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93213-00801
90Z6
October 2018
SHOP MANUAL
SHOP MANUAL
WHEEL LOADER
Troubleshooting
Operational Performance Test
90Z6
Operational Performance Test

93213-00801 Troubleshooting
Powered by CUMMINS QSM11 Engine
©2018 KCM Corporation. All rights reserved. Printed in Japan (K) Serial No. 90C7-9001 and up
（トルコ用）
93213-00801
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 Adjustment
(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.
MEMO
INTRODUCTION
To The Reader
This manual is written for an experienced technician to
provide technical information needed to maintain and
repair this machine.
 Be sure to thoroughly read this manual for correct

product information and service procedures.
Additional References
Please refer to the other materials (operation and
maintenance manual, parts catalog, engine technical
material, Kawasaki shop materials, etc.) in addition to this
manual.
Manual Composition
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/cm 2
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.
ICF Information Controller Stores the operating information and alarms.
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-1
SECTION 4
OPERATIONAL PERFORMANCE TEST

CONTENTS
Group 1 Introduction Group 5 Component Test
Operational Performance Tests....................................... T4-1-1 Hydraulic Circuit................................................................... T4-5-1
Preparation for Performance Tests................................ T4-1-2 Loading Pilot Circuit...................................................... T4-5-1
Primary Pilot Pressure (Including Brake Circuit)....... T4-5-2
Secondary Pilot Pressure................................................... T4-5-4
Group 2 Standard Secondary Pilot Pressure Adjustment
Operational Performance Standard Table.................. T4-2-1 Procedure....................................................................... T4-5-5
Main Pump P-Q Diagram................................................T4-2-10 Main Pump Delivery Pressure......................................... T4-5-6
Sensor Activating Range.................................................T4-2-12 Loading Circuit Main Relief Set Pressure..................... T4-5-8
Loading Main Relief Pressure Adjustment ........... T4-5-9
Group 3 Engine Test Steering Circuit Main Relief Set Pressure.................. T4-5-10
Engine Speed........................................................................ T4-3-1 Steering Main Relief Pressure Adjustment..........T4-5-11
Overload Relief Valve Set Pressure..............................T4-5-12
Overload Relief Valve Pressure Adjustment .......T4-5-14
Group 4 Machine Performance Test Main Pump Flow Rate Measurement.........................T4-5-16
Travel Speed.......................................................................... T4-4-1 Regulator Adjustment................................................T4-5-22
Service Brake Function Check......................................... T4-4-4 Service Brake Pressure (Front and Rear) ...................T4-5-24
Service Brake Wear Amount............................................. T4-4-6 Parking Brake Pressure.....................................................T4-5-26
Parking Brake Function Check........................................ T4-4-7 Brake Accumulator Pressure .........................................T4-5-28
Bucket Stopper Clearance, Lever (Bell Crank) Brake Warning Pressure (Pressure-Decreasing)......T4-5-30
Stopper Clearance.......................................................... T4-4-8 Brake Warning Pressure (Pressure-Increasing)........T4-5-32
Hydraulic Cylinder Cycle Time.......................................T4-4-10 Transmission Clutch Pressure........................................T4-5-34
Cylinder Drift Check..........................................................T4-4-12 Torque Converter Pressure.............................................T4-5-36
Bucket Levelness................................................................T4-4-13
Control Lever Operating Force......................................T4-4-14
Control Lever Stroke.........................................................T4-4-16 Group 6 Adjustment
Transmission Learning....................................................... T4-6-1
Lift Arm Angle Sensor Learning...................................... T4-6-4
Digging Position Adjustment.......................................... T4-6-6
90Z6 Trbl
(Blank)
90Z6 Trbl
SECTION 4 OPERATIONAL PERFORMANCE TEST
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: 55±5 °C (131±9 °F)
For EXP Specifications (S/N ~9152)

Performance Test Designation Unit Performance Remarks Reference
Standard Page
Engine Speed min-1 Power mode switch: OFF T4-3-1
Low Idle Speed (without load) 800±50 Value indicated on MPDr.
High Idle Speed (without load) 2070±50 Value indicated on MPDr.
High Idle Speed (with torque 1920±100 Second- speed forward,
converter stalled) Value indicated on MPDr.
converter stalled and relieved) Value indicated on MPDr.
Engine Speed min-1 Power mode switch: ON T4-3-1
Valve Clearance (In, Ex) mm (in) In: 0.36 (0.014) With the engine cold Refer to
Ex: 0.69 (0.027) Engine Manual
For EU Specifications (S/N 9153~)

Standard Page
Engine Speed min-1 Power mode switch: OFF T4-3-1
Engine Speed min-1 Power mode switch: ON T4-3-1
Valve Clearance (In, Ex) mm (in) In: 0.36 (0.014) With the engine cold Refer to
Ex: 0.69 (0.027) Engine Manual
T4-2-1
Group 2 Standard

Standard Page
Travel Speed (S/N ~9152) km/h (mph) Power mode switch: OFF T4-4-1
First Speed (Forward/Reverse) 6.8±0.7 (4.2±0.4) Value indicated on MPDr.
Second Speed (Forward/Reverse) 11.5±1.2 (7.1±0.7) Value indicated on MPDr.
Third Speed (Forward/Reverse) 21.6±2.2 (13.4±1.4) Value indicated on MPDr.
Fourth Speed (Forward/Reverse) 34.7±3.5 (21.6±2.2) Value indicated on MPDr.
Travel Speed (S/N 9153~) km/h (mph) Power mode switch: OFF
Travel Speed km/h (mph) Power mode switch: ON T4-4-1
Service Brake Function Check m (ft) 12 (39) or less Machine speed: 35±3 km/h T4-4-4
(21.7±1.8 mph)
Service Brake Wear Amount mm (in) T4-4-6
Brake Disc 6.2 (0.2) Allowable limit: 5.3 (0.2)
Brake Ring (t=5.0) 5.0 (0.2) Allowable limit: 4.5 (0.18)
Brake Ring (t=5.0) 5.0 (0.2) Allowable limit: 4.5 (0.18)
Parking Brake Function Check mm/5 min 0 T4-4-7
Parking Brake Wear Amount mm (in) -
Brake Disc 2.2 (0.087) Allowable limit: 2.0 (0.079)
Brake Plate 2.4 (0.094) Allowable limit: 2.2 (0.087)
Bucket Stopper Clearance mm 0 T4-4-8
Lever (Bell Crank) Stopper Clearance mm (in) 0 to 3 (0 to 0.12) T4-4-8
Front Pin Wear Amount mm (in) - Allowable limit: -1.0 (-0.03) -
Front Bushing Wear Amount mm (in) - Allowable limit: -1.5 (-0.05) -
Clearance Between Front Pin and mm (in) 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
(S/N ~9152)
Lift Arm Raise 5.5±0.3
Lift Arm Lower (Float) 3.2±0.3
Bucket Dump 1.2±0.3
Steering (engine: high idle speed) 2.9±0.3
Hydraulic Cylinder Cycle Time sec Power mode switch: OFF T4-4-10
(S/N 9153~)
Hydraulic Cylinder Cycle Time sec Power mode switch: ON T4-4-10
Cylinder Drift Check mm (in)/15 min T4-4-12
Lift Arm Cylinder 45 (1.77) or less
Bucket Cylinder 35 (1.38) or less
Bucket Bottom 200 (7.87) or less
Bucket Levelness mm (in) 10 (0.4) or less T4-4-13
T4-2-3
Group 2 Standard
Performance Test Designation Unit Performance Standard Remarks Reference

Page
Control Lever Operating Force N (kgf ) (lbf ) Two-lever T4-4-14
Lift Arm Raise 10 (1.0) (2.3) or less
Lift Arm Raise (Detent) 16 (1.6) (3.6) or less
Lift Arm Raise (Detent Release) 36 (3.7) (8.1) or less
Lift Arm Lower 10 (1.0) (2.3) or less
Lift Arm Lower (Float) 16 (1.6) (3.6) or less
Lift Arm Lower (Float Release) 36 (3.7) (8.1) or less
Bucket Control Lever Tilt (Rollback) 11 (1.1) (2.5) or less
(Detent)
(Detent Release)
Bucket Control Lever Dump 16 (1.6) (3.6) or less
Steering 17 (1.7) (3.8) or less
Forward/Reverse Lever 12 +3/-2 (1.2 +0.3/-0.2)
(2.7 +0.7/-0.4)
Accelerator Pedal 40±2 (4.1±0.2)
(9.0±0.4)
Brake Pedal (Right) 353 to 413 (36.0 to
42.1) (79.4 to 92.8)
Inching Pedal (Left) 333 to 393 (34.0 to
40.1) (74.9 to 88.3)
T4-2-4
Group 2 Standard

Page
Control Lever Operating Force N (kgf ) (lbf ) MF (Joystick type) T4-4-14
lever
Lift Arm Raise 20 (2.0) (4.5) or less
Lift Arm Raise (Detent) 40 (4.0) (9.0)or less
Lift Arm Raise (Detent Release) 50 (5.0) (11.2) or less
Lift Arm Lower 20 (2.0) (4.5) or less
Lift Arm Lower (Float) 40 (4.0) (9.0) or less
Lift Arm Lower (Float Release) 50 (5.0) (11.2) or less
Bucket Control Lever Tilt 20 (2.0) (4.5) or less
Bucket Control Lever Tilt (Detent) 40 (4.0) (9.0) or less
Bucket Control Lever Tilt (Detent 50 (5.0) (11.2) or less
Release)
Bucket Control Lever Dump 30 (3.0) (6.7) or less
Steering 17 (1.7) (3.8) or less
Forward/Reverse Lever 12 +3/-2 (1.2 +0.3/-0.2)
(2.7 +0.7/-0.4)
Accelerator Pedal 40±2 (4.1±0.2)
(9.0±0.4)
Brake Pedal (Right) 353 to 413 (36.0 to
42.1) (79.4 to 92.8)
Inching Pedal (Left) 333 to 393 (34.0 to
40.1) (74.9 to 88.3)
fNOTE: MF: Multi-Function
T4-2-5
Group 2 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 (0.16 to 0.18)
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)
Brake Pedal Application 35 to 45 (1.38 to 1.77)
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 4.5 to 5.5 (0.18 to 0.22)
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)
Brake Pedal Application 35 to 45 (1.38 to 1.77)
fNOTE: MF: Multi-Function
T4-2-6
Group 2 Standard

Page
Pedal Depressing Angle deg. (without play) T4-4-16
Accelerator Pedal 18±1
Brake Pedal (Right) 20.6±0.5
Inching Pedal (Left) 17.0±0.5
Electrolyte Density (Specification at 1.26 Allowable limit: 1.16 -
20 °C (68°F))
Tire Inflation kPa (kgf/cm2) -
(PSI)
Radial Tire Front: 471 to 490 26.5R25
(4.8 to 5.0) (68 to 71)
Rear: 373 to 392
(3.8 to 4.0) (54 to 57)
Bias Tire Front: 422 to 441 26.5-25-20PR
(4.3 to 4.5) (61 to 64)
Rear: 324 to 343
(3.3 to 3.5) (47 to 50)
T4-2-7
Group 2 Standard

Standard Page
Primary Pilot Pressure MPa (kgf/cm2) Unloader setting pressure T4-5-2
(PSI)
Cut-out Pressure 14.7±0.3 (150±3) Value indicated on MPDr.
(2132±43.5)
Cut-in Pressure 11.8±1.0 (120±10) Value indicated on MPDr.
(1711±145)
Secondary Pilot Pressure) MPa (kgf/cm2) 3.7 +0.5/-0.3 (38 +5/-3) T4-5-4
(PSI) (537 +73/-43)
Main Pump Delivery Pressure MPa (kgf/cm2) 2.0 +1.0/-0.5 (20 +10/-5) In neutral, Value indicated T4-5-6
(PSI) (290 +145/-73) on MPDr.
Loading Circuit Main Relief Set MPa (kgf/cm2) T4-5-8
Pressure (PSI)
Relief Operation of Lift Arm 29.4 +2.0/-0.5 (300 +20/-5) Value indicated on MPDr.
(4264 +290/-73)
Relief Operation of Bucket 29.4 +2.0/-0.5 (300 +20/-5) Value indicated on MPDr.
(4264 +290/-73)
Steering Relief Pressure MPa (kgf/cm2) 29.4 +2.0/-0.5 (300 +20/-5) Value indicated on MPDr. T4-5-10
(PSI) (4264 +290/-73)
Overload Relief Pressure MPa (kgf/cm2) Reference values at 35 L/ T4-5-12
(PSI) min
Lift Arm Raise 36.8 +1.0/-0 (375 +10/-0)
(5337 +145/-0)
Bucket 32.5 +1.0/-0 (331 +10/-0)
(4714 +145/-0)
T4-2-8
Group 2 Standard

Standard Page
Main Pump Flow Rate Measurement L/min - Refer to T4-2-10, 11 T4-5-16
Service Brake Pressure (Front/Rear) MPa (kgf/cm2) 4.6±0.6 (47±6) at brake pedal (right) T4-5-24
(PSI) (667±87)
Parking Brake Pressure MPa (kgf/cm2) 3.7+0.2/-0.1 (38 +2/-1) T4-5-26
(PSI) (536 +29/-14.5)
Service Brake Accumulator Pressure MPa (kgf/cm2) T4-5-28
(PSI)
Accumulator Pressure 14.7±0.3 (150±3)
(2132±43.5)
N2 Gas Charging Pressure 6.8 (69) (986)
Brake Warning Pressure (Pressure- MPa (kgf/cm2) 8±0.5 (82±5) T4-5-30
Decreasing) (PSI) (1160±73)
Brake Warning Pressure (Pressure- MPa (kgf/cm2) 10±0.5 (102±5) T4-5-32
Increasing) (PSI) (1450±73)
Transmission Clutch Pressure MPa (kgf/cm2) 2.2 to 2.4 (22 to 24) T4-5-34
(PSI) (319 to 348)
Torque Converter Pressure MPa (kgf/cm2) T4-5-36
(PSI)
Inlet Pressure 0.99 to 1.09 (10.1 to
11.1) (144 to 158)
Outlet Pressure 0.43 to 0.53 (4.4 to
5.4) (62 to 77)
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: 2000 min-1 (rpm)
MPa (kgf/cm2) (PSI) L/min (gpm)
 Hydraulic Oil Temperature: 55±5 °C (131±9 °F)
A 4.9 (50) (711) 340±3 (90±0.8)
B 19.6 (200) (2849) 340±3 (90±0.8)
fNOTE: Refer to T4-5-16.
C 26.5 (270) (3853) 315±6 (83±1.6)
D 29.4 (300) (4274) 283±6 (75±1.6)
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)
Points on P-Q Line
Pump Control Pressure Flow Rate
 Rated Pump Speed: 2000 min-1 (rpm) MPa (kgf/cm2) (PSI) L/min (gpm)
 Hydraulic Oil Temperature: 55±5 °C (131±9 °F) A 0.39 +0.01/-0 (4 +0.1/-0) (57 +1.5/-0) 340±3 (90±0.8)
f NOTE: Refer to T4-5-18. B 1.47±0.05 (15±0.5) (214±7) 100±2 (26±0.5)
C 1.67 +0.01/-0 (17 +0.1/-0) (243 +1.5/-0) 51±3 (13±0.8)
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: 55±5 °C (131±9 °F)
 Unless specified:
Engine Speed Power Mode Switch

High Idle Speed ON
• Monitor each sensor by using MPDr.
2. Sensor Activating Range
Unit: MPa (kgf/cm2) (PSI)

Item Operation Specification
Pump Delivery Pressure Neutral 1.2 to 2.6 (12 to 27) (174 to 377)
Relieved 28.7 to 32.0 (293 to 326) (4163 to 4641)
Main Relief Pressure Neutral 1.2 to 2.6 (12 to 27) (174 to 377)
Control Lever: Relieved 28.7 to 32.0 (293 to 326) (4163 to 4641)
Parking Brake Pressure Parking Brake Switch: ON 0 to 0.1 (0 to 1) (0 to 14.5)
Parking Brake Switch: OFF 3.6 to 4.3 (37 to 44) (522 to 624)
Service Brake Pressure Brake Pedal: Neutral 0 to 0.1 (0 to 1) (0 to 14.5)
Brake Pedal: Fully Depressed 4.0 to 5.2 (41 to 53) (580 to 754)
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
Low Idle Speed N No depression ON ON/OFF
(with no load)
High Idle Speed Second speed/third Full stroke ON ON/OFF
(with no load) speed forward
High Idle Speed Second speed Full stroke OFF ON/OFF
(with torque converter forward
stalled)
High Idle Speed Third speed forward Full stroke OFF ON/OFF
(with torque converter
stalled and relieved)
Declutch Position Brake Pedal Control Lever

Switch (Bucket)
Low Idle Speed OFF - Transporting
(with no load) position, No control
lever operation
High 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 (p.T4-2-1).
Remedy:
Refer to Troubleshooting B.
f NOTE: Engine System Troubleshooting (T5-6-26).
T4-3-2
Travel Speed
Summary:
Measure the time required for the machine to travel
a 50 m (164 ft) test track and check the performance
of the travel drive system (torque converter to
transmission).
Preparation:
1. Adjust air pressure of the tires evenly in advance.
 Bias Tire:
Front: 422 to 441 kPa (4.3 to 4.5 kgf/cm2)
(61 to 64 psi)
Rear: 324 to 343 kPa (3.3 to 3.5 kgf/cm2) a
(47 to 50 psi)
 Radial Tire: c b c
Front: 471 to 490 kPa (4.8 to 5.0 kgf/cm2) d e
(68 to 71 psi) 90Z6-04-04-01
Rear: 373 to 392 kPa (3.8 to 4.0 kgf/cm2)
(54 to 57 psi) a- 0.5 m (1 ft 8 in) d- End
b- Test Track e- Start
c- Acceleration/Deceleration
2. Provide a flat, solid test track 50 m (164 ft) in length, Zone
with extra length of 70 m (229 ft) on both ends
for machine acceleration and deceleration. (For
measurement at fourth speed, a 300 m (984 ft)
acceleration zone is needed.)
3. Empty the bucket and hold the lift arm with it

floated 0.5 m (1 ft 8 in) above the ground.
4. Maintain the hydraulic oil temperature at 55±5°C

(131±9 °F). Warm the axle oil satisfactorily by
repeating travel operation and brake operation.
Make a warm up operation so that the indicators of
the coolant temperature monitor and the torque
converter oil temperature monitor should rise
above the horizontal position.
T4-4-1
Measurement:
dCAUTION: Do not perform measurement in

reverse travel to avoid accident.
1. Measure in each mode (first speed to fourth speed).
2. Select the switches as follows.
Shift Switch Parking Brake Switch Accelerator Pedal Power Mode Switch
Second Speed (First
First Speed OFF Full Stroke ON/OFF
Speed Fixed Switch: ON)
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
3. Set the forward/reverse lever to the F (forward)

position. Start traveling the machine in the
acceleration zone with the accelerator pedal
depressed to the stroke end.
4. Measure the travel speed (sec) of each travel mode.
5. Repeat the measurement three times and calculate

the mean values.
6. Convert the measurement value to be expressed in

km/h.
Measurement value (seconds) = S (sec)
1
Converted value (hourly speed) = A (km/h)
A = (50×3600)/(S×1000)
90Z6-04-04-02
Evaluation: 1- Machine Speed Sensor

Remedy:
f NOTE: Travel System Troubleshooting (p.T5-6-37)
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.
 Bias Tire:
(61 to 64 psi)
Rear: 324 to 343 kPa (3.3 to 3.5 kgf/cm2)
(47 to 50 psi)
 Radial Tire:
a
(68 to 71 psi) b
Rear: 373 to 392 kPa (3.8 to 4.0 kgf/cm2) c d
(54 to 57 psi) 90Z6-04-04-03
2. On a paved dry road, prepare a 150 m (492 a- 0.5 m (1 ft 8 in) d- Brake Starting Point
ft) straight travel course (a 100 m (328 ft) of b- Stopping Distance
c- Stopping Point
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


(131±9°F). Warm the axle oil satisfactorily by
the coolant temperature monitor and the torque
above the horizontal position.
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 Switch Accelerator Pedal Power Mode Switch Declutch Position
Switch
Fourth Speed OFF Full Stroke ON OFF
3. Set the forward/reverse lever to the F (forward)

position. Start traveling the machine in the
acceleration zone with the accelerator pedal
depressed to the stroke end 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:
Stopping distance: 12 m (13 yard) or less
Remedy:
f NOTE: Brake System Troubleshooting (p.T5-6-40)
T4-4-5
Service Brake Wear Amount

Summary: 1
Check the extent of wear of the brake disc at the

service brake of the axle by using a wear gauge or
thickness gauge (5.3 mm).
Preparation:
1. Clean around inspection plug (1) of the axle and
loosen it.
2. In case of the rear axle, inspection plug (1) is located

below the center line of the differential. Loosen
inspection plug (1) after draining axle oil. T4GB-04-04-004
7 2
Measurement:
1. Operate the service brake by stepping on the brake
pedal.
2. Insert wear gauge (2) into inspection port (7) until it

contacts brake disc (6) between brake ring (3) and
brake ring (4).
Evaluation: T4GB-04-04-005
1. In case wear gauge (2) has entered between brake

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

beyond the maximum allowable limit of use or in 6
case the service brake portion has been assembled,
refer to Operational Performance Standard in T4-2.
3
 Distance (L) between Housing Surface (5) and Brake
Disc (6): 54 mm (2.13 in) 4
 Brake ring (4) thickness (default): 5.0 mm (0.2 in) T4GD-04-04-001
 Brake ring (3) thickness (default): 5.0 mm (0.2 in)
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 1/5 slope (approx. 11.3°).
2. Empty the bucket and hold the bucket with it
(131±9 °F). Warm the axle oil satisfactorily by
a
the coolant temperature monitor and the torque b
above the horizontal position. 90Z6-04-04-04
a- 0.5 m (1 ft 8 in)
b- 11.3°
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:
No movement.
Remedy:
T4-4-7
Bucket Stopper Clearance, Lever (Bell Crank)

Stopper Clearance a
Summary: b
Measure wear and deformation conditions of the

bucket stopper (dump side and rollback side) and the
clearance between lever (bell crank) stopper (b) and
the cross tube.
Preparation:
Stop the machine on a flat and level surface and apply
the parking brake.
Measurement:
 Bucket Dump Stoppers (a, b)
1. Raise the lift arm to the highest lifting position and
stop the engine. T4GB-04-04-008
2. Dump the bucket calmly with the engine stopped a- Bucket Dump Stopper b- Lever (Bell Crank) Stopper
until the lever contacts cross tube side stopper (b).
At this time, measure strokes (A and B) of the bucket
cylinder and the lift arm and dump angle (C) of the
bucket. In addition, measure the clearance between 2
bucket dump stopper (a) and the lift arm.
c
3. At the same time, measure the contact condition of
bucket dump stopper (a) (left and right).
 Bucket Roll Back Stopper (c)

1. Raise the lift arm until lift arm cylinder stroke (E)
becomes the length of the standard dimension.
2. Set the engine at idling speed and roll back the
bucket calmly until it contacts bucket roll back 1 90T4GB-04-04-10
stopper (c).
c- Bucket Rollback Stopper
3. At this time, measure strokes (D and E) of the bucket
cylinder and the lift arm cylinder and roll back angle 1- Bucket Link 2- Lever
(F) of the bucket. In addition, measure height (G)
from the ground to the center of bucket hinge pin.
4. At the same time, measure the contact condition of
bucket roll back stopper (c) (left and right).
T4-4-8
Evaluation
1. Bucket Dump Stopper 2. Bucket Rollback (Tilt) Stopper
 Cylinder Strokes (A and B)  Cylinder Strokes (D and E)
Bucket Cylinder (A) Lift Arm Cylinder (B) Bucket Cylinder (D) Lift Arm Cylinder (E)
mm (in) mm (in) mm (in) mm (in)
521±2 (20.5±0.08) 1168±2 (46±0.08) 840±2 (33.1±0.08) 260±2 (10.2±0.08)
 Bucket Dump Angle (C)  Bucket Roll Back (Tilt) Angle (F)
C (deg.) F (deg.)
48 to 50 39.5 to 41.5
 Clearance between Lever Stopper and Cross Tube (b)  Height from Ground to Bucket Hinge Pin (G)
Clearance between Stopper and Tube G (mm) (in)
mm (in) 290 (11.4)
Standard 3 (0.12) or less
Limit -  Clearance between Bucket Rollback Stopper and Lift
Arm (c)
 Clearance between Bucket Dump Stopper and Lift Clearance at Longitudinal and
Arm (a) Unsymmetrical Lateral Clearance of
Clearance at Longitudinal and Contact Each Stopper
Unsymmetrical Lateral Clearance of mm (in) mm (in)
Contact Each Stopper Standard 0 0
mm (in) mm (in)
Limit 3.0 (0.12) 4.0 (0.16)
Standard 0 0
Limit 2.0 (0.08) 5 (0.20)
fNOTE: Standard dimensions indicate those with new
tires (standard) at the specified air pressure.
fNOTE:
 Clearance at Unsymmetrical Contact (left stop
compared to right stop)
Clearance limit
Left stop Right stop
 Longitudinal and Lateral Clearance of Each Stopper
Clearance limit
Longitudinal Lateral
contact contact
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:
(Lowering)
1. Measurement is made for the following positions.
 Measurement of Lift Arm Cylinder (Raising)
Fully tilt the bucket and lower the lift arm.
 Measurement of Lift Arm Cylinder (Lowering)
Lower the lift arm until the bucket bottom surface
touches the ground horizontally.
 Measurement of Bucket Cylinder
Lift the lift arm to the highest position.
 Measurement of Steering Cylinder T487-04-03-005
Empty the bucket and take the travel forward
position.
Bucket Cylinder:
2. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).
dCAUTION: Select ground filled with sand or

something so that the bucket contacts the ground
with buffer.
T487-04-03-006
Travel Position
90Z6-4-1-1
a- 0.5 m (1 ft 8 in)
T4-4-10
Measurement:
1. Select the pedal, switches, and forward/reverse
lever as follows.
Accelerator Pedal Parking Brake Forward/Reverse Power Mode
Switch Lever Switch
Lift Arm (Raising) Full stroke (engine: high idle speed) ON N ON/OFF
Lift Arm (Lowering) Neutral (engine: low idle speed) ON N ON/OFF
Bucket Full stroke (engine: high idle speed) ON N ON/OFF
Steering Full stroke (engine: high 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:
f NOTE: Front Attachment System Troubleshooting (p.T5-
6-31)
T4-4-11
Cylinder Drift Check

Summary:
1. Measure dig function drift, which can be caused by
oil leakage in lift arm cylinder, bucket cylinder, and
the control valve, with the bucket loaded.
2. Measure in the standard front condition (standard
bucket).
3. In case measurement is made immediately after the
cylinder replacement, bleed air from the cylinder
before measurement by operating the cylinders
slowly to the stroke end several times.
Preparation:
1. Load the bucket with either soil or a weight
equivalent to the weight standard 6800 kg (14991
1
lb).
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.
(131±9 °F).
2
a
Measurement:
1. Stop the engine.
2. In 15 minutes after the engine has been stopped,
measure the change in position of lift arm cylinder T4GB-04-04-014
(2) (b), bucket cylinder (1) (b), and bottom of the
bucket (a). a- Bucket Bottom Drift Amount

the mean values.
Evaluation:
Drift amount:
Lift Arm Cylinder: 45 mm (1.77 in) or less b
Bucket Cylinder: 35 mm (1.38 in) or less
Bucket Bottom (a): 200 mm (7.87 in) or less TNEE-04-04-001
b- Cylinder Drift Amount

Remedy:
f NOTE: Front Attachment System Troubleshooting (p.T5-
6-31)
T4-4-12
Bucket Levelness
Summary:
Check left and right inclinations of the bucket.
Preparation:
1. Place the unloaded machine on a horizontal bed
on the ground. (In case a bed is not available, place
it on a horizontal flat concrete on the ground. Deal
with the measurement values as guide lines.)
2. Adjust the tire air pressure to the designated value.
3. Lower the bucket onto the ground in the horizontal 1

position.
T4GB-04-04-011
Measurement:
dCAUTION: Never put hands, feet, and measuring

instruments under the bucket.
1. Float the bucket bottom slightly above the bed.
2. Measure the vertical distance from the bed and the

bottom surface of cutting edge (1) on the left and
right ends, and confirm the difference.

the mean values.
Evaluation:
Drift amount: 10 mm (0.4 in) or less
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 Travel Position

lever, pedal, and steering wheel.
3. Measure at the grip center of each control lever.

Measure at 150 mm (6 in) from the pedal support of
each pedal.
Preparation: a
1. In the front position, empty the bucket in advance.
90Z6-4-1-1
2. Maintain the hydraulic oil temperature at 55±5 °C a- 0.5 m (1 ft 8 in)

(131±9 °F).
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/Reverse
Switch Lever
Neutral (engine: low ON N
idle speed)
dCAUTION: Prevent personal injury. Always make

sure that the area is clear and that coworkers
TNED-04-04-001
are out of the steering area before starting the

1
measurement.
3. Attach a spring balance scale (tension type) onto

each of the lift arm, bucket, and forward/reverse
lever. Measure the maximum operating force by
operating them to the stroke end.
4. In case of the pedals, attach a spring balance

scale (compression type) or a load cell onto them.
Measure the operating force when they are stepped
slightly.
MNDB-01-001
3 2
5. In case of the steering wheel, attach a spring
balance scale (tension type) onto knob (1). Measure 1- Knob 3- Brake Pedal
the maximum operating force when it is moved. 2- Accelerator Pedal

the mean values.
Evaluation:
Refer to Operational Performance Standard.
 Two-lever: p.T4-2-4
 MF (Joystick type) lever: p.T4-2-5
T4-4-15
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:
(131±9 °F).
Measurement:
1. Measure as follows.
 Measurement of Control Lever

 Lower the bucket bottom onto the ground.
 Stop the engine.
 Measure each lever stroke from neutral to the stroke
end of each control lever of lift arm, bucket, and
forward/reverse at the grip top center.
 Measurement of Pedal
 Lower the bucket bottom onto the ground.
 Stop the engine.
 Measure the stroke from neutral to the stroke end of
the pedal at the pedal top.
 Measurement of Steering Wheel

 Start the engine. (Low idle)
 Float the bucket slightly above the ground.
 Measure the number of times of rotation required
for movement of the steering wheel from the right
to the left stroke end and from the left to the right
stroke end.
2. Measure the chord length from neutral to the stroke

end. Turn the steering wheel at 30~60 rpm.

the mean values.
Evaluation:
T4-4-16
Group 5 Component Test
Hydraulic Circuit
Loading Pilot Circuit
3
8
1
4 5
2
9
90Z6-04-05-04
1- Pilot Pump 4- Loading Pilot Valve 7- Parking Brake

2- Main Pump 5- Charging Block 8- Pilot Accumulator
3- Multiple Control Valve 6- Service Brake Accumulator 9- Hydraulic Oil Tank
T4-5-1
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 1
replacing hydraulic oil. (Refer to p.T5-6-99.)
IMPORTANT: Primary pilot pressure circuit delivers

pressure oil from pilot pump (1) to the brake
circuit when pressure in service brake accumulator 3
(4) decreases, and accumulates pressure in service 2
brake accumulator (4). Therefore, the brake circuit
Arrow View A
pressure is higher than the pilot circuit pressure.
Use a pressure gauge capable of measuring 14.7 A
1
MPa (150 kgf/cm2) (2132 psi) or higher.
Summary:
Measure the pilot pressure at charging block (2).
f NOTE: Measure the pressure by using the monitor or
MPDr. (Monitoring - Main (T/M) - Service Brake Primary
Pressure)
4
Preparation:
1. Stop the engine. 2
2. Push the air bleed valve on top of the hydraulic oil

tank and bleed air.
3. Disconnect hose (3) from charging block (2) (port P) 90Z6-04-05-03

and install an adapter (charging block side).
Install the pressure gauge to the adapter.
1- Pilot Pump 3- Hose
2- Charging Block 4- Service Brake Accumulator
4. Start the engine and keep the speed at low idle.
Confirm that no oil leakage is observed at the
pressure gauge connection.

(131±9°F).
T4-5-2
Measurement:
1. Select the following conditions:
Accelerator Pedal Power Mode Switch Parking Brake Switch Forward/Reverse

Lever
Full stroke ON ON N
2. Read pressures on the pressure gauge with no load.
3. Read and record the pressures when the pointer of

the pressure gauge stops rising (cut-out pressure).
4. Keep the engine at low idle, and repeatedly

depress and release the brake pedal to reduce the
accumulator pressure.
5. Read and record the pressure when the pointer

of the pressure gauge stops and then starts rising
again (cut-in pressure).

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

decreases during measurement of primary pilot pressure,
the measured valve increases to around 16 MPa (163 kgf/
cm2) (2320 psi) for several seconds.
Evaluation:
 Cut-out Pressure: 14.7±0.3 MPa (2132 PSI)
 Cut-in Pressure: 11.8±1.0 MPa (1711 PSI)
IMPORTANT: The cut-in/cut-out pressure levels are

preset by the valve manufacturer. When it is out of
the specified range, it is highly possible that the
valve is defective. Replace the valve unit.
T4-5-3
Secondary Pilot Pressure 2
Preparation:
1. Stop the engine.
b1
tank and bleed air. b2
1 Arrow View A
3. Measure pressure between the pilot valve and
multiple control valve (2).
Disconnect pilot hose (1) from the circuit to be
measured. Install a tee and a pressure gauge. 2
A 1
j : 17, 19, 22 mm (0.67, 0.75, 0.87 in)
4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
a1

a2
(131±9 °F). 1
90Z6-04-05-05
a1- Lift Arm (Raise) b1- Lift Arm (Lower)

a2- Bucket (Roll Back) b2- Bucket (Dump)
Measurement:
Accelerator Pedal Power Mode Switch Parking Brake Switch Forward/Reverse 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:
Standard. 3.7 MPa (537 PSI)
Remedy:
Refer to Troubleshooting A for any accompanied error
code.
Refer to Troubleshooting B for observed phenomena.
fNOTE: All Actuator System Troubleshooting (p.T5-6-28)

Front Attachment System Troubleshooting (p.T5-6-31)
Steering System Troubleshooting (p.T5-6-35)
T4-5-4
Secondary Pilot Pressure Adjustment Procedure

Adjust the relief valve set-pressure in charging block (3)
as necessary.
1. Remove plug (1) from the pilot relief valve.
j : 30 mm (1.18 in)
2. Remove shim (2) from the relief valve.
3. Install the estimated number of shims (2).
fNOTE: Total thickness of shim (2) should be 1.5 mm

(0.06 in) or less.
4. Install shim (2) to the relief valve. Tighten plug (1).
m : 98.0±9.8 N·m (10±1.0 kgf·m, 72±7.2 lbf·ft)
5. After adjustment, check the set pressure.
fNOTE: Standard Change in Pressure (Reference)
Shim (2) Thickness Change in Pressure

mm (in) kPa (kgf/cm2) (psi)
0.2 (0.008) 61.8 (0.63) (9) 5
4
0.4 (0.016) 124.6 (1.27) (18) 90Z6-04-05-06
0.8 (0.031) 249.2 (2.54) (36)
2 3
5
Section V-V
90Z6-04-05-07
1- Plug 3- Shim 5- Accumulator Port

2- Pilot Relief Valve 4- Charging Block
T4-5-5
Main Pump Delivery Pressure

Summary:
Measure the main pump output pressure at the Pressure gauge
delivery port in main pump in neutral condition. Main pump
fNOTE: Measure the pressure by using the MPDr.
Preparation:
1. Stop the engine.

tank and bleed air.
1
3. Remove the plug (G1/4) from delivery pressure
check port (1) on the main pump. Install the Adapter
Hose
adapter, the hose, and the pressure gauge.
TNDB-04-05-008
l : 6 mm (0.24 in)
1- Pump 1 Delivery Pressure
4. Start the engine. Confirm that no oil leakage is Check Port

(131±9 °F).
T4-5-6
Measurement:
Full stroke ON ON N
2. Measure pressure with the control levers in neutral

without load.

the mean values.
Evaluation:
Standard (neutral):
2.0 +1.0/-0.5 MPa (290 +145/-73 PSI)
Remedy:
Refer to Troubleshooting A for any accompanied error
code.
Refer to Troubleshooting B for observed phenomena.
fNOTE: All Actuator System Troubleshooting (p.T5-6-28)

Steering System Troubleshooting (p.T5-6-35)
T4-5-7
Loading Circuit Main Relief Set Pressure

Summary:
Measure the main relief valve set pressure at the Pressure gauge
delivery port in main pump while operating the lift
arm/bucket control lever.
Preparation:
1. Stop the engine.

tank and bleed air.
2 1
3. Remove the plug (G1/4) from delivery pressure Adapter
check port (1) on the main pump. Install the Hose
adapter, the hose, and the pressure gauge. TNDB-04-05-008
l : 6 mm (0.24 in)
1- Pump Delivery Pressure 2- Pump Delivery Pressure
Check Port Sensor

(131±9 °F).
Measurement:
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:
Standard (lift arm/bucket relief operation):
29.4 +2.0/-0.5 MPa (4264 +290/-73 PSI)
T4-5-8
Loading Main Relief Pressure Adjustment
fNOTE: The main relief valve is installed to the multiple

control valve.
Procedure:
1. Loosen lock nut (1).
j : 17 mm (0.67 in)
90Z6-04-05-08
2. Turn adjusting screw (2) and adjust the relief
pressure to the specification.
1
l : 6 mm (0.24 in)
3. Tighten lock nut (1).
m : 29.5 N·m (3 kgf/cm2, 22 lbf·ft)
2
4. Check the relief set pressure.
T4GB-04-05-011

2
Adjusting Screw (2) 1/4 1/2 3/4 1
Turns
Change in MPa 4.5 8.9 13.4 17.8
Pressure (kgf/cm2) (46) (91) (137) (182)
(psi) (653) (1291) (1944) (2582)
a b
W107-02-05-129
a - Pressure Increase b - Pressure Decrease
T4-5-9
Steering Circuit Main Relief Set Pressure

Summary:
Measure the steering relief valve set pressure at the Pressure gauge
main pump delivery port and check performance of
the steering relief valve.
Preparation:
1. Stop the engine.

tank and bleed air.
1
3. Remove the plug (G1/4) from delivery pressure Adapter
check port (1) on the main pump. Install the Hose
adapter, the hose, and the pressure gauge. TNDB-04-05-008
l : 6 mm (0.24 in)
Check Port

(131±9 °F).
Measurement:
Full stroke ON ON N
2. Install the articulation lock bar. Slowly operate the

steering wheel and relieve the steering.

the mean values.
Evaluation:
Standard: 29.4 +2.0/-0.5 MPa (4264 +290/-73 PSI)
T4-5-10
Steering Main Relief Pressure Adjustment
fNOTE: The main relief valve is installed to the pump

device.
Procedure:
1. Secure lock nut (1). Remove nut (3).
j : 24 mm (0.94 in) T4GB-04-05-012
3 1
2. Secure adjusting screw (2). Loosen lock nut (1).
j : 24 mm (0.94 in)
3. Turn adjusting screw (2) and adjust the relief

pressure to the specified value.
4. Secure adjusting screw (2). Tighten lock nut (1).
m : 37 N·m (3.8 kgf/cm2, 27 lbf·ft) 2

T4GB-04-05-013
5. Secure lock nut (1). Tighten nut (3).
m : 37 N·m (3.8 kgf/cm2, 27 lbf·ft)

2
6. Check the relief set pressure.

Adjusting Screw (2) 1/4 1/2 3/4 1 a b
Turns
Change in MPa 3.8 7.5 11.3 15.0 T105-06-05-002
Pressure (kgf/cm2) (39) (77) (155) (153) a - Pressure Increase b - Pressure Decrease
(psi) (551) (1088) (1639) (2176)
T4-5-11
Overload Relief Valve Set Pressure

Summary:
1. The circuit pressure must be increased by applying
an external force while blocking the return circuit
from the control valve. This measuring method
is hazardous and the results obtained with this
method are unreliable.
2. The oil flow rate used to set the overload relief
pressure is far less than that used to set the main
relief pressure. Therefore, measuring the overload
pressure in the main circuit by increasing the main
relief set pressure more than the overload valve
set-pressure is not a proper method. In addition,
main relief valve may be designed to leak a small
quantity of oil before relieving. In this case, its pre-
leaking start pressure must be increased more than
the overload relief valve set pressure. However, the
pre-leaking start pressure is not always increased
more than the overload relief valve set-pressure as
the adjustable upper limit of the main relief valve
set-pressure is provided. Accordingly, the overload
relief valve assembly should be removed from the
machine and checked on a specified test stand at
a correct oil flow rate. Some overload relief valves
come in contact with the control valve body to
block the oil passage. When this type of overload
relief valve is checked, the control valve body must
be precisely finished as the test unit. Provide one
control valve other than that on the machine as a
test kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload relief
valve. And, assume that the overload relief valve
is functioning correctly if the obtained main relief
pressure is within the specified value range.
T4-5-12
Preparation: Pressure gauge

1. Stop the engine.

tank and bleed air.
3. Remove the plug (G1/4) from delivery pressure

check port (1) on the main pump. Install the
adapter, the hose, and the pressure gauge.
l : 6 mm (0.24 in)
4. Start the engine. Confirm that no oil leakage is 1

Adapter
Hose
5. Maintain the hydraulic oil temperature at 55±5 °C TNDB-04-05-008
(131±9 °F).
Check Port
Measurement:
Full stroke ON ON N
2. Slowly operate the bucket or lift arm control lever,

operate each cylinder to the stroke end, and relieve
each function.
3. Read pressures on the pressure gauge at this time.

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

are given for reference.
T4-5-13
Overload Relief Valve Pressure Adjustment
fNOTE: The overload relief valves are installed to the

a
multiple control valve.
fNOTE: In principle, adjust the overload relief valve c
pressure on a test stand.
Procedure:
1. Loosen lock nut (1).
j : 17 mm (0.67 in)
b
2. Turn adjusting screw (2) in order to adjust the
pressure. 90Z6-03-02-04
a- Overload Relief Valve (Bucket: Rod Side)
l : 6 mm (0.24 in) b- Overload Relief Valve (Bucket: Bottom Side)
c- Overload Relief Valve (Lift Arm: Bottom Side)
3. Tighten lock nut (1).

1
j : 17 mm (0.67 in)
m : 29.5 N·m (3 kgf/cm2, 22 lbf·ft)
4. After adjustment, check the set pressure.
2
Adjusting Screw (2) 1/4 1/2 3/4 1 W107-02-05-128
Turns 1- Lock Nut 2- Adjusting Screw
Change in MPa 5.2 10.6 15.9 21.1
Pressure (kgf/cm ) (53)
2
(108) (162) (215)
(psi) (754) (1537) (2306) (3060) 1 2
a b
W107-02-05-129
a - Pressure Increase b - Pressure Decrease
T4-5-14
(Blank)
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 (8) 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 only oil comes out.
MPDr. and a pressure gauge at the same time.
j : 41 mm (1.61 in)
Preparation: 7. Fully open the loading valve of hydraulic tester (5).

1. Stop the engine. Push the air bleed valve on top the
hydraulic oil tank and bleed air. Connect a vacuum 8. Start the engine. Confirm that no oil leakage
pump to the oil filler port. is observed at the pressure gauge connection.
Connect MPDr. and select the monitoring function.
fNOTE: Operate the vacuum pump while connecting the
pump flow rate test line.
Measurement:
2. Disconnect delivery hose (7) from main pump (1).
Connect test hose (3) to the main pump delivery 1. Maintain the hydraulic oil temperature at 55±5 °C
port. (131±9 °F).
j : 41 mm (1.61 in)
2. Measure the maximum flow rate.
3. Install test hose (3) to hydraulic tester (5) by using

adapter (4). Install adapter (6) and delivery hose (7) 3. Select the following conditions:
to hydraulic tester (5).
Accelerator Power Mode Parking Forward/
j : 41 mm (1.61 in) Pedal Switch Brake Switch Reverse
Lever
Full stroke ON ON N
4. Install a pressure gauge to main pump (1) to be
measured. (Refer to Main Relief Set Pressure.)
4. Slowly restrict the loading valve of hydraulic tester
l : 6 mm (0.24 in) (5) while relieving pressure in the bucket tilt circuit.
Measure the flow rates and engine speeds at each
pressure point specified in the P-Q curve. (Refer to
5. Disconnect hose (10) from regulator port ST (9).
T4-2-10.)
Install the plug (G1/4) to the removed hose (10) and
regulator port ST (9).
j : 17 mm (0.67 in) the mean values.
T4-5-16
Evaluation:
1. Convert the measured flow rates to those at the
specified engine speed by using the following 6 7
3 4 5
formula:
Qc = Ns×Q/Ne
Qc: Converted Flow Rate

Q: Measured Flow Rate
Ns: Specified Engine Speed: 2150 min-1
Ne: Measured Engine Speed:
1 TNED-04-05-005
Values indicated on MPDr.
2. Standard Flow Rate

Refer to Operational Performance Standard (p.T4-2-
10).
9
8 10
A
1
1
9
2
7
View A
Steering valve
Control valve
90Z6-04-05-09
1- Main Pump 5- Hydraulic Tester 9- Port ST

2- Charging Block (Port X) 6- Adapter 1-11/16-12UN×G1-1/2 10- Hose
3- Test Hose (1-11/16-12UN) 7- Delivery Hose
4- Adapter 1-11/16-12UN×G1-1/2 8- Plug
T4-5-17
 Pilot Characteristics
Summary: 2. Disconnect the hose from regulator port Pi1 (21).

Main pump performance is checked by measuring the Install the plug (G1/4) to the removed hose.
pump flow rate by using hydraulic tester (5) installed
at the main pump delivery port to be measured. Use j : 19 mm (0.75 in)
MPDr. and pressure gauge (18) at the same time.
3. Connect regulator port Pi2 (8) to the hydraulic oil
IMPORTANT: This measurement procedure is a tank.
simple method. In order to measure accurately,
disconnect the return circuit from the manifold j : 19 mm (0.75 in)
valve and connect it to the hydraulic oil tank.
fNOTE: For the machine with the emergency steering,
install tee (24), adapter (25) and hose (26) to port E in the
emergency steering block. Install hose (26) to regulator
Preparation: port Pi2.
1. While referring to steps 1 to step 3 on T4-5-16,
install hydraulic tester (5) to the main pump to be 4. Disconnect the hose from Orbitrol (steering pilot
measured. valve) port P (11).
Install adapters (15) (3 used) to pressure reducing
valve (16). Install adapter (13) and hose (14)
between Orbitrol and charging block (2).
3 4 5 6 7
Connect hose (14) to port P1 of pressure reducing
valve (16).
j : 19 mm (0.75 in)
5. Install tee (17) to port P2 of pressure reducing valve

(16). Connect pressure gauge (18) and hose (9) to
TNED-04-05-005 tee (17). Connect hose (9) to the regulator port Pi1
(21).
j : 19 mm (0.75 in)
6. Connect hose (19) and tee (20) to port T of pressure

reducing valve (16).
Disconnect hose (10) from charging block port DR
(22). Install tee (20) to charging block port DR (22).
Connect hoses (10, 19) to tee (20).
j : 22, 27 mm (0.87, 1.06 in)
7. Remove the vacuum pump. Loosen plug (12) on top

of the pump casing. Bleed air from the casing until
oil only comes out.
j : 41 mm (1.61 in)
8. Fully open the loading valve of hydraulic tester (5).
9. Start the engine.

T4-5-18
8
12
12
8
1
11
To control valve Pc1

21
To control valve Pc2 21
10
2 2 22
90Z6-04-05-10
c
Pressure Reducing Valve Port Position
16 10
20
19
P1 P2
18 15 b
T
a P2 P1 23
2
9 17 15 16 15 14 13
90Z6-04-05-13
a- To Regulator Port Pi1 (21) b- To Orbitrol Port P (11) c- To Charging Block Port DR (22)
1- Main Pump (Regulator) 8- Port Pi2 15- Adapter G3/8 21- Port Pi1
2- Charging Block 9- Hose G1/4 16- Pressure Reducing Valve 22- Port DR
3- Test Hose (1-11/16-12UN) 10- Hose G1/2 (4325439) 23- Tee 3/4-16UNFxG3/8
4- Adapter 1-11/16-12UN×G1-1/2 11- Port P (Orbitrol) 17- Tee G3/8×G1/4×G1/4
5- Hydraulic Tester 12- Plug (Regulator) 18- Pressure Gauge
6- Adapter 1-11/16-12UN×G1-1/2 13- Adapter G3/8 19- Hose G3/8
7- Delivery Hose 14- Hose G3/8 20- Tee G3/8×G1/2×G1/2
T4-5-19
Measurement:
(131±9 °F).
2. Measure pump flow rate in response to the external

command pilot pressure.
Accelerator Power Mode Parking Forward/

Pedal Switch Brake Switch Reverse
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: 2150 min-1
Ne: Measured Engine Speed:
Values indicated on MPDr.

2. Standard Flow Rate
Refer to Operational Performance Standard (p.T4-2-
11).
T4-5-20
(Blank)
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 (0.87 in) adjustment.
m : 20 N·m (2 kgf·m, 15 lbf·ft)
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 (0.67 in)
m : 20 N·m (2 kgf·m, 15 lbf·ft)
Pi
TNED-04-5-008
3. P-Q Control (Torque Adjustment) Loosen lock nut (7) and turn adjusting Do not turn it more than 1 turn.
Q
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 (1.18 in)
m : 30 N·m (3 kgf·m, 22 lbf·ft)
Pd
TDAA-04-05-006
4. P-Q Control (Torque Adjustment) Loosen lock nut (9) and turn adjusting Do not turn it more than 1 turn.
Q 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.
j : 13 mm (0.5 in)
m : 10 N·m (1 kgf·m, 7 lbf·ft)
Pd
TDAA-04-05-007
T4-5-23
Service Brake Pressure (Front and Rear)

after removing and installing the pipe lines and
replacing hydraulic oil. (Refer to Troubleshooting
B.)
Summary:
Measure the pressure at the test port of axle assembly
when the brake pedal is depressed.
Preparation:
dCAUTION: Set blocks (1) at the front and rear

tires in order not to move the machine. Keep away
from the front or back of the machine.
1. Stop the engine.

T4GB-04-05-017
tank and bleed air. 1
3. Depress brake pedal at least 50 strokes in order to

decrease the accumulated pressure left in the brake
circuit.
T4-5-24
4. Install a pressure gauge to the test port (G3/8)

provided on the axle assembly.
Either of two ports in the front axle (2) is usable for
the front wheel brake circuit pressure measurement,
and ports in the rear axle (3) for the rear wheel
brake circuit pressure. Front Axle
j : 19 mm (0.75 in)
m : 30 N·m (3.0 kgf·m) (22 lbf·ft)


(131±9°F).
Measurement:
1. Set the following conditions: Rear Axle
Accelerator Pedal Power Mode Switch

90TNED-04-05-10
Full stroke ON
2. Measure the pressure when fully depressing the

brake pedal at left side to the floor.

the mean values.
Evaluation:
Standard: 4.6±0.6 MPa (667±87 PSI)
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

replacing hydraulic oil.
Summary:
Measure the parking brake release pressure in the
parking brake release circuit. T4GB-04-05-017
1
Preparation:
dCAUTION: Set blocks (1) onto the front and rear

3
from the machine.
1. Stop the engine.

tank and bleed air.
2 4
3. Disconnect brake hose (2) from parking brake (3).

Install a pressure gauge to the removed hose.
90Z6-04-05-01
j : 19 mm, 22 mm (0.75 in, 0.87 in)


(131±9 °F).
fNOTE: Parking brake pressure sensor (4) is installed to 3

the charging block.
Transmission Assy 90Z6-04-04-02
T4-5-26
Measurement:
Engine Speed Accelerator Pedal

High idle Full stroke
2. Release the parking brake and measure the pressure

at this time.

the mean values.
Evaluation:
Standard: 3.7+0.2/-0.1 MPa (536 +29/-14.5 PSI)
Remedy:
T4-5-27
Brake Accumulator Pressure

B.)
Summary:
Measure the accumulated brake pressure at the
accumulator output port. The accumulated brake
pressure varies according to operation of the brake.
Record the maximum value.
T4GB-04-05-017
Preparation:
1
d CAUTION: Set blocks (1) onto the front and rear
from the machine.
2
1. Stop the engine.

tank and bleed air.
A
3. Depress the brake pedal at least 50 strokes in
order to decrease the accumulated pressure left in
accumulator (4) of the brake circuit.
4. Remove plug (3) from the pressure check port (G3)

of charging block (2). 4
Install a nipple and a pressure gauge to the pressure 90Z6-04-05-11
check port.
j : 19, 22 mm (0.75, 0.87 in)
l : 6 mm (0.24 in)
G3

observed at the pressure gauge connection. Arrow View A
90Z6-04-05-12
6. Maintain the hydraulic oil temperature at 55±5 °C 2- Charging Block 4- Service Brake Accumulator
(131±9 °F). 3- Plug (Port G3)
T4-5-28
Measurement:
Full stroke (Engine: high idle) ON ON N
2. Measure the maximum pressure when depressing

the brake pedal slowly several times.

the mean values.
Evaluation:
Standard: 14.7±0.3 MPa (2132±43.5 PSI)
Remedy:
T4-5-29
Brake Warning Pressure (Pressure-

Decreasing)

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

T4GB-04-05-017
1
from the machine.
1. Stop the engine.
2
tank and bleed air.
3. Depress the brake pedal at least 50 strokes in order

to decrease the accumulated pressure left in the
A
brake circuit.

of charging block (2).
Install a nipple and a pressure gauge to the pressure
check port.
4
j : 19, 22 mm (0.75, 0.87 in) 90Z6-04-05-11
l : 6 mm (0.24 in)

observed at the pressure gauge connection. G3
3
6. Maintain the hydraulic oil temperature at 55±5 °C Arrow View A
(131±9 °F). 90Z6-04-05-12

3- Plug (Port G3)
T4-5-30
Measurement:
Forward/Reverse Lever Parking Brake Switch

N ON (Parking brake applied)
2. Stop the engine. Set the key switch to the ON

position.
3. Slowly depress the brake pedal several times.

Measure the pressure when the buzzer sounds.

the mean values.
Evaluation:
Standard: 8±0.5 MPa (1160±73 PSI)
Remedy:
T4-5-31
Brake Warning Pressure (Pressure-

Increasing)

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

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

tank and bleed air.
3. Depress the brake pedal at least 50 strokes in

2
order to decrease the accumulated pressure left in
accumulator (x) of the brake circuit.

of charging block (2).
A
Install a nipple and a pressure gauge to the pressure
check port.
j : 19, 22 mm (0.75, 0.87 in)
l : 6 mm (0.24 in)
4
5. Start the engine. Confirm that no oil leakage is 90Z6-04-05-11

(131±9 °F).
G3
3
Arrow View A
90Z6-04-05-12

3- Plug (Port G3)
T4-5-32
Measurement:
Forward/Reverse Lever Parking Brake Switch

N ON (Parking brake applied)
2. Stop the engine. Set the key switch to the ON

position.
3. Depress the brake pedal several times until the

buzzer sounds.
4. Start the engine. Measure the pressure when the

buzzer stops sounding. Notice that it is difficult to
read the gauge as the pressure increases rapidly.

the mean values.
Evaluation:
Standard: 10±0.5 MPa (1450±73 PSI)
Remedy:
T4-5-33
Transmission Clutch Pressure

Summary:
Measure each operating pressure of the transmission
clutch at each check port of the transmission control
valve.
Preparation:
1. Stop the engine.
2. Remove the plug from the check port.

Install a hose, an adapter, and a pressure gauge.
l : 8 mm (0.31 in)
j : 21 mm (0.83 in)
fNOTE: Although the pressure can be measured by using

one pressure gauge, all pressures can be measured by
using six pressure gauges at the same time.

4. Maintain the torque converter oil temperature at 60

to 80°C (140 to 176°F).
T4GB-04-05-017
T4-5-34
Measurement:

from the machine.
Accelerator Pedal Brake Pedal Power Mode Switch Declutch Position Parking Brake Switch
Switch
Full stroke Full stroke MANU (Manual) OFF OFF
2. Operate the forward/reverse lever and the shift

switch for the desired clutch.
Measured Clutch Pressure Forward Reverse 1st 2nd 3rd 4th

Forward/Reverse Lever (F/N/R) F R N N N N
Shift Switch (Speed) 4 4 1 2 3 4
3. Measure each clutch pressure at each test port.

1
2
the mean values. 3
4
5
Evaluation: 6
Standard: 2.2 ~ 2.4 MPa
90Z6-04-05-02
Test Port Location
1- Forward 4- Second Speed

2- Reverse 5- Third Speed
3- First Speed 6- Fourth Speed
T4-5-35
Torque Converter Pressure

Summary:
1 2 4
Measure the inlet and outlet pressure of torque
converter pressure at each check port of torque
converter.
Preparation:
1. Stop the engine.
2. Remove the plug from the respective check port

(1, 3), and install a hose, an adapter, and a pressure
gauge to the open part.
 Inlet pressure: Port at regulator valve (2)
 Outlet pressure: Port at housing (4) 4
1
l : 6 mm (0.23 in)

4. Maintain the torque converter oil temperature at 60

to 80°C (140 to 176°F).
T4GB-04-05-024
T4-5-36
Measurement:

from the machine.
T4GB-04-05-017
1. Select the following conditions: 5
Accelerator Pedal Brake Pedal Travel Mode Switch Declutch Position Parking Brake Switch
Switch
Full stroke Full stroke MANU (Manual) OFF OFF
2. Set the forward/reverse lever to F (Forward) and the

shift switch to 4 (Fourth Speed).
Measure the pressure.

the mean values.
Evaluation:
Inlet Pressure: 0.99~1.09 MPa
Outlet Pressure: 0.43~0.53 MPa
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).
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

A 90Z6-04-06-01
conditions.
Condition:
 Declutch Position Switch: OFF
 Travel Mode: Manual Mode
 Shift Switch: 4th
 Parking Brake Switch: OFF
 Brake Pedal: Depressed (Fully)
 Accelerator Pedal: Depressed (Fully)
 Forward/Reverse Lever: Forward Position
5. Depress the accelerator pedal and raise

transmission oil temperature (2) up to 90 °C (194 °F).
1
6. When transmission oil temperature (2) is 90 °C (194
°F), stop transmission stalling with the following
machine conditions. Detail A
90Z6-04-06-02
f NOTE: Do not raise the transmission oil temperature
above 116 °C (240 °F).
Deactivation Condition:
 Accelerator Pedal: Not Depressed
 Forward/Reverse Lever: Neutral Position
TNDB-04-06-011
 Parking Brake Switch: ON
 Brake Pedal: Not Depressed 2
T4-6-1
Group 6 Adjustment
MPDr. Operation:
1
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.
2
TNDB-04-06-013
2. When transmission oil temperature (3) is 110ºC

(230ºF), select Start (1) from the pull-down menu on
the Transmission Calibration screen and click Set (2).
TNDB-04-06-011
3
3. The message on the inquiry is displayed on the

Transmission Calibration screen on MPDr.
Click Yes (4).
4 TNDB-04-06-014
4. The learning starts and Progress (C1 to C6) of

learning is displayed on the monitor.
TNDB-04-06-004
3
T4-6-2
Group 6 Adjustment
5. When the learning is completed, the Learning End

screen appears on the monitor.
T4GB-04-06-006
6. The message "Writing process in controller is

complete" is displayed on the Transmission
Calibration screen on MPDr. Click OK (5).
7. Set the key switch to the OFF position, and finish

the learning.
5 TNDB-04-06-015
fNOTE: When the machine is in deactivation condition

while learning, the learning is stopped on the way. At
this time, the message on the error is displayed on the
Transmission Calibration screen on MPDr. Perform the
learning again.
TNDB-04-06-016
8. Wait 30 seconds after turning the key switch to OFF

position.
Turn the key switch to ON position and confirm no
transmission alarm lamp turns ON.
T4-6-3
Group 6 Adjustment
Lift Arm Angle Sensor Learning

IMPORTANT: When lift arm angle sensor has been
replaced, perform lift arm angle sensor learning.
Preparation:
1. Connect MPDr. (Refer to Transmission Learning.)
3. Set front control lever lock handle (1) to UNLOCK

position.
LOCK
4. Raise lift arms to the highest level by lift arm raise
1
operation.
UNLOCK
5. Set front control lever lock handle (1) to LOCK

position.
6. Set the key switch to the OFF position. 90Z6-04-06-03
T4-6-4
Group 6 Adjustment
MPDr. Operation:
IMPORTANT: When lift arm angle sensor has been

replaced, perform lift arm angle sensor learning. 1
1. Set the key switch to the ON position.

and Arm Angle Sensor Calibration in sequence.
Then, the Arm Angle Sensor Calibration screen
appears. 2
3. Select Start (1) from the pull-down menu on the

Arm Angle Sensor Calibration screen and click Set
(2).
TNDB-04-06-017
IMPORTANT: The learning can not be performed
when the value of lift arm angle sensor is out of
range from 3.3 V to 4.3 V.
4. When the learning is completed correctly, the

buzzer sounds. The message "Writing process in
controller is complete" is displayed on the Arm
Angle Sensor Calibration screen on MPDr. Click OK
(3).
5. Set the key switch to the OFF position, and finish

the learning.
TNDB-04-06-018
3
fNOTE: In case the learning is stopped on the way, the

message on the error is displayed on the Angle Sensor
Calibration screen on MPDr. Perform the learning again.
TNDB-04-06-019
T4-6-5
Group 6 Adjustment
Digging Position Adjustment

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

system, perform the digging position adjustment after
performing the lift arm angle sensor learning.
Preparation:
1. Connect MPDr. (Refer to Transmission Learning.)
3. Set front control lever lock switch (1) to UNLOCK

Position (3).
LOCK
4. Lower the lift arms and set the bucket on the
ground horizontally. 1
UNLOCK
5. Set front control lever lock switch (1) to LOCK

Position (2).
6. Set the key switch to the OFF Position. 90Z6-04-06-03
T4-6-6
Group 6 Adjustment
MPDr. Operation:
1
1. Set the key switch to the ON position.

and Digging Position Calibration in sequence.
Then, the Digging Position Calibration screen
2
appears.
3. Select Start (1) from the pull-down menu on the

Digging Position Calibration screen and click Set (2).
TNDB-04-06-020
4. When the learning is completed correctly, the

message "Writing process in controller is complete"
is displayed on the screen on MPDr. Click ON (3).
5. Set the key switch to the OFF position and finish the
learning.
fNOTE: Digging position adjustment can be set at the

position lower than horizontal lift arm position.
3 TNDB-04-06-021
T4-6-7
Group 6 Adjustment
(Blank)
T4-6-8
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Group 4 Component Layout
Introduction........................................................................... T5-1-1 Main Component (Overview).......................................... T5-4-1
Diagnosis Procedure........................................................... T5-1-2 Main Component (Travel System)................................. T5-4-3
Electric System Inspection................................................ T5-1-5 Electric Component Layout (Overview)...................... T5-4-4
Precautions for Inspection and Maintenance .......... T5-1-6 Electrical System (Cab)....................................................... T5-4-5
Instructions for Disconnecting Connectors............... T5-1-8 Controller and Relays.................................................... T5-4-6
Fuse Inspection...................................................................T5-1-10 Right Console................................................................... T5-4-7
Fuse Box A.......................................................................T5-1-11 Monitor and Switches................................................... T5-4-8
Fuse Box B.......................................................................T5-1-11 Monitor Panel.................................................................. T5-4-9
Fusible Link Inspection....................................................T5-1-12 Electrical System (Relays)................................................T5-4-10
Battery Voltage Check......................................................T5-1-13 Engine/Fan Pump..............................................................T5-4-11
Alternator Check................................................................T5-1-14 Transmission and Torque Converter Assembly.......T5-4-12
Continuity Check...............................................................T5-1-15 Hydraulic Pump Device...................................................T5-4-13
Voltage and Current Measurement.............................T5-1-16 Multiple Control Valve......................................................T5-4-14
24-Volt Circuit................................................................T5-1-16 Charging Block....................................................................T5-4-15
5-Volt Circuit...................................................................T5-1-22 Front Axle..............................................................................T5-4-15
Check by False Signal.......................................................T5-1-23 Steering Valve......................................................................T5-4-16
Test Harness.........................................................................T5-1-24 Brake Valve...........................................................................T5-4-16
Fan Motor.............................................................................T5-4-16
Group 2 Monitor Pilot Valve.............................................................................T5-4-16
Outline..................................................................................... T5-2-1 Ride Control Group (Option).........................................T5-4-17
Monitor Panel.................................................................. T5-2-1 Secondary Steering Group (Option)...........................T5-4-18
Monitor Display............................................................... T5-2-2 Secondary Steering Pump (Option)......................T5-4-18
Vehicle Information Display....................................... T5-2-2
Operating Procedures of Service Menu....................... T5-2-3 Group 5 Troubleshooting A
How to display service menu..................................... T5-2-4 Troubleshooting A (Base Machine Diagnosis
Engine Speed................................................................... T5-2-4 By Using Fault Codes) Procedure ............................. T5-5-1
Coolant Temperature.................................................... T5-2-4 MPDr. Fault Code Reference Table................................. T5-5-3
Transmission Oil Temperature................................... T5-2-4 MC Fault Code List............................................................... T5-5-9
Hydraulic Oil Temperature.......................................... T5-2-4 Controller Hardware Failure....................................... T5-5-9
Fault Code......................................................................... T5-2-5 CAN Data Reception Failure.....................................T5-5-10
Fuel Consumption.......................................................... T5-2-5 Engine Failure................................................................T5-5-11
List of Service Menu Display....................................... T5-2-6 Pump Failure..................................................................T5-5-12
Coolant Temperature Gauge and Pilot Failure.....................................................................T5-5-13
Transmission Oil Temperature Gauge..................... T5-2-7 Proportional Solenoid Valve Failure......................T5-5-15
Fuel Gauge............................................................................. T5-2-8 Revolution Sensor Failure..........................................T5-5-20
Learning Failure............................................................T5-5-21
Group 3 e-Service Switch Failure.................................................................T5-5-21
Outline..................................................................................... T5-3-1 Temperature Sensor Failure......................................T5-5-22
List of Operation Data........................................................ T5-3-2 Other Sensor Failures..................................................T5-5-23
List of Daily Report Data.............................................. T5-3-2 Alarms on Monitor.......................................................T5-5-24
List of Frequency Distribution Data......................... T5-3-4 Monitor Controller (Monitor) Fault Code List..........T5-5-26
List of Total Operating Hours..................................... T5-3-5 Monitor Controller (Information) Fault Code List...T5-5-28
Snapshot Data....................................................................... T5-3-6 Column Display Controller Fault Code List...............T5-5-30
Communication System.................................................... T5-3-7 Communication Terminal Fault Code List.................T5-5-32
90Z6 Trbl
Air Conditioner Controller Fault Code List................T5-5-33 Group 6 Troubleshooting B
ECM Fault Code List...........................................................T5-5-34 Troubleshooting B (Machine Diagnosis by Using
MC Fault Codes 111000 to 111002..............................T5-5-41 Troubleshooting Symptom) Procedure.................. T5-6-1
MC Fault Code 111003.....................................................T5-5-42 Relationship between Machine Trouble
MC Fault Codes 111006, 111007, 111014, Symptoms and Related Parts..................................... T5-6-3
111025..............................................................................T5-5-44 Correlation between Trouble Symptoms and
Monitor Controller (Monitor) Fault Codes Part Failures.................................................................T5-6-25
113002, 113003, 113005, 113007...........................T5-5-45 Engine System Troubleshooting.............................T5-6-26
Monitor Controller (Information) Fault Codes All Actuator System Troubleshooting...................T5-6-28
114010, 114011, 114015............................................T5-5-45 Front Attachment System Troubleshooting.......T5-6-31
CAN1 Harness Check........................................................T5-5-46 Steering System Troubleshooting..........................T5-6-35
MC Fault Codes 111103, 111105..................................T5-5-49 Travel System Troubleshooting...............................T5-6-37
MC Fault Code 111200.....................................................T5-5-50 Brake System Troubleshooting................................T5-6-40
MC Fault Codes 111205, 111207..................................T5-5-51 Other System Troubleshooting...............................T5-6-41
MC Fault Codes 111217, 111312..................................T5-5-52 Engine System Troubleshooting..................................T5-6-45
MC Fault Code 111204.....................................................T5-5-53 All Actuator System Troubleshooting.........................T5-6-51
MC Fault Code 111206.....................................................T5-5-54 Front Attachment System Troubleshooting.............T5-6-56
MC Fault Code 111208.....................................................T5-5-55 Steering System Troubleshooting...............................T5-6-65
MC Fault Codes 111311, 111313..................................T5-5-56 Travel System Troubleshooting....................................T5-6-69
MC Fault Code 111411.....................................................T5-5-57 Brake System Troubleshooting.....................................T5-6-79
MC Fault Code 111412.....................................................T5-5-58 Other System Troubleshooting.....................................T5-6-83
MC Fault Code 111413.....................................................T5-5-59 Exchange Inspection........................................................T5-6-97
MC Fault Codes 111414 to 111419..............................T5-5-60 Air Bleeding Procedures for Brake (Axle)...................T5-6-99
MC Fault Code 111422.....................................................T5-5-61
MC Fault Codes 111600, 111601, 111602.................T5-5-62 Group 7 Air Conditioner
MC Fault Code 111900.....................................................T5-5-63 Outline..................................................................................... T5-7-1
Torque Converter Oil Temperature Sensor Component Layout........................................................ T5-7-2
Specification................................................................T5-5-63 Functions of Main Parts..................................................... T5-7-4
MC Fault Code 111901.....................................................T5-5-64 Troubleshooting................................................................... T5-7-8
Hydraulic Oil Temperature Sensor Air Conditioner Controller Fault Code List.................. T5-7-9
Specification................................................................T5-5-64 Air Conditioner Controller Fault Codes 11 to 22.....T5-7-10
MC Fault Code 111902.....................................................T5-5-65 Air Conditioner Controller Fault Codes 43 to 92.....T5-7-11
Axle Oil Temperature Sensor Specification.........T5-5-65 Faulty cooling................................................................T5-7-12
MC Fault Codes 111700 to 111705..............................T5-5-66 Faulty heating................................................................T5-7-19
MC Fault Codes 120000 to 120005..............................T5-5-68 Others...............................................................................T5-7-21
MC Fault Code 120014.....................................................T5-5-68 Cooling circuit check by
Column Display Controller Fault Code 115001.......T5-5-69 using manifold gauge...........................................T5-7-25
Column Display Controller Fault Code 115011.......T5-5-70 Work after Replacing Components.............................T5-7-27
Fuel Level Sensor Specifications.............................T5-5-71 Refill Compressor Oil........................................................T5-7-28
Monitor Controller (Monitor) Fault Code 120300..T5-5-72 Charge Air Conditioner with Refrigerant..................T5-7-29
Column Display Controller (Information) Fault Codes Hose and Pipe Tightening Torque................................T5-7-37
120500 to 120503.........................................................T5-5-72
Column Display Controller (Information) Fault Codes
120505 to 120507.........................................................T5-5-73
Air Conditioner Controller Fault Codes 11 to 22.....T5-5-74
Air Conditioner Controller Fault Codes 43 to 92.....T5-5-75
90Z6 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 service menu of monitor).
Example: Fuse Inspection
IMPORTANT: The monitor controller receives and
 Monitor retains a record of the electrical signal system
This group contains the display screen of monitor malfunction of each controller in the form of
and the operating procedures of service menu. fault codes by using the CAN communication. In
addition, the self-diagnosing function records the
 e-Service (Option) electrical signal system malfunction in the form of
This group contains as follows. Download data from fault codes
the monitor controller and Upload. Procedures when
starting satellite communication, when installing Example: Fault Code 111000-2: Abnormal EEPROM
the satellite communication controller and when
replacing the monitor controller. Explanation for the  Troubleshooting B (Machine Diagnosis by Using
satellite communication system. Troubleshooting Symptom)
Refer to troubleshooting B for diagnosis by using
 Component Layout trouble symptom.
Refer to these procedures when no fault codes are
displayed after diagnosing the machine by using
MPDr. (or the service menu of monitor).
Example: Even if accelerator pedal is operated,

engine speed does not change.
 Air Conditioner
This group contains system of the air conditioner,
troubleshooting, and procedures for charging air
conditioner with refrigerant.
T5-1-1
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 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 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 MPDr.
(the service menu of monitor).
fNOTE: Note that the fault codes displayed do not

necessarily indicate machine trouble. The controller
stores even temporary electrical malfunctions, such as
a drop in battery output voltage or disconnection of the
switches, sensors, etc., for inspections. For this reason,
the "RETRIAL" is required to erase the accumulated fault
codes from the controller memory and to confirm if any
fault codes are indicated after the "RETRIAL".
T5-1-3
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 harness from the negative terminal
side in battery first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses and fusible links and, in some cases,
cause fire due to short-circuit. In addition, even
when the key switch is turned OFF, the controller
may be operated for a specified time. Therefore,
disconnect the harness from the negative terminal
side in battery after setting the key switch to the
OFF position and waiting one minute or more.
2. Color coding of wire harnesses.
As for the color codes of wire harnesses in the
electrical system, refer to the table. In cases on the
design sheet where two colors are indicated for one
wire, the left initial stands for base color, while the
right initial stands for marking color.
Code R W L G Y B O Lg Br P Gr V
Light
Color Red White Blue Green Yellow Black Orange 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 harnesses, grasp them
by their connectors. Do not pull on the wire
itself. Release the lock first before attempting to
separate connectors, if a lock is provided. (Refer to
Instructions for Disconnecting Connector on page
T5-1-8.)
 The water-resistant connectors keep water out. TDAA-05-08-002
If water enters them, water will not easily drain
from them. When checking the water-resistant
connectors, take extra care not to allow water to
enter the connectors. In case water should enter the 1
connectors, reconnect only after the connectors are
thoroughly dried. 2
 Before connecting the terminal connectors, check
that no terminals are bent (3) or coming off (4). 3
In addition, as most connectors are made of brass,
check that no terminals are rusting (2).
 When connecting terminal connectors provided with 4
a lock, insert them together until the lock "clicks." TDAA-05-08-003
 Pull the harness near the connector in order to check
if it is correctly connected.
1- Correct 3- Incorrect (Bent)
2- Rust 4- Incorrect (Coming Off )
4. Precaution for using a circuit tester.

 Before using a circuit tester, refer to the instructions
in the circuit tester manual. Then, set the circuit
tester to meet the object to be measured, voltage TDAA-05-08-004
range and current polarity.
 Before starting the connector test, always check the
connector terminal numbers, referring to the circuit
diagram. When the connector size is very small, and
the standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or a pin
around the probe to make the test easier.
 When checking the connector by using a circuit
tester, insert a tester probe from the harness end
of connector in order not to damage the terminal
inside connector.
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 (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 (0.16 in)
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 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
in order to correctly inspect fuse continuity. Use a circuit e d e
tester in order to correctly inspect fuse continuity by
following the instructions described below.
1. Set the key switch to the ON position. When the

key switch is in the ON position, current from key
switch terminal M turns the battery relay ON so that
electric power is supplied to all circuits. (Refer to the
circuit diagram.)
2. Remove the fuse box cover. Set a circuit tester.

(Measurement Range: 0 to 30 V)
3. Ground the negative probe of circuit tester to

the body. Touch the terminals located (e) of fuse
box one-by-one with the positive probe of circuit
M178-07-034
tester. When normal continuity of a fuse is intact,
the circuit tester will indicate 20 to 25 V (battery
voltage). d- Terminals connected to the e- Terminals connected to loads
power source (accessories)
b
a
a, b
10 20
9 19
8 18
7 17
6 16
5 15
4 14
c 3 13
MNEC-01-047 12
2
1 11
a- Fuse Box A c- Relay Box
b- Fuse Box B M178-07-034
T5-1-10
Fuse Box A Fuse Box B
Fuse No. Capacity Connected to Fuse No. Capacity Connected to

1 5A Back-up Alarm, Back-up Lamp 1 5A Radio (Power)
2 5A Brake Lamp, 2 10 A Cigar Lighter
Turn Signal Switch
3 10 A Head Light (Low) 3 15 A Front Wiper/ Washer
4 10 A Lighting Switch 4 20 A Working Light (Front)
5 (15 A) (Option 1) (Bt) 5 10 A Rear Wiper/ Washer
6 10 A Horn 6 10 A Air Conditioner Compressor Clutch
7 10 A Flasher Relay, Hazard Light 7 10 A DC/DC Converter (Opt)
8 10 A MC (Power), Load Dump Relay, 8 15 A Seat Heater (Opt)
Information Controller (Backup Power),
Column Monitor Controller (Power),
GPS/GSM (Opt)(Power)
9 10 A ECM1 (Power) 9 10 A Beacon Light (Opt)
10 10 A ECM2 (Power), 10 20 A Air Conditioner Blower Motor
INSITE (Engine Tool) (Opt)
11 10 A Position (Tail Lamp, Width Lamp) 11 5A Dome Lamp,
Radio (Backup Power)
12 (20 A) (Option 2) (ACC) 12 10 A Neutral Relay
13 10 A Power ON, Battery Relay, 13 (15 A) (Option 3)
Buzzer in Column Monitor Controller,
Information Controller,
Declutch Position Switch,
Shift Up Delay Indicator,
ECM, MC (Key ON), ECM Main Relay,
Air Conditioner Unit, Parking Brake Relay,
Back-up Lamp Relay,
Communication Terminal (Opt)(Key ON),
Steering Pressure Switch (Opt)
14 5A Neutral Relay, 14 (10 A) (Option 4)
Alternate Droop Relay
15 10 A MC Proportional Solenoid Valve (PPV) 15 -
16 10 A Loader Control, Bucket Detent Coil, 16 -
Bucket Proximity Switch,
Height Kickout Proximity Switch,
Lift Arm Height/Lower Kickout Coil (Opt),
Pilot Shut-Off Solenoid Valve (Opt),
Hydraulic Quick Coupler Switch (Opt)
17 20 A Working Light (Rear) 17 -
Working Light (CAB Rear) (Opt)
18 5A Parking Brake Solenoid 18 -
19 10 A Head Light (High Beam), 19 -
Monitor
20 5A Secondary Steering Pump Relay (Opt) 20 -
T5-1-11
Fusible Link Inspection

Inspection 2
1. Visually inspect fusible links (1).
90Z6-05-01-01
Replacement 1, 2
4
1. Disconnect the negative cable from the battery.
2. Remove two bolts (3) and pull up to replace a

fusible link (1, 2).
3. Connect the negative cable to the battery.
3 90Z6-05-01-02
1- Fusible Link (70 A) 3- Bolt

2- Fusible Link (100 A) (3 used) 4- Fuse Element
T5-1-12
Battery Voltage Check

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

battery.
2. Start the engine. Check voltage between the

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

system.
90Z6-05-01-03
T5-1-13
Alternator Check
Generally, if the alternator has generated electricity,
alternator alarm (1) will disappear. If discharge warning
indicator (1) is displayed while the engine is running, the
alternator might be defective.
How to Check Alternator

1. Set the key switch to the ON position. Confirm that
discharge warning indicator (1) is displayed.
1 MNDB-01-008
2. Measure voltage between terminals B (power

supply) and G (ground) of alternator (2).
If the measured voltage is around 24 V, the
alternator circuit can be considered normal.
If the measured voltage is low, a shortage in battery
capacity or looseness of the wire connectors 2
of alternator circuit might be the cause of the
G
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. B
3. Next, start the engine and measure voltage

generated while the alternator rotates.
Measure voltage between terminals B and G on the
alternator side in the same manner as step 2.
If voltage is around 28 V, the alternator is operating
normally. If the rated voltage is not being generated 90Z6-05-01-04
(around 24 V), there is some trouble with the Image of voltage check
alternator or the regulator.
T5-1-14
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 harness and
check continuity between both ends:
 If the ohm-meter reading is: ∞ 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 harness
through the body as illustrated.
 If the ohm-meter reading is: ∞ Ω = Discontinuity
 0 Ω = Continuity
A a
 Single-line short-circuit check

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

Disconnect both end connectors of the harness, and
short-circuit two terminals, (A) and (B), at one end
connector, as illustrated. Then, check continuity between A a
B b
terminals (a) and (b) at the other connector. C c
If the ohm-meter reading is ∞ Ω, either line (A) - (a),
or (B) - (b) is in discontinuity. To find out which line is
discontinued, conduct the single line continuity check
on both lines individually, or, after changing the short-
circuit terminals from (A) - (B) to (A) - (C), check continuity
once more between terminals (a) and (c). By conducting
the multi-line continuity check twice, it is possible to find T107-07-05-004
out which line is discontinued. With terminals (A) and (C)
short-circuited, check continuity between terminals (a)
and (c).
 0 Ω = Line (B) - (b) has discontinuity.
 ∞ Ω = Line (A) - (a) has discontinuity.
A a
B b
C c
 Multi-line short-circuit check
Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or (C).
 0 Ω = Short-circuit exists between the lines.
 ∞ Ω = No short-circuit exists between the lines.
T107-07-05-005
T5-1-15
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 Power 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 20 to 25 V
Stopped ON or START Between (7) and Ground: Intake Air Heater *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/Generating Voltage 26 to 30 V
Fast Speed ON Between (17) and Ground: Fusible Link (140 A)/Generating 26 to 30 V
Voltage
Fast Speed ON Between (14) and Ground: Information Controller (A15) 26 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 Relay 26 to 30 V
Idle Speed ON Between (6) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (15) and Ground: Monitor Controller, Switch Panel, Air 20 to 25 V
Conditioner Unit, ECM, MC
Stopped ON Between (18) and Ground: Radio 20 to 25 V
Stopped ON Between (19) and Ground: Fusible Link (140 A) 20 to 25 V
Stopped ON Between (6) and Ground: Battery Relay 20 to 25 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.
T5-1-16
k Monitor
5 c 3 2 1
f
4 6 a
11 h
Key Switch (g) g 10
Preheat
OFF
ACC
l 15
ON
Start
8
d
18 i
ICF
14
17
j
e
9 7
19
90Z6-05-01-05
a- Battery e- Intake Air Heater i- Information Controller (ICF)

b- Alternator f- Load Dump Relay j- Fusible Link (100 A)
c- Fusible Link A (70A) g- Key Switch k- Column Monitor Controller
d- Battery Relay h- Fuse Box A l- Fuse Box B
T5-1-17

Starting Circuit
Started START Between (20) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (21) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (22) and Ground: Starter (B) 20 to 25 V
Started START Between (23) and Ground: Starter (C) 20 to 25 V
Started START Between (24) and Ground: Magnetic Switch (Switch) 20 to 25 V
Started START Between (25) and Ground: Voltage Relay (Switch) 20 to 25 V
Started START Between (26) and Ground: Fuse Box A (#4 ~ #10), Fuse Box B (#11) 20 to 25 V
Started START Between (27) and Ground: Key Switch 20 to 25 V
Started START Between (28) and Ground: Neutral Relay (Switch) 20 to 25 V
Started START Between (29) and Ground: Information Controller (C-8) 20 to 25 V
Started START Between (30) and Ground: MC (E04) 20 to 25 V
Started START Between (32) and Ground: ECM Main Relay 1 (Switch) 20 to 25 V
Started START Between (33) and Ground: ECM Main Relay 1 (Coil) 20 to 25 V
Started START Between (34) and Ground: ECM Main Relay 2 (Switch) 20 to 25 V
Started START Between (35) and Ground: ECM Main Relay 2 (Coil) 20 to 25 V
T5-1-18
e 20
22 a
Key Switch (e)
21
27 c
Preheat
OFF 24
ACC g
f 28 23
ON
Start 29 ICF
25 b
d
30 MC k 35
26
34 33
i ECM j
h
32
90Z6-05-01-06
a- Starter d- Voltage Relay g- Information Controller (ICF) j- ECM

b- Magnetic Switch e- Key Switch h- ECM Main Relay 1 k- MC
c- Battery Relay f- Neutral Relay i- ECM Main Relay 2
T5-1-19

Neutral Engine Start
Circuit *
Stopped ON Between (34) and Ground: Key Switch 20 to 25 V
Stopped ON Between (36) and Ground: Fuse Box A (#14) 20 to 25 V
Stopped ON Between (37) and Ground: MC (E13) 0V
Stopped ON Between (38) and Ground: Neutral Relay (Coil) 20 to 25 V
Stopped ON Between (39) and Ground: Neutral Relay (Switch) 0V
* Before measurement, set the forward/ reverse lever to the neutral position.
T5-1-20
34
Key Switch (a)
Preheat
OFF
ACC
ON
Start
a
e 39
c
37
e
b 38
36
MC
d
90Z6-05-01-07
a- Key Switch c- Forward/ Reverse Lever e- Neutral Relay

b- Fuse Box A d- Main Controller (MC)
T5-1-21
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 on the body 1 2
harness end connector and the body (ground).
 Key Switch: ON
ground to the body
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
(5 V power supply) on the body harness end connector 1 2
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)
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
T5-1-22
Check by False Signal

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

to terminal #3 or to the body (ground) when T107-07-05-010
checking a three-polarity connector.
Three Polarities
fNOTE: Some kinds of sensors can be monitored by the
1 2 3
service menu of the monitor.
T107-07-05-011
T5-1-23
Test Harness
Install a test harness between connectors. Check the
circuit condition depending on whether the test harness
lamp lights or extinguishes during operation.
 Wire Test Lamp
Use in order to check a single-line (discontinuity and/

or voltage).
T107-07-05-012
 During Operation: Light is ON.
 Solenoid Test Lamp

4
Use in order to check the solenoid valve unit circuits. 3
 When the corresponding control lever or switch is 1 2 2 1

operated: Light is ON.
T107-07-06-015
 Pressure Sensor Test Harness
Connect a test harness to the harness end connector

of pressure sensor. Check the state of pressure sensor
circuit.
TDAA-05-06-003
T5-1-24
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) to harness end connector (4) of pump delivery
pressure sensor (1).
3. Connect dummy sensor (2) to the female end

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

Manual for details of the monitor panel.
T5-2-1
Group 2 Monitor
Monitor Display
1
1- Monitor Display
2- Monitor Display Selection Switch
3- Monitor Display Selection Switch (Up)
4- Monitor Display Selection Switch (Down)
5- Speedometer
6- Vehicle Information Display
7- HOLD Display
8- F-N-R/Shift Position Indicator MNDB-01-008
4 3 2
9- Ride Control Indicator (Option)
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.
MNDB-01-008
1 2 3 4
Engine Speed (Figure A)

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

once on this screen, Transmission Oil Temperature is
displayed.
6
C
Transmission Oil Temperature (Figure C)
Current Transmission Oil Temperature (7) is displayed.
once on this screen, Hydraulic Oil Temperature is
displayed.
7
D
Hydraulic Oil Temperature (Figure D)
Current Hydraulic Oil Temperature (8) is displayed.
once on this screen, Fault Code is displayed.
TNDB-05-02-005
8
T5-2-4
Group 2 Monitor
Fault Code (Figure E)

1. Current fault code (5) can be displayed.
2. When some Fault Codes (5) exist and whenever

pushing monitor display selection switch (2), other
fault codes are displayed.
3. When pushing monitor display selection switch (3)

once on this screen, Fuel Consumption is displayed.
f NOTE: When the trouble of Fault Code (5) on the screen

is solved, '-----' (bar) is displayed.
MNDB-01-008
f NOTE: When Fault Code (5) does not exist, ERROR (6) is 2 3 4
displayed. In this case, '-----' (bar) is displayed.
5 6
E
TNDB-05-02-006
7
Fuel Consumption (Figure F)/ F
Average Fuel Consumption (Figure G)
1. Current Fuel Consumption (7) is displayed.

once on this screen, Average Fuel Consumption (8) TNDB-05-02-007
up to the present is displayed.
8
3. Whenever pushing monitor display selection switch G
(4) on this screen, Unit is changed (l/hgal/h).

once on this screen, Clock is displayed. (Figure H)
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 MC
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) (ºF)

A 25 (77)
E B 40 (104)
D
C 95 (203)
D 105 (221)
E (120) (248)
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) (ºF)

A 25 (77)
E B 50 (122)
D C 80 (176)
D 120 (248)
E (125) (257)
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) 10 +5/0
A
B 50 32.9±2.5
C 12 77±2.5
D 0 (EMPTY) 90±2.5
a
C
D
TNDB-05-02-011
f NOTE: When the fuel gauge reaches the (E) zone,

indictor (a) on the monitor panel is ON.
T5-2-8
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 or less) Total hours when coolant temperature is less than 80°C (176°F) during
a day.
Radiator Coolant Temperature (80 to 93 °C) Total hours when coolant temperature is 80°C (176°F) or more and less
than 94°C (201°F) during a day.
Radiator Coolant Temperature (94 to 104 °C) Total hours when coolant temperature is 94°C (201°F) or more and less
than 105°C (221°F) during a day.
Radiator Coolant Temperature (105 °C or more) Total hours when coolant temperature is 105°C (221°F) or more during
a day.
Hydraulic Oil Temperature (49 °C or less) Total hours when hydraulic oil temperature is less than 50°C (122°F)
during a day.
Hydraulic Oil Temperature (50 to 89 °C) Total hours when hydraulic oil temperature is 50°C (122°F) or more and
less than 90°C (194°F) during a day.
Hydraulic Oil Temperature (90 to 99 °C) Total hours when hydraulic oil temperature is 90°C (194°F) or more and
less than 100°C (212°F) during a day.
Hydraulic Oil Temperature (100 °C or more) Total hours when hydraulic oil temperature is 100°C (212°F) or more
during a day.
Torque Converter Oil Temperature (49 °C or less) Total hours when torque converter oil temperature is less than 50°C
(122°F) during a day.
Torque Converter Oil Temperature (50 to 89 °C) Total hours when torque converter oil temperature is 50°C (122°F) or
more and less than 90°C (194°F) during a day.
Torque Converter Oil Temperature (90 to 109 °C) Total hours when torque converter oil temperature is 90°C (194°F) or
more and less than 110°C (230°F) during a day.
Torque Converter Oil Temperature (110 °C or Total hours when torque converter oil temperature is 110°C (230°F) or
more) more during a day.
T5-3-4
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).
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 as follows.
 Communication Terminal:
Receives the data from monitor controller and GPS
antenna, and sends the data to the communication
antenna.
 GPS Antenna:
Receives location information of the machine.
 Communication Antenna:
Communicates the data.
T5-3-7
Group 3 e-Service
(Blank)
T5-3-8
Main Component (Overview)
5
2 3 4
1
12
11
10
9
8 90Z6T1-2-01
1- Bucket 6- CAB Rear Working Light 8- Rear Combination Light (Turn 10- Lift Arm (Boom) Cylinder
2- Lever (Bell Crank) (Option) Signal Light, Hazard Light, 11- Lift Arm (Boom)
3- Bucket Cylinder 7- Rear Working Light Clearance Light, Brake Light, 12- Bucket Link
4- Headlight Backup Light)
5- Front Working Light 9- Turn Signal Light, Hazard
Light, Clearance Light
T5-4-1
Main Component
20 21 22 23
19
18
17
16
15
14
13
2 1
3
12 4
5
11 10 90Z6T1-2-02
9 8 7 6
13
11 14
1- Multiple Control Valve (Loading) 16- Air Cleaner

2- Pilot Valve 17- Muffler
3- Stop Valve 18- Hydraulic Tank
4- Torque Converter Oil Filter 19- Safety Device (Pilot Shut-off Valve)
5- Charging Block (Unloader and 20- Front Attachment (Implement)
Accumulators) Pressure Sensor (at Pilot Valve) 10
6- Engine 21- Brake Valve
7- Fuel Filter 22- Orbitrol (Steering Pilot Valve)
8- Fuel Tank 23- Steering Valve
9- Engine Oil Filter 24- Fuel Cooler
10- Hydraulic Oil Cooler
11- Inter Charge Air Cooler
12- Fan Motor
13- Torque Converter Oil Cooler 24
14- Radiator
15- Coolant Level and Surge Tank
90Z6T1-2-02
T5-4-2
Main Component (Travel System)
2 3
1
4
11 10
9
90Z6T1-2-03
8 7 6
1- Front Axle 4- Hydraulic Pump 7- Rear Axle 10- Steering Accumulator

2- Brake Pressure Sensor 5- Transmission 8- Axle Support (Front) 11- Second (Front) Propeller
3- Steering Cylinder 6- Axle Support (Rear) 9- Third (Rear) Propeller Shaft Shaft
T5-4-3
Electric Component Layout (Overview)
5 6
11 4
90Z6T1-2-23
8
7
3
9
10
90Z6T1-2-04
1- Bucket Leveler Proximity Switch 6- Backup Alarm 11- Components Related with Cab (Refer to
2- Lift Arm Kickout Proximity Switch 7- Battery T5-4-5)
3- Lift Arm Angle Sensor (Option) 8- Fuel Level Sensor (at Fuel Tank)
4- Hydraulic Oil Temperature Sensor (at 9- Secondary Steering Pump (Option)
Hydraulic Tank Bottom) 10- Outside Temperature Sensor
5- Air Cleaner Restriction Switch
T5-4-4
Electrical System (Cab)
1 2
11
3
10
90Z6T1-2-05 90Z7-01-02-01
1- Radio 6- Front Wiper Motor 9- Components Related with Controllers and

2- Upper Switch Panel (Option) 7- Outside Temperature Sensor (for A/C) Relays (Refer to T5-4-6)
3- Speaker 8- Components in Right Side Console (Refer 10- Components Related with Monitor and
4- Rear Wiper Motor to T5-4-7) Switches (Refer to T5-4-8)
5- Brake Lamp Switch 11- Air Conditioner Control Unit
T5-4-5
Controller and Relays
3 A
12 11 10 9 8
17 16 15 14 13
2
22 21 20 19 18
1
27 26 25 24 23
32 31 30 29 28
7 6 33
34
Arrow View A 90Z6T1-2-06
1- Flasher Relay 15- Turn Signal Light Relay (Right) 29- Backup Lamp Relay
2- GSM (Option) 16- Horn Relay 30- CAB Working Light Relay (Front) (Option)
3- ICF (Monitor Controller) 17- Load Dump Relay 2 31- CAB Working Light Relay (Rear) (Option)
4- MCZ (Main Controller) 18- Parking Brake Relay 1 32- Secondary Steering Relay (Option)
5- MPDr. Connector 19- Parking Brake Relay 2 33- Pilot Shut-Off Relay (Option)
6- Fuse Box A 20- Engine Alternate Droop Relay 34- Voltage Relay
7- Fuse Box B 21- Brake Lamp Relay
8- ECM Relay 1 22- Load Dump Relay 1
9- Head Light Relay 23- Neutral Relay
10- High-Beam Relay 24- Turn Signal Light Relay (Left)
11- Bucket Leveler Relay 25- Front Washer Relay
12- Lift Arm Height Kickout Relay 26- Rear Wiper Relay
13- Working Lamp Relay (Front) 27- Rear Washer Relay
14- Working Lamp Relay (Rear) 28- ECM Relay 2
fNOTE: Refer to “Fuses and Relays” and “Floor Cable

Layout” in the Diagrams for the other parts.
T5-4-6
Right Console
Fingertip Control Type 20
3 (2) 21
8 9
2 (1) 10 11
12
1 (3)
22
19
18
6 13
7
15 14
17 16
90Z6T1-2-07a MNEC-01-042
fNOTE: The control lever positions can be changed.
Multi-Function Joystick Type (Option)
22 20
1
23 6 7
8
9
10
4 11 24
12
25
19
13
15 14 MNEC-01-044
17 16
90Z6T1-2-07b
1- Auxiliary Control Lever (Option) 11- Auxiliary 18- Hold Switch

2- Bucket Control Lever 12- Hydraulic Quick Coupler Switch (Option) 19- Control Lever Lock Handle (Safety Device)
3- Lift Arm Control Lever 13- Secondary Steering Operation Check 20- DSS (Down Shift Switch)
4- Forward/Reverse Switch (Option) Switch (Option) 21- Horn Switch
5- - 14- Lift Arm Auto Leveler Kickout Switch 22- Quick Power Switch
6- Auxiliary (Height) (Option) 23- Multi-Function Joystick Lever
7- Auxiliary 15- Lift Arm Auto Leveler Kickout Switch 24- Hold Switch (Under the Lever)
8- Power Mode Switch (Lower) (Option) 25- Horn Switch (Under the Lever)
9- Forward/Reverse Selector Switch (Option) 16- Auxiliary
10- Fan Reverse Rotation Switch (Option) 17- Ride Control Switch (Option)
T5-4-7
Monitor and Switches
7 8 9
4 5 6
10
3
2
11
90Z6T1-2-08
1- Front/Rear Wiper Switch 5- Forward/Reverse Lever, Shift Switch 9- Declutch Position Sensor
2- Hazard Switch 6- Monitor Panel (Refer to T5-4-9) 10- Shift Change Delay Mode Switch (Option)
3- Working Light Switch 7- Travel Mode Selector Switch 11- Turn Signal Lever, Light Switch, High-Low
4- Parking Brake Switch 8- Key Switch Beam Switch
T5-4-8
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 12- Axle Oil Temperature 22- (Not used) 32- Engine Oil Low Pressure
Indicator Indicator 23- Monitor Display Selection Indicator
2- High Beam Indicator 13- Brake Oil Low Pressure Switch (Up) 33- Air Filter Restriction Indicator
3- Working Light Indicator Indicator 24- Preheat Indicator 34- (Not used)
4- Right Turn Signal Light 14- (Not used) 25- Monitor Display Selection 35- (Not used)
Indicator 15- Secondary Steering Indicator Switch (Down) 36- (Not used)
5- (Not used) (Option) 26- Forward/Reverse Selector 37- Hydraulic Oil Temperature
6- (Not used) 16- Low Steering Oil Pressure Switch Indicator (Option) Indicator
7- Service Indicator Indicator (Option) 27- Monitor Display 38- Transmission Warning
8- Maintenance Indicator 17- Seat Belt Indicator 28- Fan Reverse Rotation Indicator
9- Parking Brake Indicator 18- Discharge Warning Indicator Indicator (Option) 39- Transmission Oil Temperature
10- Clearance Light Indicator 19- Fuel Gauge 29- Engine Warning Indicator Indicator
11- Front Control Lever Lock 20- Power Mode Indicator 30- Overheat Indicator 40- Transmission Oil Temperature
Indicator 21- Monitor Display Selection 31- Coolant Temperature Gauge Gauge
Switch
T5-4-9
Electrical System (Relays)
1 4
90Z6T1-2-19
90Z6-05-01-01
1- Battery Relay 3- Fusible Link (70 A)

2- Fusible Link (100 A) (3 used) 4- Intake Air Heater Relay
T5-4-10
Engine/Fan Pump
6
7
3
16
1 2
8
9
10
11
12
14
15
13 90Z6T1-2-09
1- Engine Oil Filter 7- After Charge Air Cooler (Intake Manifold) 12- Fuel Filter
2- Filter Outlet Pressure 8- ECM 13- Fan Pump
3- Coolant Inlet Pressure 9- ECM Cooling Plate 14- Fuel Pump
4- Coolant Temperature Sensor 10- Engine Position Sensor 15- Starter
5- Alternator 11- Engine Oil Pressure and Temperature 16- DCA4 Coolant Filter
6- Intake Manifold Pressure Sensor Sensor
T5-4-11
Transmission and Torque Converter Assembly
1 2 18
7 8
9 17 6
10
11
12
13 5
14
15
4 3
16
90Z6T1-2-10
1- Torque Converter 10- Proportional Solenoid Valve (For Reverse 15- Parking Brake Pressure Port
2- Torque Converter Charging Pump Clutch) 16- Flange (for 2nd Propeller Shaft)
3- Machine Speed Sensor 11- Proportional Solenoid Valve (For 1st 17- Torque Converter Oil Temperature
4- Transmission Output Speed Sensor Speed Clutch) Sensor
5- Transmission Middle Shaft Sensor 12- Proportional Solenoid Valve (For 2nd 18- Hydraulic Pump Device (Refer to T5-4-13)
6- Parking Brake Speed Clutch)
7- Transmission Control Valve 13- Proportional Solenoid Valve (For 3rd
8- Regulator Valve Speed Clutch)
9- Proportional Solenoid Valve (For Forward 14- Proportional Solenoid Valve (For 4th
Clutch) Speed Clutch)
fNOTE: The parking brake pressure sensor is installed to

the charging block. (See p.5-4-15.)
T5-4-12
Hydraulic Pump Device

1
5 4 T4GB-01-02-009
1- Main Pump 3- Priority Valve 5- Pilot Pump

2- Regulator 4- Pump Delivery Pressure Sensor 6- Steering Relief Valve
T5-4-13
Multiple Control Valve
7 2 3
7
6 1 4
5
8
5 4 3
90Z6T1-2-11
1- Overload Relief Valve (Lift Arm: Bottom 3- Overload Relief Valve (Bucket: Rod Side) 7- Check Valve (with 1.2 Orifice)
Side) 4- Make-up Valve (Lift Arm: Rod Side) 8- Lift Arm Spool
2- Overload Relief Valve (Bucket: Bottom 5- Main Relief Valve 9- Bucket Spool
Side) 6- Check Valve (with 1.0 Orifice)
T5-4-14
Charging Block
3 4
5
6
2
1
7
10
90Z6T1-2-13
1- Charging Block 5- Pump Torque Control Solenoid Valve 9- Service Brake Accumulator (Front)
2- Pilot Accumulator 6- Relief Valve (for Cut-in/Cut-out Pressure) 10- Pressure Sensor (Service Brake Primary
3- Pressure Sensor (Parking) 7- Pilot Relief Valve Pressure)
4- Parking Brake Solenoid Valve 8- Service Brake Accumulator (Rear)
Front Axle
1
90Z7-05-04-01
1- Axle Oil Temperature Sensor
T5-4-15
Steering Valve Fan Motor
2
90Z6T1-2-15 90Z6T1-2-14
1- Overload Relief Valve 1- Fan Speed Control Solenoid

2- Overload Relief Valve Valve (Relief Valve)
Brake Valve Pilot Valve
1 2
90Z6T1-2-17 90Z6T1-2-22
1- Pressure Switch (For Stop 2- Pressure Sensor (Service 1- Pilot Valve

Lamp) Brake Secondary Pressure for 2- Pressure Sensor (Pilot Primary Pressure)
Declutch)
T5-4-16
Ride Control Group (Option)

1
4
3
90Z6T1-2-21
1- Ride Control Valve (Option) 3- Ride Control Solenoid Valve

2- Overload Relief Valve 4- Ride Control Accumulator (Option)
90Z6T1-2-20
5- Pressure Sensor (Lift Arm Raise) (Option)
6- Multiple Control Valve
T5-4-17
Secondary Steering Group (Option)
Hydraulic Tank
90Z6T1-2-18
Main Pump
1- Secondary Steering Pump (Option) 2- Pressure Switch (Secondary Steering) 3- Secondary Steering Block (Check Valve
(Option) Assy) (Option)
Secondary Steering Pump (Option)
1
2
4 5
90Z6T1-2-16
1- Electric Motor 4- Pressure Sensor (Secondary

2- Relief Valve Steering Pump)
3- Gear Pump 5- Check Valve
T5-4-18
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, Main Controller (MC) may be faulty or the
power/ground of the sensor system may be faulty.
 When the MC fault code is displayed with other fault
code, replace MC.
 When fault code 111003-3 (Abnormal Sensor
Voltage) is displayed with other fault code, diagnose
for fault code 111003-3 first.
 In case more than one fault code other than those
described above are displayed at the same time,
diagnose for each fault code.
 It may be required that the machine is operated or
the test harness is connected at inspection.
Check the items of preparation and perform
inspection according to the procedures when
diagnosing.
fNOTE: Harness end connector viewed from the open

end side by the all connectors image shown in this
section.
1
2
T6L4-05-03-001
1- Harness End Connector 2- 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 or MP Inspection Evaluation Cause
Dr. Message Method
(A) (B) (C) (D) (E)
(F) (G) (H)
 A: Fault code
 B: Trouble details or message displayed on the Maintenance Pro Dr.
 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 T5-5-41
111001-2 Abnormal RAM MC T5-5-9 T5-5-41
111002-2 Abnormal A/D Converter MC T5-5-9 T5-5-41
111003-3 Abnormal Sensor Voltage MC T5-5-9 T5-5-42
111006-2 (MC) Engine Controller Communication Error MC T5-5-10 T5-5-44
111007-2 (MC) Information Controller Communication Error 1 MC T5-5-10 T5-5-44
111014-2 (MC) Air Conditioner Controller Communication Error MC T5-5-10 T5-5-44
111025-2 (MC) Column Monitor Controller Communication Error MC T5-5-10 T5-5-44
111103-3 Accelerator Pedal Circuit High Input MC T5-5-11 T5-5-49
111103-4 Accelerator Pedal Circuit Low Input MC T5-5-11 T5-5-49
111105-3 Abnormal Engine Speed Sensor MC T5-5-11 T5-5-49
111200-3 Lift Arm Raise Pilot Pressure Sensor Circuit High Input * MC T5-5-13 T5-5-50
111200-4 Lift Arm Raise Pilot Pressure Sensor Circuit Low Input * MC T5-5-13 T5-5-50
111204-3 Pump Delivery Pressure Sensor Circuit High Input MC T5-5-12 T5-5-53
111204-4 Pump Delivery Pressure Sensor Circuit Low Input MC T5-5-12 T5-5-53
111205-3 Lift Arm Angle Sensor Circuit High Input * MC T5-5-23 T5-5-51
111205-4 Lift Arm Angle Sensor Circuit Low Input * MC T5-5-23 T5-5-51
111206-3 Hyd. Fan Circuit Pressure Sensor Circuit High Input * MC T5-5-12 T5-5-54
111206-4 Hyd. Fan Circuit Pressure Sensor Circuit Low Input * MC T5-5-12 T5-5-54
111207-3 Refrigerant Pressure Sensor Circuit High Input MC T5-5-23 T5-5-51
111207-4 Refrigerant Pressure Sensor Circuit Low Input MC T5-5-23 T5-5-51
111208-3 Emergency Steering Check Pressure Sensor Circuit High MC T5-5-12 T5-5-55
Input *
111208-4 Emergency Steering Check Pressure Sensor Circuit High MC T5-5-12 T5-5-55
Input *
111217-3 Pilot Pressure Sensor Circuit High Input MC T5-5-13 T5-5-52
111217-4 Pilot Pressure Sensor Circuit Low Input MC T5-5-13 T5-5-52
111311-3 Service Brake Primary Pressure Sensor Circuit High Input MC T5-5-13 T5-5-56
111311-4 Service Brake Primary Pressure Sensor Circuit Low Input MC T5-5-13 T5-5-56
111312-3 Service Brake Secondary Pressure Sensor Circuit High MC T5-5-14 T5-5-52
Input
111312-4 Service Brake Secondary Pressure Sensor Circuit Low MC T5-5-14 T5-5-52
Input
111313-3 Parking Brake Pressure Sensor Circuit High Input MC T5-5-14 T5-5-56
111313-4 Parking Brake Pressure Sensor Circuit Low Input MC T5-5-14 T5-5-56
fNOTE: Error with an asterisk mark (*) is for optional function.
T5-5-3
MPDr. Fault Code Reference Table (Continued)

111411-2 Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB * MC T5-5-15 T5-5-57
111411-3 Hydraulic Fan Reverse Rotation P/S Valve FB High MC T5-5-15 T5-5-57
Current *
111411-4 Hydraulic Fan Reverse Rotation P/S Valve FB Low MC T5-5-15 T5-5-57
Current *
111412-2 Hyd. Fan P/S Valve Abnormal Feedback MC T5-5-16 T5-5-58
111412-3 Hyd. Fan P/S Valve Feedback High Current MC T5-5-16 T5-5-58
111412-4 Hyd. Fan P/S Valve Feedback Low Current MC T5-5-16 T5-5-58
111413-2 Pump Swash Angle P/S Valve Abnormal FB MC T5-5-16 T5-5-59
111413-3 Pump Swash Angle P/S Valve FB High Current MC T5-5-16 T5-5-59
111413-4 Pump Swash Angle P/S Valve FB Low Current MC T5-5-16 T5-5-59
111414-2 T/M Clutch 1st P/S Valve Abnormal FB MC T5-5-18 T5-5-60
111414-3 T/M Clutch 1st P/S Valve FB High Current MC T5-5-18 T5-5-60
111414-4 T/M Clutch 1st P/S Valve FB Low Current MC T5-5-18 T5-5-60
111415-2 T/M Clutch 2nd P/S Valve Abnormal FB MC T5-5-18 T5-5-60
111415-3 T/M Clutch 2nd P/S Valve FB High Current MC T5-5-18 T5-5-60
111415-4 T/M Clutch 2nd P/S Valve FB Low Current MC T5-5-18 T5-5-60
111416-2 T/M Clutch 3rd P/S Valve Abnormal FB MC T5-5-18 T5-5-60
111416-3 T/M Clutch 3rd P/S Valve FB High Current MC T5-5-18 T5-5-60
111416-4 T/M Clutch 3rd P/S Valve FB Low Current MC T5-5-18 T5-5-60
111417-2 T/M Clutch 4th P/S Valve Abnormal FB MC T5-5-19 T5-5-60
111417-3 T/M Clutch 4th P/S Valve FB High Current MC T5-5-19 T5-5-60
111417-4 T/M Clutch 4th P/S Valve FB Low Current MC T5-5-19 T5-5-60
111418-2 T/M Clutch Forward P/S Valve Abnormal FB MC T5-5-19 T5-5-60
111418-3 T/M Clutch Forward P/S Valve FB High Current MC T5-5-19 T5-5-60
111418-4 T/M Clutch Forward P/S Valve FB Low Current MC T5-5-19 T5-5-60
111419-2 T/M Clutch Reverse P/S Valve Abnormal FB MC T5-5-19 T5-5-60
111419-3 T/M Clutch Reverse P/S Valve FB High Current MC T5-5-19 T5-5-60
111419-4 T/M Clutch Reverse P/S Valve FB Low Current MC T5-5-19 T5-5-60
T5-5-4

111422-2 Ride Control P/S Valve Abnormal FB * MC T5-5-17 T5-5-61
111422-3 Ride Control P/S Valve FB High Current * MC T5-5-17 T5-5-61
111422-4 Ride Control P/S Valve FB Low Current * MC T5-5-17 T5-5-61
111600-3 T/M Out Speed Sensor Failure MC T5-5-20 T5-5-62
111600-4 T/M Out Speed Sensor Circuit Low Input MC T5-5-20 T5-5-62
111601-3 Torque Converter Output Speed Sensor Failure MC T5-5-20 T5-5-62
111602-3 Intermediate Shaft Speed Sensor Failure MC T5-5-20 T5-5-62
111700-xx Calibration Abort Forward MC T5-5-21 T5-5-66, 67
111700-31 Calibration Abort Forward: Un-Calibration MC T5-5-21 T5-5-67
111701-xx Calibration Abort Reverse MC T5-5-21 T5-5-66, 67
111701-31 Calibration Abort Reverse: Un-Calibration MC T5-5-21 T5-5-67
111702-xx Calibration Abort 1st MC T5-5-21 T5-5-66, 67
111702-31 Calibration Abort 1st: Un-Calibration MC T5-5-21 T5-5-67
111703-xx Calibration Abort 2nd MC T5-5-21 T5-5-66, 67
111703-31 Calibration Abort 2nd: Un-Calibration MC T5-5-21 T5-5-67
111704-xx Calibration Abort 3rd MC T5-5-21 T5-5-66, 67
111704-31 Calibration Abort 3rd: Un-Calibration MC T5-5-21 T5-5-67
111705-xx Calibration Abort 4th MC T5-5-21 T5-5-66, 67
111705-31 Calibration Abort 4th: Un-Calibration MC T5-5-21 T5-5-67
111720-2 Lift arm angle sensor is uncalibrated. MC T5-5-21 -
111900-3 Torque Converter Oil Temperature Sensor Circuit High MC T5-5-22 T5-5-63
Input
111900-4 Torque Converter Oil Temperature Sensor Circuit Low MC T5-5-22 T5-5-63
Input
111901-3 Hyd. Oil Temp Sensor Circuit High Input MC T5-5-22 T5-5-64
111901-4 Hyd. Oil Temp Sensor Circuit Low Input MC T5-5-22 T5-5-64
111902-3 Axle Oil Temperature Sensor Circuit High Input MC T5-5-22 T5-5-65
111902-4 Axle Oil Temperature Sensor Circuit Low Input MC T5-5-22 T5-5-65
111904-2 Column FNR SW Failure MC T5-5-21 -
111905-2 Implement FNR SW Failure MC T5-5-21 -
T5-5-5

113002-2 (Monitor Controller) Engine Controller Monitor T5-5-26 T5-5-45
Communication Error
113003-2 (Monitor Controller) Main Controller Communication Monitor T5-5-26 T5-5-45
Error 1
113005-2 (Monitor Controller) ICF Communication Error 1 Monitor T5-5-26 T5-5-45
113007-2 (Monitor Controller) Column Controller Monitor T5-5-26 T5-5-45
Communication Error
113303-2 Abnormal thermistor temperature (monitor inside Monitor T5-5-27 -
temperature)
114001-2 Flash Memory Read/Write Error Information T5-5-28 -
114002-2 External RAM Read/Write Error Information T5-5-28 -
114003-2 Abnormal EEPROM Information T5-5-28 -
114008-2 Abnormal Internal RAM Information T5-5-28 -
114010-2 (Information Controller) Engine Controller Information T5-5-29 T5-5-45
Communication Error
114011-2 (Information Controller) Main Controller Information T5-5-29 T5-5-45
Communication Error 1
114015-2 (Information Controller) Column Controller Information T5-5-29 T5-5-45
Communication Error
114100-2 Communication Terminal: Abnormal EEPROM Communication T5-5-32 -
Terminal
114101-2 Communication Terminal: Abnormal IB/OB Queue Communication T5-5-32 -
Terminal
114102-2 Communication Terminal: Abnormal Local Loop Back Communication T5-5-32 -
Terminal
114103-2 Communication Terminal: No Satellite Found Communication T5-5-32 -
Terminal
114104-2 Communication Terminal: Remote Loop Back Error 1 Communication T5-5-32 -
Terminal
114105-2 Communication Terminal: Remote Loop Back Error 2 Communication T5-5-32 -
Terminal
114106-2 Communication Terminal: Transmission/Receiving Communication T5-5-32 -
Data Unmatched Terminal
T5-5-6

115001-2 Abnormal REG input H level Column Display T5-5-30 T5-5-69
115002-2 CAN Communication Error Column Display T5-5-30 -
115003-2 Abnormal EEPROM Column Display T5-5-30 -
115011-3 Fuel Level Sensor Circuit High Input Column Display T5-5-30 T5-5-70
115011-4 Fuel Level Sensor Circuit Low Input Column Display T5-5-30 T5-5-70
120000-2 Hydraulic Oil Overheat Alarm MC T5-5-24 T5-5-68
120001-2 Main Pump Pressure Alarm MC T5-5-24 T5-5-68
120002-2 Axle Oil Temperature Alarm MC T5-5-24 T5-5-68
120003-2 Emergency Steering Activated (Option) MC T5-5-24 T5-5-68
120004-2 Emergency Steering Activated Pressure Alarm MC T5-5-24 T5-5-68
(Option)
120005-2 Transmission Oil Temperature Overheat Alarm MC T5-5-24 T5-5-68
120013-2 Brake Oil Pressure Alarm MC T5-5-25 -
120014-2 Overrun Alarm MC T5-5-25 T5-5-68
120300-2 System Failure Alarm Information T5-5-29 T5-5-72
120500-2 Overheat Alarm Column Display T5-5-31 T5-5-72
120501-2 Engine Error Column Display T5-5-31 T5-5-72
120502-2 Engine Oil Pressure Alarm Column Display T5-5-31 T5-5-72
120503-2 Air Cleaner Restriction Alarm Column Display T5-5-31 T5-5-73
120505-2 Brake Pressure Alarm Column Display T5-5-31 T5-5-73
120506-2 Steering Oil Pressure Alarm (Option) Column Display T5-5-31 T5-5-73
120507-2 T/M Malfunction Column Display T5-5-31 T5-5-73
fNOTE:
 Refer to page T5-5-33 for the air conditioner controller fault code list.
 Refer to page T5-5-34 for the ECM fault code list.
T5-5-7
(Blank)
T5-5-8
MC Fault Code List
Controller Hardware Failure

Fault Code Trouble or MP Dr. Cause Symptoms in Machine Operation Remedy
Message 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 pedal is Check the sensor
Voltage Faulty sensor operated, the engine speed does connected to MC.
Faulty harness not change. Check the harness.
Replace MC.
T5-5-9
CAN Data Reception Failure

111006-2 (MC) Engine Faulty harness Even if accelerator pedal is Check the harness.
Controller operated, engine speed does not
Communication change.
Error
111007-2 (MC) Information Faulty monitor Nothing observed. Check the CAN1
Controller controller harness.
Communication Faulty CAN1 harness Replace monitor
Error 1 controller.
111014-2 (MC) Air Conditioner Faulty air conditioner The air conditioner does not work. Check the CAN1
Controller controller harness.
Communication Faulty CAN1 harness Replace the
Error air conditioner
controller.
111025-2 (MC) Column Faulty column display The transmission warning indicator Check the CAN1
Monitor controller and control lever lock indicator on harness.
Communication Faulty CAN1 harness column display controller do not Replace column
Error light. display controller.
Overrun alarm control is disabled.
T5-5-10
Engine Failure
111103-3 Accelerator Pedal Voltage: more than The engine speed is fixed to 1000 Check the harness.
Circuit High Input 4.74 V min-1. Replace the
accelerator pedal
sensor.
111103-4 Accelerator Pedal Voltage: less than The engine speed is fixed to 1000 Check the harness.
Circuit Low Input 0.25 V min-1. Replace the
accelerator pedal
sensor.
111105-3 Abnormal Engine Torque converter The actual engine speed may not Check the harness.
Speed Sensor input speed sensor be obtained or displayed correctly. Check and adjust the
= 0 min-1 and Engine engine speed sensor.
speed sent from ECM
(CAN) > 500 min-1
T5-5-11
Pump Failure
111204-3 Pump Delivery Voltage: 4.75 V or Engine speed regulator for Check the harness.
Pressure Sensor more digging is deactivated. Replace the pump
Circuit High Input delivery pressure sensor.
111204-4 Pump Delivery Voltage: less than Engine speed regulator for Check the harness.
Pressure Sensor 0.25 V digging is deactivated. Replace the pump
Circuit Low Input delivery pressure sensor.
111206-3 Hyd. Fan Circuit Voltage: 4.75 V or Fan rotation direction (in normal / Check the harness.
Pressure Sensor more reverse) cannot change manually Replace the fan pump
Circuit High Input or automatically. delivery pressure sensor.
111206-4 Hyd. Fan Circuit Voltage: less than Fan rotation direction (in normal / Check the harness.
Pressure Sensor 0.25 V reverse) cannot change manually Replace the fan pump
Circuit Low Input or automatically. delivery pressure sensor.
111208-3 Emergency Steering Voltage: 4.75 V or The initial automatic check for Check the harness.
Check Pressure 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 on
monitor blinks.
111208-4 Emergency Steering Voltage: less than The initial automatic check for Check the harness.
Check Pressure 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.
Secondary steering indicator on
monitor blinks.
T5-5-12
Pilot Failure
111200-3 Lift Arm Raise Pilot Voltage: 4.75 V or Bucket speed is slow during combined Check the harness.
Pressure Sensor more operation of lift arm and bucket. Replace the pressure
Circuit High Input Ride control is not activated. sensor (lift arm raise).
Speed shift delay control is always
delayed at AUTO 2 mode.
111200-4 Lift Arm Raise Pilot Voltage: less than Bucket speed is slow during combined Check the harness.
Pressure Sensor 0.25 V operation of lift arm and bucket. Replace the pressure
Circuit Low Input Ride control is not activated. sensor (lift arm raise).
Speed shift delay control is always
delayed at AUTO 2 mode.
111217-3 Pilot Pressure Sensor Voltage: 4.75 V or Front control lever lock indicator on Check the harness.
Circuit High Input more monitor is always OFF. Replace the pressure
sensor (loading pilot
pressure).
111217-4 Pilot Pressure Sensor Voltage: less than Front control lever lock indicator on Check the harness.
Circuit Low Input 0.25 V monitor is always OFF. Replace the pressure
sensor (loading pilot
pressure).
111311-3 Service Brake Voltage: 4.75 V or The low brake oil pressure indicator is Check the harness.
Primary Pressure more always ON. Replace the pressure
Sensor Circuit High Although the service brake is applied, sensor (brake primary
Input the brake oil pressure gauge points at pressure).
the minimum value, zero.
111311-4 Service Brake Voltage: less than The low brake oil pressure indicator is Check the harness.
Primary Pressure 0.25 V always ON. Replace the pressure
Sensor Circuit Low Although the service brake is applied, sensor (brake primary
Input the brake oil pressure gauge points at pressure).
the minimum value, zero.
T5-5-13
Pilot Failure
111312-3 Service Brake Voltage: 4.75 V or The declutch control becomes Check the harness.
Secondary Pressure more ineffective. The declutch is impossible. Replace the pressure
Sensor Circuit High The speed shift does not automatically sensor (brake
Input downshift to first speed with the travel secondary pressure).
mode set in AUTO 1 mode.
111312-4 Service Brake Voltage: less than The declutch control becomes Check the harness.
Secondary Pressure 0.25 V ineffective. The declutch is impossible. Replace the pressure
Sensor Circuit Low The speed shift does not automatically sensor (brake
Input downshift to first speed with the travel secondary pressure).
mode set in AUTO 1 mode.
111313-3 Parking Brake Voltage: 4.75 V or Although the parking brake is applied, Check the harness.
Pressure Sensor more the parking brake indicator is not ON. Replace the pressure
Circuit High Input (The parking brake signal is forcibly sensor (parking
fixed to the Release side.) brake).
111313-4 Parking Brake Voltage: less than Although the parking brake is applied, Check the harness.
Pressure Sensor 0.25 V the parking brake indicator is not ON. Replace the pressure
Circuit Low Input (The parking brake signal is forcibly sensor (parking
fixed to the Release side.) brake).
T5-5-14
Proportional Solenoid Valve Failure

111411-2 Hydraulic Fan Solenoid valve output: The fan reverse rotation control Check the harness.
Reverse Rotation P/S 140 mA or more, and becomes ineffective.
Valve Abnormal FB Feedback current: more Fan rotation direction (in normal /
(Option) than 920 mA or less than reverse) cannot change manually
70 mA nor automatically.
(both detected)
111411-3 Hydraulic Fan Current: more than 920 Fan rotation direction is fixed in Check the harness.
Reverse Rotation mA reverse.
P/S Valve FB High
Current
(Option)
111411-4 Hydraulic Fan Current: less than 70 mA Fan rotation direction (in normal / Check the harness.
Reverse Rotation P/S reverse) cannot change manually
Valve FB Low Current and automatically.
(Option)
T5-5-15

111412-2 Hyd. Fan P/S Valve Solenoid valve output: The fan speed is fixed to the Check the harness.
Abnormal Feedback 140 mA or more, and maximum.
Feedback current: more
than 920 mA or less than
70 mA (both detected)
111412-3 Hyd. Fan P/S Valve Current: more than 920 The fan speed is fixed to the Check the harness.
Feedback High mA minimum.
Current
111412-4 Hyd. Fan P/S Valve Current: less than 70 mA The fan speed is fixed to the Check the harness.
Feedback Low maximum.
Current
111413-2 Pump Swash Angle Solenoid valve output: Engine speed regulator for digging Check the harness.
P/S Valve Abnormal 140 mA or more, and is deactivated.
FB Feedback current: more
70 mA
(both detected)
111413-3 Pump Swash Angle Current: more than 920 The engine stalls is remarkable at Check the harness.
P/S Valve FB High mA high loaded. In addition, the engine
Current lug-down is remarkable.
111413-4 Pump Swash Angle Current: less than 70 mA Engine speed regulator for digging Check the harness.
P/S Valve FB Low is deactivated.
Current
T5-5-16

111422-2 Ride Control P/S Solenoid valve output: Ride control selector solenoid Check the harness.
Valve Abnormal FB 140 mA or more, and valve (boom cylinder bottom side)
(Option) Feedback current: more control is disabled.
70 mA (both detected)
111422-3 Ride Control P/S Current: more than 920 Ride control selector solenoid Check the harness.
Valve FB High mA valve (boom cylinder bottom side)
Current (Option) control is always activated.
111422-4 Ride Control P/S Current: less than 70 mA Ride control selector solenoid Check the harness.
Valve FB Low Current valve (boom cylinder bottom side)
(Option) control is always deactivated.
T5-5-17

111414-2 T/M Clutch 1st P/S Solenoid valve output: 1st speed clutch gear engagement Check the harness.
Valve Abnormal FB 140 mA or more, and is not possible.
Feedback current: more If 1st speed range is selected, 2nd
than 920 mA or less than speed clutch gear is engaged.
70 mA
(both detected)
111414-3 T/M Clutch 1st Current: more than 920 1st speed clutch gear engagement Check the harness.
P/S Valve FB High mA is not possible.
Current If 1st speed range is selected, 2nd
speed clutch gear is engaged.
111414-4 T/M Clutch 1st P/S Current: less than 70 mA 1st speed clutch gear engagement Check the harness.
Valve FB Low Current is not possible.
If 1st speed range is selected, 2nd
111415-2 T/M Clutch 2nd P/S Solenoid valve output: 2nd speed clutch gear engagement Check the harness.
Feedback current: more If 2nd speed range is selected, 1st
70 mA
(both detected)
111415-3 T/M Clutch 2nd Current: more than 920 2nd speed clutch gear engagement Check the harness.
Current If 2nd speed range is selected, 1st
speed clutch gear is engaged
111415-4 T/M Clutch 2nd P/S Current: less than 70 mA 2nd speed clutch gear engagement Check the harness.
If 2nd speed range is selected, 1st
speed clutch gear is engaged
111416-2 T/M Clutch 3rd P/S Solenoid valve output: 3rd speed clutch gear engagement Check the harness.
Feedback current: more If 3rd speed range is selected, 2nd
70 mA
(both detected)
111416-3 T/M Clutch 3rd Current: more than 920 3rd speed clutch gear engagement Check the harness.
Current If 3rd speed range is selected, 2nd
111416-4 T/M Clutch 3rd P/S Current: less than 70 mA 3rd speed clutch gear engagement Check the harness.
If 3rd speed range is selected, 2nd
speed clutch gear is engaged..
fNOTE: If the 1st or 2nd speed clutch becomes defective

after the downshifting, no speed clutch is engaged (becomes
neutral condition).
T5-5-18

111417-2 T/M Clutch 4th P/S Solenoid valve output: 4th speed clutch gear engagement Check the harness.
Feedback current: more If 4th speed range is selected, 2nd
70 mA
(both detected)
111417-3 T/M Clutch 4th Current: more than 920 4th speed clutch gear engagement Check the harness.
Current If 4th speed range is selected, 2nd
111417-4 T/M Clutch 4th P/S Current: less than 70 mA 4th speed clutch gear engagement Check the harness.
If 4th speed range is selected, 2nd
111418-2 T/M Clutch Forward Solenoid valve output: Forward clutch gear engagement is Check the harness.
P/S Valve Abnormal 140 mA or more, and not possible.
FB Feedback current: more If forward is selected, T/M is in the
than 920 mA or less than neutral status.
70 mA
(both detected)
111418-3 T/M Clutch Forward Current: more than 920 Forward clutch gear engagement is Check the harness.
P/S Valve FB High mA not possible.
Current If forward is selected, T/M is in the
neutral status.
111418-4 T/M Clutch Forward Current: less than 70 mA Forward clutch gear engagement is Check the harness.
P/S Valve FB Low not possible.
Current If forward is selected, T/M is in the
neutral status.
111419-2 T/M Clutch Reverse Solenoid valve output: Reverse clutch gear engagement is Check the harness.
P/S Valve Abnormal 140 mA or more, and not possible.
FB Feedback current: more If reverse is selected, T/M is in the
than 920 mA or less than neutral status.
70 mA
(both detected)
111419-3 T/M Clutch Reverse Current: more than 920 Reverse clutch gear engagement is Check the harness.
P/S Valve FB High mA not possible.
Current If reverse is selected, T/M is in the
neutral status.
111419-4 T/M Clutch Reverse Current: less than 70 mA Reverse clutch gear engagement is Check the harness.
P/S Valve FB Low not possible.
Current If reverse is selected, T/M is in the
neutral status.
fNOTE: If the 1st or 2nd speed clutch becomes defective

after the downshifting, no speed clutch is engaged (becomes
neutral condition).
T5-5-19
Revolution Sensor Failure

111600-3 T/M Output Speed When forward or reverse Abnormal shift down feeling. Check the harness.
Sensor Failure clutch is engaged, and Selected speed range is not Replace the T/M
T/M output revolution = correctly indicated at shift change. output revolution
0 min-1, sensor (machine
T/M intermediate shaft speed sensor).
revolution > 300 min-1, or
T/C output revolution >
500 min-1.
Harness disconnection
detected at starter key
turns ON and voltage is
1.8 V or more.
111600-4 T/M Out Speed Harness disconnection Abnormal shift down feeling. Check the harness.
Sensor Circuit Low detected at starter key Selected speed range is not Replace the T/M
Input turns ON and voltage is correctly indicated at shift change. output revolution
1.1 V or less. sensor (machine
speed sensor).
111601-3 Torque Converter When forward or reverse Controls monitoring T/C speed Check the harness.
Output Speed clutch is engaged, and ratio are deactivated as it cannot be Replace the T/C
Sensor Failure T/M output revolution = calculated. output revolution
0 min-1, sensor.
T/M intermediate shaft
revolution > 300 min-1, or
T/M output revolution >
300 min-1.
111602-3 Intermediate Shaft When forward or reverse Service indicator turns on. Check the harness.
Speed Sensor Failure clutch is engaged, and If Transmission Output Revolution Replace the T/M
T/M output revolution = Sensor Error (111600-3) occurs at intermediate shaft
0 min-1, the same time, machine speed is revolution sensor
T/M intermediate shaft not displayed. (machine speed
revolution > 500 min-1, or backup sensor)
T/C output revolution >
500 min-1.
T5-5-20
Learning Failure
111700-xx Calibration Abort Transmission learning Direction changing to forward may Perform T/M learning.
Forward failed. not be smooth. See pp.T5-5-76, 77.
111700-31 Calibration Abort Transmission learning Direction changing to forward may Perform T/M learning.
Forward: Un- was not done. not be smooth. See p.T5-5-77.
Calibration
111701-xx Calibration Abort Transmission learning Direction changing to reverse may Perform T/M learning.
Reverse failed. not be smooth. See pp.T5-5-76, 77.
111701-31 Calibration Abort Transmission learning Direction changing to reverse may Perform T/M learning.
Reverse: Un- was not done. not be smooth. See p.T5-5-77.
Calibration
111702-xx Calibration Abort 1st Transmission learning Speed shifting to the 1st range may Perform T/M learning.
failed. not be smooth. See pp.T5-5-76, 77.
111702-31 Calibration Abort Transmission learning Speed shifting to the 1st range may Perform T/M learning.
1st: Un-Calibration was not done. not be smooth. See p.T5-5-77.
111703-xx Calibration Abort Transmission learning Speed shifting to the 2nd range Perform T/M learning.
2nd failed. may not be smooth. See pp.T5-5-76, 77.
111703-31 Calibration Abort Transmission learning Speed shifting to the 2nd range Perform T/M learning.
2nd: Un-Calibration was not done. may not be smooth. See p.T5-5-77.
111704-xx Calibration Abort 3rd Transmission learning Speed shifting to the 3rd range may Perform T/M learning.
111704-31 Calibration Abort Transmission learning Speed shifting to the 3rd range may Perform T/M learning.
3rd: Un-Calibration was not done. not be smooth. See p.T5-5-77.
111705-xx Calibration Abort 4th Transmission learning Speed shifting to the 4th range may Perform T/M learning.
111705-31 Calibration Abort Transmission learning Speed shifting to the 4th range may Perform T/M learning.
4th: Un-Calibration was not done. not be smooth. See p.T5-5-77.
111720-2 Lift arm angle The lift arm angle Dual lift arm auto leveler cannot be Perform lift arm angle
sensor (option) is sensor calibration is set. sensor calibration.
uncalibrated. not performed. Or, it
fails.
Switch Failure
111904-2 Column FNR SW Shift lever F & R Transmission is in the neutral Check the harness.
Failure contact ON at the condition. Replace the switch.
same time.
111905-2 Implement FNR SW Shift switch F & R Transmission is in the neutral Check the harness.
Failure contact ON at the condition. Replace the switch.
same time.
T5-5-21
Temperature Sensor Failure

Fault Code Trouble or MP Dr. Cause Symptoms in Machine Operation When Remedy
Message Trouble Occurs
111900-3 Torque Converter Oil Voltage: more than The fan speed is always fixed to the Check the harness.
Temperature Sensor 4.75 V maximum.
Circuit High Input Fan reverse rotation control is disabled.
Lift arm speed multiplication control is
disabled.
111900-4 Torque Converter Oil Voltage: less than The fan speed is always fixed to the Check the harness.
Temperature Sensor 0.25 V maximum.
Circuit Low Input Fan reverse rotation control is disabled.
Lift arm speed multiplication control is
disabled.
111901-3 Hyd. Oil Temp Sensor Voltage: more than When hydraulic oil temperature is less Check the harness.
Circuit High Input 4.35 V than 0 °C (32 °F), the auto-warm up
control is not effective.
The fan speed is always fixed to the
maximum. The fan reverse rotation
control is not activated.
111901-4 Hyd. Oil Temp Sensor Voltage: less than When hydraulic oil temperature is less Check the harness.
Circuit Low Input 0.1 V than 0 °C (32 °F), the auto-warm up
control is not effective.
The fan speed is always fixed to the
maximum. The fan reverse rotation
control is not activated.
111902-3 Axle Oil Temperature Voltage: more than Nothing observed. Check the harness.
Sensor Circuit High 4.75 V
Input
111902-4 Axle Oil Temperature Voltage: less than Nothing observed. Check the harness.
Sensor Circuit Low 0.1 V
Input
T5-5-22
Other Sensor Failures

111205-3 Lift Arm Angle Voltage: 4.75 V or Dual lift arm auto leveler operation Check the harness.
Sensor Circuit High more (option) is not effective. Replace the lift arm
Input Speed shift delay control is always angle sensor.
delayed at 2nd speed.
111205-4 Lift Arm Angle Voltage: less than Dual lift arm auto leveler operation Check the harness.
Sensor Circuit Low 0.25 V (option) is not effective. Replace the lift arm
Input Speed shift delay control is always angle sensor.
delayed at 2nd speed.
111207-3 Refrigerant Pressure Voltage: more than The fan speed is always fixed to the Check the harness.
Circuit High Input 4.74 V maximum. Replace the
refrigerant pressure
sensor.
111207-4 Refrigerant Pressure Voltage: less than The fan speed is always fixed to the Check the harness.
Sensor Circuit Low 0.25 V maximum. Replace the
Input refrigerant pressure
sensor.
T5-5-23
Alarms on Monitor
120000-2 Hydraulic Oil Hydraulic oil The alarm is displayed on the Check the harness.
Overheat Alarm temperature is high. monitor. Replace the hydraulic
oil temperature
sensor.
120001-2 Main Pump Pressure Main pump oil The alarm is displayed on the Check the harness.
Alarm pressure is high. monitor. Replace the main
pump oil pressure
sensor.
120002-2 Axle Oil Temperature Axle oil temperature The alarm is displayed on the Check the harness.
Alarm is high. monitor. Replace the axle oil
temperature sensor.
120003-2 Emergency Steering Steering oil pressure is Secondary steering is activated. Check the harness.
Activated Alarm low while machine is The alarm is displayed on the Check/replace the
moving. monitor. steering pressure
switch.
120004-2 Emergency Steering When the engine The alarm is displayed on the Check the harness.
Activated Pressure starts, secondary monitor. Replace the pressure
Alarm steering pump sensor.
delivery pressure does
not increase up to the
specified value (48
MPa (6962 PSI)).
120005-2 Transmission Transmission oil The alarm is displayed on the Check the harness.
Oil Temperature temperature is high. monitor. Replace the torque
Overheat Alarm converter oil
temperature sensor.
T5-5-24
Alarms on Monitor
120013-2 Brake Oil Pressure Brake oil pressure is The alarm is displayed on the Check the harness.
Alarm low. monitor. Check/replace the
brake oil pressure
sensor.
120014-2 Overrun Alarm The machine speed The buzzer sounds. Check the harness.
is beyond the upper Replace the machine
limit. speed sensor.
T5-5-25
Monitor Controller (Monitor) Fault Code List
Fault Code Trouble or MP Dr. Message Cause Remedy

113002-2 (Monitor Controller) Engine Faulty monitor controller Check the CAN1 harness.
Controller Communication Error Faulty CAN1 harness Replace the monitor controller.
113003-2 (Monitor Controller) Main Faulty monitor controller Check the CAN1 harness.
Controller Communication Error 1 Faulty CAN1 harness Replace the monitor controller.
113005-2 (Monitor Controller) ICF Faulty monitor controller Check the CAN1 harness.
Communication Error 1 Faulty CAN1 harness Replace the monitor controller.
113007-2 (Monitor Controller) Column Faulty monitor controller Check the CAN1 harness.
Controller Communication Error Faulty CAN1 harness Replace the monitor controller.
T5-5-26
Fault Code Trouble or MP Dr. Cause Symptoms in Machine Remedy

Message Operation When Trouble Occurs
113303-2 Abnormal thermistor Thermistor The screen of the monitor Cool the monitor and so
temperature (monitor temperature: 85°C becomes dark. on until the temperature
inside temperature) (185°F) or more inside the monitor is less
than 85°C (185°F).
Replace the monitor.
T5-5-27
Monitor Controller (Information) Fault Code

List

114001-2 Flash Memory Read/Write The internal memory After initializing the monitor controller (information)
Error of monitor controller by using MPDr., retry the troubleshooting. If the fault
is abnormal. code is displayed after retry, the monitor controller
may be broken. Replace the monitor controller.
When initializing the monitor controller (information),
all stored data is deleted.
114002-2 External RAM Read/Write The internal memory After initializing the monitor controller (information)
Error of monitor controller by using MPDr., retry the troubleshooting. If the fault
is abnormal. code is displayed after retry, the monitor controller
may be broken. Replace the monitor controller.
When initializing the monitor controller (information),
all stored data is deleted.
114003-2 Abnormal EEPROM The internal memory Retry the troubleshooting by using MPDr. If the fault
of monitor controller code is displayed after retry, the monitor controller
is abnormal. may be broken. Replace the monitor controller.
114008-2 Abnormal Internal RAM The internal memory Retry the troubleshooting by using MPDr. If the fault
of monitor controller code is displayed after retry, the monitor controller
is abnormal. may be broken. Replace the monitor controller.
T5-5-28

114010-2 (Information Controller) Engine Faulty monitor controller Check the CAN harness.
Controller Communication Error Faulty CAN harness Replace the monitor controller.
114011-2 (Information Controller) Main Faulty monitor controller Check the CAN harness.
Controller Communication Error 1 Faulty CAN harness Replace the monitor controller.
114015-2 (Information Controller) Column Faulty monitor controller Check the CAN harness.
Controller Communication Error Faulty CAN harness Check/replace the monitor
controller.
120300-2 System Failure Alarm Faulty CAN communication bus Check the CAN harness.
line.
T5-5-29
Column Display Controller Fault Code List

115001-2 Abnormal REG input Alternator generating The alternator indicator is ON. Check the harness.
H level voltage: 33.5 V or more Check the battery.
Check the alternator.
115002-2 CAN Communication Faulty column display Alarm lamps and indicators do Check the harness.
Error controller not light correctly. Replace the column
Faulty CAN1 harness display controller.
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 (pointer) points Check the harness.
Circuit High Input continues for 5 to E. Replace the fuel level
seconds. sensor.
115011-4 Fuel Level Sensor 4±2 Ω or less continues The fuel gauge (pointer) points Check the harness.
Circuit Low Input for 5 seconds. to E. Replace the fuel level
sensor.
T5-5-30

120500-2 Overheat Alarm Coolant temperature is high while Check the 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 Alarm Engine oil pressure is reduced. Check the harness.
(Detected by ECM) Replace the engine oil pressure
switch.
120503-2 Air Cleaner Restriction Clogged air cleaner. Check the harness.
Alarm Replace the air cleaner restriction
switch.
120505-2 Brake Pressure Alarm Brake oil pressure decreases below 6 Check the harness.
MPa (870 PSI). Replace the pressure sensor (brake
primary pressure).
120506-2 Steering Oil Pressure Alarm Steering pressure switch (option) Check the harness.
is OFF or defective and steering Replace the steering pressure switch.
pressure becomes 0.7 MPa (101.5 PSI)
or lower.
120507-2 T/M Malfunction Faulty transmission system Refer to the accompanied T/M
related fault code.
T5-5-31
Communication Terminal Fault Code List
Fault Code Trouble Cause Remedy

114100-2 Communication Terminal: The internal memory of satellite Replace the controller (satellite
Abnormal EEPROM communication terminal communication terminal).
(optional) is abnormal.
114101-2 Communication Terminal: The internal memory of satellite Replace the controller (satellite
Abnormal IB/OB Queue communication terminal communication terminal).
(optional) 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
T5-5-32
Air Conditioner Controller Fault Code List
Fault Trouble or MP Dr. Cause Symptoms in Machine Remedy

Code Message Operation When Trouble Occurs
11 Open circuit in air Voltage: more than Operation is controlled under Check the harness.
circulation sensor 4.95 V such circumstance as no air Replace the air circulation
circulation sensor is provided. sensor.
12 Shorted circuit in air Voltage: less than 0.3 V Operation is controlled under Check the harness.
circulation sensor such circumstance as no air Replace the air circulation
circulation sensor is provided. sensor.
13 Open circuit in fresh Voltage: more than Operation is controlled under Check the harness.
air sensor 4.88 V such circumstance as no fresh Replace the fresh air sensor.
air sensor is provided.
14 Shorted circuit in fresh Voltage: less than Operation is controlled under Check the harness.
air sensor 0.096 V such circumstance as no fresh Replace the fresh air sensor.
air sensor is provided.
17 Open circuit in solar - Operation is controlled under Check the harness.
radiation sensor such circumstance as no solar Replace the solar radiation
radiation sensor is provided. sensor.
18 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
radiation sensor is provided. sensor.
21 Open circuit in Voltage: more than The compressor clutch is Check the harness.
evaporator sensor 4.79 V disengaged. (The compressor Replace the evaporator
stops.) sensor.
22 Shorted circuit in Voltage: less than The compressor clutch is Check the harness.
evaporator sensor 0.096 V disengaged. (The compressor Replace the evaporator
stops.) sensor.
43 Abnormal air vent Shorted circuit: Air vent damper servo motor Check the harness.
damper Voltage: 0 V becomes inoperable. Replace the air vent
Open circuit: Voltage: damper servo motor.
more than 5 V
44 Abnormal air mix Shorted circuit: Air mix damper servo motor Check the harness.
damper Voltage: less than 0.2 V becomes inoperable. Replace the air vent
more than 4.8 V
51 Abnormal high/low Voltage: 0 V The compressor clutch is Check the harness.
refrigerant pressure disengaged. (The compressor Replace the high/low
stops.) pressure switch.
91 CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1 harness.
error between monitor Replace air conditioner
controller and air controller.
conditioner controller
92 CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1 harness.
controller Replace air conditioner
Faulty CAN1 harness controller.
T5-5-33
ECM Fault Code List
Fault Code Trouble or MP Dr. Message Possible Cause Symptoms in Machine Operation
MPDr. INSITE When Trouble Occurs
629-12 111 Engine Control Module – Critical Error internal to the ECM related Engine will not start.
internal failure to the memory hardware failures
or internal ECM voltage supply
circuits.
190-2 115 Engine Speed/Position Sensor No engine speed signal detected Engine will shut down and will
Circuit - lost both of two signals at both engine position sensor not start.
circuits.
190-10 121 Engine Speed/Position Sensor No engine speed signal detected -
Circuit - lost one of two signals at one of the engine position
sensor circuits.
102-3 122 Intake Manifold Pressure Sensor High voltage detected at the Derate in power output of the
#1 Circuit - shorted high intake manifold pressure sensor engine.
circuit.
102-4 123 Intake Manifold Pressure Sensor Low voltage detected on the Derate in power output of the
#1 Circuit - shorted low intake manifold pressure sensor engine.
circuit.
91-3 131 Accelerator Pedal Position High voltage detected at Severe derate (power and
Sensor Circuit - shorted high accelerator position sensor. speed). Limp home power only.
91-4 132 Accelerator Pedal Position Low voltage detected at the Severe derate (power and
Sensor Circuit - shorted low accelerator position sensor speed). Limp home power only.
circuit.
974-3 133 Remote Accelerator Pedal High voltage detected at the None on performance if remote
Position Sensor Circuit - shorted remote throttle position signal throttle is not used.
high circuit.
974-4 134 Remote Accelerator Pedal Low voltage detected at the None on performance if remote
Position Sensor Circuit - shorted remote throttle position signal throttle is not used.
low circuit.
100-3 135 Engine Oil Pressure Sensor High voltage detected at the oil No engine protection for oil
Circuit - shorted high pressure circuit. pressure.
100-4 141 Engine Oil Pressure Sensor Low voltage detected at the oil No engine protection for oil
Circuit - shorted low pressure circuit. pressure.
100-18 143 Engine Oil Pressure Low – Engine Oil Rifle Pressure - Progressive power derate
Warning Data Valid but Below Normal increasing in severity from time
Operating Range - Moderately of alert.
Severe Level. Engine oil pressure signal
indicates engine oil pressure is
below the engine protection
warning limit.
110-3 144 Engine Coolant Temperature High voltage detected at the Possible white smoke. Fan will
Sensor Circuit - shorted high coolant temperature circuit. stay on if controlled by the
electronic control module (ECM).
No engine protection for coolant
temperature.
fNOTE: INSITE is the engine service tool provided by CUMMINS INC.
T5-5-34
ECM Fault Code List
110-4 145 Engine Coolant Temperature Low voltage detected at the Possible white smoke. Fan will
Sensor Circuit - shorted low coolant temperature circuit. stay on if controlled by the
electronic control module (ECM).
No engine protection for coolant
temperature.
110-0 151 Engine Coolant Temperature Coolant temperature signal Progressive power derate with
High – Critical indicates temperature is above increasing time after alert. If
104°C (220°F). engine protection shutdown
feature is enabled, engine will
shut down 30 seconds after the
red lamp starts flashing.
105-3 153 Intake Manifold Temperature High voltage detected at the Possible white smoke. Fan will
Sensor #1 Circuit - shorted high intake manifold temperature stay on if controlled by the
sensor circuit. electronic control module (ECM).
No engine protection for intake
manifold temperature.
105-4 154 Intake Manifold Temperature Low voltage detected at the Possible white smoke. Fan will
Sensor #1 Circuit - shorted low intake manifold temperature stay on if controlled by the
sensor circuit. electronic control module (ECM).
No engine protection for intake
manifold temperature.
105-0 155 Intake Manifold Temperature #1 Intake manifold temperature Progressive power derate with
High - Critical signal indicates temperature is increasing time after alert. If
above 93°C (200°F). engine protection shutdown
620-4 187 Sensor Supply Voltage #2 Circuit Low voltage detected on the Engine will run derated. No
- shorted low ECM voltage supply line to some engine protection for oil
sensors (VSEN 2 supply). pressure or coolant level.
175-3 212 Engine Oil Temperature Sensor High voltage detected at the oil No engine protection for oil
Circuit - shorted high temperature circuit. temperature.
175-4 213 Engine Oil Temperature Sensor Low voltage detected at the oil No engine protection for oil
Circuit - shorted low temperature circuit. temperature.
175-0 214 Engine Oil Temperature High - Oil temperature signal indicates Progressive power derate with
Critical oil temperature is above 123.9°C increasing time after alert. If
(255°F). engine protection shutdown
T5-5-35
ECM Fault Code List
108-3 221 Ambient Air Pressure Sensor High voltage detected at the Derate in power output of
Circuit – shorted high ambient air pressure sensor engine.
circuit.
108-4 222 Ambient Air Pressure Sensor Low voltage detected at the Derate in power output of
Circuit – shorted low ambient air pressure circuit. engine.
620-3 227 Sensor Supply Voltage #2 Circuit High voltage detected on the Engine will run derated. No
- shorted high electronic control module (ECM) engine protection for oil
voltage supply line to some pressure and coolant level.
sensors. (VSEN 2)
190-0 234 Engine Speed High – Critical Engine speed signal indicates Fuel shutoff valve is closed until
engine speed is greater than the engine speed drops. The fuel
2650 rpm. shutoff valve will open when
engine speed falls below 2000
rpm.
632-4 254 Fuel Shutoff Valve Circuit - Less than Positive (+) 6 VDC The ECM turns off the fuel
shorted low detected at fuel shutoff circuit or shutoff supply voltage. The
an excessive current draw from engine will shut down.
the electronic control module
(ECM) or faulty ECM output
circuit.
632-3 255 Fuel Shutoff Valve Circuit - Externally supplied voltage None on performance. Fuel
shorted high detected going to fuel shutoff shutoff valve stays on.
solenoid supply circuit.
639-9 285 SAE J1939 Multiplexing PGN The ECM expected information At least one multiplexed device
Timeout Error from a multiplexed device but will not operate properly.
did not receive it soon enough,
or did not receive it at all.
639-13 286 SAE J1939 Multiplexing The ECM expected information At least one multiplexed device
Configuration Error from a multiplexed device but will not operate properly.
only received a portion of the
necessary information.
91-19 287 SAE J1939 Multiplexing The vehicle electronic control Engine will only idle.
Accelerator Pedal Sensor System unit (VECU) detected a fault with
Error its throttle pedal.
108-2 295 Ambient Air Pressure Sensor An error in the ambient air Engine is derated to no air
Circuit - data incorrect pressure sensor signal was setting.
detected by the ECM.
1384-31 299 Engine Shutdown Commanded The engine was shut down by a No action taken by the ECM.
by J1939 device other than the keyswitch
before the proper engine cool
down resulting in a filtered load
factor above the maximum
shutdown threshold.
T5-5-36
ECM Fault Code List
651-6 311 Injector Solenoid Valve Cylinder Current detected at the injector The injector for cylinder number
#1 Circuit – grounded circuit for cylinder number 1 when the 1 is turned off.
voltage is turned off.
655-6 312 Injector Solenoid Valve Cylinder Current detected at the injector The injector for cylinder No. 5 is
#5 Circuit – grounded circuit for cylinder No. 5 when the turned off.
#6 Circuit - grounded circuit for cylinder No. 6 when the turned off.
251-2 319 Real Time Clock - Power Interrupt Real-time clock lost power. None on performance. Data in
the ECM will not have accurate
time and date information.
#4 Circuit - grounded circuit for cylinder No. 4 when the turned off.
651-5 322 Injector Solenoid Valve Cylinder Injector Solenoid Driver Cylinder The current to the injector is
#1 Circuit - open circuit 1 Circuit - Current Below shut off. The engine can possibly
Normal or Open Circuit. Current misfire or run rough.
detected at injector number 1
when voltage is turned off.
#5 Circuit – open circuit 5 Circuit - Current Below shut off. The engine can possibly
T5-5-37
ECM Fault Code List
630-2 341 Engine Control Module – data Severe loss of data from the Possibly no noticeable
lost ECM due to unswitched battery performance effects, or engine
supply circuit dying, or difficulty in starting the
engine. Fault information, trip
information, and maintenance
monitor data can be inaccurate.
629-12 343 Engine Control Module - Internal ECM error due to bad Possibly none on performance,
Warning internal hardware intelligent device or component or severe derate.
failure
3509-4 352 Sensor Supply Voltage #1 Circuit Low voltage detected on the Engine is derated to no-air
- shorted low internal electronic control setting.
module (ECM) supply line to
some of the sensors.
3509-3 386 Sensor Supply Voltage #1 Circuit High voltage detected on the Engine is derated to no-air
- shorted high internal electronic control setting.
module (ECM) supply wire to the
sensors.
1043-3 387 Accelerator Pedal Position High voltage detected on the Engine will only idle.
Sensor Supply Voltage Circuit - ECM voltage supply line to the
shorted high throttle(s) (VTP supply).
100-1 415 Engine Oil Pressure Low – Critical Oil pressure signal indicates oil Progressive power derate with
pressure below the very low oil increasing time after alert. If
pressure engine protection limit. engine protection shutdown
97-15 418 Water in Fuel Indicator High – Water has been detected in the Possible white smoke, loss of
Maintenance fuel filter. power, or hard starting.
1319-2 419 Intake Manifold Boost Pressure An error in the intake manifold Engine is derated to no-air
Imbalance pressure sensor signal was setting.
detected by the ECM.
97-3 428 Water in Fuel Sensor Circuit - High voltage detected at water- -
shorted high in-fuel (WIF) sensor circuit.
97-4 429 Water in Fuel Sensor Circuit - Low voltage detected at water- -
shorted low in-fuel (WIF) sensor circuit.
T5-5-38
ECM Fault Code List
558-2 431 Accelerator Pedal Idle Validation No voltage detected -
Circuit - data incorrect simultaneously on both the idle
validation off-idle and on-idle
signal pins.
558-13 432 Accelerator Pedal Idle Validation Voltage detected at idle Engine will only idle.
Circuit - out of calibration validation on-idle circuit when
voltage at throttle position
circuit indicates the pedal is
not at idle or voltage detected
at idle validation off-idle circuit
when voltage at throttle position
circuit indicates the pedal is at
rest.
102-2 433 Intake Manifold Pressure Sensor Voltage signal at the intake Derate to no-air setting.
Circuit - data incorrect manifold pressure circuit
indicates high intake manifold
pressure but other engine
characteristics indicate that
intake manifold pressure must
be low.
627-2 434 Power Lost without Ignition Off Supply voltage to the electronic Possible no noticeable
control module (ECM) fell below performance effects or engine
(+) 6.2-VDC for a fraction of dying or hard starting. Fault
a second or the ECM was not information, trip information,
allowed to power down correctly and maintenance monitor data
(retain battery voltage for 30 can be inaccurate.
seconds after keyswitch is turned
off ).
100-2 435 Engine Oil Pressure Sensor An error in the oil pressure None on performance; no engine
Circuit - data incorrect sensor signal was detected by protection for oil pressure.
the ECM.
168-18 441 Battery #1 Voltage Low - Warning Battery voltage below Possible no noticeable
normal operating level due performance effects or possible
to unswitched battery supply rough idle.
circuit.
168-16 442 Battery #1 Voltage High - Battery voltage above -
Warning normal operating level due
to unswitched battery supply
circuit.
1043-4 443 Accelerator Pedal Position Low voltage detected on the Engine will only idle.
Sensor Supply Voltage Circuit - electronic control module
shorted low (ECM) voltage supply line to the
throttle(s).
T5-5-39
ECM Fault Code List
702-3 527 Auxiliary Input/Output #2 Circuit Less than + 17.0 VDC detected at No action taken by the electronic
- shorted high the switched output A signal pin control module (ECM).
of the 31-pin OEM connector.
703-3 529 Auxiliary Input/Output #3 Circuit Less than + 17 VDC detected at No action taken by the ECM.
- shorted high the switched output B signal pin
at the electronic control module
(ECM).
558-4 551 Accelerator Pedal Idle Validation No voltage detected Engine will only idle.
Circuit - shorted low simultaneously on both the idle
validation off-idle and on-idle
circuits.
167-16 596 Electrical Charging System High battery voltage detected Yellow lamp will be lit until high
Voltage High - warning level by the battery voltage monitor battery voltage condition is
feature. corrected.
167-1 598 Electrical Charging System Very low battery voltage Red lamp lit until very low
Voltage Low - Critical Level detected by the battery voltage battery voltage condition is
monitor feature. corrected. The electronic control
module (ECM) can increase
idle speed and deactivate idle
decrement switch if idle speedup
is enabled.
166-2 951 Cylinder Power Imbalance Cylinder Power Imbalance Engine can have rough idle or
between cylinders Between Cylinders. A power misfire.
imbalance between cylinders
was detected by the electronic
control module (ECM).
T5-5-40
MC Fault Codes 111000 to 111002
Fault Code Trouble or MP Dr. Message 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 is operated

normally with the fault code displayed after retrial, the
machine can be operated as it is.
T5-5-41
MC Fault Code 111003

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

Message
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
sensor harness end #1 and harness #1.
chassis.
Check shorted circuit in harness 0Ω Shorted circuit in
between sensor harness end #1 harness #1 and #3.
and #3.
- Normal in above check. Faulty MC
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
90Z6-05-05-01
1- Main Controller (MC) 7- Lift Arm Angle Sensor (Option) 11- Service Brake Secondary 15- Transmission Oil Temperature
2- Accelerator Pedal Sensor 8- Hydraulic Fan Circuit Pressure Pressure Sensor (for Declutch) Sensor
3- Pump Delivery Pressure Sensor Sensor (Option) 12- Refrigerant Pressure Sensor 16- Axle Oil Temperature Sensor
4- Primary Pilot Pressure Sensor 9- Parking Brake Pressure Sensor 13- Secondary Steering Check 17- Atmospheric Temperature
5- Lift Arm Raise Pressure Sensor 10- Service Brake Primary Pressure Pressure Sensor (Option) Sensor
(Option) Pressure Sensor 14- Hydraulic Oil Temperature
6- Steering Pressure Switch Sensor
T5-5-42
Connector (Harness end of connector viewed from the

open end side)
 Pressure Sensor (Lift Arm Raise)  Lift Arm Angle Sensor (Option)
 Pressure Sensor (Brake Secondary Pressure)
 Pressure Sensor (Primary Pilot Pressure)
90Z7-05-CN04
90Z7-05-CN01
 Pressure Sensor (Refrigerant Pressure)
 Steering Pressure Switch (Option)
90Z7-05-CN05
90Z6-05-CN01
 Accelerator Pedal Sensor
 Pressure Sensor (Brake Primary Pressure)

 Pump Delivery Pressure Sensor
 Hydraulic Fan Circuit Pressure Sensor (Option)
 Secondary Steering Pump Delivery Pressure Sensor
(Option)
90Z6-05-CN02
90Z7-05-CN03
fNOTE: S: Signal
G: Ground (chassis)
P: 5 V or 24 V power supply
T5-5-43
MC Fault Codes 111006, 111007, 111014,

111025
Preparation
 Disconnect the connectors from each controller.
 Check the wiring connections first.
 Check the CAN1 harness between the controllers.
(Refer to CAN1 Harness Check on T5-5-46 to 48.)
Fault Code Trouble or MP Dr. Message Inspection Method Cause
111006-2 (MC) Engine Controller Continuity check (open circuit) Open circuit in harness.
Communication Error
Discontinuity check (shorted circuit) Shorted circuit in harness.
111007-2 (MC) Information Controller Continuity check (open circuit) Open circuit in harness.
111014-2 (MC) Air Conditioner Continuity check (open circuit) Open circuit in harness.
Controller Communication
Error Discontinuity check (shorted circuit) Shorted circuit in harness.
111025-2 (MC) Column Monitor Continuity check (open circuit) Open circuit in harness.
Communication Error
T5-5-44
Monitor Controller (Monitor) Fault Codes

113002, 113003, 113005, 113007
Monitor Controller (Information) Fault Codes
114010, 114011, 114015
Preparation
 Disconnect the connectors from each controller.
 Check the CAN1 harness between the controllers.
(Refer to CAN1 Harness Check on T5-5-46 to 48.)
Fault Code Trouble or MP Dr. Message Inspection Method Cause
113002-2 (Monitor Controller) Engine Continuity check (open circuit) Open circuit in harness.
113003-2 (Monitor Controller) Main Continuity check (open circuit) Open circuit in harness.
Error 1 Discontinuity check (shorted circuit) Shorted circuit in harness.
113005-2 (Monitor Controller) ICF Continuity check (open circuit) Open circuit in harness.
113007-2 (Monitor Controller) Column Continuity check (open circuit) Open circuit in harness.
114010-2 (Information Controller) Continuity check (open circuit) Open circuit in harness.
Engine Controller
Communication Error Discontinuity check (shorted circuit) Shorted circuit in harness.
114011-2 (Information Controller) Main Continuity check (open circuit) Open circuit in harness.
Error 1 Discontinuity check (shorted circuit) Shorted circuit in harness.
114015-2 (Information Controller) Continuity check (open circuit) Open circuit in harness.
Column Controller
Communication Error Discontinuity check (shorted circuit) Shorted circuit in harness.
T5-5-45
CAN1 Harness Check

Preparation
 Before continuity check, set the key switch to the OFF position.
Evaluation
Continuity (0 Ω) Discontinuity (∞ Ω)
Continuity check Correct Disconnected
(open circuit)
Discontinuity check Shorted circuit Correct
(shorted circuit)
Inspection CAN Harness Main Controller (MC) Engine Control Information Controller
Module (ECM) (ICF)
Continuity check between High side #D2 #46 #C-5
Main Controller (MC) and each Low side #D3 #37 #C-11
controller
Discontinuity check between High side #D2 - #E1 #46 - #29 #C-5 - #A-19
CAN circuit and ground circuit #D2 - #E2 #46 - #30 #C-5 - #A-29
in each controller #D2 - #F4 #46 - #39 #C-5 - #A-30
#C-5 - #C-9
#D2 - #F5 #46 - #40 #C-5 - #C-14
#D2 - #F6 #46 - #50 #C-5 - #C-15
Low side #D3-#E1 #37 - #29 #C-11 - #A-19
#D3-#E2 #37 - #30 #C-11 - #A-29
#D3-#F4 #37 - #39 #C-11 - #A-30
#C-11 - #C-9
#D3-#F5 #37 - #40 #C-11 - #C-14
#D3-#F6 #37 - #50 #C-11 - #C-15
T5-5-46
CAN1 Harness Check
Inspection CAN Harness Main Controller (MC) Engine Control Information Controller
Module (ECM) (ICF)
Discontinuity check between High side #D2 - #E5 #46 - #7 #C-5 - #C-1
CAN circuit and power circuit #D2 - #E6 #46 - #8 #C-5 - #C-2
in each controller #D2 - #F1 #46 - #17 -
#D2 - #F2 #46 - #18 -
#D2 - #F3 #46 - #28 -
Low side #D3 - #E5 #37 - #7 #C-11 - #C-1
#D3 - #E6 #37 - #8 #C-11 - #C-2
#D3 - #F1 #37 - #17 -
#D3 - #F2 #37 - #18 -
#D3 - #F3 #37 - #28 -
Discontinuity check between High side #D2 - #E04 #46 - #38 #C-5 - #C-7
CAN circuit and key signal
circuit in each controller
Low side #D3 - #E04 #37 - #38 #C-11 - #C-7
Discontinuity check between - #D2 - #D3 #46-#37 #C-5 - #C-11

CAN (High side) circuit and
CAN (Low side) circuit in each
controller
T5-5-47
Connector (Harness end)
 MC-D Connector  ECM Connector (50-pole)
90Z6-05-MCD
 MC-E Connector
90Z6-05-ECM
90Z7B-05-MCE
 MC-F Connector
90Z6-05-MCF
 Information Controller-A Connector
90Z6-05-ICFA
 Information Controller-C Connector
90Z6-05-ICFC
T5-5-48
MC Fault Codes 111103, 111105

Preparation

Message
111103-3 Accelerator Pedal Circuit Measure resistance 0Ω Shorted circuit in harness
High Input between accelerator pedal #1 and #2.
sensor end #1 and #2.
- Normal in above Faulty accelerator pedal
check. sensor.
111103-4 Accelerator Pedal Circuit Measure voltage between Voltage: less than Open circuit in rear
Low Input accelerator pedal sensor 0.25 V console harness #2
connector pins #2 and #6. (power supply line).
Measure voltage between Voltage: less than Open circuit in rear
accelerator pedal sensor 0.25 V console harness #1 (signal
connector pins #1 and #6. line).
--- Normal in above Faulty accelerator pedal
check. sensor.
111105-3 Abnormal Engine Speed Torque converter input Faulty engine speed
Sensor speed sensor = 0 min-1 and sensor
Engine speed sent from
ECM (CAN) > 500 min-1

 Accelerator Pedal Sensor Connector (Rear Console Accelerator pedal
Cable Assy) sensor
90Z6-05-CN02
fNOTE: P: 5 V or 24 V power supply

S: Signal
G: Ground (chassis)
90Z6-05-05-02
 Accelerator Pedal Sensor Connector (Arrow View X)
(G) 6 1 (B)
1- Black: APS signal (L) 5 2 (W)

2- White: APS ground
3- Red: APS supply (5V) (O) 4 3 (R)
4- Orange: IVS supply (5V)
5- Blue: Idle active
6- Green: Throttle active
90Z6-05-05-03
T5-5-49

Preparation
 Connect the test harness and dummy sensor.
 Before inspection, set the key switch to the ON
position.

Message
111200-3 Lift Arm Raise Pilot Retry by using MPDr. Un-displayed fault Faulty sensor.
Pressure Sensor Circuit code
High Input (Option) Measure voltage between B Voltage: 4.75 V or Shorted circuit in harness
and chassis. more #1 and #2.
111200-4 Lift Arm Raise Pilot Retry by using MPDr. Un-displayed fault Faulty sensor.
Low Input (Option) Measure voltage between A Voltage: less than Open circuit in harness #1.
and chassis. 0.25 V
Measure voltage between A Voltage: less than Open circuit in harness #3.
and C (GND). 0.25 V
- Normal in above Open circuit in harness #2.
check.
fNOTE: Lift arm raise pilot pressure sensor (for ride

control option) is mounted at the multiple control valve.
Refer to p. T5-4-17 for the sensor location.
C B A
TDAA-05-06-003
T5-5-50

Preparation

Message
111205-3 Lift Arm Angle Sensor Measure resistance 0Ω Shorted circuit in harness
Circuit High Input between lift arm angle #1 and #2.
(Option) 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 harness #1.
Circuit Low Input lift arm angle sensor 0.25 V
(Option) harness end #1 and chassis.
Measure voltage between Voltage: less than Open circuit in harness #3.
lift arm angle sensor 0.25 V
harness end #1 and #3.
- Normal in above Faulty lift arm angle
check. sensor.
111207-3 Refrigerant Pressure Measure resistance 0Ω Shorted circuit in harness
Circuit High Input between refrigerant #1 and #2.
pressure sensor end #1 and
#2.
- Normal in above Open circuit refrigerant
check. pressure sensor.
111207-4 Refrigerant Pressure Measure voltage between Voltage: less than Open circuit in harness #1.
Sensor Circuit Low Input refrigerant pressure sensor 0.25 V
harness end #1 and chassis.
Measure voltage between Voltage: less than Open circuit in harness #3.
refrigerant pressure sensor 0.25 V
harness end #1 and #3.
- Normal in above Faulty refrigerant pressure
check. sensor.

 Lift Arm Angle Sensor  Refrigerant Pressure Sensor
90Z7-05-CN04 90Z7-05-CN05
fNOTE: See p. T5-4-4 for the lif arm angle sensor

location. fNOTE: P: 5 V or 24 V power supply
S: Signal
G: Ground (chassis)
fNOTE: See p. T5-7-2 for the refrigerant pressure sensor
location.
T5-5-51

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

Message
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 harness
111217-4 Pilot Pressure Sensor Retry by using MPDr. Un-displayed fault Faulty sensor.
Circuit Low Input code
and chassis. 0.25 V
and C (GND). 0.25 V
Normal in above Open circuit in harness #2.
check.
111312-3 Service Brake Secondary Retry by using MPDr. Un-displayed fault Faulty sensor.
High Input Measure voltage between B Voltage: 4.75 V or Shorted circuit in harness
111312-4 Service Brake Secondary Retry by using MPDr. Un-displayed fault Faulty sensor.
Low Input Measure voltage between A Voltage: less than Open circuit in harness #1.
and chassis. 0.25 V
and C (GND). 0.25 V
Normal in above Open circuit in harness #2.
check.
C B A
TDAA-05-06-003
fNOTE: The pilot (primary) pressure sensor is installed to

the pilot valve. (See p. T5-4-16)
The service brake secondary pressure sensor is installed to
the brake valve. (See p. T5-4-16)
Refer to the F&S S/M Section 3 for the sensor specifications.
T5-5-52

Preparation
position.

Message
111204-3 Pump Delivery Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
Sensor Circuit High Input code
Measure voltage between B Voltage: 4.75 V or Shorted circuit in harness
111204-4 Pump Delivery Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
Sensor Circuit Low Input code
and chassis. 0.25 V
and C (GND). 0.25 V
check.
C B A
TDAA-05-06-003
fNOTE: The pump delivery pressure sensor is installed

to the main pump. Refer to p. T5-4-13 for the sensor
location. Refer to F&S S/M Section T3-1 for more
information.
T5-5-53

Preparation
position.

Message
111206-3 Hyd. Fan Circuit Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
Sensor Circuit High Input code
(Option) Measure voltage between B Voltage: 4.75 V or Shorted circuit in harness
111206-4 Hyd. Fan Circuit Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
Sensor Circuit Low Input code
(Option) Measure voltage between A Voltage: less than Open circuit in harness #1.
and chassis. 0.25 V
and C (GND). 0.25 V
check.
 For Reversing Fan (Option)

fNOTE: The fan circuit pressure sensor is installed to the
fan control valve.
Refer to the F&S S/M Section 3-3 for the sensor
2
specifications.
1
4
1- Fan Motor
3 2- Radiator Assembly
3- Fan Valve (Option)
4- Fan Circuit Pressure Sensor (Option)
90Z6-03-03-03
C B A
TDAA-05-06-003
T5-5-54

Preparation
position.

Message
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 harness
(Option) and chassis. more #1 and #2.
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 harness #1.
(Option) and chassis. 0.25 V
and C (GND). 0.25 V
check.
fNOTE: The secondary steering pump delivery pressure

sensor (option) is installed to the steering valve. (See p.
T5-4-18, lower #4)
Refer to the F&S S/M Section 3 for the sensor
specifications.
C B A
TDAA-05-06-003
T5-5-55

Preparation
position.

Message
111311-3 Service Brake Primary Retry by using MPDr. Un-displayed fault code Faulty sensor.
Pressure Sensor Circuit
High Input Measure voltage between B Voltage: 4.75 V or more Shorted circuit in
and chassis. harness #1 and #2.
111311-4 Service Brake Primary Retry by using MPDr. Un-displayed fault code Faulty sensor.
Pressure Sensor Circuit Measure voltage between A Voltage: less than 0.25 V Open circuit in
Low Input and chassis. harness #1.
Measure voltage between A Voltage: less than 0.25 V Open circuit in
and C (GND). harness #3.
- Normal in above check. Open circuit in
harness #2.
111313-3 Parking Brake Pressure Retry by using MPDr. Un-displayed fault code Faulty sensor.
Sensor Circuit High Input
Measure voltage between B Voltage: 4.75 V or more Shorted circuit in
and chassis. harness #1 and #2.
111313-4 Parking Brake Pressure Retry by using MPDr. Un-displayed fault code Faulty sensor.
Sensor Circuit Low Input Measure voltage between A Voltage: less than 0.25 V Open circuit in
and chassis. harness #1.
Measure voltage between A Voltage: less than 0.25 V Open circuit in
and C (GND). harness #3.
- Normal in above check. Open circuit in
harness #2
C B A
TDAA-05-06-003
fNOTE: The service brake primary pressure sensor (for

service brake pressure alarm) and parking brake pressure
sensor are installed to the charging block. (See p. T5-4-
15.)
Refer to the F&S S/M Section 3-7 for the sensor
specifications.
T5-5-56

Preparation

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

 Solenoid Valve Connector
2
90Z6-05-CN03
4
1- Fan Motor
2- Radiator Assembly
1 3- Fan Valve (Option)
4- Fan Reverse Control Solenoid Valve (Option)
5- Fan Speed Control Solenoid Valve (Option)
3
90Z6-03-03-03
T5-5-57

Preparation

Message
111412-2 Hyd. Fan P/S Valve Measure resistance 0/∞Ω Faulty solenoid valve.
Abnormal Feedback between solenoid valve #1 (Normal value:
and #2. 22±0.4 Ω)
#1 and chassis.
Control P/S FB
check. #1 and #2.
111412-3 Hyd. Fan P/S Valve Measure resistance 0Ω Faulty solenoid valve.
Feedback High Current between solenoid valve #1 (Normal value:
and #2. 22±0.4 Ω)
check. #1 and #2.
111412-4 Hyd. Fan P/S Valve Measure resistance ∞Ω Faulty solenoid valve.
Feedback Low Current between solenoid valve #1 (Normal value:
and #2. 22±0.4 Ω)
#1 and chassis.
Control P/S FB

90Z7-05-CN10
fNOTE: When the optional reversing fan is installed,

the connector of fan speed control solenoid is as shown
below. Refer to the previous page for the solenoid Fan Speed Control
location with optional reversing fan function. Solenoid Valve
90Z6T1-2-14
TNED-05-05-20
fNOTE: Fan speed control solenoid valve is installed to
the fan motor.
T5-5-58

Preparation

Message
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 chassis.
Monitor Pump Torque 0 mA Open circuit in harness #2.
Control P/S Valve Output
FB.
check. #1 and #2.
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)
check. #1 and #2.
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 chassis.
Monitor Pump Torque 0 mA Open circuit in harness #2.
Control P/S Valve Output
FB.

90Z6-05-CN03
fNOTE: The pump torque control (swash angle) solenoid

valve is installed to the charging block.
90Z6-03-07-17
T5-5-59

Preparation

Message
111414-2 T/M Clutch 1st P/S Valve Measure resistance 0/∞Ω Faulty solenoid valve.
Abnormal FB between solenoid valve #1 (Normal voltage:
111415-2 T/M Clutch 2nd P/S Valve and #2. 22±0.4 Ω)
Abnormal FB Measure voltage between 0V Open circuit in harness #1.
111416-2 T/M Clutch 3rd P/S Valve solenoid valve harness end
Abnormal FB #1 and chassis.
111417-2 T/M Clutch 4th P/S Valve Each clutch P/S FB 0 mA Open circuit in harness #2.
Abnormal FB
111418-2 T/M Clutch Forward P/S
Valve Abnormal FB
check. #1 and #2.
111419-2 T/M Clutch Reverse P/S
Valve Abnormal FB
111414-3 T/M Clutch 1st P/S Valve Measure resistance 0Ω Faulty solenoid valve.
FB High Current between solenoid valve #1 (Normal voltage:
FB High Current
111416-3 T/M Clutch 3rd P/S Valve
FB High Current
111417-3 T/M Clutch 4th P/S Valve
FB High Current
check. #1 and #2.
Valve FB High Current
Valve FB High Current
111414-4 T/M Clutch 1st P/S Valve Measure resistance ∞Ω Faulty solenoid valve.
FB Low Current between solenoid valve #1 (Normal voltage:
FB Low Current
111416-4 T/M Clutch 3rd P/S Valve Measure voltage between 0V Open circuit in harness #1.
FB Low Current solenoid valve harness end
111417-4 T/M Clutch 4th P/S Valve #1 and chassis.
FB Low Current
Valve FB Low Current Each clutch P/S FB 0 mA Open circuit in harness #2.
Valve FB Low Current

fNOTE: The solenoid valves are installed to the
transmission control valve. (See p. T5-4-12.)
TNED-05-05-020
T5-5-60

Preparation

Message
111422-2 Ride Control P/S Valve Measure resistance 0/∞Ω Faulty solenoid valve.
Abnormal FB (Option) between solenoid valve #1 (Normal voltage:
and #2. 22±0.4 Ω)
#1 and chassis.
Ride Control (Bottom) P/S 0 mA Open circuit in harness #2.
FB
check. #1 and #2.
111422-3 Ride Control P/S Valve FB Measure resistance 0Ω Faulty solenoid valve.
High Current (Option) between solenoid valve #1 (Normal voltage:
and #2. 22±0.4 Ω)
check. #1 and #2.
111422-4 Ride Control P/S Valve FB Measure resistance ∞Ω Faulty solenoid valve.
Low Current (Option) between solenoid valve #1 (Normal voltage:
and #2. 22±0.4 Ω)
#1 and chassis.
Ride Control P/S FB 0 mA Open circuit in harness #2.

TNED-05-05-20
fNOTE: The ride control solenoid valve is installed to the

ride control valve (option). (Refer to p. T5-4-17.)
T5-5-61
MC Fault Codes 111600, 111601, 111602

Preparation
position.

Message
111600-3 T/M Output Speed Check harness Abnormal in harness Abnormal harness.
Sensor Failure check
Normal in harness check Faulty sensor.
111600-4 T/M Output Speed Check harness Abnormal in harness Abnormal harness.
Sensor Circuit Low Input check
111601-3 Torque Converter Check harness Abnormal in harness Abnormal harness.
Output Speed Sensor check
Failure Normal in harness check Faulty sensor.
111602-3 Intermediate Shaft Check harness Abnormal in harness Abnormal harness.
Speed Sensor Failure check
C B A
TDAA-05-06-003
fNOTE: Refer to p. T5-4-12 for each sensor.
T5-5-62

Preparation

Message
111900-3 Torque Converter Oil Measure resistance between Refer to the table. Faulty sensor.
Temperature Sensor sensor #1 and chassis GND.
Circuit High Input Measure voltage between 0V Open circuit in harness #1.
sensor harness end #1 and
chassis.
- Normal in above Improper grounding
check. between chassis
111900-4 Torque Converter Oil Measure resistance between Refer to the table. Faulty sensor.
Temperature Sensor sensor #1 and chassis GND.
Circuit Low Input - Normal in above Shorted circuit in harness
check. #1.
Torque Converter Oil Temperature Sensor

Specification
Torque Converter Oil Resistance (kΩ)

Temperature (°C (°F))
25 (77) (7.6)
40 (104) (4.0)
50 (122) 2.7±0.22
80 (176) 0.92±0.073
95 (203) (0.56)
105 (221) (0.42)
120 (248) 0.276±0.014
fNOTE: Refer to p. T5-4-12 for the sensor location.
 Torque Converter Oil Temperature Sensor
Harness connector 35829-20130

(#1) is inserted here.
Terminal Bolt
 Rear Chassis Harness Connector CN.112

#1
CN112
T5-5-63

Preparation

Message
111901-4 Hyd. Oil Temp Sensor Measure resistance Refer to the table. Faulty sensor.
Circuit Low Input between sensor #1 and #2.
check. #1.
111901-3 Hyd. Oil Temp Sensor Measure resistance Refer to the table. Faulty sensor.
Circuit High Input between sensor #1 and #2.
chassis.
check.
Hydraulic Oil Temperature Sensor Specification
Hydraulic Oil Resistance (kΩ)

Temperature (°C (°F))
-30 (-22) 25.4 1
-20 (-4) 15.0
-10 (14) 9.16
0 (32) 5.74
10 (50) 3.7
20 (68) 2.45
30 (86) 1.66
40 (104) 1.15
50 (122) 0.811
60 (140) 0.584
70 (158) 0.428
2
80 (176) 0.318
90 (194) 0.24 90Z6-05-05-04
100 (212) 0.1836
110 (230) 0.1417 1- Hydraulic Oil Tank
2- Hydraulic Oil Temperature Sensor
120 (248) 0.1108

 Hydraulic Oil Temperature Sensor
90Z7-05-CN11 35829-60160
T5-5-64

Preparation

Message
111902-3 Axle Oil Temperature Measure resistance Refer to the table. Faulty sensor.
Sensor Circuit High Input between sensor #1 and #2.
chassis.
check.
111902-4 Axle Oil Temperature Measure resistance Refer to the table. Faulty sensor.
Sensor Circuit Low Input between sensor #1 and #2.
check. #1.
Axle Oil Temperature Sensor Specification Connector (Harness end)
Hydraulic Oil Temperature Resistance (kΩ)  Axle Oil Temperature Sensor

(°C (°F))
-30 (-22) 112.5
-20 (-4) 67.9
-10 (14) 42.4
90Z7-05-CN12
0 (32) 27.2
10 (50) 17.9
20 (68) 12.1
25 (77) 10 fNOTE: Axle oil temperature sensor is installed to the
30 (86) 8.3 front axle. (See p. T5-4-15.)
40 (104) 5.8
50 (122) 4.2
60 (140) 3.1
70 (158) 2.3
80 (176) 1.7
90 (194) 1.3
100 (212) 1.0
110 (230) 0.78
120 (248) 0.62
130 (266) 0.49
140 (284) 0.39
150 (302) 0.32
160 (320) 0.27
170 (338) 0.22
180 (356) 0.18
T5-5-65
Fault Code Trouble or MP Dr. Message Symptoms in Machine Remedy

Operation When Trouble
Occurs
111700-6 Calibration Abort Forward: Key-off Transmission learning Perform T/M learning.
111701-6 Calibration Abort Reverse: Key-off failed. Refer to T4-6.
111702-6 Calibration Abort 1st: Key-off Shifting may not be
111703-6 Calibration Abort 2nd: Key-off smooth.
111704-6 Calibration Abort 3rd: Key-off
111705-6 Calibration Abort 4th: Key-off
111700-7 Calibration Abort Forward: Stop Order from MPDr. Transmission learning Perform T/M learning.
111701-7 Calibration Abort Reverse: Stop Order from MPDr. failed. Refer to T4-6.
111702-7 Calibration Abort 1st: Stop Order from MPDr. Shifting may not be
111703-7 Calibration Abort 2nd: Stop Order from MPDr. smooth.
111704-7 Calibration Abort 3rd: Stop Order from MPDr.
111705-7 Calibration Abort 4th: Stop Order from MPDr.
111700-8 Calibration Abort Forward: Transmission learning Start engine and
Engine RPM < 600rpm, or RPM > 1000 rpm failed. perform T/M learning.
111701-8 Calibration Abort Reverse: Shifting may not be Refer to T4-6.
Engine RPM < 600rpm, or RPM > 1000 rpm smooth.
111702-8 Calibration Abort 1st:
Engine RPM < 600rpm, or RPM > 1000 rpm
111703-8 Calibration Abort 2nd:
111704-8 Calibration Abort 3rd:
111705-8 Calibration Abort 4th:
111700-9 Calibration Abort Forward: Parking Brakelight Off Transmission learning Apply parking brake and
111701-9 Calibration Abort Reverse: Parking Brakelight Off failed. perform T/M learning.
111702-9 Calibration Abort 1st: Parking Brakelight Off Shifting may not be Refer to T4-6.
111703-9 Calibration Abort 2nd: Parking Brakelight Off smooth.
111704-9 Calibration Abort 3rd: Parking Brakelight Off
111705-9 Calibration Abort 4th: Parking Brakelight Off
111700-10 Calibration Abort Forward: Transmission learning Check and wait until
T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC failed. the T/C oil temperature
111701-10 Calibration Abort Reverse: Shifting may not be becomes normal.
T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC smooth. Perform T/M learning.
111702-10 Calibration Abort 1st: Refer to T4-6.
T/C Oil Temp. < 55DC or T/C Oil Temp. > 80DC
111703-10 Calibration Abort 2nd:
111704-10 Calibration Abort 3rd:
111705-10 Calibration Abort 4th:
111700-11 Calibration Abort Forward: Travel Speed != 0 km/h Transmission learning Apply parking brake and
111701-11 Calibration Abort Reverse: Travel Speed != 0 km/h failed. perform T/M learning.
111702-11 Calibration Abort 1st: Travel Speed != 0 km/h Shifting may not be Refer to T4-6.
111703-11 Calibration Abort 2nd: Travel Speed != 0 km/h smooth.
111704-11 Calibration Abort 3rd: Travel Speed != 0 km/h
111705-11 Calibration Abort 4th: Travel Speed != 0 km/h
T5-5-66
Fault Code Trouble or MP Dr. Message Symptoms in Machine Remedy

Operation When Trouble
Occurs
111700-12 Calibration Abort Forward: FNR != N Transmission learning Set FNR lever to neutral
111701-12 Calibration Abort Reverse: FNR != N failed. position and perform
111702-12 Calibration Abort 1st: FNR != N Shifting may not be T/M learning. Refer to
111703-12 Calibration Abort 2nd: FNR != N smooth. Refer to T4-6.
111704-12 Calibration Abort 3rd: FNR != N
111705-12 Calibration Abort 4th: FNR != N
111700-13~16 Calibration Abort Forward: Step 1-2 errors Transmission learning Perform T/M learning.
111701-13~16 Calibration Abort Reverse: Step 1-2 errors failed. Refer to T4-6.
111702-13~16 Calibration Abort 1st: Step 1-2 errors Shifting may not be Check harness.
111703-13~16 Calibration Abort 2nd: Step 1-2 errors smooth.
111704-13~16 Calibration Abort 3rd: Step 1-2 errors
111705-13~16 Calibration Abort 4th: Step 1-2 errors
111700-17 Calibration Abort Forward: Step 2 error Transmission learning Perform T/M learning.
111701-17 Calibration Abort Reverse: Step 2 error failed. Refer to T4-6.
111702-17 Calibration Abort 1st: Step 2 error Shifting may not be Check harness.
111703-17 Calibration Abort 2nd: Step 2 error smooth.
111704-17 Calibration Abort 3rd: Step 2 error
111705-17 Calibration Abort 4th: Step 2 error
111700-18~20 Calibration Abort Forward: Step 3 errors Transmission learning Perform T/M learning.
111701-18~20 Calibration Abort Reverse: Step 3 errors failed. Refer to T4-6.
111702-18~20 Calibration Abort 1st: Step 3 errors Shifting may not be Check harness.
111703-18~20 Calibration Abort 2nd: Step 3 errors smooth.
111704-18~20 Calibration Abort 3rd: Step 3 errors
111705-18~20 Calibration Abort 4th: Step 3 errors
111700-21 Calibration Abort Forward: EEPROM Write Failure Transmission learning Perform T/M learning.
111701-21 Calibration Abort Reverse: EEPROM Write Failure failed. Refer to T4-6.
111702-21 Calibration Abort 1st: EEPROM Write Failure Shifting may not be Replace MC.
111703-21 Calibration Abort 2nd: EEPROM Write Failure smooth.
111704-21 Calibration Abort 3rd: EEPROM Write Failure
111705-21 Calibration Abort 4th: EEPROM Write Failure
111700-31 Calibration Abort Forward: Un-Calibration Shifting may not be Perform T/M learning.
111701-31 Calibration Abort Reverse: Un-Calibration smooth. Refer to T4-6.
111702-31 Calibration Abort 1st: Un-Calibration
111703-31 Calibration Abort 2nd: Un-Calibration
111704-31 Calibration Abort 3rd: Un-Calibration
111705-31 Calibration Abort 4th: Un-Calibrationf
T5-5-67
Fault Code Trouble or MP Dr. Message Inspection Method Evaluation Cause

120000-2 Hydraulic Oil Overheat Disconnect the connector Displayed fault code Faulty MC or shorted
Alarm from the hydraulic oil circuit in harness.
temperature sensor (see p. Un-displayed fault Faulty hydraulic oil
T5-5-74). code temperature sensor.
Retry by using MPDr.
120001-2 Main Pump Pressure Alarm Disconnect the connector Displayed fault code Faulty MC or shorted
from the main pump oil circuit in harness.
pressure sensor (see p. Un-displayed fault Faulty main pump oil
T5-5-61). code pressure sensor.
120002-2 Axle Oil Temperature Disconnect the connector Displayed fault code Faulty MC or shorted
Alarm from the axle oil circuit in harness.
temperature sensor (see p. Un-displayed fault Faulty axle oil
120003-2 Emergency Steering Disconnect the connector Correct Faulty harness.
Activated Alarm (Option) from the steering oil Incorrect Faulty secondary
pressure switch (option). steering check switch.
120004-2 Emergency Steering Disconnect the connector Displayed fault code Faulty MC or shorted
Activated Pressure Alarm from the steering oil circuit in harness.
(Option) pressure switch (option) Un-displayed fault Faulty steering
(see p. T5-5-22). code pressure switch.
120005-2 Transmission Oil Disconnect the connector Displayed fault code Faulty MC or shorted
Temperature Overheat from the transmission oil circuit in harness.
Alarm temperature sensor (see p. Un-displayed fault Faulty transmission oil

120014-2 Overrun Alarm Disconnect the connector - -
from the machine speed
sensor.
T5-5-68
Column Display Controller Fault Code

115001

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

 Monitor Controller-2B Connector
REG Input
90Z6-05-M2B
fNOTE: Refer to p. T5-1-14 for the alternator check.
T5-5-69
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.
Measure voltage between 0V Open circuit in
sensor harness end #1 and harness #1.
chassis.
- Normal in above Open circuit in
check. harness #2.
115011-4 Fuel Level Sensor Circuit Measure resistance Refer to the table. Faulty sensor.
Low Input between sensor #1 and #2.
- Normal in above Shorted circuit in
check. harness #1 and #2.
Fuel Gauge No. Fuel Level (%) Fuel Sensor (Ω)

A 100 (FULL) 10 (+5/0)
A B 50 32.9±2.5
C 0 (EMPTY) 90±2.5
C
TNED-05-05-008

 Fuel Sensor
90Z7-05-CN11
T5-5-70
Fuel Level Sensor Specifications
100.6±10 mm (3.96±0.4 in)
212.5 mm (8.37 in)

F
349.9±10 mm (13.78±0.4 in)

in)
6.3
mm(
0
R16 1/2
Float
Float
35828-60470C
 Fuel Sensor Harness Connector  Fuel Sensor Circuit
Gauge
Unit (Blue) GND (Black)
DC12V
Unit
35828-60470C1 35828-60470
fNOTE: Refer to the table on the previous page for the

resistance.
T5-5-71
Monitor Controller (Monitor) Fault Code 120300

120300-2 System Failure Alarm Check CAN harness. - Faulty CAN harness.
Column Display Controller (Information) Fault Codes 120500 to 120503

120500-2 Overheat Alarm Disconnect a connector Displayed fault code Faulty column display
from the overheat switch controller or shorted
(Coolant temperature circuit in harness.
switch on the engine). Un-displayed fault Faulty overheat
Retry by using MPDr. code switch.
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 harness.
MPDr. Un-displayed fault Faulty air filter
code restriction switch.

 Column Display Controller (Monitor) 1-A Connector
Overheat (GY)
90Z6-05-M1A
Air Cleaner Restriction (RL) Engine Oil Pressure (V)
T5-5-72
Column Display Controller (Information) Fault Codes 120505 to 120507

120505-2 Brake Pressure Alarm Disconnect brake primary Displayed fault code Faulty column display
pressure sensor. Retry by controller or shorted
using MPDr. circuit in harness.
Un-displayed fault Faulty brake primary
code pressure sensor.
120506-2 Steering Oil Pressure Alarm Disconnect a connector Displayed fault code Faulty column display
(for Secondary Steering from the steering oil controller or shorted
Option) pressure switch. Retry by circuit in harness.
using MPDr. Un-displayed fault Faulty steering oil
code pressure switch.
120507-2 Transmission Malfunction Check the accompanied - -
T/M solenoid or revolution
sensor error, and check for
the error.
Service Brake Primary Pressure Sensor Connector (Harness end)

 Column Display Controller (Monitor) 1-A Connector
90Z6-05-M1A
Steering Oil Pressure (RB)
 Column Display Controller (Monitor) 1-B Connector
90Z6-05-M1B
Brake Pressure (O)
90Z6-05-05-07
fNOTE: Service brake primary pressure sensor is installed

to the charging block.
Refer to F&S S/M p.T3-7-13 for the specifications.
The steering oil pressure switch is installed to the
optional secondary steering block. (See p. T5-4-18.)
T5-5-73
Air Conditioner Controller Fault Codes 11 to

22
Preparation
position.

Message
11 Open circuit in re- Measure resistance ∞ Ω (Normal value: Faulty sensor.
circulated air sensor between sensor #1 and #2. 300 to 430 kΩ)
chassis.
check.
12 Shorted circuit in re- Measure resistance 0 Ω (Normal value: Faulty sensor.
circulated air sensor between sensor #1 and #2. 300 to 430 kΩ)
check. #1 and #2.
13 Open circuit in outdoor Measure resistance ∞ Ω (Normal value: Faulty sensor.
ambient temperature between sensor #1 and #2. 100 to 210 kΩ)
sensor Measure voltage between 0V Open circuit in harness #1.
chassis.
check.
14 Shorted circuit in Measure 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.
18 Shorted circuit in solar Check continuity between 0Ω Shorted circuit in harness
radiation sensor sensor harness end #1 and #1 and #2.
#2.
- Normal in above Faulty sensor.
check.
21 Open circuit in frost Measure resistance ∞ Ω (Normal value: Faulty sensor.
sensor between sensor #1 and #2. 100 to 115 kΩ)
chassis.
check.
22 Shorted circuit in frost Measure resistance 0 Ω (Normal value: Faulty sensor.
sensor between sensor #1 and #2. 100 to 115 kΩ)
check. #1 and #2.
T5-5-74
Air Conditioner Controller Fault Codes 43 to

92
Preparation
position.

Message
43 Abnormal air vent Measure voltage between 0V Faulty controller or open circuit
damper servo air vent damper servo motor in harness between controller
motor harness end 7C and chassis. and air vent damper servo
(AUTO/OFF switch / blower motor.
switch: ON)
Measure voltage between 0V Faulty controller or open circuit
air vent damper servo motor in harness between controller
harness end 7C and 25D. (AUTO/ and air vent damper servo
OFF switch / blower switch: ON) motor.
- Normal in Faulty air vent damper servo
above check. motor.
44 Abnormal air mix Measure voltage between 0V Faulty controller or open circuit
damper servo air mix damper servo motor in harness between controller
motor harness end 7D and chassis. and air mix damper servo motor.
(AUTO/OFF switch / blower
switch: ON)
Measure voltage between 0V Faulty controller or open circuit
air mix damper servo motor in harness between controller
harness end 7D and 25E. (AUTO/ and air mix damper servo motor.
OFF switch / blower switch: ON)
- Normal in Faulty air mix damper servo
above check. motor.
51 Abnormal Measure voltage between High 0 V Faulty controller or open circuit
refrigerant and low pressure switch harness in harness between controller
pressure high and end A21 and A05. (AUTO/OFF and High and low pressure
low. switch / blower switch: ON) switch.
- Normal in Faulty High and low pressure
above check. switch.
91 CAN Check continuity in CAN1 Normal Faulty controller.
communication harness. Abnormal Faulty CAN1 harness.
error
92 CAN bus off error Check continuity in CAN1 Normal Faulty controller.
harness. Abnormal Faulty CAN1 harness.
T5-5-75
(Blank)
T5-5-76
Troubleshooting B (Machine Diagnosis by

Using Troubleshooting Symptom) Procedure
Refer to troubleshooting B procedures for diagnosis
by using trouble symptom when no fault codes are
displayed.
 Diagnosis Procedure
 The diagnosis procedures for the observed machine
abnormality without any fault codes are explained in
this group.
 Perform diagnosis by using MPDr. or the service
menu of monitor first.
 In case any fault code has not been displayed by
diagnosis, perform inspection according to the
procedures when diagnosing.
 When the fault code is displayed, refer to the
troubleshooting A group and diagnose.
 On the front section pages of this group, there are
the tables indicating the relationship between
machine trouble symptoms and related parts
which may cause such trouble if failed. Start the
troubleshooting with more probable causes selected
by referring to these tables.
fNOTE: Harness end connector viewed from the open

end side by the all connectors image shown in this
section.
1
2
T6L4-05-03-001
1- Harness End Connector 2- 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 becomes 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 Although the accelerator pedal Open circuit: Travel mode is
in machine min-1. is operated, hydraulic load is not always Manual mode.
operation As pump displacement is held at released. 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 - See p. T5-5-49 for the accelerator -
pedal sensor.
Descriptions T2-2 T2-2 T2-2
of Control
(Refer to 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: Delutch Position Switch
Monitoring
Evaluation - - -
by using Test
Harness
Note - When quick power mode control Brake Pedal Depressing Amount:
is effective. Two modes, Fully and Lightly
(Quick power mode is not with the declutch position switch
activated when travel is in neutral set in the ON position
or the travel load is light.)
of Control
(Refer to 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. MC holds the travel in neutral.
in control
system when
trouble occurs
Symptoms Cooling fan does not rotate in Although forward/reverse lever
in machine reverse. is operated, machine does not
operation The fan reverse rotation indicator travel forward/reverse.
when trouble on monitor is not ON. (The The FNR indication on monitor is
occurs indicator does not blink when not shifted.
shifting.)
Evaluation by - 111904 (F/R input at the same
Fault Code time)
Evaluation by - MC: Forward/Reverse Lever (F)/
Monitoring (N)/(R)
Evaluation - -
by using Test
Harness
Note - -
Descriptions T2-2, 2-4 T2-2, T2-5
of Control
(Refer to F&S
S/M)
T5-6-5
Parts Forward/Reverse Selector Switch Forward/Reverse Switch
Item
Function Selects forward/reverse lever or Shifts forward clutch solenoid
forward/reverse switch operation valve, and reverse clutch solenoid
valve of transmission.
Symptoms MC makes forward/reverse switch MC 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 - 111905 (F/R simultaneous input)
Fault Code
Evaluation by MC: Forward/Reverse Selector MC: Forward/Reverse Switch (F)/
Monitoring Switch (N)/(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 has priority)
Descriptions T2-2, T2-5 T2-2, T2-5
of Control
(Refer to F&S
S/M)
T5-6-6
Parts Shift Switch Downshift Switch (DSS) Hold Switch
Item
Function Shifts speed shift solenoid valves Shifts speed shift solenoid valves Shifts speed shift solenoid valves
(1, 2, and 3) of transmission. of transmission and shifts down of transmission and holds the
the speed shift during automatic speed shift during automatic
speed shift. speed shift.
Symptoms MC holds the speed shift in Same as shown below. Same as shown below.
in control second speed.
system when
trouble occurs
Symptoms The speed shift is held in second 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 or AUTO 2 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 first speed from The shift indication on monitor is not shifted.
second speed in AUTO 1 mode. not shifted.
Evaluation by - - -
Fault Code
Evaluation by MC: Shift Switch MC: DSS Switch MC: Shift Hold Switch
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T2-2, T2-5 T2-2 T2-2
of Control
(Refer to F&S
S/M)
T5-6-7
Parts Ride Control Switch, Ride Control

Switch (AUTO) (Option)
Item
Function Shifts ride control solenoid valves
(rod side and bottom side) 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, Ride
Monitoring Control Switch (AUTO)
Evaluation -
by using Test
Harness
Note -
Descriptions T2-2, T2-4
of Control
(Refer to F&S
S/M)
T5-6-8
Parts Parking Brake Switch Front Control Lever Lock Switch
Item
Function Shifts parking brake solenoid Shifts pilot shut-off (control lever
valve. lock) solenoid valve.
Symptoms Same as shown below. Same as shown below.
in control
system when
trouble occurs
Symptoms Although the parking brake Open circuit: Front control lever
in machine switch is turned ON/OFF, the lock switch is always OFF. Pilot
operation parking brake is not released/ shut-off solenoid valve is not
when trouble applied with the engine running. shifted. The lift arm and bucket
occurs are not operated although the
control lever is operated with the
front control lever lock switch set
in UNLOCK position.
Shorted circuit: Front control
lever lock switch is always ON.
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
of Control
(Refer to 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 (248°F) converter oil temperature is
system when when open circuit occurs. 120°C (248°F) when open circuit
trouble occurs (Hydraulic oil temperature: occurs.
120°C (248°F) is not displayed on
monitoring.)
Symptoms When hydraulic oil temperature The color of transmission oil
in machine is 0°C (32°F) or less when starting temperature on monitor is red.
operation engine, auto-warming up control The buzzer sounds and the
when trouble is not operated. indicator is displayed.
occurs
Evaluation by 111901 111900
Fault Code
Evaluation by MC: Hydraulic Oil Temperature MC: Torque Converter Oil
Monitoring Temperature
Evaluation - -
by using Test
Harness
Note Refer to p. T5-5-64 for the Refer to pp. T5-4-12, T5-5-63 for
temperature sensor. the temperature sensor.
Descriptions T2-2 T2-2
of Control
(Refer to F&S
S/M)
T5-6-10
Parts Pump Delivery Pressure Sensor Hyd. Fan Circuit Pressure Sensor Secondary Steering Pump
(Option) Delivery Pressure Sensor (Option)
Item
Function Detects pump delivery pressure. Detects hydraulic fan circuit 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 The secondary steering pump is
in machine not activated. switch is operated, fan rotation operated normally. (When the
operation direction can not change. engine starts)
when trouble
occurs
Evaluation by 111204 111206 111208
Fault Code
Evaluation by MC: Pump Delivery Pressure MC: Hydraulic Fan Circuit Pressure MC: Secondary Steering Pump
Monitoring Delivery Pressure
Evaluation - - -
by using Test
Harness
Note Refer to p. T5-4-13 for the sensor. Refer to p. T5-5-54 for the sensor. Refer to p. T5-4-18 for the sensor.
Possible to judge if sensor or Possible to judge if sensor or Possible to judge if sensor or
harness is faulty by switching harness is faulty by switching harness is faulty by switching
pressure sensor with other pressure sensor with other pressure sensor with other
pressure sensor. pressure sensor. pressure sensor.
of Control
(Refer to 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 Open circuit: Secondary steering When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control operation condition: Steering following symptoms occur. following symptoms occur.
system when pressure decreases.
trouble occurs
Symptoms Secondary steering pump is Although the parking brake The low brake oil pressure
in machine operated when the harness is is applied, the parking brake indicator is always ON.
operation disconnected while traveling. indicator is not ON.
when trouble The low steering oil pressure The machine may not accelerate
occurs indicator is always ON. by possible parking brake
dragging because parking brake
ON/OFF cannot be judged.
Evaluation by - 111313 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 Refer to p. T5-4-18 for the Refer to p. T5-4-15 for the sensor. Refer to p. T5-4-15 for the sensor.
pressure switch location. Possible to judge if pressure Possible to judge if pressure
Possible to judge if pressure sensor is faulty or port is clogged sensor is faulty or port is clogged
sensor is faulty or port is clogged by switching pressure sensor with by switching pressure sensor with
by switching pressure switch with other pressure sensor. other pressure sensor.
pump delivery pressure switch.
Descriptions T2-2 T2-2, T2-4 T2-2, T2-4
of Control
(Refer to 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 Front attachment operation
in machine automatically downshift to first kickout control is not activated. circuit selection control is not
operation speed with the travel mode set in The lift arm auto leveler height activated during combined
when trouble AUTO 1 mode. kickout control is not activated. operation of lift arm and bucket
occurs The declutch control is not dump.
activated. The ride 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 Declutch)
Evaluation - - -
by using Test
Harness
Note Refer to p. T5-4-16 for the sensor. Refer to p. T5-4-4 for the sensor Refer to p. T5-4-17 for the sensor.
location. 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
(Refer to 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 OFF (Lock) position, front
occurs control lever lock indicator is not
ON.
Evaluation by 111217
Fault Code
Evaluation by MC: Pilot Pressure Sensor
Monitoring
Evaluation -
by using Test
Harness
Note Refer to p. T5-4-16 for the sensor.
Possible to judge if pressure
sensor is faulty or port is clogged
by switching pressure sensor with
other pressure sensor.
Descriptions T2-2, T2-4
of Control
(Refer to F&S
S/M)
T5-6-14
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 bad extremely during
operation automatic speed shift. automatic speed shift.
when trouble Possible to judge if sensor is Possible to judge if sensor is
occurs faulty by switching sensor with faulty by switching sensor with
other sensor. other sensor.
Evaluation by 111105-3 - 111602-3
Fault Code
Evaluation by Torque Converter Actual Input Torque Converter 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
(Refer to F&S
S/M)
fNOTE: Refer to p. T5-4-12 for the sensors.
T5-6-15
Parts Machine Speed Sensor Pressure Sensor (Refrigerant

Pressure)
Item
Function Detects transmission output Detects air conditioner
shaft speed. refrigerant pressure.
Symptoms When abnormality is detected, When output is 0 V or 5 V, the
in control the following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms The speed meter continues to The fan speed is fixed to the
in machine display 0 km/h. maximum. The fan reverse
operation The overrun alarm control is not rotation control is not activated.
when trouble effective.
occurs The ride control is not effective.
Fault Code
Evaluation by MC: Machine Speed Pulse MC: Air Conditioner Refrigerant
Monitoring Pressure
Evaluation - -
by using Test
Harness
Note Refer to p. T5-4-12 for the sensor Refer to p. T5-7-2 for the sensor.
location.
Possible to judge if speed sensor
is faulty by switching pressure
sensor with other speed sensor.
of Control
(Refer to F&S
S/M)
T5-6-16
Parts Ride Control Solenoid Valve

(Option)
Item
Function Shifts ride control main spool in
control valve.
Connects the rod side circuit to
the tank.
in control
system when
trouble occurs
Symptoms High current: The ride control is
in machine always activated.
operation Low current: The ride control is
when trouble not effective.
occurs
Evaluation by 111422
Fault Code
Evaluation by MC: Ride Control P/S Output, Ride
Monitoring Control P/S Output FB
Evaluation Install light harness tool.
by using Test Check output signals from MC
Harness and harness condition.
Note Refer to pp. T5-4-17 for the
solenoid valves.
Descriptions T2-2, 2-4
of Control
(Refer to F&S
S/M)
T5-6-17
Parts Parking Brake Solenoid Valve Pump Swash Plate Tilt Solenoid
Valve (Pump Torque Control
Item Solenoid)
Function Applies and releases parking Supplies control pressure to main
brake by using pilot pressure oil. pump.
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 minimum.
operation is not supplied to parking brake.) The loading movement becomes
when trouble When open: The parking brake slow.
occurs is applied. (Pilot pressure oil is Low current: Engine speed
supplied to parking brake.) regulation for digging is
deactivated.
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 This solenoid valve can be Refer to p. T5-5-59 for the
manually turned ON/OFF. solenoid valve.
Refer to p. T5-4-15 for the
solenoid valve location.
Descriptions T2-2, 2-4 T2-2
of Control
(Refer to F&S
S/M)
T5-6-18
Parts Hyd. Fan Speed Control Solenoid Hyd. Fan Reverse Rotation
Valve Control Solenoid Valve (Option)
Item
Function Control hydraulic fan rotation Shifts hydraulic fan reverse
speed. 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
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 Refer to p. T5-5-58 for the Refer to p. T5-5-57 for the
solenoid valve. solenoid valve.
Descriptions T2-2, 2-4 T2-2, 2-4
of Control
(Refer to F&S
S/M)
T5-6-19
Parts Forward/ Reverse Clutch Solenoid Speed Shift Solenoid Valves (1, 2,
Valves and 3)
Item
Function Shifts forward spool, and reverse Shifts spools in speed shift
spool of transmission control solenoid valves (1, 2, and 3) of
valve. transmission control valve.
in control
system when
trouble occurs
Symptoms Defective clutch gears cannot Defective clutch gears cannot
in machine engage. engage.
operation
when trouble
occurs
Evaluation by MC: 111418, 111419 MC: 111414, 111415, 111416,
Fault Code 111417
Evaluation by T/M Clutch Forward P/S Valve T/M Clutch 1st P/S Valve Output
Monitoring Output T/M Clutch 1st P/S Valve FB
T/M Clutch Forward P/S Valve FB T/M Clutch 2nd P/S Valve Output
T/M Clutch Reverse P/S Valve T/M Clutch 2nd P/S Valve FB
Output T/M Clutch 3rd P/S Valve Output
T/M Clutch Reverse P/S Valve FB T/M Clutch 3rd P/S Valve FB
T/M Clutch 4th P/S Valve Output
T/M Clutch 4th P/S Valve FB
Evaluation - -
by using Test
Harness
Note Refer to p. T5-4-12 for the Refer to p. T5-4-12 for the
solenoid valves. solenoid valves.
of Control
(Refer to F&S
S/M)
fNOTE: Refer to pp. T5-5-18, 19 for the detailed machine operation when trouble occurs.
T5-6-20
Parts Main Relief Valve for Main Pump Overload Relief Valve
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
(Refer to F&S
S/M)
fNOTE: Refer to p. T5-6-57 and F&S S/M Section T3-2 Control Valve for each valve.
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 engine.
Machine speed does not increase.
Evaluation by -
Fault Code
Evaluation by -
Monitoring
Evaluation -
by using Test
Harness
Note -
Descriptions T2-4
of Control
(Refer to F&S
S/M)
fNOTE: Refer to F&S S/M Section T3-2 Control Valve for each valve.
T5-6-22
Parts Ride Control Valve Main Spool Fan Reversing Spool (Fan Valve)
(Optional Ride Control Valve) (Option)
Item
Function Is shifted by pilot pressure from Is shifted by pilot pressure
ride control solenoid valve. from fan reverse rotation
Connects the accumulator to control solenoid valve in fan
lift arm cylinder circuit and valve. Changes the fan rotation
increases/decreases the lift arm direction (in normal / reverse).
cylinder bottom pressure.
in control
system when
trouble occurs
Symptoms If stuck in neutral position, the If stuck in normal direction
in machine ride control is not activated. position, the fan always rotates in
operation If stuck in ride control operating normal direction.
when trouble position, digging operation is not If stuck in reverse direction
occurs smooth. position, the fan always rotates
in reverse direction. Overheating
occurs easily.
Evaluation by - -
Fault Code
Evaluation by - -
Monitoring
Evaluation - -
by using Test
Harness
Note - -
of Control
(Refer to F&S
S/M)
T5-6-23
Parts Main Relief Valve (Steering)
Item
Function Prevents pressure in main pump
circuit from exceeding the set
pressure when a steering wheel is
operated.
in control
system when
trouble occurs
Symptoms If stuck in fully closed position,
in machine steering hose may be damaged.
operation If stuck in fully open position,
when trouble steering wheel rotation speed
occurs becomes slow.
Evaluation by -
Fault Code
Evaluation by -
Monitoring
Evaluation -
by using Test
Harness
Note -
Descriptions T2-4
of Control
(Refer to F&S
S/M)
T5-6-24
Correlation between Trouble Symptoms and

Part Failures
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
The trouble symptoms in this table are described

provided that each trouble occurs independently. In
case more than one trouble occurs at the same time, find
out all faulty components while checking all suspected
components in each trouble symptom.
The marks / in this table indicate the influence to

trouble symptom.
: Related, required to check

: Related. However, in case this component fails,
other trouble symptom will be more noticeable so
that this component will not be the direct cause of the
trouble concerned.
T5-6-25
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.
Main Controller (MC)
Engine Control Module (ECM)  
Information Controller (ICF)
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)  (#9, #10)  (#14)
Fuse Box B  (#12)
Neutral Relay  
Voltage Relay 
ECM Main Relay  
Starter 
Engine Unit 
Coolant Temperature Sensor
Heater Relay
Intake Air Heater
Pump Delivery Pressure Sensor
: Check required : Related
T5-6-26
Trouble Symptom E-4 E-5

Power mode is not shifted Even if key switch is turned
down when pushing power OFF, engine does not stop.
Parts mode switch.
Main Controller (MC)  
Engine Control Module (ECM) 
Information Controller (ICF) 
MPDr. 
Key Switch 
Power Mode Switch 
Parking Brake Switch
Forward/Reverse Lever
Forward/Reverse Selector
Switch (Option)
Forward/Reverse Switch
(Option)
Battery
Battery Relay 
Fuse Box A
Fuse Box B
Starter Relay 1
ECM Main Relay 
Engine Actuator Relay 
Starter
Engine Unit 
Hydraulic Oil Temperature
Sensor
Torque Converter Oil
Temperature Sensor
Pressure Sensor (Parking Brake)
T5-6-27
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.
Main Controller (MC) 
Battery
Fuse Box A  (#16)
Pilot Shut-Off Relay (Option) 
Front Control Lever Lock Switch 
(Option)
Power Mode Switch 
Pilot Pump  
Charging Block 
Brake Priority Valve  
Charge Relief Valve  
Pump Torque Control Solenoid 
Valve
Pilot Shut-Off Valve  
Pilot Valve  
Pressure Sensor (Primary Pilot  
Pressure)
Pressure Sensor (Lift Arm Raise) 
(Option)
Spool (Multiple Control Valve)  
Spool (Steering Valve) 
Main Relief Valve (Multiple 
Control Valve)
Cylinder
Main Pump 
Pump Delivery Pressure Sensor 
Pump Regulator 
Pilot Filter 
T5-6-28
Trouble Symptom A-3

Actuator of front attachment
does not stop even if a
Parts control lever is set to neutral.
Engine Control Module (ECM)
Key Switch
Forward/Reverse Lever
Pilot Shut-Off Relay
Front Control Lever Lock Switch
Battery
Engine Unit
Engine Speed Sensor (Main)
Engine Speed Sensor (Sub)
Main Pump
Fan Pump
Pump Regulator
Torque Control Solenoid Valve
Pressure Sensor (Primary Pilot
Pressure)
Pilot Valve 
Multiple Control Valve 
Pilot Filter
Hydraulic Oil Temperature
Sensor
Torque Converter Oil
Temperature Sensor
T5-6-29
Trouble Symptom A-5 A-6

Fan speed does not change. Fan does not rotate in
reverse when pushing fan
Parts reverse rotation switch.
(option)
Main Controller (MC)  
Engine Control Module (ECM) 
MPDr. 
Key Switch
Power Mode Switch
Fan Reverse Rotation Switch 
(Option)
Battery
Fuse Box A
Fuse Box B
Fan Speed Control Solenoid  (without reversing fan)
Valve  (with reversing fan)
Fan Reverse Rotation Control 
Solenoid Valve (Option)
Fan Control Valve (Option)  (with reversing fan) 
Fan Motor  
Fan Pump  
Engine Unit
Engine Speed Sensor (Main)
Engine Speed Sensor (Sub)
Coolant Temperature Sensor 
Boost Temperature Sensor 
Hydraulic Fan Circuit Pressure  
Sensor
Hydraulic Oil Temperature 
Sensor
Torque Converter Oil 
Temperature Sensor
Pressure Sensor (Refrigerant  
Pressure)
Pressure Sensor (Parking Brake) 
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
Main Controller (MC) 
Battery
Fuse Box B
Front Control Lever Lock Switch
(Option)
Power Mode Switch
Pilot Pump  
Brake Priority Valve 
Pilot Relief Valve 
Charge Relief Valve 
Torque Control Solenoid Valve 
Front Control Lever Lock
Solenoid Valve (Combination
Valve) (Option)
Pilot Valve 
Pressure Sensor (Primary Pilot 
Pressure)
(Option)
Spool (Multiple Control Valve)  
Main Relief Valve (Multiple   (Overload)
Control Valve)
Pump Control Valve (Multiple 
Control Valve)
Cylinder 
Main Pump 
Priority Valve 
Pump Regulator
Pilot Filter 
T5-6-31

Front attachment drifts Shock during bucket
remarkably (when the engine dumping is large when
is stopped). stopping lift arm raise /
Parts lower operation.
Pilot Valve  
Shockless Valve  (Lift Arm)
(Option)
Spool (Multiple Control Valve)  
Load Check Valve (Multiple 
Control Valve)
Cylinder 
Main Pump
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.)
Battery
Battery Relay
Fuse Box A  (#16)  (#16)
Lift Arm Angle Sensor (Option)
Bucket Proximity Switch 
Charging Block
Pilot Valve  (Bucket)  (Lift Arm)
Bucket Detent Relay 
Bucket Detent Coil 
Lift Arm Raise Side Coil (Pilot 
Valve)
Spool (Multiple Control Valve)  (Bucket)  (Lift Arm)
Cylinder
Main Pump
T5-6-33
Trouble Symptom F-7 F-8 F-9

Lift arm auto leveler height Lift arm auto leveler lower Ride control (option) is not
kickout control (option) is kickout control (option) is activated.
Parts not activated. not activated.
Main Controller (MC)   
MPDr.  (Lift Arm Angle Sensor  (Lift Arm Angle Sensor  (Setting: ON)
Learning) Learning)
Fuse Box A  (#16)  (#16)
Lift Arm Angle Sensor (Option)   
Machine Speed Sensor 
Ride Control Switch (Option) 
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)
Flow Regulator Valve
(Option)
Ride Control Solenoid Valve 
(Option)
Spool (Control Valve)  (Lift Arm)  (Lift Arm)
Spool (Ride Control Valve) 
(Option)
Cylinder  (Lift Arm)
Accumulator (Ride Control) 
(Option)
Main Pump
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
Main Controller (MC) 
Brake Charge Valve 
Pilot Relief Valve 
Charge Relief Valve 
Torque Control Solenoid Valve  
Pressure Sensor (Primary Pilot  
Pressure)
Orbitrol (Steering Pilot Valve)   
Overload Relief Valve (Steering  
Valve)
Steering Pressure Switch 
Steering Cylinder (Left, Right)  
Steering Accumulator 
Main Pump  
Steering Relief Valve (Priority  
Valve)
Steering Priority Valve   
Pump Regulator 
Pilot Filter 
T5-6-35
Trouble Symptom S-4

Secondary steering
(option) does not operate.
(Automatic operation check
Parts when the engine starts)
Main Controller (MC) 
MPDr.  (Setting: ON)
Battery
Fuse Box A  (#20)
Secondary Steering Relay 
(Option)
Machine Speed Sensor 
Charging Block
Orbitrol (Steering Pilot Valve)
Spool (Steering Valve)
Steering Pressure Switch 
(Option)
Secondary Steering Pump 
Delivery Pressure Sensor
(Option)
Steering Cylinder (Left, Right)
Steering Accumulator
Main Pump
Secondary Steering Motor 
(Option)
Secondary Steering Pump 
(Option)
T5-6-36
Travel System Troubleshooting
Trouble Symptom T-1 T-2 T-3

Although forward/reverse Although forward/reverse Clutch cut is not operated.
lever is operated, machine lever is set to neutral (Declutch Control)
does not travel forward/ position, machine travels.
Parts reverse. (Neutral Control)
Battery
Brake Valve 
Forward/Reverse Lever  (Forward / Reverse)  (Neutral)  (Forward)
Forward/Reverse Switch  
(Option)
Forward/Reverse Selector  
Switch (Option)
Declutch Position Switch 
Drive Unit (Transmission Assy)   
Transmission Control Valve   
Torque Converter Input Speed 
Sensor
Torque Converter Output Speed 
Sensor
Transmission Intermediate Shaft
Speed Sensor
Machine Speed Sensor 
Forward Clutch Solenoid Valve   
Reverse Clutch Solenoid Valve  
Propeller Shaft 
Axle 
Pressure Sensor (Brake 
Secondary Pressure)
Pressure Sensor (Parking Brake) 
T5-6-37

Travel mode can not be Although shift switch is Although vehicle speed
changed. operated, speed shift does changes, speed shift does
Parts not change. not change automatically.
(Manual Speed Shift Control) (Automatic Speed Shift Control)
Battery
Travel Mode Selector Switch   (Manual Mode)  (AUTO 1/AUTO 2 Mode)
Shift Switch 
Drive Unit (Transmission Assy)  
Transmission Control Valve  
Torque Converter Input Speed  
Sensor
Torque Converter Output Speed  
Sensor
Speed Sensor
Machine Speed Sensor  
Speed Shift Solenoid Valve  
Pressure Sensor (Brake
Secondary Pressure)
T5-6-38

Speed shift is not shifted Speed shift is not held when Speed shift retard control is
down when pushing pushing hold switch. not activated.
Parts downshift switch (DSS). (Effective in automatic speed (Effective in automatic speed
shift control mode) shift control mode)
Main Controller (MC)   
Information Controller (ICF) 
Key Switch  (ON)
Battery 
Fuse Box A
Fuse Box B
Travel Mode Selector Switch 
Forward/Reverse Lever 
Forward/Reverse Switch 
(Option)
Forward/Reverse Selector 
Switch (Option)
Shift Switch
Downshift Switch (DSS) 
Hold Switch 
Drive Unit (Transmission Assy)   
Transmission Control Valve   
Torque Converter Input Speed  
Sensor
Torque Converter Output Speed  
Sensor
Speed Sensor
Machine Speed Sensor   
Speed Shift Solenoid Valve   
Lift Arm Angle Sensor (Option) 
(Option)
T5-6-39
Brake System Troubleshooting
Trouble Symptom B-1 B-2 B-3

Parking brake is not Parking brake is not applied. Service brake function
released. (When the engine lowers.
Parts runs. )
Key Switch  (ON)
Battery
Fuse Box A  (#13, #18)  (#13)
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
Charging Block  
Pressure Sensor (Parking Brake)  
Charge Relief Valve  
Pressure Sensor (Brake Primary 
Pressure)
Service Brake Accumulator 
Brake Valve 
Axle (Service Brake) 
Pressure Sensor (Brake 
Secondary Pressure)
Pilot pump  
Pilot Filter  
Engine
Remark The parking brake can be
released with the residual
pressure in the service brake
accumulator even when the
engine is stopped.
T5-6-40
Other System Troubleshooting
Trouble Symptom O-1 O-2 O-3

Clearance light, tail light, Head light is not ON. Head light is not shifted to
and license plate light are high beam.
Parts not ON.
Column Display Controller  (Indicator)  (Indicator)  (Indicator)
Key Switch  (ON)  (ON)
Battery 
Fuse Box A  (#4, #14)  (#3, #4)  (#4, #19)
Fuse Box B
Light Switch   
Dimmer Switch  
Head Light Relay 
High Beam Relay 
Head Light   (High Beam)
Clearance Light 
Tail Light 
License Plate Light (Option) 
T5-6-41

Hazard light is not operated. Turn signal light is not Horn does not sound.
operated.
Parts
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  
Horn Relay 
Turn Signal Light (Hazard Light)  
Horn 
T5-6-42

Reverse light is not ON. Brake light is not ON. Work light does not light.
Reverse buzzer does not
Parts sound.
Column Display Controller  (Indicator)
Key Switch  (ON)  (ON)  (ON)
Battery
Fuse Box A  (#1, #13)  (#2)  (#4, #17)
Fuse Box B
Forward/Reverse Lever  (R)
Forward/Reverse Selector
Switch (Option)
Forward/Reverse Switch  (R)
(Option)
Brake Light Switch (Brake Pedal) 
Light Switch 
Work Light Switch 
Reverse Buzzer Relay 
Brake Light Relay 
Work Light (Front) Relay 
Work Light (Rear) Relay 
Reverse Light 
Reverse Buzzer 
Brake Light 
Work Light 
T5-6-43

Wiper is not operated. Washer is not operated. Cab light is not ON.
Parts
Column Display Controller 
Key Switch  (ON)  (ON)
Battery 
Fuse Box A
Fuse Box B  (#3, #5)  (#3, #5)  (#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 
T5-6-44

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 the
OFF position are operated normally, the harness
 This trouble has nothing to do with the electronic between battery and key switch terminal B is
control system such as Main Controller (MC). considered normal.
Procedure Inspection Method Condition Evaluation Cause

1 Measure battery voltage - The measured values are Faulty battery
and electrolyte density out of normal range
(Normal range: Voltage:
24 V or more, Electrolyte
density: 1.26 or more)
2 Replace the neutral relay Set the key switch to Starter: Rotating Faulty neutral relay
with other general relay START after replacing
relays
3 Measure voltage between Key switch: START 0V Open circuit in harness
neutral relay harness end between key switch and
#3 and chassis neutral relay
4 Replace the starter cut Set the key switch to Starter: Rotating Faulty starter cut relay
relay with new one START after replacing
relay
5 Measure voltage between Key switch: START 0V Open circuit in harness
starter cut relay harness between neutral relay
end #3 and #2 and starter cut relay
6 Measure voltage at Key switch: START 0V Open circuit in harness
starter relay harness end between starter cut relay
terminal C and starter relay
7 Check continuity Key switch: ON ∞Ω Open circuit in harness
between starter cut between starter cut relay
relay harness end #2 and and chassis (GND)
chassis
Connectors
 Neural Relay (Harness end)  Starter Cut Relay (Harness end)
90Z6-05-06-01 90Z6-05-06-02
T5-6-45
(E-1 Starter does not rotate)

8 Measure voltage at Key switch: ON 0V Faulty battery relay
starter terminal B
9 Measure voltage at Key switch: START 0V Faulty starter relay
starter terminal C
10 Check continuity Key switch: START ∞Ω Faulty key switch
between key switch #1
and #4
11 Monitor Forward/Reverse Forward/reverse lever: N OFF is displayed Faulty forward/reverse
Lever (N) lever
12 - - The above checks Faulty starter
resulted all normal.
Connectors
 Starter Cut Relay (Harness end)  Key Switch (Switch end)
90Z6-05-06-02 90Z6-05-06-03
T5-6-46
E-2 Even if starter rotates, engine does not start.
Preparation
 Check that #9, #10 fuses in fuse box A are not
abnormal.
 Check that the fuel filter is not clogged.

1 Measure voltage Key switch: ON 0V Open circuit in harness
between ECM main relay between ECM main relay
1 (A1) harness end #3 and 1 (A1) and fuse #9 in fuse
chassis. box A.
between ECM main relay between ECM main relay
2 (C1) harness end #3 and 2 (C1) and fuse #10 in
chassis. fuse box A.
3 Measure voltage between Key switch: ON 0V Open circuit in harness
ECM main relay 1 (A1), 2 between ECM main relay
(C1) harness end #1 and 1 (A1), 2 (C1) and fuse #13
chassis. in fuse box A.
4 - - The check mentioned Faulty ECM or engine unit
above is normal
Connectors
 ECM Main Relay (Harness end)
90Z6-05-06-01
T5-6-47
E-3 Engine starts with forward/reverse lever set in

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

Start Circuit (p. T2-5-10).
 Refer to SYSTEM / Hydraulic System (F&S S/M T2-4).

1 Check continuity - ∞Ω Open circuit in harness
between neutral relay between forward/reverse
(B6) harness end #2 and lever and neutral relay
FNR switch (column)
harness end #2 (R) or #4
(F)
2 Replace the neutral relay Forward/reverse lever: F Starter: Not rotating Faulty neutral relay
with other general relay or R
Set the key switch to
START after replacing
relays
3 - - The above checks Find out cause of trouble
resulted all normal. by tracing other trouble
symptoms
Connectors
 Neural Relay (B6) (Harness end)  FNR Switch (Column) (Harness end)
90Z6-05-06-01 90Z6-05-06-04
T5-6-48
E-4 Power mode is not activated when pushing

power mode switch.
Preparation

1 Monitor Power Mode Power mode switch: ON OFF is displayed Faulty power mode
Switch switch or open circuit in
harness between power
mode switch and Main
Controller (MC)
2 - - The check (1) above Faulty MC
resulted normal
T5-6-49
E-5 Even if key switch is turned OFF, engine does

not stop.
Preparation
 Remove 70 A fusible link (1) and stop the engine as
emergency procedures first.
 In case other trouble symptoms occur, perform

troubleshooting of these troubles first.
 If the fault code is not displayed, the key switch may

be faulty.
 Refer to SYSTEM / Electrical System (F&S S/M T2-5).

1
90Z6-05-01-01
T5-6-50

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 (F&S S/M T2-5).
exist in the pilot shut-off circuit.
 Check that #16 fuse in fuse box A is not abnormal.
 Pilot valve and multiple control valve spools are

unlikely to be faulty at the same time.

1 Switch pilot shut-off relay Front control lever lock The symptom disappears Faulty pilot shut-off relay
(C6)(option) with other handle, front control
general relay lever lock switch (option):
UNLOCK position
2 Monitor Pilot Primary Front control lever lock Pressure is not detected Faulty front control lever
Pressure switch (option): UNLOCK lock switch
position
3 Measure resistance - 0/∞ Ω Faulty pilot shut-off
between pilot shut-off solenoid valve
solenoid valve #1 and #2
4 Check continuity Connect pilot shut-off ∞Ω Open circuit in harness
between pilot shut-off solenoid valve harness between pilot shut-off
relay harness end #4 and end terminal #2 to chassis solenoid valve and pilot
chassis shut-off relay
5 - - The check mentioned Faulty pilot valve
above is normal
Connectors
 Pilot Shut-off Relay (C6) (Harness end)
90Z6-05-06-01
T5-6-51
A-2 Actuator speed of front attachment and

steering are slow.
Specification Remark
Primary Pilot Pressure 3.7 +0.4/-0.1 MPa (537 +58/-15 PSI) Accelerator pedal: Full stroke
Preparation
 The pump flow rate is minimized due to some  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 (F&S S/M T2-4).

1 Monitor Lift Arm Raise Lift arm relief operation The measured values are Faulty pilot relief valve in
Pilot Pressure (option) not within the normal manifold valve
values (Normal value: 3.4
to 4.2 MPa) (493 to 609
PSI)
2 Monitor Pilot Primary - The measured values are Clogged pilot filter
Pressure not within the normal
values (Normal value: 3.7
to 5.3 MPa) (537 to 769
PSI)
3 Disassemble and inspect - There is abnormality Faulty priority valve
the priority valve (charging block) (stuck
(charging block) spool)
4 Measure pressure at port Accelerator pedal: Fully The measured values are Faulty priority valve
LS of priority valve (main) depressed without load not within the normal (main) (stuck spool)
(Control lever: Neutral) values (Normal value: 1.2
to 2.6 MPa) (174 to 377
PSI)
5 - - The check mentioned Faulty pump device
above is normal
LS
TNED-05-01-003
Main Pump
T5-6-52
A-3 Actuator of front attachment does not stop

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

1 Set the front control - Actuator stops Faulty pilot valve (stuck spool)
lever lock switch to LOCK
position
2 - - The check (1) above resulted Faulty multiple control valve
normal. (stuck spool)
T5-6-53
A-5 Fan speed does not change.
Preparation
 The sensors detect the conditions necessary to
operate fan speed control. Therefore, if these sensors
fails, fan speed control becomes ineffective.
 Accelerator pedal sensor, coolant temperature

sensor, boost temperature sensor, hydraulic
oil temperature sensor, torque converter oil
temperature sensor, and pressure sensor (refrigerant
pressure) are also engaged in the fan speed control.
However, if these sensors fail, other operating
functions will be also affected.
 Refer to SYSTEM / Control System / Fan Speed

Control (p. T2-2-48).

1 Monitor Target Hydraulic Engine: Running Fan speed does not Faulty ECM or MC
Fan Speed change according
to accelerator pedal
depressing amount
2 Monitor Hydraulic Fan Engine: Running Fan pump delivery Faulty fan pump
Circuit Pressure (option) pressure does not change
according to accelerator
pedal depressing amount
3 Disassemble and inspect - There is abnormality Faulty fan speed control
the fan speed control solenoid valve
solenoid valve
4 Disassemble and inspect - There is abnormality Faulty fan control valve
the fan control valve
(option)
5 - - The check mentioned Faulty fan motor
above is normal
Fan Speed Control

Solenoid Valve
Fan Speed Control

Solenoid Valve
90Z6T1-2-14 TNEE-01-02-031
Fan Motor (Standard) Fan Control Valve (with Reversing Fan Option)
T5-6-54
A-6 Fan does not rotate in reverse when pushing

fan reverse rotation switch. (option)
Preparation
 Refer to SYSTEM / Control System / Fan Reverse
Rotation Control (p. T2-2-50).

1 Monitor Fan Reversing Parking brake is applied OFF is displayed Faulty fan reverse
Switch Fan reverse rotation rotation switch
switch: ON
2 Measure resistance - 0/∞ Ω (Normal value: 22 Faulty fan reverse
between fan reverse Ω) rotation control solenoid
rotation control solenoid valve
valves #1 and #2
between fan reverse between fan reverse
rotation control solenoid rotation control solenoid
valve harness end #1 and valve and Main Controller
chassis (MC)
4 - - The above checks Faulty MC
Fan Reverse Rotation

Control Solenoid Valve
TNEE-01-02-031
Fan Control Valve (with Reversing Fan Option)
T5-6-55

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

Set Pressure
Lift arm and bucket 29.4 +0.2/-0.5 MPa
relief operation (4264 +29/-72.5 PSI)
Preparation
 If operating speeds are extremely slow, pump control
may be faulty.
Faulty pilot system may also cause this trouble.

1 Monitor Pump Delivery Lift arm relief operation The measured values Faulty main relief valve
Pressure are out of the specified (readjust)
range.
2 - - The check (1) above Find out cause of trouble
resulted normal. by tracing other trouble
symptoms
fNOTE: Refer to p. T4-5-6 for the pump delivery pressure

measurement.
1
2
3 90Z6-05-06-05
1- Overload Relief Valve (Lift Arm Bottom Side, Raise)

2- Overload Relief Valve (Bucket Bottom Side, Roll Back)
3- Overload Relief Valve (Bucket Rod Side, Dump)
4- Main Relief Valve
T5-6-56
F-2 Some cylinders are not operated or speeds

are slow.
Overload Relief Standard Remark

Valve Set Pressure
Lift Arm Raise 36.8 +1.0/0 MPa
(5337 +145/0 PSI)
Bucket 32.5 +1.0/0 MPa
(4714 +145/0 PSI)
Preparation
 When parking brake is released normally, the
primary pilot pressure is considered to be normal.

1 Measure Pilot Secondary Full operation of bucket The measured values Faulty pilot valve
Pressure roll back/dump and lift are out of the specified
arm raise/lower range.
(Normal range: 3.4 ~ 4.2
MPa)
2 Replace overload relief - Symptom is observed Faulty overload relief
valves, of which the set with the replaced relief valve
pressure are the same valve.
3 - - The above checks Faulty control valve spool
resulted all normal. (stuck)
Faulty cylinder (faulty
seal kit)
fNOTE: Refer to p. T4-5-12 for the overload relief set

pressure measurement.
1
2
3 90Z6-05-06-05

2- Overload Relief Valve (Bucket Bottom Side, Roll Back)
3- Overload Relief Valve (Bucket Rod Side, Dump)
4- Main Relief Valve
T5-6-57
F-3 Front attachment drifts remarkably.

1 Set the front control lever - The symptom disappears Faulty pilot valve
lock lever to LOCK position
2 Replace the overload relief - The symptom disappears Faulty overload relief valve
valve
3 Disassemble and inspect the - Abnormality found Faulty cylinder (seal kit)
cylinder
4 - - The above checks resulted all Damaged control valve spool
normal. Broken spring
Loosened spool end
Leakage Check Within the Lift Arm Cylinder

1. Lower the bucket edge onto the ground with the 3
bucket cylinder rod slightly extended from the fully
retracted position. 1
2. Remove the hose from the lift arm cylinder rod side,
4
and drain the oil from the cylinder and the hose.
(Cover the removed hose ends to prevent dust or
dirt.)
3. Extend the bucket cylinder rod, and lift the bucket.
If any oil comes out from the hose connection port
and the lift arm cylinder rod retracts, oil leakage 2 5
occurs within the cylinder. 90Z6-05-06-06
If no oil comes out from the hose connection port
but the lift arm cylinder rod retracts, oil leakage 2- Overload Relief Valve (Bucket Bottom Side, Roll Back)
occurs in the multiple control valve. 3- Overload Relief Valve (Bucket Rod Side, Dump)
4- Lift Arm Spool
5- Bucket Spool
T5-6-58
F-4 Shock during bucket dump operation is

large when stopping lift arm raise / lower
operation.
Preparation
 Check that control levers are not abnormal first.

1 Disassemble and inspect the - Abnormality found Faulty restriction valve
restriction valve (slow return
valve)
2 - - The check mentioned above Stuck control valve spool, or
is normal faulty cylinder (faulty seal kit)
T5-6-59
F-5 Bucket auto leveler control is not activated.

(Detent is not held.)
Preparation
 Refer to SYSTEM / Control System / Bucket Auto
Leveler Control (p.T2-2-74).

pilot valve bucket roll between #16 fuse in fuse
back side coil harness box A and pilot valve
end #2 and chassis bucket roll back side coil
2 Replace the bucket auto- Bucket roll back detent The symptom disappears Faulty bucket auto-
leveler relay with other control lever operation leveler
general relay
3 Measure resistance - 0/∞ Ω Faulty pilot valve bucket
between pilot valve roll back side coil
bucket roll back side coil
harness ends #1 and #2
bucket proximity switch between bucket
harness end #1 and proximity switch and
chassis bucket leveler relay
5 - - The above checks Faulty bucket proximity
resulted all normal. switch
Connectors
 Bucket Roll Back Side Coil (Harness end)  Bucket Roll Back Side Coil (Coil end)
90Z6-05-CN03 90Z6-05-CN05
 Bucket Roll Back Side Coil (Harness end)
90Z6-05-CN04
T5-6-60
F-6 Lift arm float control is not activated. (Detent

is not held.)
Preparation
 Refer to SYSTEM / Control System / Lift Arm Float
Control (p.T2-2-76).

pilot valve lift arm lower between #16 fuse in fuse
side coil harness end #2 box A and pilot valve lift
and chassis arm lower side coil
2 Check continuity - ∞Ω Improper grounding in
between pilot valve pilot valve lift arm lower
lift arm lower side coil side coil
harness end #1 and
chassis
3 - - The above checks Faulty pilot valve lift arm
resulted all normal. lower side coil
Connectors
 Lift Arm Lower Side Coil (Harness end)
90Z6-05-CN03
T5-6-61
F-7 Lift arm auto leveler height kickout control

(option) is not activated.
Preparation
 Refer to SYSTEM / Control System / Lift Arm Auto
Leveler Height Kickout Control (Option) (p.T2-2-64).

pilot valve lift arm raise between #16 fuse in fuse
and chassis arm raise side coil
2 Monitor Lift Arm Auto Lift arm auto leveler OFF is displayed Faulty lift arm auto leveler
Leveler Switch (Raise) switch (raise): ON switch (raise)
(option)
3 - - The above checks Faulty pilot valve lift arm
resulted all normal. raise side coil
Connectors
 Lift Arm Raise Side Coil (Harness end)
90Z6-05-CN03
T5-6-62
F-8 Lift arm auto leveler lower kickout control

(option) is not activated.
Preparation
 Refer to SYSTEM / Control System / Lift Arm Auto
Leveler Lower Kickout Control (Option) (p.T2-2-66).

pilot valve lift arm lower between #16 fuse in fuse
and chassis arm lower side coil
2 Monitor Lift Arm Auto Lift arm auto leveler OFF is displayed Faulty lift arm auto leveler
Leveler Switch (lower) switch (lower): ON switch (lower)
(option)
4 - - The check mentioned Faulty pilot valve lift arm
above is normal lower side coil
Connectors
 Lift Arm Lower Side Coil (Harness end)
90Z6-05-CN03
T5-6-63
F-9 Ride control (option) is not activated.
Preparation
 Check the ride control setting with the monitor or
MPDr. first. The activating conditions for ride control
are different according to the settings.
 Refer to SYSTEM / Control System / Ride Control

(Option) (p. T2-2-52).
 When other actuator (front attachment) is operated

normally, the primary pilot pressure is considered to
be normal.

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

90Z6-05-CN06
fNOTE: Refer to p.T5-4-17 for the ride control solenoid

valve location.
T5-6-64

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

Set Pressure
Steering relief 29.4 +0.2/-0.5 MPa
operation (4264 +29/-72.5 PSI)
Preparation
 If operating speeds are extremely slow, pump control
may be faulty. Faulty pilot system may also cause this
trouble.

1 Monitor Pump Delivery Steering relief operation The measured values are Faulty steering relief
Pressure not within the normal valve (readjust)
values
2 - - The above check resulted Find out cause of trouble

normal. by tracing other trouble
symptoms
fNOTE: Refer to p. T4-5-10 for the steering relief pressure

measurement and adjustment.
T5-6-65
S-2 Steering operation is slow.
Standard Remark
Steering cylinder 2.9±0.3 Accelerator pedal: Fully depressed
operation time Power mode switch: OFF
(sec) Bucket: Empty
Preparation
 Check that the steering wheel is not abnormal first.
 If speed of front attachment is also slow, the main

system may be faulty (A-2).

1 Measure Steering Relief - The measured values are Faulty main relief valve
Pressure not within the normal (steering)
values (Normal value:
28.9 to 31.4 MPa) (4192 to
4554 PSI)
2 Disassemble and inspect - There is abnormality Faulty priority valve
the priority valve
3 - - The above checks Stuck steering valve spool
resulted all normal. or faulty steering cylinder
(faulty seal kit)
fNOTE: Refer to p. T4-5-10 for the steering relief pressure

measurement and adjustment.
T5-6-66
S-3 Shock of steering operation is large.
Preparation
 Check that the steering wheel is not abnormal first.  Release any remaining pressure before checking gas
pressure in the accumulator.
 The steering valve and stop valve may be faulty.

1 Check accumulator gas - There is abnormality Low gas pressure or leak
pressure
2 Disassemble and inspect the - There is abnormality Faulty stop valve
stop valve
3 Disassemble and inspect the - There is abnormality Faulty steering valve (stuck
steering valve spool, clogged orifice)
4 - - The above checks resulted all Faulty steering cylinder (faulty
normal. seal kit)
90Z6 07-52-03
1- Steering Accumulator 2- Steering Cylinder
fNOTE: Steering Accumulator Gas Pressure: 8.0 MPa
T5-6-67
S-4 Secondary steering (option) is not operated.

(Automatic operation check when the engine starts)
Preparation
 Check the secondary steering control setting with
the MPDr. first.
 Refer to SYSTEM / Control System / Secondary

Steering Control (Option) (p. T2-2-70).
 Check that #20 fuse in fuse box A is not abnormal.
 The secondary steering check switch may be faulty

when secondary steering operation cannot be
checked manually.

1 Monitor Secondary Steering Engine starts The measured values are Faulty secondary steering
Pump Delivery Pressure not at the normal level (4.8 pump unit
MPa)
2 Replace secondary steering Set the key switch The symptom disappears Faulty secondary steering
relay with other general relay to START after relay
replacing relays
3 - - The above checks resulted Faulty main controller (MC)
all normal.
T5-6-68

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

Lever Priority Control (Option) (p. T2-2-32).

1 Monitor Forward/Reverse Forward/reverse OFF is displayed Faulty forward/reverse
Lever (F) lever: F, R lever, or open circuit in
harness between forward/
reverse lever and main
controller (MC)
2 Measure transmission clutch Forward/reverse The measured values Faulty transmission control
pressure lever: F, R are out of normal range valve
MPa)
3 - - The above checks resulted Faulty MC
all normal.
fNOTE: Refer to p. T4-5-34 for the transmission clutch

T5-6-69
T-2 Although forward/reverse lever is set to

neutral position, machine travels.
Preparation
 Refer to SYSTEM / Control System / Neutral Control
(p. T2-2-30).

1 Monitor Forward/Reverse Forward/reverse lever: N OFF is displayed Faulty forward/reverse
Lever (N) lever, or open circuit
in harness between
forward/reverse lever and
main controller (MC)
2 Measure transmission Forward/reverse lever: N Pressure is measurable Faulty transmission
clutch pressure (not "0"). control valve
resulted normal.

T5-6-70
T-3 Declutch is not operated.
 Declutch specified operation pressure

Declutch Position Switch Brake pedal angle: Brake pedal angle:
Lightly applied (N) Fully applied (D)
Speed Shift: 1st 1.25 MPa (181 psi) or more 2.5 MPa (363 psi) or more
Speed Shift: 2nd 0.6 MPa (91.4 psi) or more 1.5 MPa (215 psi) or more
Preparation
 Refer to SYSTEM / Control System / Declutch Control  When other actuator (front attachment) is operated
(p. T2-2-42). normally, the pilot pump (primary pilot pressure) is
considered to be normal.

1 Monitor Declutch Declutch position switch: OFF is displayed Faulty declutch position
Position Switch N, D (0 is displayed on the switch
monitor) Open circuit in harness
between declutch
position switch and main
controller (MC)
2 Monitor Service Brake Declutch/brake pedal The measured values are Faulty brake system
Secondary Pressure (For operation (Right brake out of the specified range (brake valve) or faulty
Declutch) pedal (option)) pressure sensor (brake
secondary pressure)
3 Measure transmission - The measured values Faulty transmission
clutch pressure are out of normal range control valve
MPa)
fNOTE: Refer to p. T4-5-24 for the service brake

secondary pressure measurement.
1
90Z6T1-2-17
2
1- Service Brake Secondary Pressure Sensor

2- Brake Valve
T5-6-71
T-4 Travel mode cannot be changed.
Preparation

1 Monitor Travel Mode Driving mode switch: Manual mode is always Faulty driving mode switch
Selector Switch AUTO 1/ AUTO 2 displayed (0 is displayed on Open circuit in harness
mode the monitor) between driving mode switch
and main controller (MC)
2 - - The check (1) above resulted Faulty MC
normal.
T5-6-72
T-5 Although shift switch is operated, speed shift

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

Shift Control (p. T2-2-34).

1 Monitor Shift Switch and Shift switch: 1/2/3/4 The position of shift Faulty shift switch
Operate Shift Switch position switch is not identical to Open circuit in harness
the displayed range on between shift switch and
monitor main controller (MC)
2 Measure transmission - The measured values Faulty transmission
clutch pressure are out of normal range control valve
MPa)

T5-6-73
T-6 Although vehicle speed changes, speed shift

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

Shift Control (p. T2-2-36).

1 Monitor Travel Mode Driving mode switch: Manual mode is always Faulty driving mode switch
Selector Switch AUTO 1/ AUTO 2 displayed (0 is displayed on Open circuit in harness
mode the monitor). between driving mode switch
and main controller (MC)
2 Monitor Power Mode Power mode switch: OFF is displayed. Faulty power mode switch
Switch ON Open circuit in harness
between power mode switch
and MC
3 - - The check above resulted Faulty MC
normal.
T5-6-74
T-7 Speed shift is not shifted down when pushing

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


1 Monitor DSS Switch Downshift switch OFF is displayed Faulty downshift switch (DSS)
(DSS): ON Open circuit in harness between
While machine is downshift switch (DSS) and main
travelling controller (MC)
2 - - The check (1) above Faulty MC
resulted normal.
T5-6-75
T-8 Speed shift is not held when pushing hold

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


1 Monitor Shift Hold Hold switch: ON OFF is displayed Faulty shift hold switch
Switch Open circuit in harness
between shift hold switch and
main controller (MC)
2 - - The check (1) above resulted Faulty MC
normal.
T5-6-76
T-9 Speed shift delay control is not activated.
Preparation
 Check the speed shift delay control setting with the
monitor first.
 Check the parking brake is OFF (not applied).
 Refer to SYSTEM / Control System / Speed Shift Delay


1 Monitor Forward/ Forward/reverse N is displayed Faulty forward/reverse lever
Reverse Lever (F), (R) lever: F and R Open circuit in harness
between forward/reverse
lever and main controller (MC)
2 Monitor Travel Mode Travel mode: AUTO Manual mode is displayed (0 Faulty driving mode switch
Selector Switch 1/AUTO 2 mode is displayed on the monitor) Open circuit in harness
between driving mode switch
and MC
3 Monitor Machine Travel operation Speedometer: 0 km/h (mph) Faulty machine speed sensor
Speed (For Open circuit in harness
Speedometer) between machine speed
sensor and monitor controller
4 Monitor Shift Switch Shift switch: 2nd Other than 2nd is displayed Faulty shift switch
Open circuit in harness
between shift switch and MC
5 Monitor Speed Shift Speed shift delay OFF is kept Faulty speed shift delay mode
Delay Mode Switch mode switch: ON switch, or open circuit in
harness between speed shift
delay mode switch and MC
6 - - The above checks resulted all Find out cause of trouble
normal. by tracing other trouble
symptoms
T5-6-77
(Blank)
T5-6-78
Brake System Troubleshooting

B-1 Parking brake is not released. (When the
engine runs)
Preparation
 When other actuator (loading) is operated normally,
the primary pilot pressure is considered to be
normal.

1 Monitor Parking Brake Parking brake switch: ON OFF is displayed Faulty parking brake
Switch (applied) switch
Engine: Running
2 Monitor Parking Brake Parking brake switch: OFF
The measured values Stuck spool in parking
Pressure (released) are out of normal range brake solenoid valve
Engine: Running (Normal range: 3.6 ~ 3.9
MPa)
3 Monitor Secondary Front control lever lock The measured values Faulty charging block
Pilot Pressure (Loading switch: UNLOCK position are out of normal range (pilot accumulator)
Primary Pilot Pressure) Engine: Running (Normal range: 3.6 ~ 3.9
MPa)
4 Monitor Primary Pilot Parking brake switch: OFF The measured values Faulty charging block
Pressure (Service Brake Engine: Running are out of normal range (brake priority valve)
Primary Pressure) (Normal range: 11.8 ~
14.7 MPa)
5 Replace parking brake Parking brake switch: OFF The symptom disappears Faulty parking brake relay
relay 1 with other general Engine: Running 1
relay
6 Replace parking brake Parking brake switch: OFF The symptom disappears Faulty parking brake relay
relay 2 with other general Engine: Running 2
relay
7 - - The above checks Faulty main controller
resulted all normal. (MC)
fNOTE:
 Refer to p. T4-5-1 for the primary pilot pressure
measurement.
 Refer to p. T4-5-4 for the secondary piot pressure
measurement.
 Refer to p. T4-5-26 for the parking brake pressure
measurement.
T5-6-79
B-2 Parking brake is not applied.
Wear amount of Specification Allowable Limit

parking brake mm (in) mm (in)
Brake Disc 2.2 (0.087) 2.0 (0.079)
Brake Plate 2.4 (0.094) 2.2 (0.087)
Preparation

1 Monitor Parking Brake Parking brake switch: ON ON is displayed Faulty parking brake
Signal Output Key switch: ON switch
2 Monitor Parking Brake Key switch: ON Pressure is detected Stuck spool in parking
Pressure brake solenoid valve
3 Check the wear amount - Allowable limit or less Faulty brake disc and
of parking brake faulty brake friction plate
4 - - The above checks Faulty main controller
resulted all normal. (MC)
fNOTE: Refer to p. T4-5-26 for the parking brake pressure

measurement.
T5-6-80
B-3 Service brake function lowers.
Wear amount of Specification Allowable Limit

service brake (mm) (mm)
Brake Disc 6.2 5.3
Brake Ring 5.0 4.5
Preparation

1 Monitor Service Brake Refer to page T4-5-1. The measured values Faulty charging block
Primary Pressure are out of normal range (brake priority valve)
(Normal range: 11.8 ~ Faulty service brake
14.7 MPa) primary pressure sensor
2 Monitor Service Brake Brake pedal: Fully The measured values are Faulty brake valve
Secondary Pressure depressed not within the normal Faulty service brake
values (Normal value: secondary pressure
4.6 ± 0.6 MPa) sensor
3 Measure Service Brake Refer to page T4-5-28. The measured values are Faulty brake accumulator
Accumulator Pressure not within the normal
values (Normal value:
14.7 ± 0.3 MPa)
4 Check the wear amount Refer to page T4-4-6. - The wear amount of
of service brake brake disc is beyond the
allowable limit
fNOTE: The service brake primary pressure sensor is

installed to the charging block (see p. T5-4-15).
The service brake secondary pressure sensor is installed
to the brake valve (see p. T5-4-16).
Refer to F&S S/M for the sensor specifications.
T5-6-81
(Blank)
T5-6-82

O-1 Clearance light, tail light, and license plate
light are not ON.
Preparation
 Check that the clearance light, tail light, and license
plate light are not broken first.
 Check #4, #11 fuses in fuse box A when the clearance

lights, tail light, and license plate light on both sides
are not ON at the same time.
 Failure of the clearance light indicator lighting will be

also affected.

1 Monitor Lighting Light switch: Clearance OFF is displayed. Faulty lighting switch
Switch light position (or Head Open circuit in harness between
light position) light switch and fuses #4 or #11
in fuse box A
2 - - The check (1) above Faulty fuse #4, #11 in fuse box A
resulted normal.
T5-6-83
O-2 Head light is not ON.
Preparation
 Check that the head lights are not broken first.  Check that the light switch is the head light position.
 The light switch may be faulty (O-1) when the head  Refer to SYSTEM / Electrical System (F&S S/M T2-5).
lights on both sides are not ON at the same time.
 Check #3, #4 fuses in fuse box A when the head lights
on both sides are not ON at the same time.

1 Set the light switch to Key switch: ON The head lights (left/ Faulty light switch
the low beam position Light switch: Head light right) are not ON
position
2 Replace head light relay Key switch: ON The head lights (left/ Faulty head light relay (A2)
(A2) with other general Light switch: Low beam right) are ON
relay position
3 Measure voltage Key switch: ON 0V Open circuit in harness between
between head light Light switch: Low beam head light relay (A2) and light
relay (A2) harness end position switch
#1 and chassis Faulty light switch
between head light Light switch: Low beam head light relay (A2) and #3 fuse
relay (A2) harness end position in fuse box A
#3 and chassis Faulty #3 fuse in fuse box A
between head light Light switch: Low beam head light (left) and head light
(left) harness end #512 position relay (A2)
and chassis
between head light Light switch: Low beam head light (right) and head light
(right) harness end #512 position relay (A2)
and chassis
Connectors
 Head Light Relay (A2) (Harness end)  Head Light (Left/Right)
#512
90Z6-05-06-01 90Z7-05-06CN-01
T5-6-84
O-3 Head light is not shifted to high beam.
Preparation
 Check #4, #19 fuse in fuse box A when the high  Failure of the high beam indicator lighting will be
beams at both sides are not ON. also affected.
 Check the wiring connections first.  Refer to SYSTEM / Electrical System (F&S S/M T2-5).
 Check that the light switch is the head light position.

1 Set the light switch to Key switch: ON High beam is not ON Faulty light switch
the high beam position Light switch: Head light
position
2 Replace high beam Key switch: ON High beam is ON Faulty high beam relay
relay (A3) with other Light switch: High beam
general relay position
between high beam Light switch: High beam high beam relay and light switch
relay harness end #1 position
and chassis
between high beam Light switch: High beam high beam relay and #19 fuse in
relay harness end #3 position fuse box A
and chassis Faulty #19 fuse in fuse box A
between head light Light switch: High beam head light (left) and high beam
(left) harness end #511 position relay (A3)
and chassis
between head light Light switch: High beam head light (right) and high beam
(right) harness end #511 position relay (A3)
and chassis
7 - - The above checks Faulty head light (right/left)
resulted all normal. Faulty grounding
Connectors
 High Beam Relay (A3) (Harness end)  Head Light (Left/Right)
#511
90Z6-05-06-01 90Z7-05-06CN01
T5-6-85
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 (F&S S/M T2-5).
lights do not blink at the same time.
Faulty flasher relay may also cause this trouble.  Check the wiring connections first.

1 Turn the hazard light Key switch: OFF Hazard light is not Faulty hazard light switch
switch ON operated. Open circuit in harness between
hazard light switch and #7 fuse
in fuse box A
2 Measure voltage at Flasher relay: remains 0V Faulty flasher relay
terminal L in flasher relay installed Faulty grounding
Hazard light switch: ON
3 Replace turn signal light Hazard light switch: ON Symptom is Faulty turn signal light relay (left
relay (left) with turn observed on the or right)
signal light relay (right) opposite side.
4 Measure voltage between Hazard light switch: ON 0V Open circuit in harness between
turn signal light relay turn signal light relay (left/right)
(left/right) harness end #1 and hazard light switch
and chassis Faulty diode (Hazard 1 or 2)
turn signal light relay turn signal light relay (left/right)
(left/right) harness end #3 and flasher relay
and chassis
hazard lights (right front/ hazard lights (right front/ right
right rear) harness end rear) and turn signal light relay
#501A/#501B and chassis (right) (A8)
hazard lights (left front/ hazard lights (left front/ left rear)
left rear) harness end and turn signal light relay (left)
#531 and chassis (B7)
8 - - The above checks Faulty #7 fuse in fuse box A
Connectors
 Turn Signal Light Relay  Hazard Light (Front)  Hazard Light (Rear)  Flasher Relay
(Left/Right) (Harness end) (Front chassis F2) (Rear chassis CLL,CLR) (Harness end)
#501B
#502B
#502A
#501A
L
90Z6-05-06-01 90Z6-05-CN07 90Z6-05-CN08 90Z6-05-CN09
T5-6-86
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 Key switch: ON All turn signal lights do Faulty turn signal lever
lever to the right and left not blink. Open circuit in harness
between turn signal lever
and #2 fuse in fuse box A
2 Replace turn signal light Key switch: ON The turn signal light (left) Faulty turn signal light
relay (left) (B7) with other Turn signal lever: Left is ON relay (left)
general relay position
turn signal light relay Turn signal lever: Left between turn signal light
(left) (B7)harness end #1 position relay (left) and turn signal
and chassis lever
Faulty diode Hazard 2
4 Replace turn signal light Key switch: ON The turn signal light Faulty turn signal light
relay (right) (A8) with Turn signal lever: Right (right) is ON relay (right)
other general relay position
turn signal light relay Turn signal lever: Right between turn signal light
(right) (A8) harness end position relay (right) and turn
#1 and chassis signal lever
Faulty diode Hazard 1
Connector
 Turn Signal Light Relay (Left/Right) (Harness end)
90Z6-05-06-01
T5-6-87
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 Replace horn relay (A9) with Horn switch: ON Horn sounds Faulty horn relay
other general relay
2 Measure voltage between Horn switch: ON 0V Open circuit in harness between
horn relay harness end #1 horn relay and #6 fuse in fuse
and chassis box A
Faulty #6 fuse in fuse box A
3 - - The above checks Faulty horn switch
resulted all normal. Open circuit in harness between
horn switch and horn relay
Connector
 Horn Relay (Harness end)
90Z6-05-06-01
T5-6-88
O-7 Reverse light is not ON. Reverse buzzer 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 (F&S S/M T2-5).
at both sides and reverse buzzer are not operated at
the same time.  Check the wiring connections first.
Faulty forward/reverse lever (T-1) may also cause this
trouble.

1 Replace reverse buzzer relay Key switch: ON Reverse light is ON Faulty reverse buzzer relay
(C2) with other general relay Forward/reverse and reverse buzzer
lever: R position sounds.
2 Measure voltage between Key switch: ON 0V Open circuit in harness between
reverse lights (left/right) Forward/reverse reverse lights (left/right) and
harness end #505 and lever: R position reverse buzzer relay
chassis
reverse buzzer harness end Forward/reverse reverse buzzer and reverse
#1 and chassis lever: R position buzzer relay
reverse buzzer relay harness reverse buzzer relay and #13 fuse
end #1 and chassis in fuse box A, or faulty #13 fuse
reverse buzzer relay harness reverse buzzer relay and #1 fuse
end #3 and chassis in fuse box A
6 - - The above checks Faulty reverse lights (left/right)
Connectors
 Reverse Buzzer Relay (Harness end)  Reverse Buzzer  Reverse Light (Left/Right)
#505
90Z6-05-06-01 90Z7-05-CN10 90Z7-05-06CN03
T5-6-89
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 Replace brake light Brake light switch: ON The symptom Faulty brake light relay
relay (B4) with other (Brake pedal is applied) disappears
general relay
2 Measure voltage - 0V Open circuit in harness between
between brake light brake light relay and #2 fuse in
relay harness end #1 fuse box A
and chassis Faulty #2 fuse in fuse box A
3 - - The above checks Faulty brake light switch
resulted all normal. Open circuit in harness between
brake light switch and brake light
relay
Connector
 Brake Light Relay (Harness end)
90Z6-05-06-01
T5-6-90
O-9 Work light does not light.
Preparation
 Check that the work lights are not broken first.  Failure of blinking of the work light indicator will be
also affected.
 The light switch may be faulty (O-1) when the work
lights at both front and rear sides are not ON at the  Refer to SYSTEM / Electrical System (F&S S/M T2-5).
same time.
 Check #17 fuse in fuse box A and #4 fuse in fuse box
B when only the light at front or rear side is ON.

1 Set work light switch to ON Key switch: ON Work light is not ON. Faulty work light switch
1/ON 2 Open circuit in harness between
work light switch and light
switch
2 Replace work light relays Key switch: ON Work light on the Faulty work light relay (front/
(front/rear) each other or Work light switch: opposite side is ON. rear)
with other general relay ON 2 position
work light relay (front/rear) Work light switch: work light relay (front/rear) and
harness end #1 and chassis ON 2 position work light switch
work light relay (front) (A6) work light relay (front) and #4
harness end #3 and chassis fuse in fuse box A
work light relay (front) Work light switch: work light (front) and work light
harness end and chassis ON 2 position relay (front)
work light relay (rear) (A7) work light relay (right) and #17
harness end #3 and chassis fuse in fuse box A
work light (rear) harness Work light switch: work light (rear) and work light
end #2 and chassis ON 2 position relay (rear)
8 - - The above checks Faulty work light (front/rear)
Connectors
 Working Light Relay (Harness end)  Work Light (Front)  Work Light (Rear)
90Z6-05-06-01 90Z7-05-06CN02 90Z7-05-06CN04
T5-6-91
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 (F&S S/M T2-5).
wiper relay is activated. Next, check if electric power
is routed to the wiper motor.  Check the wiring connections first.
 Front Wiper

1 Monitor Front Wiper Key switch: ON OFF is displayed. Faulty column display
Relay 1 Output Front wiper/ washer controller
switch: LOW
2 Monitor Front Wiper Key switch: ON OFF is displayed. Faulty column display
Relay 2 Output Front wiper/ washer controller
switch: HI
3 Monitor Front Wiper Key switch: ON The position of front Faulty front wiper/ washer
Switch Front wiper/ washer wiper/ washer switch switch
switch: LOW/HI is not identical to the Open circuit in harness
display on monitor. between front wiper/ washer
switch and column display
controller
between front wiper relay
1, 2 and column display
controller
4 Replace front wiper Key switch: ON The opposite wiper is Faulty front wiper relay 1, 2
relay 1, 2 with each Front wiper/ washer operated.
other switch: LOW
5 - - The above checks Faulty front wiper motor
T5-6-92
 Rear Wiper
Preparation
 The rear wiper/ washer switch may be faulty when
the rear wiper is not operated.

1 Set rear wiper/ washer Key switch: ON Rear wiper is not Faulty rear wiper/ washer
switch to LOW operated. switch
between rear wiper/ washer
switch and rear wiper relay
2 Replace rear wiper relay Key switch: ON Rear wiper is operated. Faulty rear wiper relay
with other general relay Rear wiper/ washer
switch: LOW
3 Check continuity Key switch: ON ∞Ω Open circuit in harness
between rear wiper Rear wiper/ washer between rear wiper relay and
relay harness end #2 switch: LOW rear wiper/ washer switch
and body
between rear wiper Rear wiper/ washer between rear wiper relay and
relay harness end #1 switch: LOW #5 fuse in fuse box B
and chassis Faulty #5 fuse in fuse box B
5 - - The above checks Faulty rear wiper motor
Connector
 Rear Wiper Relay (B9) (Harness end)
90Z6-05-06-01
T5-6-93
O-11 Washer is not operated.
Preparation
 Front Washer
1 Replace the front Front wiper/ washer Front washer is Faulty front washer relay
washer relay (B8) with switch: ON position operated.
other general relay
2 Check continuity Front wiper/ washer ∞Ω Open circuit in harness between
between front washer switch: ON position front washer relay and front
relay harness end #2 wiper/ washer switch
and chassis
between front washer front washer relay and #3 fuse in
relay harness end #1 fuse box B
and chassis Faulty #3 fuse in fuse box B
4 Monitor Front Washer Front wiper/ washer OFF is displayed Faulty front wiper/ washer switch
Switch switch: Washer ON Open circuit in harness between
front wiper/ washer switch and
column display controller
5 Measure voltage Front wiper/ washer 0V Open circuit in harness between
between front washer switch: ON position front washer relay and front
motor harness end #1 washer motor
and chassis
6 - - The above checks Faulty front washer motor
Connector
 Front Washer Relay (B8) (Harness end)  Front Washer Motor
90Z6-05-06-01 90Z6-05-CN10
T5-6-94
 Rear Washer
Preparation
 The rear wiper/ washer switch may be faulty when
the rear washer is not operated.

1 Replace the rear washer Key switch: ON Rear washer is Faulty rear washer relay
relay (B10) with other Rear wiper/ washer operated
general relay switch: Washer ON
2 Check continuity Key switch: ON ∞Ω Open circuit in harness between
between front washer Rear wiper/ washer rear washer relay and rear wiper/
relay harness end #2 switch: Washer ON washer switch
and chassis
between rear washer Rear wiper/ washer rear washer relay and #5 fuse in
relay harness end #1 switch: Washer ON fuse box B
and chassis
between rear washer Rear wiper/ washer rear washer relay and rear washer
motor harness end #1 switch: Washer ON motor
and chassis
5 - - The above checks Faulty rear washer motor
resulted all normal. Faulty #5 fuse in fuse box B
Connector
 Rear Washer Relay (B10) (Harness end)  Rear Washer Motor
90Z6-05-06-01 90Z6-05-CN10
T5-6-95
O-12 Cab dome light is not ON.
Preparation
 Check #11 fuse in fuse box B when the cab dome
light and rear cab dome light are not ON at the same
time.

1 Set cab dome light switch - Cab dome light is not ON. Faulty cab dome bulb
to ON position Open circuit in harness
between cab light and #11
fuse in fuse box B
2 Set cab dome light switch Door open/close Cab dome light is not ON. Faulty door open/close
to Door Interlocking switch: ON switch
Position
3 Set cab rear dome light - Cab rear dome light is not Faulty cab dome bulb
switch to ON position ON. Open circuit in harness
between cab rear dome light
and #11 fuse in fuse box B
4 - - The above checks Faulty #11 fuse in fuse box B
T5-6-96
Exchange Inspection
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging
the suspected part / component with another part /
component having identical characteristics.
Many sensors and solenoid valves used on this machine

are identical. Therefore, by using this switch-check
method, faulty part /component, and/or harness can be
easily found.
Example: Pilot Pressure Sensor Circuit High Input (MC

fault code 111217-3)
Check Method:
1. Replace pressure sensor (primary pilot) (1) with
pressure sensor (parking brake) (2).
2. Retry troubleshooting.
Result:
In case Parking Brake Pressure Sensor Circuit High Input
(MC Fault Code 111313-3) is displayed, the pressure
sensor (primary pilot) is considered to be faulty. 1
In case Pilot Pressure Sensor Circuit High Input (MC fault

code 111217-3) is displayed, the pressure sensor (primary 90Z6T1-2-22
pilot) harness is considered to be faulty.
90Z6T1-2-13
T5-6-97
Applicability of Switch-Check Method
Fault Code Trouble Remedy

111204-3 Pump Delivery Pressure Sensor Circuit High Input Compatible Harness / Sensor
111204-4 Pump Delivery Pressure Sensor Circuit Low Input
111311-3 Service Brake Primary Pressure Sensor Circuit High Input
111311-4 Service Brake Primary Pressure Sensor Circuit Low Input
111206-3 Hyd. Fan Circuit Pressure Sensor Circuit High Input (Option)
111206-4 Hyd. Fan Circuit Pressure Sensor Circuit Low Input (Option)
111208-3 Emergency Steering Check Pressure Sensor Circuit High Input (Option)
111208-4 Emergency Steering Check Pressure Sensor Circuit Low Input (Option)
111217-3 Pilot Pressure Sensor Circuit High Input Compatible Harness / Sensor
111217-4 Pilot Pressure Sensor Circuit Low Input
111313-3 Parking Brake Pressure Sensor Circuit High Input
111313-4 Parking Brake Pressure Sensor Circuit Low Input
111200-3 Lift Arm Raise Pilot Pressure Sensor Circuit High Input (Option)
111200-4 Lift Arm Raise Pilot Pressure Sensor Circuit Low Input (Option)
T5-6-98
Air Bleeding Procedures for Brake (Axle)

IMPORTANT: If air is mixed in the brake system, the
1
brake function is reduced and serious hazard
after removing and installing the pipe lines and 1
replacing hydraulic oil.
In addition, bleed air from the brake system until
hydraulic oil (about 0.5 L (0.13 gal)) is drawn from
each wheel (4 places) after bubbles stops.
fNOTE: Perform this work on all wheels (4 places) by two

or more persons. Air bleed plug (1) is located around the
center on front and rear axles.
90T4GB-05-04-04
1. Set the parking brake switch of front console to the
ON position, start the engine, and increases service
brake oil pressure.
2
2. Connect clear vinyl tube (2) to either one of two air 1
bleed plugs (1).
Insert the other end of clear vinyl tube (2) into clear
container (3) filled with hydraulic oil.
3. Depress brake pedal (4) several times. 3

Then, depress and hold brake pedal (4) to the stroke
end.
4. Loosen air bleed plug (1) under condition in step 3 T4GB-05-04-005

and drain hydraulic oil and air for several seconds.
5. Tighten air bleed plug (1).
6. Drain hydraulic oil after bubbles stops in steps 3 to 5

repeatedly.
fNOTE: When bubbles do not disappear after hydraulic

oil (about 0.5 L (0.13 gal)) is discharged, repeat step 3 to
step 5.
7. Bleed air at other 3 places in the same way as step 3

to step 5.
4
T4GB-05-04-006
IMPORTANT: After air bleeding is completed at 4
places, bleed air at 4 places again. fNOTE: The right brake pedal is optional.
Bleed air in the same way as step 3 to step 5 twice
and check that no air remains inside.
T5-6-99
(Blank)
T5-6-100
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
selected by air vent damper servo motor (1) in accordance
Either fresh or re-circulated air is induced into the air with the set-ventilation mode.
conditioner unit by operating fresh / re-circulated air
damper servo motor (6). The air conditioning controller controls the air
conditioning system. The air conditioning controller
The induced air flows out of the vents through evaporator controls the damper operation by corresponding to
(5) or heater (15) by blower motor (11). the job site conditions such as atmospheric and cab
Evaporator (5) is a device used to cool the air. Heater (15) inside air temperatures, coolant temperature, operator’s
is a device used to warm the air. In the air conditioning set-temperature, and the selected ventilation mode. In
system, after the refrigerant is compressed by the addition, the air conditioning controller displays the air
compressor, it is sent to evaporator (5) in which the conditioning system operation status on the monitor.
refrigerant expands to cool the air.
Heater (15) warms air by first absorbing heat from
warmed engine coolant. Evaporator (5) and heater (15)
allow the introduced air to circulate in the system to
maintain the temperature at the set temperature.
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
6 1
2
5 3
TNDB-05-07-001
4
10 7
11
90Z7-05-07-01 90Z6-05-07-01
1- Solar Radiation Sensor 5- Fresh Air Filter 9- Receiver Tank

2- Key Switch 6- Air Conditioner Controller (Switch Panel) 10- A/C Gas High/Low Pressure Switch (ACP)
3- Accelerator Pedal 7- Compressor 11- Refrigerant Pressure Sensor (ACG)
4- Air Conditioner Unit 8- Air Conditioner Condenser
T5-7-2
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
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
T5-7-4
 Frost Sensor (CN12)

Monitors the fin temperature which is cooled by the
evaporator. When the temperature is higher than
3°C (37°F) (approx. 4.2 kΩ), the controller turns the
compressor relay ON. When the temperature is lower
TDAA-05-07-006
than 2°C (36°F) (approx. 4.5 kΩ), the controller turns the
compressor relay OFF. Therefore, the evaporator in the air
conditioner unit is prevented from freezing. The electrical
resistance in the frost sensor is 100 Ω to 115 kΩ.
 High/Low Pressure Switch (CN14)

Controls the compressor clutch solenoid while
monitoring the compressor circuit pressure. The high/low #A052
pressure switch consists of a pressure gauge and a switch. #A211
The pressure gauge detects the lower pressure range TDAA-05-07-007
(0.196 MPa ~ 0.216 MPa) (28.4 ~ 31.3 PSI) and the surge
pressure range (2.55 ~ 3.14 MPa) (370 ~ 455 PSI). When
the circuit pressure is reduced to the lower pressure range
or increases to the surge pressure range, the pressure
gauge turns the switch OFF so that the compressor
operation stops. If the pressure is reduced to the lower
range, a lack of refrigerant is suspected. Therefore, TDAA-05-07-014
damage to the compressor due to a lack of refrigerant
is prevented. In case the pressure increases to the surge
range, damage to the air conditioner circuit parts due to
excessively high circuit pressure is prevented.
 Re-circulated Air Sensor (CN11)

Monitors the temperatures 0 ~ 25°C (32 ~ 77°F) around
TDAA-05-07-008
the re-circulated air inlet as the interior air temperatures
and converts them to the electrical resistance values.
The temperatures 0 ~ 25°C (32 ~ 77°F) corresponds to a
resistance of 1.645 kΩ (0°C) (32°F) to 5 kΩ (25°C) (77°F)
respectively.
The electrical resistance in the air circulation sensor is 300
Ω to 430 kΩ.
TDAA-05-07-009
 Outdoor Ambient Temperature Sensor (CN15)
Monitors the temperature around the rear side of the
machine as the fresh air temperature, and converts
the temperature to the electrical resistance value. The
electrical resistance in the fresh air sensor is 100 Ω to 210
kΩ.
T5-7-5
 Solar Radiation Sensor (CN16)

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

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

Controls opening/closing of the air mixing door in
response to the set temperature.
The damper consists of a motor, link mechanism, and
potentiometer.
The motor opens or closes the air mix door via the link
TDAA-05-07-012
mechanism.
The potentiometer converts the link movements (the
mix door strokes) to the voltage. Both ends of the
potentiometer are energized by 5 V from terminals #7
(+) and #25 (-) in controller so that the potentiometer
outputs voltage of 0.5 to 4.5 V from the center terminal
to terminal #19 in controller corresponding to the link
movement.
When the set temperature is determined by temperature
UP/DOWN signal from the controller, the controller
calculates voltage (Vr) corresponding the link position.
Further more, the controller checks the air mix door
position by voltage (Vf ) from the potentiometer. Then,
after the controller decides the motor rotational direction
(polarity of motor) based on the differential voltage
between Vr and Vf, the controller sends out the current
from terminals #15 and #16.
The controller drives the motor until voltage (Vf )
becomes equal to voltage (Vr).
T5-7-6
 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 TDAA-05-07-013
(vent louvers strokes) to the voltage. Both ends of the
potentiometer are energized by 5 V from terminals #7
(+) and #25 (-) in controller so that the potentiometer
outputs voltage of 0.5 to 4.5 V from the center terminal
to terminal #20 in controller corresponding to the link
movement.
Depending on the MODE switch set position, vent louvers

are operated as shown below:
When the front and rear air vent louvers positions
are selected, the controller calculates potentiometer
voltage (Vr). Furthermore, the controller checks the vent
louvers positions by receiving voltage (Vf ) from the
potentiometer. Then, after the controller decides the
motor rotational direction (polarity of motor) based on
the differential voltage between Vr and Vf, the controller
sends out the current from terminals #31 and #32. The
controller drives the motor until voltage (Vf ) becomes
equal to voltage (Vr).
MODE switch 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
T5-7-7
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.
T5-7-8
Air Conditioner Controller Fault Code List
Fault Code Trouble Cause Symptoms in Machine Operation Remedy

When Trouble Occurs.
11 Open circuit in re- Voltage: more than Operation is controlled under such Check the harness.
circulated air sensor 4.95 V circumstance as no re-circulated Replace the re-
air sensor is provided. circulated air sensor.
12 Shorted circuit in re- Voltage: less than 0.3 V Operation is controlled under such Check the harness.
circulated air sensor circumstance as no re-circulated Replace the re-
air sensor is provided. circulated air sensor.
13 Open circuit in Voltage: more than Operation is controlled under Check the harness.
outdoor ambient 4.88 V such circumstance as no outdoor Replace the outdoor
temperature sensor ambient temperature sensor is ambient temperature
provided. sensor.
14 Shorted circuit in Voltage: less than Operation is controlled under Check the harness.
outdoor ambient 0.096 V such circumstance as no outdoor Replace the outdoor
temperature sensor ambient temperature sensor is ambient temperature
provided. sensor.
18 Shorted circuit Voltage: more than Operation is controlled under such Check the harness.
in solar radiation 5.04 V circumstance as no solar radiation Replace the solar
sensor sensor is provided. radiation sensor.
21 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.
22 Shorted circuit in Voltage: less than The compressor clutch is Check the harness.
frost sensor 0.096 V disengaged. (The compressor Replace the frost
stops.) sensor.
43 Abnormal air vent Shorted circuit: Air vent damper servo motor Check the harness.
damper servo motor Voltage: 0 V becomes inoperable. Replace the air vent
more than 5 V
44 Abnormal air mix Shorted circuit: Air mix damper servo motor servo Check the harness.
damper servo motor Voltage: less than 0.2 V motor becomes inoperable. Replace the air vent
more than 4.8 V
51 Abnormal high/low Voltage: 0 V The compressor clutch is Check the harness.
refrigerant pressure disengaged. (The compressor Replace the high/low
stops.) pressure switch.
91 CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1
error between monitor harness.
controller and air Replace air conditioner
conditioner controller controller.
92 CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1
controller harness.
Faulty CAN1 harness Replace air conditioner
controller.
T5-7-9
Air Conditioner Controller Fault Codes 11 to 22

Preparation
position.
Fault Code Trouble Inspection Method Evaluation Cause

11 Open circuit in re- Measurement of resistance ∞ Ω (Normal value: 300 Faulty sensor.
circulated air sensor between sensor #1 and #2. kΩ to 430 kΩ)
Measurement of voltage 0V Open circuit in harness
between sensor harness #1.
end #1 and body.
- Normal in above check. Open circuit in harness
#2.
12 Shorted circuit in re- Measurement of resistance 0 Ω (Normal value: 300 Faulty sensor.
circulated air sensor between sensor #1 and #2. kΩ to 430 kΩ)
- Normal in above check. Shorted circuit in harness
#1 and #2.
13 Open circuit in Measurement of resistance ∞ Ω (Normal value: 100 Faulty sensor.
outdoor ambient between sensor #1 and #2. kΩ to 210 kΩ)
temperature sensor Measurement of voltage 0V Open circuit in harness
end #1 and body.
#2.
14 Shorted circuit in Measurement of resistance 0 Ω (Normal value: 100 Faulty sensor.
outdoor ambient between sensor #1 and #2. kΩ to 210 kΩ)
temperature sensor - Normal in above check. Shorted circuit in harness
#1 and #2.
18 Shorted circuit in Continuity check between 0Ω Shorted circuit in harness
solar radiation sensor sensor harness end #1 and #1 and #2.
#2.
- Normal in above check. Faulty sensor.
21 Open circuit in frost Measurement of resistance ∞ Ω (Normal value: 100 Faulty sensor.
sensor between sensor #1 and #2. kΩ to 115 kΩ)
Measurement of voltage 0V Open circuit in harness
end #1 and body.
#2.
22 Shorted circuit in frost Measurement of resistance 0 Ω (Normal value: 100 Faulty sensor.
sensor between sensor #1 and #2. kΩ to 115 kΩ)
- Normal in above check. Shorted circuit in harness
#1 and #2.
T5-7-10
Air Conditioner Controller Fault Codes 43 to 92

Preparation
position.
Fault Code Trouble Inspection Method Evaluation Cause

43 Abnormal air vent Measurement of voltage 0V Faulty controller or open circuit
damper servo motor between air vent damper servo in harness between controller
motor harness end 7C and body. and air vent damper servo
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
switch: ON)
- Normal in Faulty air vent damper servo
above check. motor.
44 Abnormal air mix Measurement of voltage 0V Faulty controller or open circuit
damper servo motor between air mix damper servo in harness between controller
motor harness end 7D and body. and air mix damper servo
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
switch: ON)
- Normal in Faulty air mix damper servo
above check. motor.
51 Abnormal high/low Measurement of voltage 0V Faulty controller or open circuit
refrigerant pressure between high/low pressure in harness between controller
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.
91 CAN communication Continuity check in CAN1 Normal Faulty controller.
error harness. Abnormal Faulty CAN1 harness.
92 CAN bus off error Continuity check in CAN1 Normal Faulty controller.
harness. Abnormal Faulty CAN1 harness.
T5-7-11
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
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
T5-7-12
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 A/M Setting link again
link
T5-7-13
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 with refrigerant level after purging
too high (approx. Faulty compressor Breakage of head gasket Replace compressor
0.29 MPa (42 PSI) or Breakage of inlet valve Replace compressor
more) 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 Piston is locked Replace compressor
(142 PSI) or 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 Faulty expansion valve To D
(7.25 PSI) or 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
T5-7-14
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
T5-7-15
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 Lack of Clogged fin with Cleaning of fin
(368 PSI) or condenser dirt or mud (washing)
more) cooling
Overcharge air Remove refrigerant thoroughly and
conditioner with recharge refrigerant to proper level
refrigerant after purging
Air incorporation Remove refrigerant thoroughly and
in refrigeration recharge refrigerant to proper level
cycle after purging
Too low Abnormally low ambient temperature
(0.98 MPa Low refrigerant To B
(142 PSI) or Clogged during refrigeration cycle To C
less) Faulty expansion valve To D
T5-7-16
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
T5-7-17
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
T5-7-18
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
Faulty wiring of Shorted circuit check Repair
evaporator sensor
Faulty the frost sensor Characteristic check Replace frost sensor
characteristics
T5-7-19
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
T5-7-20
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
T5-7-21
 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 armature 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.
T5-7-22
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.

 Blower Motor Relay  Blower motor
TDAB-05-07-020 TDAB-05-07-027
 Power Transistor
TDAB-05-07-028
T5-7-23
Compressor clutch does not operate.

Preparation
 Check that fresh air temperature is 0˚C (32˚F) or
more first. When fresh air temperature is less than
0˚C (32˚F), the air conditioner controller turns the
compressor clutch OFF in order to protect the
compressor.
 Check that fault code 21 or 22 (abnormal frost
sensor) is not displayed. When the frost sensor is
abnormal, the compressor clutch does not operate.
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.
 Compressor Relay  Compressor Clutch
TDAB-05-07-019 TDAB-05-07-024
T5-7-24
Cooling circuit check by using manifold gauge
Condition:
 Engine Speed: 1500 min-1
 Cab Window: Fully Open
 Air Conditioner: ON
 Airflow volume: Maximum
 Temperature Control Switch: Maximum cool
 Fresh / re-circulated air selection: Re-circulated Air
 Air conditioner inlet temperature: 30 ~ 35°C (86 ~
95°F)
1. In normal
 Low-pressure side pressure: 0.15 ~ 0.25 MPa (21.8 ~
36.3 PSI)
 High-pressure side pressure: 1.37 ~ 1.57 MPa (198.7 ~
227.7 PSI)
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
T5-7-25
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
T5-7-26
Work after Replacing Components

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

 Purging
 Charge air conditioner with refrigerant
 Warm-up operation
 Inspection
T5-7-27
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.
fNOTE: Compressor oil quantity: 160 cm3 (9.8 in3)
1 2
TDAA-05-07-015
1- New Compressor 2- Replacing Compressor
T5-7-28
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
T5-7-29
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). 2
Connect high-pressure side charge hose (3) and
low-pressure side charge hose (6) on manifold
3
gauge (1) to the high-pressure side charge valve
(“D” marked) and to the low-pressure side charge
valve (“S” marked) located on the compressor, 5
respectively.
Connect charge hose (5) located on the center of 4
manifold gauge (1) to vacuum pump (4).
W115-02-10-005
2. Open high pressure valve (2) and low pressure valve 1

(7) on manifold gauge (1). 7
Perform purging for 10 minutes or more by
operating vacuum pump (4).
W115-02-10-005
T5-7-30
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) (-14.5 PSI), close high
2
pressure valve (2) and low pressure valve (7) and
stop vacuum pump (4).
Wait for approximately five minutes and confirm
that the pointer does not return to 0.
4. With high pressure valve (2) and low pressure valve W115-02-10-005
(7) on manifold gauge (1) closed, connect charge
hose (5) to refrigerant container (8).
7 1
W115-02-10-007
5. Open valve (9) of refrigerant container (8). Push air

bleed valve (10) on manifold gauge (1) to purge 10 1
air in charge hose (5) with the refrigerant pressure.
When draining refrigerant, immediately release air
bleed valve (10).
5
9
W115-02-10-007
T5-7-31
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). W115-02-10-008
Close high pressure valve (2) and valve (9) of
refrigerant container (8) when high pressure gauge
(11) reading reaches 98 kPa (1 kgf/cm2) (14.2 PSI). 1
fNOTE: Use warm water of 40˚C (104˚F) or less to warm

refrigerant container (8) to aid in charging operation. 11
2
5
9
IMPORTANT: Use the leak tester for R134a.

7. After charging, check the line connections for gas
leaks using leak tester. W115-02-10-007
T5-7-32
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: Low 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:

900 ± 50 g (1.98 ± 0.1 lb) 2
10. If refrigerant container (8) becomes empty during

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

manifold gauge (1) and valve (9) of refrigerant
container (8), and stop the engine.
T5-7-33
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
dCAUTION: 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, 142 psi).
13. After checking refrigerant quantity, disconnect the

low-pressure-side charge hose first.
Disconnect the low-pressure-side charge hose.
Wait for the high-pressure-side pressure to drop to
less than 980 kPa (10 kgf/cm2, 142 psi).
Disconnect the high-pressure-side charge hose.
T5-7-34
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.
dCAUTION: 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 W115-02-10-013
conditioner component.
 Check each component for abnormalities.
 Carry out ON-OFF check of the compressor clutch.
 Check compressor fan belt tension.
 Check the coolant level in the radiator.
 Operate the air conditioner and check the
performance.
W115-02-10-014
T5-7-35
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.
fNOTE: When the machine is in normal and the air

conditioner is operated with the following conditions, air
vent temperature decrease approx. 20°C (68°F) or less. (it
may be different under special environment.)

 Engine Speed: High Idle
 Cab Window: Fully closed
 Fresh / re-circulated air selection: Re-circulated Air
 Season: Summer
T5-7-36
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) (lbf·ft)
Nut type Pipe with dia. 8 12 to 15
TDAA-05-07-016
(Fig. A) (1.2 to 1.5)
(8.7 to 10.8)
B
Pipe with D1/2 20 to 25
(2.0 to 2.5)
(14.5 to 18.1)
Pipe with D5/8 30 to 35
(3.0 to 3.5)
(21.7 to 25.3)
Block joint Receiver M6 Bolt 4.0 to 7.0
(Fig. B) (4T) (0.4 to 0.7)
(3.0 to 5.0)
M6 Bolt (6T) 8.0 to 12
for other than (0.8 to 1.2)
Receiver (5.8 to 8.7)
TDAA-05-07-017
T5-7-37
(Blank)
T5-7-38
INDEX
111000 to 111002...................................................................T5-5-41 Alarms on Monitor..................................................................T5-5-24
111003.........................................................................................T5-5-42 All Actuator System Troubleshooting.............T5-6-28, T5-6-51
111006, 111007........................................................................T5-5-44 Alternator Check......................................................................T5-1-14
111014.........................................................................................T5-5-44 Axle (Service Brake), Air Bleeding......................................T5-6-99
111025.........................................................................................T5-5-44 Axle Oil Temperature Sensor Specification....................T5-5-65
111103.........................................................................................T5-5-49
B
111105.........................................................................................T5-5-49
111200.........................................................................................T5-5-50 Battery Voltage Check...........................................................T5-1-13
111204.........................................................................................T5-5-53 Bell Crank Stopper Clearance................................................ T4-4-8
111205.........................................................................................T5-5-51 Brake (Axle), Air Bleeding.....................................................T5-6-99
111206.........................................................................................T5-5-54 Brake Accumulator Pressure................................................T4-5-28
111207.........................................................................................T5-5-51 Brake Circuit Pilot Pressure.................................................... T4-5-2
111208.........................................................................................T5-5-55 Brake Pressure, Test
111217.........................................................................................T5-5-52 Parking...................................................................................T4-5-26
111311.........................................................................................T5-5-56 Service...................................................................................T4-5-24
111312.........................................................................................T5-5-52 Brake System Troubleshooting..........................T5-6-40, T5-6-79
111313.........................................................................................T5-5-56 Brake Valve.................................................................................T5-4-16
111411.........................................................................................T5-5-57 Brake Warning Pressure (Pressure-Decreasing)............T4-5-30
111412.........................................................................................T5-5-58 Brake Warning Pressure (Pressure-Increasing).............T4-5-32
111413.........................................................................................T5-5-59 Bucket Levelness.....................................................................T4-4-13
111414 to 111419...................................................................T5-5-60 Bucket Stopper Clearance...................................................... T4-4-8
111422.........................................................................................T5-5-61 C
111600, 111601, 111602.......................................................T5-5-62 CAN Data Reception Failure................................................T5-5-10
111700 to 111705...................................................................T5-5-66 CAN1 Harness Check..............................................................T5-5-46
111900.........................................................................................T5-5-63 Charge Air Conditioner with Refrigerant........................T5-7-29
111901.........................................................................................T5-5-64 Charging Block.........................................................................T5-4-15
111902.........................................................................................T5-5-65 Check by False Signal.............................................................T5-1-23
113002, 113003........................................................................T5-5-45 Column Display Controller (Information) Fault Codes
113005.........................................................................................T5-5-45 120500 to 120503..............................................................T5-5-72
113007.........................................................................................T5-5-45 120505 to 120507..............................................................T5-5-73
114010, 114011........................................................................T5-5-45 Column Display Controller Fault Code
114015.........................................................................................T5-5-45 115001...................................................................................T5-5-69
115001.........................................................................................T5-5-69 115011...................................................................................T5-5-70
115011.........................................................................................T5-5-70 List...........................................................................................T5-5-30
120000 to 120005...................................................................T5-5-68 Communication System......................................................... T5-3-7
120014.........................................................................................T5-5-68 Communication Terminal Fault Code List......................T5-5-32
120300.........................................................................................T5-5-72 Component Layout................................................................... T5-4-1
120500 to 120503...................................................................T5-5-72 Compressor Oil, Refill.............................................................T5-7-28
120505 to 120507...................................................................T5-5-72 Continuity Check.....................................................................T5-1-15
24-Volt Circuit...........................................................................T5-1-16 Control Lever Operating Force...........................................T4-4-14
5-Volt Circuit..............................................................................T5-1-22 Control Lever Stroke...............................................................T4-4-16
A Controller..................................................................................... T5-4-6
Accumulator Pressure, Brake...............................................T4-5-28 Controller Hardware Failure.................................................. T5-5-9
Adjustment.................................................................................. T4-6-1 Coolant Temperature............................................................... T5-2-4
Air Bleeding Procedures for Brake (Axle)........................T5-6-99 Coolant Temperature Gauge................................................. T5-2-7
Air Conditioner Cooling circuit check by using manifold gauge...........T5-7-25
Component Layout............................................................. T5-7-2 Correlation between Trouble Symptoms and
Functions of Main Parts..................................................... T5-7-4 Part Failures..........................................................................T5-6-25
Outline..................................................................................... T5-7-1 Cut-in/Cut-out Pressure ......................................................... T4-5-2
Troubleshooting................................................................... T5-7-8 Cylinder Drift Check...............................................................T4-4-12
Work after Replacing Components.............................T5-7-27 D
Air Conditioner Controller Fault Code List...... T5-5-33, T5-7-9 Daily Report Data, List............................................................. T5-3-2
Air Conditioner Controller Fault Codes Diagnosing Procedure, Introduction.................................. T5-1-1
11 to 22.................................................................T5-5-74, T5-7-10 Diagnosis Procedure................................................................ T5-1-2
43 to 92.................................................................T5-5-75, T5-7-11 Digging Position Adjustment............................................... T4-6-6
90Z6 Trbl
INDEX
Drift Check, Cylinder..............................................................T4-4-12 I
E Instructions for Disconnecting Connectors..................... T5-1-8
e-Service, Outline...................................................................... T5-3-1 L
e-Service Data List Learning Failure.......................................................................T5-5-21
Daily Report Data................................................................. T5-3-2 Lever Stopper Clearance......................................................... T4-4-8
Frequency Distribution Data........................................... T5-3-4 Lift Arm Angle Sensor Learning........................................... T4-6-4
Operation Data..................................................................... T5-3-2 List, e-Service Data
Service Menu Display......................................................... T5-2-6 Daily Report Data................................................................. T5-3-2
Total Operating Hours........................................................ T5-3-5 Frequency Distribution Data........................................... T5-3-4
ECM Fault Code List................................................................T5-5-34 Operation Data..................................................................... T5-3-2
Electric Component Layout (Overview)............................ T5-4-4 Service Menu Display......................................................... T5-2-6
Electric System Inspection..................................................... T5-1-5 Total Operating Hours........................................................ T5-3-5
Electrical System (Cab)............................................................ T5-4-5 Loading Circuit Main Relief Set Pressure.......................... T4-5-8
Electrical System (Relays).....................................................T5-4-10 Loading Main Relief Pressure Adjustment....................... T4-5-9
Engine Failure...........................................................................T5-5-11 Loading Pilot Circuit................................................................. T4-5-1
Engine Speed................................................................T4-3-1, T5-2-4
Engine System Troubleshooting.......................T5-6-26, T5-6-45 M
Engine Test................................................................................... T4-3-1 Main Component (Overview)............................................... T5-4-1
Engine/Fan Pump....................................................................T5-4-11 Main Component (Travel System)....................................... T5-4-3
Exchange Inspection..............................................................T5-6-97 Main Pump Delivery Pressure............................................... T4-5-6
Main Pump Flow Rate Measurement...............................T4-5-16
F Main Pump P-Q Diagram......................................................T4-2-10
Fan Motor...................................................................................T5-4-16 MC Fault Code
Fault Code.................................................................................... T5-2-5 111000 to 111002..............................................................T5-5-41
Fault Code List 111003...................................................................................T5-5-42
Air Conditioner Controller..............................................T5-5-33 111006, 111007..................................................................T5-5-44
Column Display Controller.............................................T5-5-30 111014...................................................................................T5-5-44
Communication Terminal...............................................T5-5-32 111025...................................................................................T5-5-44
ECM.........................................................................................T5-5-34 111103...................................................................................T5-5-49
MC............................................................................................. T5-5-9 111105...................................................................................T5-5-49
Monitor Controller (Monitor).........................................T5-5-26 111200...................................................................................T5-5-50
Monitor Controller (Information).................................T5-5-28 111204...................................................................................T5-5-53
MPDr......................................................................................... T5-5-3 111205...................................................................................T5-5-51
Faulty cooling...........................................................................T5-7-12 111206...................................................................................T5-5-54
Faulty heating...........................................................................T5-7-19 111207...................................................................................T5-5-51
Frequency Distribution Data, List........................................ T5-3-4 111208...................................................................................T5-5-55
Front Attachment System Troubleshooting 111217...................................................................................T5-5-52
.................................................................................T5-6-31, T5-6-56 111311...................................................................................T5-5-56
Front Axle...................................................................................T5-4-15 111312...................................................................................T5-5-52
Fuel Consumption..................................................................... T5-2-5 111313...................................................................................T5-5-56
Fuel Gauge................................................................................... T5-2-8 111411...................................................................................T5-5-57
Fuel Level Sensor Specifications........................................T5-5-71 111412...................................................................................T5-5-58
Fuse Box A..................................................................................T5-1-11 111413...................................................................................T5-5-59
Fuse Box B..................................................................................T5-1-11 111414 to 111419..............................................................T5-5-60
Fuse Inspection........................................................................T5-1-10 111422...................................................................................T5-5-61
Fusible Link Inspection..........................................................T5-1-12 111600, 111601, 111602.................................................T5-5-62
H 111700 to 111705..............................................................T5-5-66
111900...................................................................................T5-5-63
Hose Tightening Torque........................................................T5-7-37
111901...................................................................................T5-5-64
How to display service menu................................................ T5-2-4
111902...................................................................................T5-5-65
Hydraulic Circuit........................................................................ T4-5-1
120000 to 120005..............................................................T5-5-68
Hydraulic Cylinder Cycle Time............................................T4-4-10
120014...................................................................................T5-5-68
Hydraulic Oil Temperature..................................................... T5-2-4
List............................................................................................. T5-5-9
Hydraulic Oil Temperature Sensor Specification..........T5-5-64
Monitor......................................................................................... T5-4-8
Hydraulic Pump Device.........................................................T5-4-13
Monitor, Outline......................................................................... T5-2-1
90Z6 Trbl
INDEX
Monitor Controller (Information) Fault Code Service Brake Function Check............................................... T4-4-4
114010, 114011..................................................................T5-5-45 Service Brake Pressure (Front and Rear) .........................T4-5-24
114015...................................................................................T5-5-45 Service Brake Wear Amount.................................................. T4-4-6
List...........................................................................................T5-5-28 Service Menu, How to display.............................................. T5-2-4
Monitor Controller (Monitor) Fault Code Service Menu, Operating Procedures................................ T5-2-3
113002, 113003..................................................................T5-5-45 Snapshot Data............................................................................ T5-3-6
113005...................................................................................T5-5-45 Standard Table............................................................................ T4-2-1
113007...................................................................................T5-5-45 Steering Circuit Main Relief Set Pressure........................T4-5-10
120300...................................................................................T5-5-72 Steering Main Relief Pressure Adjustment.....................T4-5-11
List...........................................................................................T5-5-26 Steering System Troubleshooting....................T5-6-35, T5-6-65
Monitor Display.......................................................................... T5-2-2 Steering Valve...........................................................................T5-4-16
Monitor Panel...............................................................T5-2-1, T5-4-9 Switch Failure............................................................................T5-5-21
MPDr. Fault Code Reference Table...................................... T5-5-3 Switches........................................................................................ T5-4-8
Multiple Control Valve...........................................................T5-4-14
T
O Temperature Sensor Failure.................................................T5-5-22
Operating Procedures of Service Menu............................ T5-2-3 Test Harness..............................................................................T5-1-24
Operation Data, List.................................................................. T5-3-2 Torque Converter Assembly................................................T5-4-12
Operational Performance Standard Table........................ T4-2-1 Torque Converter Oil Temperature Sensor
Operational Performance Tests............................................ T4-1-1 Specification........................................................................T5-5-63
Other Sensor Failures.............................................................T5-5-23 Torque Converter Pressure...................................................T4-5-36
Other System Troubleshooting.........................T5-6-41, T5-6-83 Total Operating Hours, List.................................................... T5-3-5
Overload Relief Valve Pressure Adjustment...................T4-5-14 Transmission Assembly.........................................................T5-4-12
Overload Relief Valve Set Pressure....................................T4-5-12 Transmission Clutch Pressure.............................................T4-5-34
Transmission Learning............................................................. T4-6-1
P
Transmission Oil Temperature.............................................. T5-2-4
Parking Brake Function Check.............................................. T4-4-7 Transmission Oil Temperature Gauge................................ T5-2-7
Parking Brake Pressure..........................................................T4-5-26 Travel Speed................................................................................ T4-4-1
Performance Test....................................................................... T4-4-1 Travel System Troubleshooting.........................T5-6-37, T5-6-69
Pilot Failure................................................................................T5-5-13 Troubleshooting A (By Fault Codes)................................... T5-5-1
Pilot Valve...................................................................................T5-4-16 Troubleshooting B (By Troubleshooting Symptom)..... T5-6-1
Pipe Tightening Torque.........................................................T5-7-37
Precautions for Inspection and Maintenance ................ T5-1-6 V
Preparation for Performance Tests...................................... T4-1-2 Vehicle Information Display.................................................. T5-2-2
Primary Pilot Pressure.............................................................. T4-5-2 Voltage and Current Measurement..................................T5-1-16
Proportional Solenoid Valve Failure.................................T5-5-15
Pump Delivery Pressure.......................................................... T4-5-6
Pump Failure.............................................................................T5-5-12
Pump Output Pressure............................................................ T4-5-6
R
Refill Compressor Oil..............................................................T5-7-28
Refrigerant, Charge Air Conditioner.................................T5-7-29
Regulator Adjustment...........................................................T4-5-22
Relationship between Machine Trouble Symptoms and
Related Parts.......................................................................... T5-6-3
Relays............................................................................................. T5-4-6
Revolution Sensor Failure.....................................................T5-5-20
Ride Control Group (Option)...............................................T5-4-17
Right Console.............................................................................. T5-4-7
S
Secondary Pilot Pressure........................................................ T4-5-4
Secondary Pilot Pressure Adjustment Procedure.......... T4-5-5
Secondary Steering Group (Option).................................T5-4-18
Secondary Steering Pump (Option).................................T5-4-18
Sensor Activating Range......................................................T4-2-12
90Z6 Trbl
INDEX
(Blank)
90Z6 Trbl

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93213-00801

Operational Performance Test

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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

fNOTE: The numerical value in this manual might be

Symbol / Name Explanation

OPERATIONAL PERFORMANCE TEST

Operational Performance Tests

Precautions for Evaluation of Test Data

Preparation for Performance Tests

TEST AREA and TOOL

MAKE PRECISE MEASUREMENT

For EXP Specifications (S/N ~9152)

For EU Specifications (S/N 9153~)

Performance Test Designation Unit Performance Remarks Reference

Performance Test Designation Unit Performance Remarks Reference

Performance Test Designation Unit Performance Standard Remarks Reference

Performance Test Designation Unit Performance Standard Remarks Reference

fNOTE: MF: Multi-Function

Performance Test Designation Unit Performance Standard Remarks Reference

fNOTE: MF: Multi-Function

Performance Test Designation Unit Performance Standard Remarks Reference

Performance Test Designation Unit Performance Remarks Reference

Performance Test Designation Unit Performance Remarks Reference

Main Pump P-Q Diagram

 P-Q Control by Pump Control Pilot Pressure Signal

MPa (kgf/cm2) Pi1-Pi2

Sensor Activating Range

Engine Speed Power Mode Switch

• Monitor each sensor by using MPDr.

2. Sensor Activating Range

Unit: MPa (kgf/cm2) (PSI)

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

Forward/Reverse Accelerator Pedal Parking Brake Switch Power Mode Switch

Declutch Position Brake Pedal Control Lever

3. Empty the bucket and hold the lift arm with it

4. Maintain the hydraulic oil temperature at 55±5°C

dCAUTION: Do not perform measurement in

1. Measure in each mode (first speed to fourth speed).

2. Select the switches as follows.

3. Set the forward/reverse lever to the F (forward)

4. Measure the travel speed (sec) of each travel mode.

5. Repeat the measurement three times and calculate

6. Convert the measurement value to be expressed in

Evaluation: 1- Machine Speed Sensor

Service Brake Function Check

3. Empty the bucket and hold the lift arm with it

4. Maintain the hydraulic oil temperature at 55±5°C

dCAUTION: Do not perform measurement in

2. Select the switches as follows.

3. Set the forward/reverse lever to the F (forward)

4. Release the accelerator pedal and step on the right

5. Measure the distance from the brake starting point

6. Repeat the measurement three times and calculate

Service Brake Wear Amount

Check the extent of wear of the brake disc at the

2. In case of the rear axle, inspection plug (1) is located

2. Insert wear gauge (2) into inspection port (7) until it

1. In case wear gauge (2) has entered between brake

2. In the method above, in case the wear amount is