disassemble and inspect the - There is abnormalityFaulty steering valve (stuck
steering valve spool, clogged orifice)
3 - - The check mentioned Faulty steering cylinder (faulty
above is normal seal kit)
T5-6-71
S-4 Secondary steering (option) is not operated.

(Check automatic operation when the engine
starts)
Preparation
 Check the secondary steering control setting with  The secondary steering check switch may be faulty
the MPDr. first. when secondary steering operation cannot be
 Refer to SYSTEM/Control System/Secondary Steering checked manually.
Control (Option).
 Check that #20 fuse in fuse box A is not abnormal.

1 Monitor Secondary Steering Engine starts The measured Faulty secondary steering pump
Pump Delivery Pressure values are not within unit
the normal values
(Normal value: 4.8
MPa)
2 Switch secondary steering Set the key switch The symptom Faulty secondary steering relay
relay with other general relay to START after disappears
switching relays
above is normal
T5-6-72
Travel System Troubleshooting

T-1 Although forward/reverse lever is operated,
machine does not travel forward/reverse.
Preparation
 The transmission may be faulty when the
transmission warning indicator lights.
 Refer to SYSTEM/Control System/Forward/Reverse
Lever Priority Control (Option).

1 Monitor Forward/Reverse Forward/reverse OFF is displayed Faulty forward/reverse lever,
Lever (F) and (R) lever: F, R or open circuit in wire harness
between forward/reverse lever
and TCU
2 Measure transmission clutch Forward/reverse The measured Faulty transmission control valve
pressure lever: F, R values are not within
the normal values
(Normal value: Clutch
ON: 1.6 to 1.8 MPa)
3 - - The check mentioned Faulty TCU
above is normal
T5-6-73
T-2 Although forward/reverse lever is set to

neutral position, machine travels.
Preparation
 Refer to SYSTEM/Control System/Neutral Control.

1 Monitor Forward/Reverse Forward/reverse OFF is displayed Faulty forward/reverse lever,
Lever (N) lever: N or open circuit in wire harness
and TCU
2 Measure transmission clutch Forward/reverse The measured Faulty transmission control
pressure lever: N values are not within valve
the normal values
(Normal value: 0 MPa)
above is normal
T5-6-74
T-3 Declutch is not operated.
 Declutch pressure
Declutch Position Brake pedal Brake pedal
Switch depressing depressing
amount: Small (N) amount: Large
(D)
Speed Shift: First 1.68 MPa or more 2.87 MPa or more
Speed Shift: 1.44 MPa or more 3.35 MPa or more
Second
Preparation
 Refer to SYSTEM/Control System/Declutch Control.
 When other actuator (front attachment) is operated
normally, the pilot pump (primary pilot pressure) is
considered to be normal.

1 Monitor Declutch Position Declutch position OFF is displayed (0 Faulty declutch position switch
Switch switch: N, D is displayed on the or open circuit in wire harness
monitor) between declutch position
switch and MC
2 Monitor Service Brake Brake pedal (right) The measured Faulty brake system (brake
Secondary Pressure (For operation values are not within valve) or faulty pressure sensor
Declutch) the normal values (brake secondary pressure)
(Normal value:
Above)
3 Measure transmission clutch - The measured Faulty transmission control
pressure values are not within valve
the normal values
(Normal value:
Declutch: 0 to 0.3
MPa)
above is normal
T5-6-75
T-4 Travel mode can not be shifted.
Preparation

1 Monitor Travel Mode Selector Travel mode Manual mode is Faulty travel mode selector
Switch selector switch: always displayed (0 switch, or open circuit in wire
AUTO 1/AUTO 2 is displayed on the harness between travel mode
mode monitor) selector switch and MC
above is normal
T5-6-76
T-5 Although shift switch is operated, speed shift

does not change.
Preparation
 Check that the travel mode is Manual mode.
 Refer to SYSTEM/Control System/Manual Speed Shift
Control.

1 Monitor Shift Switch and Shift switch: The position of shift Faulty shift switch or open
Operate Shift Switch 2/3/4/5 position switch is not identical circuit in wire harness between
to the display of shift switch and TCU
monitoring
2 Measure transmission clutch - The measured Faulty transmission control
pressure values are not within valve
the normal values
(Normal value: Clutch
ON: 1.6 to 1.8 MPa)
above is normal
T5-6-77
T-6 Although vehicle speed changes, speed shift

does not change automatically.
Preparation
 Check that the travel mode is AUTO 1/AUTO 2 mode.
 Refer to SYSTEM/Control System/Automatic Speed
Shift Control.

1 Monitor Travel Mode Selector Travel mode Manual mode is Faulty travel mode selector
Switch selector switch: always displayed (0 switch, or open circuit in wire
AUTO 1/ AUTO 2 is displayed on the harness between travel mode
mode monitor) selector switch and MC
above is normal
T5-6-78
T-7 Speed shift is not shifted down when pushing

downshift switch (DSS).
Preparation
 Refer to SYSTEM/Control System/Downshift Control.

1 Monitor DSS Switch Downshift switch OFF is displayed Faulty downshift switch (DSS),
(DSS): ON or open circuit in wire harness
Travel operation between downshift switch (DSS)
and TCU
above is normal
T5-6-79
T-8 Speed shift is not held when pushing hold

switch.
Preparation
 Refer to SYSTEM/Control System/Shift Holding
Control.

1 Monitor Hold Switch Hold switch: ON OFF is displayed Faulty hold switch or open
circuit in wire harness between
hold switch and TCU
above is normal
T5-6-80
T-9 Speed shift retard control (Option) is not

activated.
Preparation
 Refer to SYSTEM/Control System/Speed Shift Retard
Control.

1 Monitor Forward/Reverse Forward/reverse N is displayed Faulty forward/reverse lever,
Lever (F), (R) lever: F and R or open circuit in wire harness
and TCU
2 Monitor Travel Mode Selector Travel mode: Manual mode is Faulty travel mode selector
Switch AUTO 1/AUTO 2 displayed (0 is switch, or open circuit in wire
mode displayed on the harness between driving mode
monitor) switch and MC
3 Monitor Actual Vehicle Speed Travel operation 0 km/h is displayed Faulty vehicle speed sensor,
or open circuit in wire harness
between vehicle speed sensor
and monitor controller
4 Monitor Shift Switch Shift switch: 3rd, 1st or 2nd is Faulty shift switch, or open
4th, or 5th displayed circuit in wire harness between
shift switch and TCU
5 Monitor Shift Change Delay SHift change delay OFF is kept Faulty shift change delay mode
Mode Switch mode switch: ON switch, or open circuit in wire
harness between speed shift
retard mode switch and MC
T5-6-81
(Blank)
T5-6-82
Brake System Troubleshooting

B-1 Parking brake is not released. (When the
engine runs)
Preparation

1 Monitor Parking brake switch Parking brake OFF is displayed Faulty parking brake switch
switch: ON
(Release)
Engine: Running
2 Monitor Parking brake signal Parking brake OFF is displayed Faulty column display controller
switch: ON
(Release)
Engine: Running
3 Monitor Parking Brake Parking brake The measured Stuck spool in parking brake
Pressure switch: ON values are not within solenoid valve
(Release) the normal values
Engine: Running (Normal value: 10.8
to 17 MPa)
4 Monitor Service Brake Parking brake The measured values Faulty parking brake
Primary Pressure switch: OFF are not within the accumulator
(Apply) normal values
Engine: Running (Normal value: 15 to
17 MPa)
5 Switch parking brake relay 1 Parking brake The symptom Faulty parking brake relay 1
with other general relay switch: ON disappears
(Release)
Engine: Running
6 Switch parking brake relay 2 Parking brake The symptom Faulty parking brake relay 2
with other general relay switch: ON disappears
(Release)
Engine: Running
above is normal
T5-6-83
B-2 Parking brake is not applied.
Wear amount of Specification Allowable Limit

parking brake (mm) (mm)
(mm)
Brake Disc 2.2 1.9
Brake Friction Pad 6.0 4.5
Preparation

1 Monitor Parking Brake Signal Parking brake ON is displayed Faulty parking brake switch
Output switch: OFF
(Apply)
Engine: Running
2 Monitor Parking Brake Key switch: ON Pressure is detectedStuck spool in parking brake
Pressure solenoid valve
3 Check the wear amount of - ≤ Allowable limit Faulty brake disc and faulty
parking brake brake friction pad
above is normal
T5-6-84
B-3 Service brake braking force becomes weak.
Wear amount Specification Allowable Limit

of service brake (mm) (mm)
(mm)
Brake Disc - 4.0
Preparation

1 Monitor Service Brake - The measured Faulty brake charge valve
Primary Pressure values are not within
the normal values
(Normal value: 10.8
to 17.0 MPa)
2 Monitor Service Brake Brake pedal: Full The measured Faulty brake valve
Secondary Pressure stroke values are not within
the normal values
(Normal value:
6.6±0.6 MPa)
3 Check the wear amount of Refer to T4-4 - The wear amount of brake disc
service brake is beyond the allowable limit of
use
T5-6-85
(Blank)
T5-6-86
Other System Troubleshooting

O-1 Clearance light, and tail light are not ON.
Preparation
 Check that the clearance light, tail light, and license
plate light are not broken first.  Failure of the clearance light indicator lighting will be
 Check #4 fuse in fuse box A when the clearance also affected.
lights at both sides, tail light, and license plate light  Refer to SYSTEM/Electrical System.
are not ON at the same time.  Check the wiring connections first.
 Check #11 fuse in fuse box A when only the light at
one side is not ON.

1 Monitor Light Switch Light switch: OFF is displayed Faulty light switch
Clearance light Open circuit in wire harness
position or Head between light switch and #4 and
light position #11 fuses in fuse box A
2 - - The check mentioned Faulty #4, #11 fuses in fuse box A
above is normal
T5-6-87
O-2 Head light is not ON.
Preparation
 Check that the head lights are not broken first.  Check that the light switch is the head light position.
 The light switch may be faulty (O-1) or the dimmer  Refer to SYSTEM/Electrical System.
switch may be faulty when the head lights at both  Check the wiring connections first.
sides are not ON at the same time.
 Check #4 and #3 fuses in fuse box A.

1 Set the dimmer switch to the Key switch: ON The head lights (left/ Faulty dimmer switch, or open
low beam position Light switch: Head right) are not ON circuit in wire harness between
light position dimmer switch and light switch
2 Switch head light relay with Key switch: ON The head lights (left/ Faulty head light relay
other general relay Dimmer switch: right) are ON
Low beam position
head light relay harness end Dimmer switch: between head light relay and
#1 and body Low beam position light switch, or faulty dimmer
switch
head light relay harness end Dimmer switch: between head light relay and #3
#3 and body Low beam position fuse in fuse box A, or faulty #3
fuse
head light (left) harness end Dimmer switch: between head light (left) and
#512A and body Low beam position head light relay (left)
head light (right) harness end Dimmer switch: between head light (right) and
#512B and body Low beam position head light relay (right)

 Head Light Relay  Head Light (Left/Right)
#512A
#512B
T183-05-04-003 TNED-05-06-003
T5-6-88
O-3 Head light is not shifted to high beam.
Preparation
 Check #19 fuse in fuse box A when the high beams at  Failure of the high beam indicator lighting will be
both sides are not ON. also affected.
 Check that the light switch is the head light position.  Refer to SYSTEM/Electrical System.

1 Set the dimmer switch to the Key switch: ON High beam is not ON Faulty dimmer switch, or open
high beam position Light switch: Head circuit in wire harness between
light position dimmer switch and light switch
2 Switch high beam relay with Key switch: ON High beam is ON Faulty high beam relay
other general relay Dimmer switch:
High beam
position
high beam relay harness end Dimmer switch: between high beam relay and
#1 and body High beam dimmer switch
position
high beam relay harness end Dimmer switch: between high beam relay and
#3 and body High beam #19 fuse in fuse box A, or faulty
position #19 fuse
head light (left) harness end Dimmer switch: between head light (left) and
#511A and body High beam high beam relay
position
6 Measure voltage between Key switch: ON 0V Faulty head light (right), or open
head light (right) harness end Dimmer switch: circuit in wire harness between
#511B and body High beam head light (right) and high beam
position relay
7 - - The check mentioned Faulty head light (right/left) or
above is normal faulty ground

 High Beam Relay  Head Light (Left/Right)
#511B
#511A
T183-05-04-003 TNED-05-06-003
T5-6-89
O-4 Hazard light is not operated.
Preparation
 Check that the turn signal lights (hazard lights) are  Failure of blinking of the turn signal light indicators
not broken first. at both sides will be also affected.
 Check #7 fuse in fuse box A when all turn signal  Refer to SYSTEM/Electrical System.
lights do not blink at the same time. Faulty flasher  Check the wiring connections first.
relay may also cause this trouble.

1 Turn the hazard light switch Key switch: OFF Hazard light is not Faulty hazard light switch, open
ON operated circuit in wire harness between
hazard light switch and #7 fuse
in fuse box A
2 Measure voltage at terminal L Hazard light 0V Faulty flasher relay or faulty
in flasher relay switch: ON ground
3 Switch turn signal light relay Hazard light Symptom is reversed Faulty turn signal light relays
(left) with turn signal light switch: ON (left/right)
relay (right)
4 Measure voltage between Hazard light 0V Open circuit in wire harness
turn signal light relay (left/ switch: ON between turn signal light relay
right) harness end #1 and (left/right) and hazard light
body switch, or faulty diode P(k)
turn signal light relay (left/ switch: ON between turn signal light relay
right) harness end #3 and (left/right) and flasher relay
body
hazard lights (right front/ switch: ON between hazard lights (right
right rear) harness end front/ right rear) and turn signal
#501A/#501B and body light relay (right)
hazard lights (left front/ switch: ON between hazard lights (left
left rear) harness end front/ left rear) and turn signal
#502A/#502B and body light relay (left)
8 - - The check mentioned Faulty #7 fuse in fuse box A
above is normal
Connector (Wire Harness end)

 Turn Signal Light Relay (Left/  Hazard Light (Front)  Hazard Light (Rear)  Flasher Relay
Right)
#501B
#501A #502B
#502A
T183-05-04-003 TNED-05-06-003 TNED-05-06-003 TNED-05-06-001
T5-6-90
O-5 Turn signal light is not operated.
Preparation
 Check #2 fuse in fuse box A when all turn signal
lights do not blink.

1 Operate the turn signal lever Key switch: ON All turn signal lights Faulty turn signal lever, or open
to the right and left do not blink circuit in wire harness between
turn signal lever and #2 fuse in
fuse box A
turn signal light relay (left) Turn signal lever: between turn signal light relay
harness end #1 and body Left position (left) and turn signal lever, or
faulty diode k
turn signal light relay (right) Turn signal lever: between turn signal light relay
harness end #1 and body Right position (right) and turn signal lever, or
faulty diode P

 Turn Signal Light Relay (Left/Right)
T183-05-04-003
T5-6-91
O-6 Horn does not sound.
Preparation
 Check that the horn is not broken first.
 Check #6 fuse in fuse box A when the horn does not
sound by pushing two horn switches.

1 Switch horn relay with other Horn switch: ON Horn sounds Faulty horn relay
general relay
2 Measure voltage between Horn switch: ON 0V Open circuit in wire harness
horn relay harness end #1 between horn relay and #6 fuse
and body in fuse box A, or faulty #6 fuse
3 - - The check mentioned Faulty horn switch or open
above is normal circuit in wire harness between
horn switch and horn relay

 Horn Relay
T183-05-04-003
T5-6-92
O-7 Reverse light is not ON. Reverse buzzer

(Option) does not sound.
Preparation
 Check that the reverse light and reverse buzzer are  Check that the forward/reverse lever is in the R
not broken first. position.
 Check #1 fuse in fuse box A when the reverse lights  Refer to SYSTEM/Electrical System.
at both sides and reverse buzzer are not operated  Check the wiring connections first.
at the same time. Faulty forward/reverse lever (T-1)
may also cause this trouble.

1 Switch reverse buzzer relay Key switch: ON Reverse light is ON Faulty reverse buzzer relay
with other general relay and reverse buzzer
sounds
reverse lights (left/right) between reverse lights (left/
harness end #505D/#505C right) and reverse buzzer relay
and body
reverse buzzer harness end between reverse buzzer and
#2 and body reverse buzzer relay
reverse buzzer relay harness between reverse buzzer relay
end #1 and body and #13 fuse in fuse box A, or
faulty #13 fuse
reverse buzzer relay harness between reverse buzzer relay
end #3 and body and #1 fuse in fuse box A, or
faulty #1 fuse
6 - - The check mentioned Faulty reverse lights (left/right)
above is normal or faulty ground

 Reverse Buzzer Relay  Reverse Light (Left/Right)
#505D
#505C
T183-05-04-003 TNED-05-06-003
T5-6-93
O-8 Brake light is not ON.
Preparation
 Check that the brake lights are not broken first.
 Check #2 fuse in fuse box A when the brake lights at
both sides are not ON.

1 Switch brake light relay with Brake light switch: The symptom Faulty brake light relay
other general relay ON (Brake pedal is disappears
operated)
2 Measure voltage between Brake light switch: 0V Open circuit in wire harness
brake light relay harness end ON (Brake pedal is between brake light relay and
#1 and body operated) #2 fuse in fuse box A, or faulty
#2 fuse
3 - - The check mentioned Faulty brake light switch, or
above is normal open circuit in wire harness
between brake light switch and
brake light relay

 Brake Light Relay
T183-05-04-003
T5-6-94
O-9 Work light does not light.
Preparation
 Check that the work lights are not broken first.  Failure of blinking of the work light indicator will be
 The light switch may be faulty (O-1) when the work also affected.
lights at both front and rear sides are not ON at the  Refer to SYSTEM/Electrical System.
same time.  Check the wiring connections first.
 Check #4 fuse in fuse box B and #17 fuse in fuse box
A when only the light at one side is not ON.

1 Set work light switch to ON 1/ Key switch: ON Work light is not ON Faulty work light switch or open
ON 2 Light switch: circuit in wire harness between
work light switch and light
switch
2 Switch work light relays Key switch: ON Work light is ON Faulty work light relay (front/
(front/rear) with other general Work light switch: rear)
ON 2 position
work light relay (front/rear) Work light switch: between work light relay (front/
harness end #1 and body ON 2 position rear) and work light switch
work light relay (front) Work light switch: between work light relay (front)
harness end #3 and body ON 2 position and #4 fuse in fuse box B, or
faulty #4 fuse
work light (front) harness end Work light switch: between work light (front) and
#1 and body ON 2 position work light relay (front)
work light relay (rear) harness Work light switch: between work light relay (rear)
end #3 and body ON 2 position and #17 fuse in fuse box A, or
faulty #17 fuse
work light (rear) harness end Work light switch: between work light (rear) and
#1 and body ON 2 position work light relay (rear)
8 - - The check mentioned Faulty work light relay (front/
above is normal rear) or faulty ground

 Work Light Relays (Front/Rear)  Work Lights Front/Rear
TNED-05-06-006
T183-05-04-003
T5-6-95
O-10 Wiper is not operated.
Preparation
 The wiper is driven by electric power routed via  In case the front washer is also not operated, check
the relay circuit. The relay circuit of front wiper is #3 fuse in fuse box B. In case the rear washer is also
controlled by the column display controller. not operated, check #5 fuse in fuse box B.
 In case the wiper is not operated, first check if the  Refer to SYSTEM/Electrical System.
wiper relay is activated. Next, check if electric power  Check the wiring connections first.
is routed to the wiper motor.
 Front Wiper
1 Monitor Front Wiper Relay 1 Key switch: ON OFF is displayed Faulty column display controller
Output Front wiper/
washer switch:
LOW
2 Monitor Front Wiper Relay 2 Key switch: ON OFF is displayed Faulty column display controller
Output Front wiper/
washer switch:
HIGH
3 Monitor Front Wiper Switch Key switch: ON The position of front Faulty front wiper/washer
Front wiper/ wiper/washer switch switch, or open circuit in wire
washer switch: is not identical to the harness between front wiper/
LOW/HIGH display of monitoring washer switch and column
display controller, or open circuit
in harness between front wiper
relay 1/2 and column display
controller
4 Switch front wiper relay 1/2 Key switch: ON Wiper is operated Faulty front wiper relay 1/2
with other general relay Front wiper/
washer switch:
LOW/HIGH
5 - - The check mentioned Faulty front wiper motor
above is normal

 Front Wiper Relay 1
 Front Wiper Relay 2
T183-05-04-003
T5-6-96
 Rear Wiper
Preparation
 The rear wiper/washer switch may be faulty when
the rear wiper is not operated.

1 Set rear wiper/washer switch Key switch: ON Rear wiper is not Faulty rear wiper/washer switch,
to LOW operated or open circuit in wire harness
between rear wiper/washer
switch and rear wiper relay
2 Switch rear wiper relay with Key switch: ON Rear wiper is Faulty rear wiper relay
other general relay Rear wiper/washer operated
switch: LOW
3 Check continuity between Key switch: ON 0Ω Open circuit in wire harness
rear wiper relay harness end Rear wiper/washer between rear wiper relay and
#2 and body switch: LOW rear wiper/washer switch
rear wiper relay harness end Rear wiper/washer between rear wiper relay and #5
#1 and body switch: LOW fuse in fuse box B, or faulty #5
fuse
5 - - The check mentioned Faulty rear wiper motor
above is normal

 Rear Wiper Relay
T183-05-04-003
T5-6-97
O-11 Washer is not operated.
Preparation
 Front Washer
1 Switch the front washer relay Front wiper/ Front washer is Faulty front washer relay
with other general relay washer switch: ON operated
position
2 Check continuity between Front wiper/ 0Ω Open circuit in wire harness
front washer relay harness washer switch: ON between front washer relay and
end #2 and body position front wiper/washer switch
front washer relay harness between front washer relay and
end #1 and body #3 fuse in fuse box B, or faulty
#3 fuse
4 Monitor Front Washer Switch Front wiper/ OFF is displayed Faulty front wiper/washer
washer switch: switch, or open circuit in wire
Washer ON harness between front wiper/
washer switch and column
display controller
5 Measure voltage between Front wiper/ 0V Open circuit in wire harness
front washer motor harness washer switch: ON between front washer relay and
end #2 and body position front washer motor
6 - - The check mentioned Faulty front washer motor
above is normal

 Front Washer Relay  Front Washer Motor
T183-05-04-003 TNED-05-06-006
T5-6-98
 Rear Washer
Preparation
 The rear wiper/washer switch may be faulty when
the rear washer is not operated.

1 Switch the rear washer relay Key switch: ON Rear washer is Faulty rear washer relay
with other general relay Rear wiper/washer operated
switch: Washer ON
2 Check continuity between Key switch: ON ∞Ω Open circuit in wire harness
rear washer relay harness end Rear wiper/washer between rear washer relay and
#2 and body switch: Washer ON rear wiper/washer switch
rear washer relay harness end Rear wiper/washer between rear washer relay and
#1 and body switch: Washer ON #5 fuse in fuse box B
rear washer motor harness Rear wiper/washer between rear washer relay and
end #2 and body switch: Washer ON rear wiper motor
5 - - The check mentioned Faulty rear wiper motor or faulty
above is normal #5 fuse in fuse box B

 Rear Washer Relay  Rear Washer Motor
T183-05-04-003 TNED-05-06-006
T5-6-99
O-12 Cab light is not ON.
Preparation
 Check #11 fuse in fuse box B when the cab light and
rear cab light are not ON at the same time.

1 Set cab light switch to ON - Cab light is not ON Faulty cab light, open circuit in
position wire harness between cab light
and #11 fuse in fuse box B
2 Set cab light switch to Door Door open/close Cab light is not ON Faulty door open/close switch
Interlocking Position switch: ON
3 Set rear cab light switch to - Rear cab light is not Faulty rear cab light, open circuit
ON position ON in wire harness between rear
cab light and #11 fuse in fuse
box B
T5-6-100
Exchange Inspection
1 2
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging
the suspected part/component with another part/
component having identical characteristics.
Many sensors and solenoid valves used on this machine

are identical. Therefore, by using this switch-check
method, faulty part/component, and/or harness can be
easily found.
Example: Service Brake Primary Pressure Sensor High

Input (MC Fault Code 111311-3)
Check Method:
1. Switch connectors of pressure sensor (brake primary
pressure) and pressure sensor (parking brake).
4 3 TNDB-05-06-001
2. Retry troubleshooting.
1- Pressure Sensor (Brake 3- Pressure Sensor (Parking

Result: Primary Pressure) Brake)
In case Parking Brake Pressure Sensor High Input (MC 2- Brake Charge Valve 4- Parking Brake Solenoid Valve
fault code 111313-3) is displayed, the pressure sensor
(brake primary pressure) is considered to be faulty.
In case Service Brake Primary Pressure Sensor High Input

(MC fault code 111311-3) is displayed, the pressure sensor
(brake primary pressure) harness is considered to be
faulty.
T5-6-101
Applicability of Switch-Check Method

Fault Code Trouble Remedy
111204-3 Pump Delivery Pressure Sensor High Input Applicable (Harness/Sensor)
111204-4 Pump Delivery Pressure Sensor Low Input
111206-3 Fan Pump Delivery Pressure Sensor High Input
111206-4 Fan Pump Delivery Pressure Sensor Low Input
111311-3 Service Brake Primary Pressure Sensor High Input
111311-4 Service Brake Primary Pressure Sensor Low Input
111313-3 Parking Brake Pressure Sensor High Input
111313-4 Parking Brake Pressure Sensor Low Input
111208-3 Emergency Steering Pump Delivery Pressure Sensor High
Input
111208-4 Emergency Steering Pump Delivery Pressure Sensor Low
Input
111217-3 Primary Pilot Pressure Sensor High Input Applicable (Harness/Sensor)
111217-4 Primary Pilot Pressure Sensor Low Input
111200-3 Lift Arm Raise Pilot Pressure Sensor High Input
111200-4 Lift Arm Raise Pilot Pressure Sensor Low Input
T5-6-102
Air Bleeding Procedures for Brake (Axle)

IMPORTANT: If air is mixed in the brake system, the
brake function is reduced and serious hazard
replacing hydraulic oil.
In addition, bleed air from the brake system until
hydraulic oil (about 0.5 liters) is drawn from each
wheel (4 places) after bubbling stops.
fNOTE: Perform this work on all wheels (4 places) by two 1
TNDJ-05-06-002
or more persons. Air bleed plug (1) is located around the
center on front and rear axles.
1. Set the parking brake switch of front console to the
ON position, start the engine, and increases service
brake oil pressure.
2
2. Attach clear vinyl tube (2) onto one end of air bleed 1
plug (1). Insert other of clear vinyl tube (2) into clear
container (3) filled with hydraulic oil.
3. Depress brake pedal (4) several times. Then, depress
and hold brake pedal (4) to the stroke end.
3
4. Loosen air bleed plug (1) under condition in step 3
and drain hydraulic oil and air for several seconds.
5. Tighten air bleed plug (1).
6. Repeat steps 3 to 5 until air bubbles stop coming T4GB-05-04-005
out with the hydraulic oil.
fNOTE: When bubbling does not stop after hydraulic oil

(about 0.5 liters) is drawn, repeat until bubbling stops in
step 3 to step 5.
7. Bleed air at other 3 places in the same way as step 3
to step 5.
IMPORTANT: After air bleeding work is completed at
4 places, bleed air at 4 places again.
Bleed air in the same way as step 3 to step 5 twice
and check that no air remains inside.
4
T4GB-05-04-006
T5-6-103
(Blank)
T5-6-104
Outline
Operation layout of the air conditioning system is The vents (operator’s front/rear vent, foot vent, and the
illustrated below. front window) can be simultaneously or independently
Either fresh or re-circulated air is induced into the air selected by air vent damper servo motor (1) in accordance
conditioner unit by operating fresh / re-circulated air with the set-ventilation mode.
damper servo motor (6). The air conditioning controller controls the air
The induced air flows out of the vents through evaporator conditioning system. The air conditioning controller
(5) or heater (15) by blower motor (11). Evaporator (5) is controls the damper operation by corresponding to
a device used to cool the air. Heater (15) is a device used the job site conditions such as atmospheric and cab
to warm the air. In the air conditioning system, after the inside air temperatures, coolant temperature, operator’s
refrigerant is compressed by the compressor, it is sent set-temperature, and the selected ventilation mode. In
to evaporator (5) in which the refrigerant expands to addition, the air conditioning controller displays the air
cool the air. Heater (15) warms air by first absorbing heat conditioning system operation status on the monitor.
from warmed engine coolant. Evaporator (5) and heater
(15) allow the introduced air to circulate in the system to
maintain the temperature at the set temperature.
8
7
1 5
10 9
2 3
16
TDAA-05-07-001
15 14 13 12 11
1- Air Vent Damper Servo Motor 6- Fresh/Re-circulated Air 10- Re-circulated Air Induction 14- Air Mix Damper Servo Motor
2- Defroster Vent Damper Servo Motor Port 15- Heater Core
3- Rear Vent 7- Re-circulated Air Sensor 11- Blower Motor 16- Foot Vent
4- Front Vent 8- Fresh Air Induction Port 12- Power Transistor
5- Evaporator 9- Re-circulated Air Filter 13- Frost Sensor
T5-7-1
Component Layout
10 1
11
8 TNDF-05-07-001
12 14
13
b 29 28 27 TNEJ-05-07-001
a- Engine b- To Radiator (Lower)
1- Solar Radiation Sensor 9- Fresh Air Filter 11- Outdoor Ambient 14- Receiver Tank
5- Accelerator Pedal 10- Air Conditioner Controller Temperature Sensor 27- Compressor
6- Key Switch (Switch Panel) 12- High/Low Pressure Switch 28- V Belt (A/C)
8- Air Conditioner Unit 13- Air Conditioner Condenser 29- Pulley (A/C)
T5-7-2
 Air Conditioner Unit
19
18
17
16
15
20
21
22
23
24
25
TNDB-05-07-028
26
15- Re-circulated Air Filter 18- Fresh/Re-circulated Air 21- Heater Core 25- Power Transistor
16- Compressor Relay Damper Servo Motor 22- Air Mix Damper Servo Motor 26- Blower Motor
17- Re-circulated Air Sensor 19- Frost Sensor 23- Air Vent Damper Servo Motor
20- Evaporator 24- Blower Motor Relay
T5-7-3
 Air Conditioner Condenser
2 1
TNCC-05-08-003
1- Condenser 2- Electric Fan (Blower)
T5-7-4
(Blank)
T5-7-5
Functions of Main Parts

The functions of the main parts for the air conditioner
are described below. The connector No. is shown in the
parentheses after the part name.
 Controller
Controls the air conditioning system. According to
the operator’s requests sent via the switches, and the
information regarding the air and refrigerant temperature
sent from the sensors, the controller judges the air
TNDB-05-07-002
conditioner operating status and controls the blower
motor and/or compressor operation as needed by
operating the relays. In addition, the controller informs
the operator of the air conditioner operating status by
displaying the information on the monitor panel.
 Power Transistor (CN7)

An electric switch to control blower motor voltage.
TDAA-05-07-003
 Blower Motor Relay (CN3)

Supplies 24 volts of electricity to the blower motor when
the air conditioner is operated. The blower motor relay is
turned ON when excited by the current from terminal #30
in controller.
TDAA-05-07-004
 Compressor Relay (CN4)

Supplies 24 volts of electricity to the compressor clutch
when the air conditioner is operated. The compressor
relay is turned ON when excited by the current from
terminal #29 in controller.
TDAA-05-07-005
T5-7-6
 Frost Sensor (CN12)

Monitors the fin temperature which is cooled by the
evaporator. When the temperature is higher than 3 °C
(approx. 4.2 kΩ), the controller turns the compressor relay
ON. When the temperature is lower than 2 °C (approx.
TDAA-05-07-006
4.5 kΩ), the controller turns the compressor relay OFF.
Therefore, the evaporator in the air conditioner unit is
prevented from freezing. The electrical resistance in the
frost sensor is 100 Ω to 115 kΩ.
 High/Low Pressure Switch (CN14)

Controls the compressor clutch solenoid while
monitoring the compressor circuit pressure. The high/ #A052
low pressure switch consists of a pressure gauge and a #A211
switch. The pressure gauge detects the lower pressure TDAA-05-07-007
range (0.196 MPa to 0.216 MPa) and the surge pressure
range (2.55 MPa to 3.14 MPa). When the circuit pressure
is reduced to the lower pressure range or increases to
the surge pressure range, the pressure gauge turns the
switch OFF so that the compressor operation stops.
If the pressure is reduced to the lower range, a lack
of refrigerant is suspected. Therefore, damage to the TDAA-05-07-014
compressor due to a lack of refrigerant is prevented. In
case the pressure increases to the surge range, damage
to the air conditioner circuit parts due to excessively high
circuit pressure is prevented.
 Re-circulated Air Sensor (CN11)

Monitors the temperatures (0 to 25 C) around the re-
TDAA-05-07-008
circulated air inlet as the interior air temperatures and
converts them to the electrical resistance values. The
temperatures 0 °C to 25 °C corresponds to a resistance of
1.645 kΩ (0 °C) to 5 kΩ (25 °C) respectively.
The electrical resistance in the air circulation sensor is 300
Ω to 430 kΩ.
 Outdoor Ambient Temperature Sensor (CN15) TDAA-05-07-009

Monitors the temperature around the rear side of the
machine as the fresh air temperature, and converts
the temperature to the electrical resistance value. The
electrical resistance in the fresh air sensor is 100 Ω to 210
kΩ.
T5-7-7
 Solar Radiation Sensor (CN16)

Converts the amount of solar radiation (illumination
intensity) at the cab front to the current values.
TDAA-05-07-010
 Fresh/Re-circulated Air Damper Servo Motor (CN10)

Opens or closes the fresh/re-circulated air selection
louvers. The damper consists of a motor, link mechanism,
and position sensing switch. The motor opens or closes
the fresh/re-circulated air selection louvers via the link
mechanism.
TDAA-05-07-011
T5-7-8
 Air Mix Damper Servo Motor (CN9)

Controls opening/closing of the air mixing door in
response to the set temperature. The damper consists of
a motor, link mechanism, and potentiometer. The motor
opens or closes the air mix door via the link mechanism.
The potentiometer converts the link movements (the
mix door strokes) to the voltage. Both ends of the
potentiometer are energized by 5 V from terminals #7 TDAA-05-07-012
(+) and #25 (-) in controller so that the potentiometer
outputs voltage of 0.5 to 4.5 V from the center terminal
to terminal #19 in controller corresponding to the link
movement. When the set temperature is determined by
temperature UP/DOWN signal from the controller, the
controller calculates voltage (Vr) corresponding the link
position. Further more, the controller checks the air mix
door position by voltage (Vf ) from the potentiometer.
Then, after the controller decides the motor rotational
direction (polarity of motor) based on the differential
voltage between Vr and Vf, the controller sends out the
current from terminals #15 and #16. The controller drives
the motor until voltage (Vf ) becomes equal to voltage
(Vr).
T5-7-9
 Air Vent Damper Servo Motor (CN8)

Opens or closes the front and rear air vent, foot vent,
and defroster vent louvers. The damper consists of a
motor, link mechanism, and potentiometer. The motor
opens or closes vent louvers via the link mechanism. The
potentiometer converts the link movements (vent louvers
strokes) to the voltage. Both ends of the potentiometer
are energized by 5 V from terminals #7 (+) and #25 (-) TDAA-05-07-013
in controller so that the potentiometer outputs voltage
of 0.5 to 4.5 V from the center terminal to terminal #20
in controller corresponding to the link movement.
Depending on the MODE switch set position, vent louvers
are operated as shown below:
When the front and rear air vent louvers positions
are selected, the controller calculates potentiometer
voltage (Vr). Furthermore, the controller checks the vent
louvers positions by receiving voltage (Vf ) from the
potentiometer. Then, after the controller decides the
motor rotational direction (polarity of motor) based on
the differential voltage between Vr and Vf, the controller
sends out the current from terminals #31 and #32. The
controller drives the motor until voltage (Vf ) becomes
equal to voltage (Vr).
MODE switch Front Rear Foot Defroster

position air air air vent
vent vent vent
   
TNED-05-07-005
   
TNED-05-07-006
   
TNED-05-07-007
   
TNED-05-07-008
   
TNED-05-07-009
   
TNED-05-07-010
: Open : Closes
T5-7-10
Troubleshooting
IMPORTANT:
 When replacing the compressor due to the
breakage of compressor from internal lock,
sufficiently clean the air conditioner circuit or
replace all the parts.
 When cleaning is insufficient or all the parts are
not replaced, the air conditioner may be broken
due to contaminants remaining in the circuit.
 Using deteriorated LLC (coolant) or low-
concentration LLC, the heater core will receive
a bad influence and it may lead water leaks
and shorten the service life of machine.
Replace coolant and manage LLC concentration
according to the Operator's Manual. MNEC-01-052
How to Display and Delete Air Conditioner
Controller Fault Code 1 2 3 4 5
The fault code of air conditioner controller is displayed
on LCD panel (4) of air conditioner controller (1).
How to Display
1. Push OFF switch (2) and stop the air conditioner.
2. Push Up and Down buttons of temperature control
switch (3) beyond three seconds at the same time. MNDB-01-011
a
3. The current fault code is displayed at temperature
display (a) on LCD panel (4). Example: E11 1- Air Conditioner Controller 4- LCD Panel
2- OFF Switch 5- Blower Switch
4. When some fault codes exist and whenever pushing 3- Temperature Control Switch
Up or Down button of temperature control switch
(3), other fault codes are displayed.
How to Delete
1. Push Up and Down buttons of blower switch (5)
beyond three seconds at the same time.
2. The fault code displayed at temperature display (a)
on LCD panel (4) is deleted. E-- is displayed.
How to Return to Normal Display

1. When pushing OFF switch (2) or setting the key
switch to the ON position from the OFF position,
the fault code displayed at temperature display
(a) on LCD panel (4) is changed into the normal
temperature display.
T5-7-11
Air Conditioner Controller Fault Code List

E11 Open circuit in re- Voltage: more than Operation is controlled under Check the harness.
circulated air sensor 4.95 V such circumstance as no re- Replace the re-
circulated air sensor is provided. circulated air
sensor.
E12 Shorted circuit in re- Voltage: less than 0.3 V Operation is controlled under Check the harness.
circulated air sensor such circumstance as no re- Replace the re-
circulated air sensor is provided. circulated air
sensor.
E13 Open circuit in Voltage: more than Operation is controlled under Check the harness.
outdoor ambient 4.88 V such circumstance as no outdoor Replace the
temperature sensor ambient temperature sensor is outdoor ambient
provided. temperature
sensor.
E14 Shorted circuit in Voltage: less than Operation is controlled under Check the harness.
outdoor ambient 0.096 V such circumstance as no outdoor Replace the
temperature sensor ambient temperature sensor is outdoor ambient
provided. temperature
sensor.
E18 Shorted circuit in solar Voltage: more than Operation is controlled under Check the harness.
radiation sensor 5.04 V such circumstance as no solar Replace the solar
radiation sensor is provided. radiation sensor.
E21 Open circuit in frost Voltage: more than The compressor clutch is Check the harness.
sensor 4.79 V disengaged. (The compressor Replace the frost
stops.) sensor.
E22 Shorted circuit in frost Voltage: less than The compressor clutch is Check the harness.
sensor 0.096 V disengaged. (The compressor Replace the frost
stops.) sensor.
E43 Abnormal air vent Shorted circuit: Air vent damper servo motor Check the harness.
damper servo motor Voltage: 0 V becomes inoperable. Replace the air
Open circuit: Voltage: vent damper servo
more than 5 V motor.
E44 Abnormal air mix Shorted circuit: Air mix damper servo motor Check the harness.
damper servo motor Voltage: less than 0.2 V servo motor becomes inoperable. Replace the air
Open circuit: Voltage: vent damper servo
more than 4.8 V motor.
E51 Abnormal high/low Voltage: 0 V The compressor clutch is Check the harness.
refrigerant pressure disengaged. (The compressor Replace the high/
stops.) low pressure
switch.
E91 CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1
error between monitor harness.
controller and air Replace air
conditioner controller conditioner
controller.
E92 CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1
controller harness.
Faulty CAN1 harness Replace air
conditioner
controller.
T5-7-12
Air Conditioner Controller Fault Codes E11 to

E22
Preparation
position.

E11 Open circuit in re- Measurement of resistance ∞ Ω (Normal value: Faulty sensor.
circulated air sensor between sensor #1 and #2. 300 to 430 kΩ)
Measurement of voltage 0V Open circuit in harness #1.
between sensor harness
end #1 and body.
- Normal in above Open circuit in harness #2.
check.
E12 Shorted circuit in re- Measurement of resistance 0 Ω (Normal value: Faulty sensor.
circulated air sensor between sensor #1 and #2. 300 to 430 kΩ)
- Normal in above Shorted circuit in harness
check. #1 and #2.
E13 Open circuit in outdoor Measurement of resistance ∞ Ω (Normal value: Faulty sensor.
ambient temperature between sensor #1 and #2. 100 to 210 kΩ)
sensor Measurement of voltage 0V Open circuit in harness #1.
end #1 and body.
check.
E14 Shorted circuit in Measurement of resistance 0 Ω (Normal value: Faulty sensor.
outdoor ambient between sensor #1 and #2. 100 to 210 kΩ)
temperature sensor - Normal in above Shorted circuit in harness
check. #1 and #2.
E18 Shorted circuit in solar Continuity check between 0Ω Shorted circuit in harness
radiation sensor sensor harness end #1 and #1 and #2.
#2.
- Normal in above Faulty sensor.
check.
E21 Open circuit in frost Measurement of resistance ∞ Ω (Normal value: Faulty sensor.
sensor between sensor #1 and #2. 100 to 115 kΩ)
Measurement of voltage 0V Open circuit in harness #1.
end #1 and body.
check.
E22 Shorted circuit in frost Measurement of resistance 0 Ω (Normal value: Faulty sensor.
sensor between sensor #1 and #2. 100 to 115 kΩ)
- Normal in above Shorted circuit in harness
check. #1 and #2.
T5-7-13
Air Conditioner Controller Fault Codes E43 to

E92
Preparation
position.

E43 Abnormal air vent Measurement of voltage 0V Faulty controller or open circuit
damper servo between air vent damper servo in harness between controller
motor motor harness end 7C and body. and air vent damper servo
(AUTO/OFF switch / blower motor.
switch: ON)
Measurement of voltage 0V Faulty controller or open circuit
between air vent damper servo in harness between controller
motor harness end 7C and 25D. and air vent damper servo
(AUTO/OFF switch / blower motor.
switch: ON)
- Normal in Faulty air vent damper servo
above check. motor.
E44 Abnormal air mix Measurement of voltage 0V Faulty controller or open circuit
damper servo between air mix damper servo in harness between controller
motor motor harness end 7D and body. and air mix damper servo motor.
(AUTO/OFF switch / blower
switch: ON)
Measurement of voltage 0V Faulty controller or open circuit
between air mix damper servo in harness between controller
motor harness end 7D and 25E. and air mix damper servo motor.
(AUTO/OFF switch / blower
switch: ON)
- Normal in Faulty air mix damper servo
above check. motor.
E51 Abnormal high/ Measurement of voltage 0V Faulty controller or open circuit
low refrigerant between high/low pressure in harness between controller
pressure switch harness end A21 and and high/low pressure switch.
A05. (AUTO/OFF switch / blower
switch: ON)
- Normal in Faulty high/low pressure switch.
above check.
E91 CAN Continuity check in CAN1 Normal Faulty controller.
communication harness. Abnormal Faulty CAN1 harness.
error
E92 CAN bus off error Continuity check in CAN1 Normal Faulty controller.
harness. Abnormal Faulty CAN1 harness.
T5-7-14
(Blank)
T5-7-15
Faulty cooling (1)
Condition:
 Fault code: Un-displayed
 Airflow volume: faulty
Blower motor Normal speed Clogged re-circulated air filter Filter cleaning
rotates Clogged fresh air filter Filter cleaning
Obstacles are found in inlet area Remove obstacles
Deformation or breakage of blower Replacement of blower
Frosted evaporator To A
Adhered dirt on evaporator surface Evaporator surface cleaning
Slow speed Power source decreases Check battery charging
system
Poor battery terminal contact Repair
Faulty blower motor Replace
Faulty power transistor Replace
Blower motor Faulty blower motor relay Replace
does not rotate Faulty blower motor Replace
Blower interferes with case Repair
Faulty controller Replace the controller
Faulty ground in body Make sure to ground
Faulty wiring, disconnection of connector Wirings inspection
Blowout of power transistor thermal fuse due to locked motor Replace motor
Blowout of fuse Replace with the Blower motor is locked Replace blower motor
same capacity fuse Faulty wiring Refer to wiring diagram and
check
Shorted circuit Wirings inspection
T5-7-16
A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace clutch relay
magnet clutch circuit
Faulty wiring of frost Shorted circuit check Repair
sensor
Faulty frost sensor Characteristic check Replace frost sensor.
characteristics
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator range mm or less)
(faulty sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace magnet clutch
T5-7-17
Faulty cooling (2)
Condition:
 Fault Code: Un-displayed
 Airflow volume: Normal
 Compressor: Compressor rotates normally
 Compressor pressure: Normal
Fresh air enters Close window and door
Readjust fresh/re-circulated air
selection damper
Disconnection of air Setting link again
mix dumper servo
motor link
T5-7-18
(Blank)
T5-7-19
Faulty cooling (3)
Condition:
 Compressor: Compressor rotates normally
 Compressor pressure: Abnormal
Pressure on low- Overcharge air conditioner Remove refrigerant thoroughly and recharge refrigerant to proper
pressure side is too with refrigerant level after purging
high (approx. 0.29 Faulty compressor Breakage of head gasket Replace compressor
MPa or more) Breakage of inlet valve Replace compressor
Clogged foreign matter into inlet Replace compressor
valve
Excessive open of Faulty valve Replace valve
expansion valve
Pressure on high- Abnormally low ambient temperature
pressure side is too Low refrigerant To B
low (pressure is not Faulty compressor Swash plate shoe is locked Replace compressor
approx. 0.98 MPa or Piston is locked Replace compressor
more) Faulty suction discharge valve Replace compressor
Faulty expansion valve Clogged valve (foreign matter) Replace valve
Temporary clogged due to freezing Thoroughly perform purging
valve (water intrusion) after replacing valve and
receiver
Pressure on low- Abnormally low ambient temperature
pressure side is too Low refrigerant To B
low (pressure is Clogged during refrigeration cycle To C
approx. 0.05 MPa or Faulty expansion valve To D
less) Frosted evaporator To A
Pressure is high on Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing)
both sides of high- Overcharge air conditioner Remove refrigerant thoroughly and recharge refrigerant to proper
pressure and low- with refrigerant level after purging
pressure
Pressure is low on Lack of refrigerant
both sides of high-
pressure and low-
pressure
T5-7-20
sensor
Faulty frost sensor Characteristic check Replace frost sensor
characteristics
B: Low refrigerant
Low refrigerant Low refrigerant quantity Charge refrigerant to proper level
Gas leak Check leak and charge with refrigerant
after repairing faulty
C: Clogged during refrigeration cycle

Clogged during refrigeration Clogged receiver dryer Replace
cycle Clogged foreign matter in piping Replace
D: Faulty expansion valve

Temporary clogged due to freezing valve Thoroughly perform purging after
(water intrusion) replacing valve and receiver
T5-7-21
Faulty cooling (4)
Condition:
 Compressor: Compressor does not rotate normally
Broken V belt or slipping Replace V belt
Faulty compressor (locked) Replace
Faulty magnet Repair or Open circuit in stator coil Replace
clutch replace. Air gap between rotor and stator is too large Repair or
Replacement
Clutch slipping Slip caused by key breakage or inserting no key Replace key
Greasy clutch surface Remove oil
Layer shorted coil Replace
Battery voltage drop Charge
Clogged foreign matter between rotor and stator Overhaul
Clutch does Check Faulty controller Replace the
not operate wiring controller
due to faulty Faulty compressor clutch relay Replace
electrical Faulty frost sensor Replace
system Faulty high/low refrigerant pressure switch Replace
Abnormal high Too high Abnormally high ambient temperature
pressure (2.54 MPa or Lack of Clogged fin with Cleaning of fin
more) condenser dirt or mud (washing)
cooling
Overcharge air Remove refrigerant thoroughly and
conditioner with recharge refrigerant to proper level
refrigerant after purging
Air incorporation Remove refrigerant thoroughly and
in refrigeration recharge refrigerant to proper level
cycle after purging
Too low Abnormally low ambient temperature
(0.98 MPa or Low refrigerant To B
less) Clogged during refrigeration cycle To C
Faulty expansion valve To D
T5-7-22
sensor
Faulty frost sensor Characteristic check Replace frost sensor
characteristics
B: Low refrigerant
Low refrigerant Low refrigerant quantity Charge refrigerant to proper level
Gas leak Check leak and charge with refrigerant
after repairing faulty
C: Clogged during refrigeration cycle

Clogged during refrigeration Clogged receiver dryer Replace
cycle Clogged foreign matter in piping Replace
D: Faulty expansion valve

Temporary clogged due to freezing valve Thoroughly perform purging after
(water intrusion) replacing valve and receiver
T5-7-23
Faulty cooling (5)
Condition:
 Fault Code: 44 (Abnormal air mix damper servo motor)
Faulty wiring, open Wirings inspection
circuit, disconnection of
connector
Faulty servo motor Replace
Clogged foreign matter Remove foreign matter
Condition:
 Fault Code: 51 (Abnormal high/low refrigerant pressure)
High pressure cut is Abnormally high ambient temperature
operated Lack of condenser Clogged fin with dirt or mud Cleaning of fin (washing)
cooling
Overcharge air Remove refrigerant thoroughly and recharge refrigerant to proper
conditioner with level after purging
refrigerant
Air incorporation in Remove refrigerant thoroughly and recharge refrigerant to proper
refrigeration cycle level after purging
Low pressure cut is Abnormally low ambient temperature
operated Low refrigerant Low refrigerant quantity Charge refrigerant to proper
level
Gas leak Check leak and charge with
refrigerant after repairing faulty
Faulty compressor Swash plate shoe is locked Replace compressor
Piston is locked Replace compressor
Faulty suction discharge valve Replace compressor
Temporary clogged due to Thoroughly perform purging
freezing valve (water intrusion) after replacing valve and
receiver
T5-7-24
(Blank)
T5-7-25
Faulty heating (1)
Condition:
 Fault code: Un-displayed
Faulty air flow Blower motor Normal speed Clogged re-circulated air filter Filter cleaning
volume rotates Clogged fresh air filter Filter cleaning
Obstacles are found in inlet area Remove obstacles
Deformation or breakage of blower Replacement of blower
Adhered dirt on evaporator surface Evaporator surface
cleaning
Slow speed Power source decreases Check battery charging
system
Poor battery terminal contact Repair
Blower motor Blowout of fuse Replace with the Blower motor is Replace blower motor
does not rotate same capacity fuse locked
Faulty wiring Refer to wiring diagram
and check
Shorted circuit Wirings inspection
Faulty blower motor relay Replace
Blower interferes with case Repair
Faulty controller Replace the controller
Faulty ground in body Make sure to ground
Faulty wiring, disconnection of connector Wirings inspection
Blowout of power transistor thermal fuse due to locked Replace motor
motor
Air flow volume Coolant temperature is low
is normal Coolant Disconnection of air mix damper link Setting link again
temperature is Air incorporation in hot-water circuit Air Bleeding Circuit
normal Clogging, breakage and bending of piping Repair or replace.
Extremely low ambient temperature
Low engine coolant level Charge engine coolant
to proper level
Broken heater core Replace heater core
T5-7-26
Faulty wiring of Shorted circuit check Repair
evaporator sensor
Faulty the frost sensor Characteristic check Replace frost sensor
characteristics
T5-7-27
Faulty heating (2)
Condition:
 Fault Code: 44 (Abnormal air mix damper servo motor)
Clogged foreign matter Remove foreign
matter
Faulty wiring, open circuit, Wirings inspection
disconnection of connector
Faulty damper Replace
T5-7-28
Others
 Faulty air vent switch

Fault code is un-displayed Disconnection of link Setting link again
Fault code 43 (Abnormal air vent damper Faulty wiring, open circuit, Wirings inspection
servo motor) disconnection of connector
 Faulty fresh/re-circulated air selection

Fault code is un-displayed Disconnection of link Setting link again
Faulty wiring, open circuit, Wirings inspection
disconnection of connector
 Ambient temperature is higher or lower than set-temperature

Fault code 11 (Open circuit in re- Open circuit in harness, disconnection Wirings inspection
circulated air sensor) of connector
Open circuit in air circulation sensor Replace
Fault code 12 (Shorted circuit in re- Shorted circuit in harness Wirings inspection
circulated air sensor) Shorted circuit in air circulation sensor Replace
Fault code is un-displayed (Normal re- Faulty cooling, faulty heating Check by referring to the items of
circulated air sensor) faulty cooling and faulty heating
T5-7-29
 Noise
Case connection. Louver resonance. Repair or replace.
Blower fan motor connection. Fan contacts case. Foreign matter Remove foreign matter. Readjust fan
enters case. motor location.
Brush friction noise, metal and/or Slight noise is unavoidable. Replace if
thrust washer contact. loud.
Gas blowing sound (roaring). Gas vibration noise (compressor No functional problem exists.
discharge and/or suction gas noise).
Expansion valve connection. Whistle Abnormal noise from expansion Replace expansion valve if whistle
sound. Gas blowing sound. valve. Expansion valve is normally sound is heard. Gas flow noise can be
functioning. slightly heard.
Clutch disengaging sound. Faulty clutch bearing, and/or idle Replace.
pulley bearing.
Contact of clutch amature due to Repair or replace clutch. Re-tighten
resonance. Loose belt. Loose screws. screws.
Compressor rotating sound. Noisy compressor. Repair or replace.
Vibration due to V belt looseness. Re-adjust belt. Re-tighten screws.
Loose screws.
 Others
Water leak. Water splash. Broken heater core. Broken hose. Replace.
Clogged case drain port and/or drain Clean.
hose.
Abnormal smell. Absorbed cigarette and dust smell on Clean evaporator. When humidity is
evaporator fins. 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.
T5-7-30
(Blank)
T5-7-31
Blower motor does not operate.

Preparation
Procedure Inspection Method Condition Evaluation Cause (check point)

1 Switch compressor relay with Key Switch: ON Blower motor Faulty blower motor relay.
blower motor relay. Blower Switch: ON does not operate.
2 Measurement of voltage Key Switch: ON 0V Open circuit in harness
between terminal #41B of blower between fuse #3 and
motor relay harness end and blower motor relay.
body.
between terminal #43B of blower Blower Switch: ON between blower motor
motor harness end and body. relay and blower motor.
4 Continuity check between - 0Ω Faulty blower motor.
terminals #1 and #2 of blower
motor harness end.
between terminal #44B of power Blower Switch: ON between blower motor
transistor harness end and body. and power transistor.
6 Measurement of voltage Key Switch: ON 0V Faulty air conditioner
between terminal #9B of power Blower Switch: ON controller.
transistor harness end and body.
7 - - Procedures as Faulty power transistor.
steps 1 to 6 above
are normal.
Connector (Harness end)

 Blower Motor Relay  Blower motor
TDAB-05-07-020 TDAB-05-07-027
 Power Transistor
TDAB-05-07-028
T5-7-32
Compressor clutch does not operate.

Preparation
 Check that fresh air temperature is 0 ˚C or more first.
When fresh air temperature is less than 0 ˚C, the air
conditioner controller turns the compressor clutch
OFF in order to protect the compressor.
 Check that fault code 21 or 22 (abnormal frost
sensor) is not displayed. When the frost sensor is
abnormal, the compressor clutch does not operate.
Procedure Inspection Method Condition Evaluation Cause (check point)

1 Switch compressor relay with Key Switch: ON Compressor is not Faulty compressor relay.
blower motor relay. Blower Switch: ON operable.
between terminal #48A of between fuse #3 and
compressor relay harness end compressor relay.
and body.
between terminal #42A of Blower Switch: ON between compressor relay
compressor clutch relay harness and compressor clutch.
end and body.
4 - - Procedures as Faulty compressor clutch.
steps 1 to 3 above
are normal.
Connector (Harness end)

 Compressor Relay  Compressor Clutch
TDAB-05-07-024
TDAB-05-07-019
T5-7-33
Cooling circuit check by using manifold gauge
Condition:
 Engine Speed: 1500 min-1
 Cab Window: Fully Open
 Air Conditioner: ON
 Airflow volume: Maximum
 Temperature Control Switch: Maximum cool
 Fresh / re-circulated air selection: Re-circulated Air
 Air conditioner inlet temperature: 30 to 35 °C
1. In normal
 Low-pressure side pressure: 0.15 to 0.25 MPa
 High-pressure side pressure: 1.37 to 1.57 MPa
f NOTE: The reading of manifold gauge may depend on
conditions.
TDAA-05-07-018
2. Lack of refrigerant quantity
TroublePressure is low on both sides of high-pressure

and low-pressure. Cooling performance is
low.
Cause Refrigerant quantity is low. Gas leak.
Remedy Check and repair of gas leak. Charge air
TDAA-05-07-019
3. Excessive refrigerant, lack of condenser cooling
TroublePressure is high on both sides of high-

pressure and low-pressure. Cooling
performance is low.
Cause Overcharge air conditioner with refrigerant.
Faulty condenser cooling.
Remedy Adjust refrigerant quantity. Clean condenser.
Check for machine cooling system.
TDAA-05-07-020
4. Water incorporation in circuit.
TroubleAfter using a certain period of time, low-

pressure side gradually indicates negative
pressure.
Cause Water is mixed in circuit.
Remedy Replace receiver tank. Thoroughly perform
purging before charging refrigerant to
remove water.
TDAA-05-07-021
T5-7-34
5. Faulty compression of compressor
TroubleLow-pressure side is high and high-pressure

side is low. High-pressure becomes equal to
low-pressure immediately after stopping the
air conditioner.
Cause Faulty compressor.
Remedy Check and repair of compressor.
TDAA-05-07-022
6. Refrigerant does not circulate (clogged circuit)
TroubleWhen absolutely clogging, low-pressure side

indicates negative pressure quickly. When
slightly clogging, low-pressure side gradually
indicates negative pressure.
Cause Dirt or water adheres or freezes to expansion
valves, refrigerant does not flow.
Remedy Replace receiver tank. Perform purging. TDAA-05-07-023
7. Air incorporation in circuit

pressure and low-pressure. When touching
low-pressure piping, it is not cold.
Cause Air is mixed in system.
Remedy Replace refrigerant. Perform purging.
TDAA-05-07-024
8. Excessive open of expansion valve

pressure and low-pressure. Frost (dew)
adheres to low-pressure piping.
Cause Faulty expansion valve.
Remedy Check for installation of thermal cylinder.
TDAA-05-07-025
T5-7-35
Work after Replacing Components

The following work is required after replacing compressor,
high pressure hose, low pressure hose, condenser,
receiver tank, liquid hose, and air conditioner unit. The
same work is required when gas leakage is found.
1. Refill Compressor Oil

2. Charge Air Conditioner with Refrigerant
 Purging
 Charge air conditioner with refrigerant
 Warm-up operation
 Inspection
T5-7-36
Refill Compressor Oil

When replacing the cooling circuit parts, refill compressor
oil to the specified level.
Replacement Compressor Condenser Evaporator Receiver D hose L hose S hose

parts (between (between (between
compressor condenser unit and
and and unit) compressor)
condenser)
Oil- Refer to the 40 cm3 40 cm3 20 cm3 6 to 9 cm3/m 2 to 4 cm3/m 8 to 11 cm3/m
replenishing following. (2.4 in3) (2.4 in3) (1.2 in3) (0.4 to 0.5 (0.1 to 0.2 (0.5 to 0.7
quantity in3/m) in3/m) in3/m)
 In case of replacing compressor  Compressor oil refill container

New compressor (1) is charged with oil required for Oil type Part No Quantity
cooling circuit. When replacing new compressor (1), drain
ND-OIL8 4422696 40 cm3 (2.4 in3)
excess oil from new compressor (1). Adjust oil level so
that it is the same level as oil (B) in compressor (2) to be
replaced.
f NOTE: Compressor oil quantity: 160 cm3 (9.8 in3)
1 2
TDAA-05-07-015
1- New Compressor 2- Replacing Compressor
T5-7-37
Charge Air Conditioner with Refrigerant

Necessity of Purging
Be sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or other
gases remain in the A/C circuit.
1. Pressure rise in the high pressure side

If air remains in the air conditioner circuit, this disturbs
the heat exchange between refrigerant and air in the
condenser, causing pressure to rise in the high pressure
side (compressor side).
Usually, refrigerant gas is easily liquefied; however,
air cannot be liquefied and remains as a gas in the
condenser because the temperature at which air
liquefies is extremely low. That is, liquidation of the
refrigerant gas in the condenser decreases by the W115-02-10-001
amount of air in the circuit, and the gas pressure in the
high pressure side increases accordingly.
2. Metal corrosion
If air remains in the air conditioner circuit, a chemical
reaction between refrigerant and moisture in the air
takes place, and as a result, hydrochloric acid, that
corrodes metals such as aluminum, copper and iron, is
produced.
W115-02-10-002
3. Plugging of the expansion valve by moisture

When high pressure refrigerant gas passes through
the expansion valve, gas pressure decreases and
temperature drops. Moisture included in high pressure
refrigerant gas in the air conditioner circuit freezes at
the expansion valve orifice, plugging refrigerant flow.
Operation of the air conditioner becomes unstable and
cooling efficiency lowers.
W115-02-10-003
T5-7-38
Procedures for charging air conditioner with

refrigerant
1
7
IMPORTANT: Do not mistake the charge hose
connections.
6
1. Close high pressure valve (2) and low pressure valve
(7) on manifold gauge (1). Connect high-pressure 2
side charge hose (3) and low-pressure side charge
hose (6) on manifold gauge (1) to the high-pressure
3
side charge valve (“D” marked) and to the low-
pressure side charge valve (“S” marked) located on
the compressor, respectively. Connect charge hose 5
(5) located on the center of manifold gauge (1) to
vacuum pump (4). 4
W115-02-10-005
2. Open high pressure valve (2) and low pressure valve

(7) on manifold gauge (1). Perform purging for 10 1
minutes or more by operating vacuum pump (4). 7
W115-02-10-005
T5-7-39
IMPORTANT: If the pointer returns to 0, retighten the 7

line connections and perform purging again.
3. When the low pressure gauge reading falls below
-0.1 MPa (-750 mmHg), close high pressure valve (2)
2
and low pressure valve (7) and stop vacuum pump
(4). Wait for approximately five minutes and confirm
that the pointer does not return to 0.
4. With highpressure valve (2) and lowpressure valve

(7) on manifold gauge (1) closed, connect charge W115-02-10-005
hose (5) to refrigerant container (8).
7 1
 Refrigerant
Specification Part No. Volume (g)
R134a 4333767 200
4454005 250
2
4351827 300
5. Open valve (9) of refrigerant container (8). Push air

8
bleed valve (10) on manifold gauge (1) to purge
air in charge hose (5) with the refrigerant pressure.
When draining refrigerant, immediately release air
W115-02-10-007
bleed valve (10).
10 1
5
9
W115-02-10-007
T5-7-40
IMPORTANT:
 Always stop the engine when charging the air
 Do not position the refrigerant container upside
down during charging operation.
 When changing the refrigerant container during
charging operation, be sure to purge air from
the charge hose, as shown in step 10.
 Charge the low-pressure side hose first.
6. Fully tighten charge hose (5) connection to gauge
manifold (1). Open high pressure valve (2) and
valve (9) of refrigerant container (8). Charge with
refrigerant (R134a). Close high pressure valve (2)
and valve (9) of refrigerant container (8) when high
pressure gauge (11) reading reaches 98 kPa (1 kgf/ W115-02-10-008
cm2).
fNOTE: Use warm water of 40˚C or less to warm 1

refrigerant container (8) to aid in charging operation.
11
2
5
9
8
IMPORTANT: Use the leak tester for R134a.
7. After charging, check the line connections for gas
leaks using leak tester.
W115-02-10-007
T5-7-41
8. Confirm that high pressure valve (2) and low 1

pressure valve (7) on gauge manifold (1) and valve
7
(9) of refrigerant container (8) are closed. Start the
engine and operate the air conditioner.
Operating Conditions of the Air Conditioner 2
 Engine Speed: Slow Idle
9
W115-02-10-007
IMPORTANT: Do not open high pressure valve (2) on
manifold gauge (1).
9. Open low pressure valve (7) on manifold gauge (1)
1
and valve (9) of refrigerant container (8) to charge
with refrigerant. 7
fNOTE: Required refrigerant quantity: 950±50 g

10. If refrigerant container (8) becomes empty during 2
the charging work, replace refrigerant container (8)
with a new refrigerant container as follows:
 Close high pressure valve (2) and low pressure valve
(7) on manifold gauge (1).
 Replace the empty container with new refrigerant 9
container (8).
 Tighten, then slightly loosen refrigerant container (8)
8
joint.
 Slightly open low pressure valve (7) on manifold
gauge (1).
 When refrigerant container (8) joint starts to leak,
immediately tighten refrigerant container (8) joint
W115-02-10-007
and close low-pressure valve (7) on manifold gauge
(1).
11. After charging, close low pressure valve (7) on

manifold gauge (1) and valve (9) of refrigerant
container (8), and stop the engine.
T5-7-42
IMPORTANT: If the air conditioner is operated with

very low refrigerant, a bad load will be exerted
on the compressor. If the air conditioner is
overcharged with refrigerant, cooling efficiency
will lower and abnormal high pressure will arise in
the air conditioner circuit, causing danger.
12. Start the engine and operate the air conditioner
again. Check that cold air blow out from the vents.
Operating Conditions of the Air Conditioner
d CAUTION: When attempting to disconnect the
high-pressure-side charge hose, refrigerant and
compressor oil may spout. Disconnect the high-
pressure side charge hose after the high-pressure
side pressure drops to less than 980 kPa (10 kgf/
cm2).
13. After checking refrigerant quantity, disconnect the
low-pressure-side charge hose first. Disconnect the
low-pressure-side charge hose. Wait for the high-
pressure-side pressure to drop to less than 980 kPa
(10 kgf/cm2, 142 psi). Disconnect the high-pressure-
side charge hose.
T5-7-43
Warm-up Operation
After charting the air conditioner, carry out warm-
up operation five minute to lubricate system with
compressor oil.

Inspection
After warm-up operation, carry out gas leak check and
performance check.
d CAUTION: Refrigerant will produce poisonous
material if exposed to heat of 1000 °C or more.
Never bring refrigerant close to a fire.
1. Check the air conditioner for gas leaks using a leak
tester.
 Perform checking under well-ventilated conditions.
 Thoroughly wipe off dust from the charge hose
connections of the compressor.
 Pay special attention to check the line connections.
 If any gas leaks are found, retighten the line
connections.
2. Performance Check. Carry out performance check

of the air conditioner after checking each air
conditioner component. W115-02-10-013
 Check each component for abnormalities.

 Carry out ON-OFF check of the compressor clutch.
 Check compressor fan belt tension.
 Check the coolant level in the radiator.
 Operate the air conditioner and check the
performance.
W115-02-10-014
T5-7-44
3. The checklist before the summer season is as

follows:
 Check each air conditioner component for
abnormalities.
 Check the line connections for oil leaks.
 Check refrigerant quantity.
 Check the engine cooling circuit.
 Check V belt for wear. Replace if necessary.
 Check for clogged condenser.
4. Off-Season Maintenance
 During off-season, operate the idler pulley and
compressor at least once a month for a short time to
check for any abnormal sounds.
 Do not remove the compressor belts during 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.
f NOTE: When the machine is in normal and the air
conditioner is operated with the following conditions, air
vent temperature decrease approx. 20 °C or less. (it may
be different under special environment.)
 Engine Speed: Fast Idle
 Cab Window: Fully closed
 Fresh / re-circulated air selection: Re-circulated Air
 Season: Summer
T5-7-45
Hose and Pipe Tightening Torque A
Use the following tightening torque values when

connecting the pipes.
Joint Location Tube or Bolt Size Tightening

Torque
N·m (kgf·m)
TDAA-05-07-016
Nut type Pipe with dia. 8 12 to 15
(Fig. A) (1.2 to 1.5)
B
Pipe with D1/2 20 to 25
(2.0 to 2.5)
Pipe with D5/8 30 to 35
(3.0 to 3.5)
Block joint Receiver M6 Bolt 4.0 to 7.0
(Fig. B) (4T) (0.4 to 0.7)
M6 Bolt (6T) 8.0 to 12
for other than (0.8 to 1.2)
Receiver
TDAA-05-07-017
T5-7-46
INDEX
111000 to 111002...................................................................T5-5-61 Brake System Troubleshooting..........................T5-6-41, T5-6-83
111003.........................................................................................T5-5-62 Brake Warning Pressure (Pressure-Decreasing)............T4-5-30
111006, 111007........................................................................T5-5-65 Brake Warning Pressure (Pressure-Increasing).............T4-5-32
111011.........................................................................................T5-5-65 Bucket Levelness.....................................................................T4-4-13
111014.........................................................................................T5-5-70 Bucket Stopper Clearance...................................................... T4-4-8
111025.........................................................................................T5-5-70
111100.........................................................................................T5-5-71
C
111103 ........................................................................................T5-5-72
111106, 111107........................................................................T5-5-72 CAN Data Reception Failure................................................T5-5-10
111200.........................................................................................T5-5-74 CAN1 Harness Check..............................................................T5-5-66
111203.........................................................................................T5-5-74 Charge Air Conditioner with Refrigerant........................T5-7-36
111204.........................................................................................T5-5-76 Check by False Signal.............................................................T5-1-25
111206.........................................................................................T5-5-76 Column Display Controller (Information) Fault Codes
111208.........................................................................................T5-5-77 120500 to 120503..............................................................T5-5-89
111217.........................................................................................T5-5-75 120505...................................................................................T5-5-89
111311.........................................................................................T5-5-78 Column Display Controller Fault Code
111312.........................................................................................T5-5-75 115001...................................................................................T5-5-87
111313.........................................................................................T5-5-78 115011...................................................................................T5-5-88
111411.........................................................................................T5-5-79 120506, 120507..................................................................T5-5-90
111412.........................................................................................T5-5-80 120510 to 120512..............................................................T5-5-90
111413.........................................................................................T5-5-81 120515, 120516..................................................................T5-5-90
111422.........................................................................................T5-5-82 120518...................................................................................T5-5-90
111901.........................................................................................T5-5-83 Column Display Controller Fault Code List....................T5-5-21
120003, 120004........................................................................T5-5-84 Communication System......................................................... T5-3-7
120014.........................................................................................T5-5-85 Communication Terminal Fault Code List......................T5-5-24
24-Volt Circuit...........................................................................T5-1-18 Component Layout................................................................... T5-4-1
5-Volt Circuit..............................................................................T5-1-24 Component Test........................................................................ T4-5-1
Compressor clutch does not operate...............................T5-7-31
Compressor Oil, Refill.............................................................T5-7-35
A Continuity Check.....................................................................T5-1-16
Adjustment.................................................................................. T4-6-1 Control Lever Operating Force...........................................T4-4-14
Air Bleeding, Brake (Axle).................................................. T5-6-103 Control Lever Stroke...............................................................T4-4-16
Air Conditioner Control Valve.............................................................................T5-4-15
Component Layout............................................................. T5-7-2 Controller..................................................................................... T5-4-7
Functions of Main Parts..................................................... T5-7-6 Controller Hardware Failure.................................................. T5-5-9
Outline..................................................................................... T5-7-1 Coolant Temperature............................................................... T5-2-4
Troubleshooting.................................................................T5-7-11 Coolant Temperature Gauge................................................. T5-2-7
Air Conditioner Controller Fault Code.............................T5-7-11 Cooling circuit check by using manifold gauge...........T5-7-32
How to Display....................................................................T5-7-11 Correlation between Trouble Symptoms and
Air Conditioner Controller Fault Code List....T5-5-24, T5-7-12 Part Failures..........................................................................T5-6-24
Air Conditioner Controller Fault Codes Cylinder Drift Check...............................................................T4-4-12
E11 to E22.............................................................................T5-7-13
E43 to E92.............................................................................T5-7-14
D
All Actuator System Troubleshooting.............T5-6-27, T5-6-53
Alternator Check......................................................................T5-1-15 Daily Report Data...................................................................... T5-3-2
Average Fuel Consumption................................................... T5-2-5 Diagnosing Procedure, Introduction.................................. T5-1-1
Axle (Brake), Air Bleeding.................................................. T5-6-103 Diagnosis Procedure................................................................ T5-1-2
Digging Position Adjustment............................................... T4-6-7
Drive Unit...................................................................................T5-4-17
B
Battery Voltage Check...........................................................T5-1-14
E
Bell Crank Stopper Clearance................................................ T4-4-8
Blower motor does not operate.........................................T5-7-30 e-Service, Outline...................................................................... T5-3-1
Brake (Axle), Air Bleeding.................................................. T5-6-103 ECM Fault Code List................................................................T5-5-25
Brake Accumulator Pressure................................................T4-5-28 Electric System Inspection..................................................... T5-1-5
Brake Charge Valve.................................................................T5-4-18 Electrical System (Around Fuel Tank and Radiator
Brake Primary Pressure............................................................ T4-5-1 Assembly).............................................................................T5-4-13
80Z6 Trbl
INDEX
Electrical System L
(Around Hydraulic Oil Tank)...........................................T5-4-12 Learning Failure.......................................................................T5-5-18
(Cab).......................................................................................... T5-4-6 Lever Stopper Clearance......................................................... T4-4-8
(Components Related with Relays).............................T5-4-11 Lift Arm Angle Sensor Learning........................................... T4-6-5
(Overview).............................................................................. T5-4-5 List of Operation Data.............................................................. T5-3-2
Engine..........................................................................................T5-4-14 List of Service Menu Display................................................. T5-2-6
Engine Failure...........................................................................T5-5-11 Loading Circuit Main Relief Set Pressure.......................... T4-5-8
Engine Speed................................................................T4-3-1, T5-2-4 Loading Main Relief Pressure Adjustment....................... T4-5-9
Engine System Troubleshooting.......................T5-6-25, T5-6-47 Loading Pilot Primary Pressure............................................. T4-5-4
Engine Test................................................................................... T4-3-1 Lubricant Consumption.......................................................... T4-3-3
Exchange Inspection........................................................... T5-6-101
M
F Machine Information Display................................................ T5-2-2
Fan Pump...................................................................................T5-4-14 Main Component...................................................................... T5-4-2
Fan Valve (Option)...................................................................T5-4-16 Main Component (Overview)............................................... T5-4-1
Fault Code.................................................................................... T5-2-5 Main Component (Travel System)....................................... T5-4-3
Fault Code List Main Pump Delivery Pressure............................................... T4-5-6
Air Conditioner Controller..............................................T5-5-24 Main Pump Flow Rate Measurement...............................T4-5-16
Column Display Controller.............................................T5-5-21 Main Pump P-Q Diagram......................................................T4-2-10
Communication Terminal...............................................T5-5-24 Manifold Valve..........................................................................T5-4-18
ECM.........................................................................................T5-5-25 MC Fault Codes
MC............................................................................................. T5-5-9 111000 to 111002..............................................................T5-5-61
MPDr......................................................................................... T5-5-3 111003...................................................................................T5-5-62
TCU..........................................................................................T5-5-41 111006, 111007..................................................................T5-5-65
Faulty cooling (1).....................................................................T5-7-16 111011...................................................................................T5-5-65
Faulty heating (1).....................................................................T5-7-24 111106, 111107..................................................................T5-5-72
Faulty heating (2).....................................................................T5-7-26 111200...................................................................................T5-5-74
Frequency Distribution Data................................................. T5-3-4 111203...................................................................................T5-5-74
Front Attachment System Troubleshooting 111204...................................................................................T5-5-76
.................................................................................T5-6-31, T5-6-59 111205...................................................................................T5-5-73
Front Axle...................................................................................T5-4-17 111206...................................................................................T5-5-76
Fuel Consumption..................................................................... T5-2-5 111208...................................................................................T5-5-77
Fuel Gauge................................................................................... T5-2-8 111217...................................................................................T5-5-75
Fuse Box A..................................................................................T5-1-11 111311...................................................................................T5-5-78
Fuse Box B..................................................................................T5-1-12 111312...................................................................................T5-5-75
Fuse Inspection........................................................................T5-1-10 111313...................................................................................T5-5-78
Fusible Link Inspection..........................................................T5-1-13 111411...................................................................................T5-5-79
111412...................................................................................T5-5-80
H 111413...................................................................................T5-5-81
111422...................................................................................T5-5-82
Hose Tightening Torque........................................................T5-7-44
111901...................................................................................T5-5-83
How to display service menu................................................ T5-2-4
120003...................................................................................T5-5-84
Hydraulic Cylinder Cycle Time............................................T4-4-10
120004...................................................................................T5-5-84
Hydraulic Oil Tank, Electrical System................................T5-4-12
120014...................................................................................T5-5-85
Hydraulic Oil Temperature..................................................... T5-2-4
MC Fault Code List.................................................................... T5-5-9
Hydraulic Oil Temperature Sensor....................................T5-5-83
Monitor......................................................................................... T5-4-9
Specification........................................................................T5-5-83
Monitor, Outline......................................................................... T5-2-1
Monitor Display.......................................................................... T5-2-2
I Monitor Panel............................................................ T5-2-1, T5-4-10
Instructions for Disconnecting Connectors..................... T5-1-8 MPDr. Fault Code Reference Table...................................... T5-5-3
Multiple Control Valve...........................................................T5-4-15
80Z6 Trbl
INDEX
O Switches........................................................................................ T5-4-9
Operating Procedures of Service Menu............................ T5-2-3
Operational Performance Standard Table........................ T4-2-1 T
Operational Performance Tests............................................ T4-1-1
TCU Fault Code List.................................................................T5-5-41
Other Failures............................................................................T5-5-19
Test Harness..............................................................................T5-1-26
Other System Troubleshooting.........................T5-6-43, T5-6-87
Torque Converter Oil Temperature Gauge....................... T5-2-7
Overload Relief Valve Pressure Adjustment...................T4-5-14
Torque Converter Pressure (Inlet)......................................T4-5-36
Overload Relief Valve Set Pressure....................................T4-5-12
Total Operating Hours............................................................. T5-3-5
Transmission Clutch Pack Combination..........................T4-5-35
P Transmission Clutch Pressure.............................................T4-5-34
Parking Brake Function Check.............................................. T4-4-7 Transmission Learning............................................................. T4-6-1
Parking Brake Pressure..........................................................T4-5-26 Transmission Oil Temperature.............................................. T5-2-4
Parking Brake Solenoid Valve Block..................................T5-4-18 Transmission Oil Temperature Gauge................................ T5-2-7
Pilot Failure................................................................................T5-5-13 Travel Speed................................................................................ T4-4-1
Pipe Tightening Torque.........................................................T5-7-44 Travel System Troubleshooting.........................T5-6-37, T5-6-73
Precautions for Inspection and Maintenance................. T5-1-6 Troubleshooting A (Base Machine Diagnosis
Preparation for Performance Tests...................................... T4-1-2 by Using Fault Codes) Procedure................................... T5-5-1
Primary Pilot Pressure (Including Brake Circuit)............. T4-5-1 Troubleshooting B (Machine Diagnosis
Primary Pilot Pressure Adjustment Procedure................ T4-5-3 by Using Troubleshooting Symptom) Procedure..... T5-6-1
Priority Valve.............................................................................T5-4-16
Proportional Solenoid Valve Failure.................................T5-5-16 V
Pump Device.............................................................................T5-4-15
Vehicle Information Display.................................................. T5-2-2
Pump Failure.............................................................................T5-5-12
Voltage and Current Measurement..................................T5-1-18
R
W
Radiator Assembly.................................................................... T5-4-4
Work after Replacing Components...................................T5-7-34
Refill Compressor Oil..............................................................T5-7-35
Refrigerant, Charge Air Conditioner.................................T5-7-36
Regulator Adjustment...........................................................T4-5-22
Relationship between Machine Trouble Symptoms
and Related Parts................................................................. T5-6-3
Relays............................................................................ T5-4-7, T5-4-11
Ride Control Valve (Option).................................................T5-4-20
Right Console.............................................................................. T5-4-8
S
Secondary Pilot Pressure........................................................ T4-5-4
Secondary Steering Pump (Option).................................T5-4-19
Secondary Steering Valve (Option)...................................T5-4-19
Sensor Activating Range......................................................T4-2-12
Service Brake Accumulator Pressure................................T4-5-28
Service Brake Function Check............................................... T4-4-4
Service Brake Pressure (Front and Rear)..........................T4-5-24
Service Brake Primary Pressure............................................ T4-5-1
Service Brake Wear Amount.................................................. T4-4-6
Service Menu Display List....................................................... T5-2-6
Service menu, How to display.............................................. T5-2-4
Service Menu, Operating Procedures................................ T5-2-3
Snapshot Data............................................................................ T5-3-6
Specification of Hydraulic Oil Temperature Sensor....T5-5-83
Standard Values......................................................................... T4-2-1
Steering Circuit Main Relief Set Pressure........................T4-5-10
Steering System Troubleshooting....................T5-6-35, T5-6-69
Steering Valve...........................................................................T5-4-19
80Z6 Trbl
INDEX
(Blank)
80Z6 Trbl

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93209-00770

SECTION AND GROUP SECTION 4 OPERATIONAL

All information, illustrations and

 Be sure to thoroughly read this manual for correct

Quantity To Convert From Into Multiply By

Symbol / Name Explanation

 When you see these symbols on your machine or in this

Understand Signal Words

 DANGER indicates an imminently hazardous situation

 CAUTION also calls attention to safety messages in this

 To avoid confusing machine protection with personal SA-1223

 f NOTE indicates an additional explanation for an

 Keep a first aid kit and fire extinguisher on hand.

Wear Protective Clothing

You may need:

 Avoid wearing loose clothing, jewelry, or other items that

 Operating equipment safely requires the full attention of

 Wear a suitable hearing protective device such as

 In the walk-around inspection, be sure to cover all points

Use Handrails and Steps

 Do not use any controls as handholds.

Never Ride Attachment

Adjust Operator’s Seat

 The seat should be adjusted whenever changing the

 Before leaving the machine, be sure to first lower the front

Fasten Your Seat Belt

 Prior to operating the machine, thoroughly examine

 Take extra care not to run over bystanders. Confirm the

Handle Starting Aids Safely

 Starting fluid is highly flammable.

 Keep all sparks and flame away when using it.

 Start the engine only when seated in the operator's seat.

 If the engine must be jump started, be sure to follow the

 Investigate the configuration and ground conditions of

ROPS: Roll-Over Protective Structure

Provide Signals for Jobs Involving Multiple

 Only the operator should be on the machine. Keep riders

 When driving on level ground, hold the bucket at mark

 Be sure to detour around any obstructions.

 Driving on a slope may cause the machine to slip or

 Driving across the face of a slope or steering on a slope

 When driving the machine on a job site with the bucket

Drive on Snow Safely

 The machine may slip more easily than expected on

 Be sure to empty the bucket.

Avoid Injury from Rollaway Accidents

 Keep all personnel away from the machine by sounding

 Avoid carrying the bucket or attachment over the co-

 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become

Dig with Caution

 Before digging, check the location of cables, gas lines, and

Perform Truck Loading Safely

Never move any part of the machine or load closer to any

Precautions for Operation

 Take care to avoid coming in contact with overhead

Precautions for Lightning

 In the event of an electrical storm, immediately stop

Never attach a sling or chain to the bucket teeth or to the

Protect Against Flying Debris

 Guard against injury from flying pieces of metal or debris;

Store Attachments Safely

 Securely store attachments and implements to prevent