Arıza Giderme PDF

93215-00602
95Z7
January 2017
SHOP MANUAL
SHOP MANUAL
WHEEL LOADER
Troubleshooting
Operational Performance Test
95Z7
Operational Performance Test

Troubleshooting
93215-00602
Powered by ISUZU 6WG1 ENGINE
Serial No. 97J1-0101 and up

97J1-5001 and up
©2017 KCM Corporation. All rights reserved. Printed in Japan (K)
（アメリカ・オセアニア用）
93215-00602
SECTION 4 OPERATIONAL
SECTION AND GROUP PERFORMANCE TEST
CONTENTS Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
SHOP MANUAL
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.
(Blank)
INTRODUCTION
To The Reader
This manual is written for trained and skilled technicians

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 and Kawasaki Shop Manual, etc.) in addition to
this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
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 engine,
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:
 Shop Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual (disassembly and 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 d CAUTION:
Indicated potentially hazardous situation which could, if
for personal injury or machine damage.
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.
Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed
instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention to
component/part weights. f NOTE:
Indicates supplementary technical information.
To avoid injury and damage, be sure to use appropriate
lifting techniques and equipment when lifting heavy
parts.
Units Used
SI Units (International System of Units) are used in this Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
manual. MKSA (Meter, Kilogram, Second, Ampere) system
units and English units are also indicated in parentheses A table for conversion from SI units to other system units
just behind SI units. is shown below for reference purposes.
Quantity To Convert From Into Multiply By

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

different from the above-mentioned table.
IN-02
SECTION 4
OPERATIONAL PERFORMANCE TEST

CONTENTS
Group 1 Introduction Group 5 Component Test

Operational Performance Tests...................................... T4-1-1 Primary Pilot Pressure
Preparation for Performance Tests ............................... T4-1-2 (Unloader Valve Setting Pressure) ........................... T4-5-1
Secondary Pilot Pressure .................................................. T4-5-3
Solenoid Valve Set Pressure ............................................ T4-5-4
Group 2 Standard Main Pump Delivery Pressure......................................... T4-5-7
Operational Performance Standard Table ................. T4-2-1 Loading Circuit Main Relief Set Pressure .................... T4-5-8
Sensor Activating Range ................................................T4-2-10 Main Relief Valve Pressure Adjustment
Procedure .................................................................... T4-5-9
Group 3 Engine Test Steering Circuit Main Relief Set Pressure..................T4-5-10
Engine Speed ....................................................................... T4-3-1 Steering Relief Valve (1) Pressure Adjustment
Procedure ..................................................................T4-5-11
Loading/Steering Overload Relief Valve Set
Group 4 Machine Performance Test Pressure......................................................................T4-5-12
Travel Speed ......................................................................... T4-4-1 Service Brake Pressure (Front and Rear) ..................T4-5-16
Service Brake Function Check ........................................ T4-4-4 Parking Brake Pressure ....................................................T4-5-18
Service Brake Wear Amount............................................ T4-4-6 Brake Accumulator Pressure ........................................T4-5-20
Parking Brake Function Check ....................................... T4-4-7 Accumulator Pressure ................................................T4-5-21
Bucket Stopper, Lever (Bell Crank) Stopper Number of Brake Pedal Applications ...................T4-5-21
Clearance .......................................................................... T4-4-8 Accumulator Charge Time........................................T4-5-21
Hydraulic Cylinder Cycle Time ......................................T4-4-10 Brake Warning Pressure (Pressure-Decreasing) .....T4-5-22
Cylinder Drift Check .........................................................T4-4-12 Brake Warning Pressure (Pressure-Increasing) .......T4-5-24
Bucket Levelness ...............................................................T4-4-13 Transmission Clutch Pressure .......................................T4-5-26
Control Lever Operating Force.....................................T4-4-14 Transmission Clutch Pack Combination ..............T4-5-27
Control Lever Stroke ........................................................T4-4-16 Torque Converter Pressure ............................................T4-5-28
Group 6 Adjustment
Rewrite of Exhaust Filter Serial No. ............................... T4-6-1
Maintenance of Exhaust Filter ........................................ T4-6-2
Measuring Method of No-Load-Max Differential
Pressure ............................................................................. T4-6-3
Zero-Point Calibration (Correction) .............................. T4-6-5
95Z7 Performance Test

(Blank)
95Z7 Performance Test

SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
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
Group 1 Introduction
Preparation for Performance Tests

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

1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 200 m (656 ft 2 in), and to make
the steering operate.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
4. Prepare the measuring instruments and tools. Use
MPDr. if possible.
PRECAUTIONS
1. Before starting to test, agree upon the signals to be
employed for communication among coworkers.
Once the test is started, be sure to communicate
with each other using these signals, and to follow
them without fail.
2. Operate the machine carefully and always give first
priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
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: Fully Applied
procedures.  Power Mode Switch: ON
Values indicated in parentheses are reference values.  Hydraulic Oil Temperature: 55±5°C (131±9 °F)
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) 850±50 Value indicated on MPDr.
High Idle Speed (without load) 1950±50 Value indicated on MPDr.
High Idle Speed (with torque 1700±100 Second- speed forward,
converter stalled) Value indicated on MPDr.
High Idle Speed (with torque 1540±100 Third- speed forward, Value
converter stalled and relieved) indicated on MPDr.
*Engine Speed min-1 Power mode switch: ON T4-3-1
Low Idle Speed (without load) 850±50 Value indicated on MPDr.
High Idle Speed (without load) 1950±50 Value indicated on MPDr.
High Idle Speed (with torque 1875±100 Second- speed forward,
converter stalled) Value indicated on MPDr.
High Idle Speed (with torque 1540±100 Third- speed forward, Value
converter stalled and relieved) indicated on MPDr.
Engine Compression Pressure MPa (kgf/cm2) 2.94 (30.0) (426) Engine speed: 200 min-1 Refer to
(psi) Coolant temperature: 20°C Engine Manual
(68°F)
Valve Clearance (In, Ex) mm (in) 0.4 (0.0157) With the engine cold Refer to
Engine Manual
fNOTE: *Engine speed should be tested under the following conditions. Refer to Group 3 Engine Test.
Coolant temperature: 80°C (176°F) or higher
Torque converter oil temperature: 60~80°C (140~176°F)
Hydraulic oil temperature: 50°C (122°F) or higher
Axle oil temperature: 60°C (140°F) or higher
Fan revolution speed: Max.
Parking brake: Applied (ON)
Forward/Reverse Lever and Switch: Forward (F)
T4-2-1
Group 2 Standard

Standard Page
*Travel Speed km/h (mph) Power mode switch: OFF T4-4-1
First Speed 6±1 (3.7±0.6) Value indicated on MPDr.
Second Speed 11±1 (6.8±0.6) Value indicated on MPDr.
Third Speed 19±2 (11.8±1.2) Value indicated on MPDr.
Fourth Speed (Forward Only) 35±4 (21.7±2.5) Value indicated on MPDr.
*Travel Speed km/h (mph) Power mode switch: ON T4-4-1
First Speed 6±1 (3.7±0.6) Value indicated on MPDr.
Second Speed 11±1 (6.8±0.6) Value indicated on MPDr.
Third Speed 19±2 (11.8±1.2) Value indicated on MPDr.
Fourth Speed (Forward Only) 35±4 (21.7±2.5) Value indicated on MPDr.
Service Brake Function Check m (yd) 12 (13) or less Machine speed: 35±3 km/h T4-4-4
(21.7±1.9 mph)
Service Brake Wear Amount mm (in) T4-4-6
Brake Disc 7.2 (0.28) Allowable limit: 6.1 (0.24)
Brake Ring (t=7.0) 7.0 (0.27) Allowable limit: 6.4 (0.25)
Parking Brake Function Check mm (in)/5 min 0 T4-4-7
Parking Brake Wear Amount mm (in) -
Brake Disc 7.4 (0.291) Allowable limit: 7.2 (0.283)
Brake Plate 5.0 (0.197) Allowable limit: 4.8 (0.189)
Bucket Stopper Clearance mm (in) 5±2 (0.2±0.08) T4-4-8
Bell Crank (Lever) Stopper Clearance mm (in) 0 T4-4-8
Front Pin Wear Amount mm (in) - Allowable limit: -1.0 (-0.04) -
Front Bushing Wear Amount mm (in) - Allowable limit: -1.5 (-0.06) -
Clearance Between Front Pin and mm (in) 0.3 (0.01) -
Bushing
fNOTE: *Travel speed should be tested under the following conditions. Refer to Group 4 Machine Performance Test.
Coolant temperature: 80°C (176°F) or higher
Torque converter oil temperature: 60~80°C (140~176°F)
Hydraulic oil temperature: 50°C (122°F) or higher
Axle oil temperature: 60°C (140°F) or higher
Fan revolution speed: Max.
T4-2-2
Group 2 Standard

Standard Page
Hydraulic Cylinder Cycle Time sec Power mode switch: OFF T4-4-10
Lift Arm Raise 6.8±0.3
Lift Arm Lower (Float) 4.5±0.3
Bucket Dump 1.2±0.3
Steering (engine: low idle speed) 3.6±0.3
Steering (engine: high idle speed) 3.0±0.4
Hydraulic Cylinder Cycle Time sec Power mode switch: ON T4-4-10
Lift Arm Raise 6.3±0.3 Parking brake switch: ON
Lift Arm Lower (Float) 4.5±0.3 Shift lever position: N
Bucket Dump 1.2±0.3
Steering (engine: low idle speed) 3.6±0.3
Steering (engine: high idle speed) 3.0±0.4
Cylinder Drift Check mm (in)/min T4-4-12
Lift Arm Cylinder 3 (0.12) or less
Bucket Cylinder 4 (0.16) or less
Bucket Levelness mm (in) 30 (1.18) or less T4-4-13
T4-2-3
Group 2 Standard

Standard 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 (3.6) (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 (3.6) (8.1) or less
Bucket Control Lever Roll Back 11 (1.1) (2.5) or less
(Detent)
(Detent Release)
Bucket Control Lever Dump 16 (1.6) (3.6) or less
Steering 19.6 (2.0) (4.4) or
less
Forward/Reverse Lever 12+3-2 (1.2+0.3-0.2)
(2.7+0.7-0.4)
Accelerator Pedal 40±2 (4.0±0.2)
(9.0±0.4)
Brake Pedal (Right) 291+35-30 (29.7+3.6-3.1)
(65.4+7.9-6.7)
Declutch Pedal (Left) 281±30 (28.7±3.1)
(63.2±6.7)
T4-2-4
Group 2 Standard

Standard Page
Control Lever Operating Force N (kgf ) (lbf ) MF (Joystick type) lever T4-4-14
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
(Detent)
Bucket Control Lever Roll Back 50 (5.0) (11.2) or
(Detent Release) less
Bucket Control Lever Dump 30 (3.0) (6.7) or less
Steering 16 (1.6) (3.6) or less
Forward/Reverse Lever 12+3-2 (1.2+0.3-0.2)
(2.7+0.7-0.4)
Accelerator Pedal 40±2 (4.0±0.2)
(9.0±0.4)
Brake Pedal (Right) 291+35-30 (29.7+3.6-3.1)
(65.4+7.9-6.7)
Declutch Pedal (Left) 281±30 (28.7±3.1)
(63.2±6.7)
fNOTE: MF: Multi-Function
T4-2-5
Group 2 Standard

Standard Page
Control Lever Stroke mm (in) Two-lever T4-4-16
Lift Arm Raise 42±5 (1.7±0.2)
Lift Arm Raise (Detent) 65±5 (2.6±0.2)
Lift Arm Lower 32±5 (1.3±0.2)
Lift Arm Lower (Float) 55±5 (2.2±0.2)
Bucket Control Lever Roll Back 42±5 (1.7±0.2)
(Detent)
Bucket Control Lever Dump 55±5 (2.2±0.2)
Steering Wheel Rotation 4 to 5 (0.16 to 0.20)
(Right 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 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)
(Detent)
Bucket Control Lever Dump 79±10 (3.1±0.4)
Steering Wheel Rotation 4 to 5 (0.16 to 0.20)
(Right Max. to Left Max.)
Forward/Reverse Lever 50±5 (1.7±0.2)
Steering Wheel Play 5 to 15 (0.2 to 0.6)
Brake Pedal Application 35 to 45
(1.38 to 1.77)
fNOTE: MF: Multi-Function
T4-2-6
Group 2 Standard
Performance Test Designation Unit Performance Standard Remarks Reference

Page
Pedal Depressing Angle deg. (without play) T4-4-16
Accelerator Pedal 18±1
Brake Pedal (Right) 17.2±1.5
Declutch Pedal (Left) 15.1±1.5
Electrolyte Density 1.28 -
(Specification at 20°C (68°F))
Tire Inflation kPa (kgf/cm2) -
(psi)
Bias Tire Front: 539 (5.5) (78) 29.5-25-28PR
Rear: 441 (4.5) (64)
Radial Tire Front: 490 (5.0) (71) 29.5R25
Rear: 392 (4.0) (57)
T4-2-7
Group 2 Standard

Standard Page
Unloader Valve Setting Pressure MPa (kgf/cm2) T4-5-1
(engine: low idle speed) (psi)
Cut-out Pressure 11.8±0.5 (120±5)
(1711±73)
Cut-in Pressure 6.9±0.5 (70±5)
(1000±73)
Secondary Pilot Pressure MPa (kgf/cm2) 3.5±0.5 (36±5) T4-5-3
(psi) (508±73)
Solenoid Valve Set Pressure MPa (kgf/cm2) T4-5-4
(psi)
Parallel/Tandem Switching 3.5±0.2 (36±2)
Solenoid Valve (508±29)
Auto Brake Solenoid Valve 0.84±0.1 (8.6±1)
(122±15)
Main Pump Delivery Pressure MPa (kgf/cm2) 4.0+1.0-0.5 (41+10-5) In neutral, Value indicated T4-5-7
(psi) (580+145-73) on MPDr.
Loading Circuit Main Relief Set MPa (kgf/cm2) T4-5-8
Pressure (psi)
Relief Operation of Lift Arm 31.4±0.5 (320±5) Value indicated on MPDr.
(4554±73)
Relief Operation of Bucket 31.4±0.5 (320±5) Value indicated on MPDr.
(4554±73)
Steering Circuit Main Relief Set MPa (kgf/cm2) 27.4±0.5 (279±5) Value indicated on MPDr. T4-5-10
Pressure (psi) (3974±73)
Steering Accumulator N2 Charging MPa (kgf/cm2) 5.0 (51) (725)
Pressure (psi)
Overload Relief Valve Set Pressure MPa (kgf/cm2) Reference values at 50 L/ T4-5-12
(psi) min
Lift Arm Lower 37.3±0.5 (380±5)
(5410±73)
Bucket 37.3±0.5 (380±5)
(5410±73)
Steering 32.5±0.5 (331±5)
(4714±73)
Service Brake Pressure (Front/Rear) MPa (kgf/cm2) 3.96±0.3 (40.4±3.1) T4-5-16
(psi) (574±43.5)
Parking Brake Pressure MPa (kgf/cm2) 3.0 to 3.7 (31 to 38) T4-5-18
(psi) (435 to 537)
T4-2-8
Group 2 Standard

Standard Page
Service Brake Accumulator Pressure T4-5-20
Accumulator Pressure MPa (kgf/cm2) 11.8±0.5 (120±5)
(psi) (1711±73)
Accumulator Charge Time sec 15 or less
Number of Brake Pedal at least 3 times
Applications
Accumulator N2 Charging Pressure MPa (kgf/cm2) 2.94±0.1 (30±1)
(psi) (426±14)
Brake Warning Pressure MPa (kgf/cm2) 3.9±0.5 (40±5) T4-5-22
(Pressure-Decreasing) (psi) (566±73)
Brake Warning Pressure MPa (kgf/cm2) 4.4±0.5 (45±5) T4-5-24
(Pressure-Increasing) (psi) (638±73)
Transmission Clutch Pressure MPa (kgf/cm2) T4-5-26
(psi)
1st, Lock-up 2.3 to 2.7 (23.5 to
27.5) (336 to 392)
R, 2nd, 3rd, H, L 2.5 to 3.0 (25.5 to
30.6) (363 to 435)
Torque Converter Pressure MPa (kgf/cm2) T4-5-28
(psi)
Input Pressure 0.8±0.1 (8±1)
(116±14.5)
Output Pressure 0.6±0.1 (6±1)
(87±14.5)
T4-2-9
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 ON
Speed
• Monitor each sensor by using MPDr.
2. Sensor Activating Range
Item Operation Specification

Pump Delivery Pressure Neutral MPa (kgf/cm2) (psi) 3.5 to 5.0 (36 to 51) (508 to 725)
Relieved MPa (kgf/cm2) (psi) 30.9 to 31.9 (315 to 325)
(4482 to 4627)
Implement Pressure Neutral MPa (kgf/cm2) (psi) 3.5 to 5.0 (36 to 51) (508 to 725)
Implement Lever: Relieved MPa (kgf/cm2) (psi) 30.9 to 31.9 (315 to 325)
(4482 to 4627)
Parking Brake Pressure Parking Brake Switch: ON MPa (kgf/cm2) (psi) 0 to 1.7 (0 to 17.3) (0 to 247)
Parking Brake Switch: OFF MPa (kgf/cm2) (psi) 2.0 to 3.7 (20.4 to 37.7) (290 to 537)
Service Brake Pressure Brake Pedal: Neutral MPa (kgf/cm2) (psi) 0 to 0.1 (0 to 1) (0 to 14.5)
Brake Pedal: Fully Depressed MPa (kgf/cm2) (psi) 3.7 to 4.3 (37.7 to 43.8) (537 to 624)
T4-2-10
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 is
80 °C (176 °F) or higher, axle oil temperature 60 °C
(140 °F) or higher, hydraulic oil temperature 50 °C
(122 °F) or higher, and transmission oil temperature
falls within 60°C (140°F) to 80 °C (176 °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 Control Lever

Switch (Bucket) (Lift Arm (Boom))
Low Idle Speed OFF - Transporting Transporting
(with no load) position, No control position, No control
lever operation lever operation
High Idle Speed OFF Full stroke Transporting Transporting
(with no load) position, No control position, No control
lever operation lever operation
High Idle Speed OFF Full stroke Transporting Transporting
(with torque converter position, No control position, No control
stalled) lever operation lever operation
High Idle Speed OFF Full stroke Transporting In horizontal position
(with torque converter position, Bucket or raised higher
stalled and relieved) is rolled back and
relieved.
Evaluation:
Refer to Operational Performance Standard (p.T4-2-1).
Remedy:
Refer to Troubleshooting B.
f NOTE: Engine System Troubleshooting (T5-6-28).
T4-3-2
Travel Speed
Summary:
1. Measure the time required for the machine to travel
a 50 m (164 ft) test track and check the performance
of the travel drive system (torque converter to
transmission).
Preparation:
1. Adjust air pressure of the tires in advance.
 Radial Tire (29.5R25):

Front: 471~490 kPa (4.8~5.0 kgf/cm2) (68~71 psi)
Rear: 373~392 kPa (3.8~4.0 kgf/cm2) (54~57 psi)
 Bias Tire (29.5-25-28PR):

Rear 422~441 kPa (4.3~4.5 kgf/cm2) (61~64 psi) 95T4GB-04-04-01
2. Provide a flat, solid test track 50 m (164 ft) in length,

a- 550 mm (1.8 ft) d- End
with extra length of 70 m (230 ft) on both ends b- Test Track e- Start
for machine acceleration and deceleration. (For c- Acceleration/Deceleration
measurement at fourth speed, a 300 m (984 ft) Zone
acceleration zone is needed.)
3. Empty the bucket and hold the lift arm with it
floated 550 mm (1.8 ft) 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 Accelerator Pedal Power Mode

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

position. Start traveling the machine in the
acceleration zone with the accelerator pedal
depressed to the stroke end.
4. Measure the travel speed (sec) of each travel mode.
5. Repeat the measurement three times and calculate
the mean values.
6. Convert the measurement value to be expressed in
km/h.
Measurement value (seconds) = S (sec)
Converted value (hourly speed) = A (km/h)
A = (50×3600)/(S×1000)
Evaluation:
Remedy:
1
f NOTE: Travel System Troubleshooting (p.T5-6-39) 95Z7-04-04-01
1- Machine Speed Sensor
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.
 Radial Tire (29.5R25):

Rear: 373~392 kPa (3.8~4.0 kgf/cm2) (54~57 psi)
 Bias Tire (29.5-25-28PR):

Rear 422~441 kPa (4.3~4.5 kgf/cm2) (61~64 psi)
2. On a paved dry road, prepare a 150 m (492

ft) straight travel course (a 100 m (328 ft) of
acceleration zone and a 50 m (164 ft) of test track) 95T4GB-04-04-02
and set the brake starting point.
a- 550 mm (1.8 ft)
3. Empty the bucket and hold the lift arm with it b- Braking Distance
floated 550 mm (1.8 ft) above the ground. c- Stop Position
d- Brake Starting Point
T4-4-4
Measurement:
dCAUTION: Do not perform measurement in

reverse travel to avoid accident.
1. Measure in high-speed mode.
2. Select the switches as follows.
Shift Switch Parking Brake Accelerator Pedal Power Mode Declutch Position
Switch Switch Switch
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.T5-6-42)
T4-4-5
Service Brake Wear Amount

Summary:
1. Check the wear of the service brake discs in the axle
by using slide calipers.
Preparation:
1. Clean around inspection plug (1) of the axle and
remove it.
Measurement:
95T4GB-04-04-04
1. Operate the service brake by stepping on the brake
pedal.
2. Insert calipers (2) into the inspection hole to
measure the dimension A between the edge
of brake housing (4) and piston (5) which fits
separation disc (6).
Evaluation:
The limit for dimension A is 48.3 mm (1.9 in).
Note that dimension A is 44.8 mm (1.76 in) when the
brake discs (6, 7) are new and unused.
95T4GB-04-04-06
1- Plug (of Inspection Hole) 5- Piston

2- Slide Calipers 6- Separation Disc
3- Axle Housing 7- Friction Disc
4- Brake Housing
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
floated 550 mm (1.8 ft) above the ground.
95T4GB-04-04-03
Measurement:
a- 550 mm (1.8 ft)
1. Climb the slope and set the parking brake switch to b- 11.3° (20%)
the ON position.
2. Stop the engine.
3. Put a mark (white line) on each tire and the road
surface respectively.
4. After five minutes, 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
Summary:
1. Measure wear and deformation conditions of the
bucket stopper (cross pipe side and roll back side)
and the clearance between bucket dump stopper
and lift arm.
Preparation:
1. Stop the machine on a plane road surface and apply
the parking brake.
a
Measurement: b
 Bucket Dump Stoppers (a, b)
1. Raise the lift arm to the highest lifting position and
stop the engine.
2. Dump the bucket calmly with the engine stopped
until the lever contacts cross pipe side stopper (b).
At this time, measure strokes (A and B) of the bucket
cylinder and the lift arm and dump angle (C) of the
bucket. In addition, measure the clearance between
bucket dump stopper (a) and the lift arm.
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)
T4GB-04-04-008
becomes the length of the standard dimension.
2. Set the engine at idling speed and roll back the a- Bucket Dump Stopper b- Cross Pipe Dump Stopper
bucket calmly until it contacts bucket roll back
stopper (c).
3. At this time, measure strokes (D and E) of the bucket
cylinder and the lift arm cylinder and roll back angle
(F) of the bucket. In addition, measure height (G)
from the ground to the center of bucket hinge pin. c
4. At the same time, measure the contact condition of

bucket roll back stopper (c) (left and right).
90T4GB-04-04-10
c- Bucket Roll Back Stopper
T4-4-8
Evaluation:
1. Bucket Dump Stopper 2. Bucket Roll Back Stopper
 Cylinder Strokes (A and B) (Reference)  Cylinder Strokes (D and E) (Reference)
Bucket Cylinder (A) Lift Arm Cylinder (B) Bucket Cylinder (D) Lift Arm Cylinder (E)
(mm (in)) (mm (in)) (mm (in)) (mm (in))
361±2 (14.2±0.08) 1285±2 (50.6±0.08) 791±2 (31.1±0.08) 294±2 (11.6±0.08)
 Bucket Dump Angle (C)  Bucket Roll Back Angle (F)
C (deg.) F (deg.)
47 to 50 39 to 41
 Clearance between Cross Pipe Dump Stopper and  Height from Ground to Bucket Hinge Pin (G)
Lever (b) (With 29.5R25 tires)
Clearance between Stopper and Lever G (mm (in))

Standard 0 (Even contact both sides) 270 (10.6)
 Clearance between Bucket Dump Stopper and Lift  Clearance between Bucket Roll Back Stopper and Lift
Arm (a) Arm (c)
Clearance between Stopper and Lift Clearance between Stopper and Lift
Arm Arm
Standard 5±2 (0.2±0.08) Standard 0 (Even contact both sides)
fNOTE:
Standard dimensions indicate those with new tires
(standard) at the specified air pressure.
When installing roll-back stoppers, the stoppers must
have a smooth radius and must contact lift arm on
both sides. The bucket cylinder must retain 3~5 mm of
rod within the cylinders so the piston does not hit the
cylinder head.
T4-4-9
Hydraulic Cylinder Cycle Time Lift Arm Cylinder:

(Raising)
Summary:
1. Measure the operating time of cylinders for
the lift arm, bucket, and steering and check the
performance of the cylinder drive system (main
pump to each cylinder).
2. The bucket should be empty.
T4GB-04-04-016
Preparation:
1. Measurement is made for the following positions.
(Lowering)
 Measurement of Lift Arm Cylinder (Raising)
Fully roll back the bucket and lower the lift arm.
 Measurement of Lift Arm Cylinder (Lowering)
Lower the lift arm until the bucket bottom surface
touches the ground horizontally.
 Measurement of Bucket Cylinder
Lift the lift arm to the highest position.
 Measurement of Steering Cylinder
Empty the bucket and take the travel forward T487-04-03-005
position.
(131±9°F). Bucket Cylinder:
dCAUTION: Select ground filled with sand or

something so that the bucket contacts the ground
with buffer.
T487-04-03-006
Travel Position
95Z7-4-1
A- 550 mm (1.8 ft)
T4-4-10
Measurement:
1. Set the pedal, switches, and forward/reverse lever as
follows.
Accelerator Pedal Parking Brake Forward/ Power Mode

Switch Reverse Lever Switch
Lift Arm (Raising) Full stroke (engine: 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 roll-back 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-
6-33)
T4-4-11
Cylinder Drift Check

Summary:
1. Measure cylinder natural 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 9520 kg (20990
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
(rolling back).
(131±9°F).
Measurement:
1. Stop the engine.
2. In 15 minutes after the engine has been stopped,
measure the change in position of lift arm cylinder
(2), bucket cylinder (1), and bottom of the bucket. 90T4GB-04-04-14
3. Repeat the measurement three times and calculate a- Drift Amount

the mean values.
Evaluation:
Drift amount: Lfit arm: 3 mm (0.12 in) or less
Bucket: 4 mm (0.16 in) or less
Remedy: B
Refer to Troubleshooting B. A
f NOTE: Front Attachment System Troubleshooting (p.T5- T4GB-04-04-015

6-33)
T4-4-12
Bucket Levelness
Summary:
1. Check left and right inclinations of the bucket.
Preparation:
1. Place the unloaded machine on a level platen on
the ground. (In case a platen 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
all evenly.
3. Lower the bucket onto the ground in the horizontal
position.
1
Measurement:
T4GB-04-04-011
dCAUTION: Never put hands, feet, and measuring
instruments under the bucket.
1. Float the bucket bottom slightly above the platen.
2. Measure the vertical distance from the platen and
the bottom surface of cutting edge (1) on the left
and right ends, and confirm the difference.
the mean values.
Evaluation:
Drift amount: 30 mm (1.18 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
lever, pedal, and steering wheel. Travel Position
3. Measure at the grip center of each control lever.

Measure at 150 mm (6 in) from the pedal support of
each pedal.
Preparation:
1. In the front position, empty the bucket in advance. A
95Z7-4-1
(131±9°F).
A- 550 mm (1.8 ft)
T4-4-14
Measurement:
1. Measure for each control lever, pedal, and steering
wheel.
2. Set the pedal, switches, and forward/reverse lever as
follows.
Accelerator Pedal Parking Brake Forward/

Switch Reverse 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
measurement.
1
3. Attach a spring balance scale (tension type) onto
each of the lift arm, bucket, and forward/reverse
lever. Measure the maximum operating force by
operating them to the stroke end.
4. In case of the pedals, attach a spring balance
scale (compression type) or a load cell onto them.
Measure the operating force when they are stepped
slightly.
5. In case of the steering wheel, attach a spring
balance scale (tension type) onto knob (1).
Measure the maximum operating force when it is MNEC-01-036
3 2
moved.
1- Knob 3- Brake Pedal
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 and run at 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.
the mean values.
Evaluation:
T4-4-16
Primary Pilot Pressure (Unloader Valve

Setting Pressure)
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 1
after removing and installing the pipe lines and
replacing hydraulic oil. (Refer to Troubleshooting
B.)
IMPORTANT: Primary pilot pressure circuit delivers

pressure oil from the accessory pump to the brake
circuit when pressure in service brake accumulator
(1) decreases, and accumulates pressure in service
brake accumulator (1). Therefore, the brake circuit
pressure is higher than the pilot circuit pressure. 3
Use a pressure gauge capable of measuring 11.8
MPa (120 kgf/cm2) (1710 psi) or higher.
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil 95TNED-04-05-01
tank and bleed air.
3. Remove plug (2) on the reducing valve (3). Install
the pressure gauge to the port. 2
3
fNOTE: Plug (4) can also be used for the measurement.
4
4. Start the engine and keep the speed at low idle.
Confirm that no oil leakage is observed at the
pressure gauge connection.
5. Maintain the hydraulic oil temperature at 55±5°C 3
(131±9°F).
95TNED-04-05-02
1- Brake Accumulators 3- Reducing Valve (for Brake Oil

2- Plug (G1/4) Pressure)
4- Plug (G3/8)
T4-5-1
Measurement:
1. Select the following conditions:
Accelerator Power Mode Parking Forward/

Pedal Switch Brake Reverse
Switch Lever
Full stroke ON ON N
2. Measure the pressure 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 value.
fNOTE: When pressure in the service brake accumulator

decreases during measurement of primary pilot pressure,
the measured value increases to around 11.8 MPa (120
kgf/cm2) (1710 psi) for several seconds.
Evaluation:
 Cut-in Pressure: 6.9±0.5 MPa (1000±73 PSI)
 Cut-out Pressure: 11.8±0.5 MPa (1711±73 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.
T4-5-2
Secondary Pilot Pressure

Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove plug (5) on the manifold block of
combination valve (6). Install the pressure gauge to
the port.
4. Start the engine. Confirm that no oil leakage is
6
observed at the pressure gauge connection.
(131±9°F).
Measurement:
1. Select the following conditions:
Accelerator Power Mode Parking Forward/ 95TNED-04-05-01

Pedal Switch Brake Reverse
Switch Lever
Full stroke ON ON N
2. Measure the pressure with no load. 6

5
3. Read and record the pressures on the pressure
gauge.
the mean value.
95TNED-04-05-03
Evaluation:
5- Plug (Z1) (G1/4) 6- Combination Valve
Standard. 3.5±0.5 MPa (508±73 PSI) (Manifold Block)
Remedy:
Refer to Troubleshooting A for any accompanied error
code.
Refer to Troubleshooting B for observed phenomena.
fNOTE: All Actuator System Troubleshooting (p.T5-6-30)

Front Attachment System Troubleshooting (p.T5-6-33)
Steering System Troubleshooting (p.T5-6-37)
Brake System Troubleshooting (p.T5-6-42)
T4-5-3
Solenoid Valve Set Pressure 1
2
- Parallel/Tandem Switching Solenoid Valve (3)
3
Preparation:
1. Stop the engine.
2. Push air bleed valve (1) on top of hydraulic oil tank
(2) and bleed air.
3. Connect MPDr. and select the monitoring function.
4. Disconnect the hose from the SJ port and install
a pressure gauge to the port. Additional parts
installation, such as hose, tee, or adapter, as shown
is suggested for easier connection of the pressure 95TNED-04-05-04
gauge.
4 3
(131±9°F).
Measurement:
1. Set the following conditions:
Accelerator Pedal Power Mode Switch

95TNED-03-11-01
Full stroke ON
3
2. Perform combined operation of lift arm raise and
bucket fully roll back. 5
3. Read the values on both MPDr. and the pressure
gauge.
the mean values.
Evaluation:
8 7 6
Standard: 3.5±0.2 MPa (508±29 PSI)
T157-05-04-002
1- Air Bleeder Valve 5- Pressure Gauge
2- Hydraulic Oil Tank 6- Adapter
3- Solenoid Valve Unit (for 7- Tee
Parallel/Tandem Switching) 8- Hose
4- Solenoid Valve Unit (for Auto
Brake)
T4-5-4
- Auto Brake Solenoid Valve (4) 1
Preparation: 2
1. Stop the engine.
4
2. Push air bleed valve (1) on top of hydraulic oil tank
(2) and bleed air.
3. Connect MPDr.
4. Install a pressure gauge to the SA port.
5. Disconnect the solenoid harness from parallel/
tandem switching solenoid (9), and connect it to
auto brake solenoid (10) to supply power to the
auto brake solenoid. 95Z7-04-05-04
6. Start the engine. Confirm that no oil leakage is 10 9
(131±9°F). 4
Measurement:

Full stroke ON
2. Perform combined operation of lift arm raise and 95TNED-03-11-01

bucket fully roll back.
1- Air Bleeder Valve 9- Solenoid Connector (for
3. Read the value on the pressure gauge.
2- Hydraulic Oil Tank Parallel/Tandem Switching)
4. Repeat the measurement three times and calculate 4- Solenoid Valve Unit (for Auto 10- Solenoid Connector (for Auto
the mean value. Brake) Brake)
fNOTE:
The pressure measured at the SA port maybe unstable
in the beginning due to the circuit feature. Wait until it
becomes stable.
If the auto brake solenoid does not operate without
the disconnection error, the MC may be defective .
Evaluation:
T4-5-5
Solenoid Valve Adjustment Procedure 11

13
IMPORTANT: As O-ring (11) is damaged and oil
leakage may cause, do not loosen adjusting screw 12
(12) excessively.
Do not loosen adjusting screw (12) more than 2
turns.
1. Loosen lock nut (13). Turn adjusting screw (12) and

adjust the set pressure.
2. After adjustment, tighten lock nut (13). a

b TDAA-04-05-013
j : 13 mm (0.51 in)
m : 5 N·m (0.5 kgf·m) (3.69 lbf·ft) a- 0.663 mm (0.026 in) b- 2.0 mm (0.079 in)
l : 3 mm (0.12 in) 13 12
3. After adjustment, check the set pressure. 4 3
fNOTE: Standard Change in Pressure (Reference)

Screw Turns 1/4 1/2 3/4 1
Change in kPa 111 222 333 444
Pressure (kgf/cm2) (1.1) (2.3) (3.4) (4.5)
(psi) (16.1) (32.2) (48.3) (64.4)
95TNED-03-11-01
13 12
c d
W107-02-05-129
c- Pressure Increase d- Pressure Decrease
3- Solenoid Valve Unit (for 11- Adjusting Screw

Parallel/Tandem Switching) 12- Lock Nut
4- Solenoid Valve Unit (for Auto 13 O-Ring
Brake)
T4-5-6
Main Pump Delivery Pressure Multiple control valve
Preparation:
1. Stop the engine. Main pump
tank and bleed air.
3. Remove the plug (G1/4) from pressure check port
(1). Install a pressure gauge with an adapter, hose, if
needed.
j : 19 mm (0.75 in)
1
(131±9°F).
Measurement:
1. Set the following conditions: 95T4GB-04-05-08

Pedal Switch Brake Switch Reverse 1- Check Port (G1/4)
Lever
Full stroke ON ON N
2. Measure pressure with the control levers in neutral

without load.
the mean value.
Evaluation:
Standard (neutral): 4.0+1.0-0.5 MPa (580+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.T5-6-30)

Front Attachment System Troubleshooting (p.T5-6-33)
Steering System Troubleshooting (p.T5-6-37)
T4-5-7
Loading Circuit Main Relief Set Pressure

Multiple control valve
Summary:
Measure the main relief set pressure at port (1) in the
Main pump
main pump delivery circuit.
Preparation:
1. Stop the engine.
tank and bleed air.
3. Remove the plug (G1/4) from pressure check port
1
(1). Install an adapter, hose, and the pressure gauge.
j : 19 mm (0.75 in)
5. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).
95T4GB-04-05-08
1- Check Port (G1/4)

Measurement:

Pedal Switch Brake Switch Reverse
Lever
Full stroke ON ON N
2. Operate the bucket or lift arm control levers slowly,

so as to operate each cylinder to the stroke end
(both extend and retract), and relieve each function.
the mean values.
Evaluation:
Standard (relief operation): 31.4±0.5 MPa (4554±73 PSI)
T4-5-8
Main Relief Valve Pressure Adjustment Procedure

1 2
IMPORTANT: Do not loosen screw (4). If erroneously
loosened, refer to NOTE below.
1. Secure adjusting screw (2). Loosen lock nut (1).
j : 32 mm (1.26 in)
2. Turn adjusting screw (2) in order to adjust the relief
3 4
pressure to the specification.
Turning the screw clockwise (direction: a) increases 95T4GB-04-05-10
the pressure.
1- Lock Nut 3- Lock Nut (Not Used)
j : 27 mm (1.06 in) 2- Adjusting Screw 4- Adjusting Screw (Not Used)
3. Secure adjusting screw (2). Tighten lock nut (1).
m : 47 to 61 N·m (4.8 to 6.2 kgf·m)

(34.7 to 45.0 lbf·ft)
4. Check the relief set pressures. 2
Standard Change in Pressure (Reference)

Adjusting Screw (2) 1/4 1/2 3/4 1
Turns a b
Change in MPa 3.23 6.45 9.68 12.9
Pressure (kgf/cm2) 32.9 65.8 98.6 131.5
T105-06-05-002
(psi) 468 936 1403 1871
a- Pressure Increase b- Pressure Decrease
fNOTE: Do not loosen screw (4) for adjustment (not
necessary). If loosened, tighten it fully to the end and
secure lock nut (3) with the following torque.
j : Screw (4): 22 mm (0.87 in)
m : 38 to 50 N·m (3.9 to 5.0 kgf·m)

(28 to 36 lbf·ft)
T4-5-9
Steering Circuit Main Relief Set Pressure

1, 3
Summary:
Measure the steering relief valve set pressure at test
ports (1) at steering cylinder (2) joint adapters to check
performance of the steering relief valve.
Preparation:
1. Stop the engine.
tank and bleed air.
2
3. Remove the plug (G1/4) from test port (1) at the
steering cylinder, and install a pressure gauge.
Additional parts installation, such as hose, tee, or 95Z7OM-7-21-2
adapter, is suggested for easier connection of the
pressure gauge.
l : 6 mm (0.24 in)
2
3
f NOTE: North America equipped machines have fittings
(3) at test ports (1).

observed at the pressure gauge connection. 1

(131±9 °F). 2 1
95Z7-04-05-02
Measurement:
1. Set the following conditions: 1- Steering Relief Pressure 2- Steering Cylinders
Check Port 3- Fitting (USA only)
Lever
Full stroke ON ON N
2. Install the articulation lock bar. Turn the steering

wheel slowly but at 80 rpm or more to relieve the
steering, and measure and record the pressure.
the mean values.
Evaluation:
Standard: 27.4±0.5 MPa (3974±73 PSI)
T4-5-10
Steering Relief Valve (1) Pressure Adjustment

Procedure
1. Loosen lock nut (2).
j : 13 mm (0.51 in)
2. Turn adjusting screw (3) to adjust the relief pressure.
Turning the screw clockwise (direction: a) increases
the pressure.
l : 4 mm (0.16 in)
3. Secure lock nut (2).
m : 17 to 19 N·m (1.7 to 1.9 kgf·m) 1

(12.5 to 14 lbf·ft) 90T4GB-04-05-12
4. Check the relief set pressures.

2
fNOTE: Standard Change in Pressure (Reference)

Adjusting Screw (3) 1/4 1/2 3/4 1
Turns
Change in MPa 3.2 6.4 9.6 12.8
Pressure (kgf/cm2) (32.5) (65) (97.5) (130)
(psi) (464) (928) (1392) (1856)
90T4GB-04-05-13
1- Steering Relief Valve 2- Lock Nut

3- Adjusting Screw
a b
T105-06-05-002
a- Pressure Increase b- Pressure Decrease
T4-5-11
Loading/Steering Overload Relief Valve Set

Pressure
Summary:
Since there is no method to measure the accurate
overload relief valve pressure for the following reasons,
it is recommended to measure the main relief pressure
while releasing each front function respective to the
measuring overload relief valve, when needed.
The overload relief valve function can be assumed as
correct if the obtained main relief pressure is within the
specified value range.
<Reasons>
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.
3. Main relief valve may be designed to leak a small
quantity of oil before reliving. 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.
T4-5-12
Preparation: Multiple control valve

1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil Main pump
tank and bleed air.
3. Install a pressure gauge.

(Loading Circuit)
Remove the plug (G1/4) from pressure check port
(1). Additional parts installation, such as hose, tee,
or adapter, is suggested for easier connection of the 1
pressure gauge.
l : 19 mm (0.75 in)
(Steering Circuit)
Remove the plug (G1/4) from pressure check port
(2).
fNOTE: North America equipped machines have fittings

95T4GB-04-05-08
(3) at test ports (2).
1- Loading Relief Pressure Check

4. Start the engine. Confirm that no oil leakage is Port (G1/4)

(131±9 °F).
3
2
95Z7-04-05-02
2- Steering Relief Pressure 3- Fitting (USA only)

Check Port
T4-5-13
Measurement:
Accelerator Power Mode Parking Brake Forward/

Pedal Switch Switch Reverse
Lever
Full stroke ON ON N
2. For loading circuit, operate the bucket or lift arm

control levers slowly, so as to operate each cylinder
to the stroke end (both extend and retract), and
relieve each function.
For steering circuit, install the articulation lock bar.
Turn the steering wheel slowly but at 80 rpm or
more to relieve the steering.
the mean values.
Evaluation:
Performance of the overload relief valves are normal
if the measured pressure falls within the main relief
normal pressure range.
Standard:
Loading circuit: 37.3±0.5 MPa (5410±73 PSI)
Steering circuit: 32.5±0.5 MPa (4714±73 PSI)
fNOTE: The overload relief pressure values at each port

are given for reference. Refer to page T4-5-12.
T4-5-14
(Blank)
T4-5-15
Service Brake Pressure (Front and Rear)

may occur. Bleed air from the brake system
B.)
Summary:
Measure the pressure at the test port of axle assembly
when 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
2. Push the air bleed valve on top of the hydraulic oil 1

tank and bleed air.
3. Depress brake pedal at least 50 strokes in order to 3
decrease the accumulated pressure left in the brake
circuit. Rear Axle
4. Remove air bleeder screw (2, 3) on the axle
assembly and install a pressure gauge instead.
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.
j : 19 mm (0.75 in)
m : 30 N·m (3.0 kgf·m) (22 lbf·ft)

2
Front Axle
(131±9 °F).
95TNED-04-05-10
2- Air Bleeder Screw (Front 3- Air Bleeder Screw (Rear Axle)

Axle)
T4-5-16
Measurement:

Full stroke ON
2. Measure the pressure when fully depressing the

brake pedal at left side to the floor.
the mean values.
Evaluation:
Standard: 3.96±0.3 MPa (574±43.5 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.
T4-5-17
Parking Brake Pressure

B.)
Summary:
Measure the parking brake release pressure in the
parking brake release circuit.
Preparation: T4GB-04-05-017

1

1. Stop the engine. 5
2. Push air bleed valve (2) on top of the hydraulic oil 2

tank and bleed air.
3. Disconnect parking brake hose (3) and remove
elbow fitting (4) from the combination valve. Install
a pressure gauge to combination valve block (5)
4
directly.
observed at the pressure gauge connection. 3

(131±9 °F).
95M4GB-06-04
2- Air Bleed Valve 5- Combination Valve (Manifold

3- Parking Brake Hose Block)
4- Elbow Fitting
T4-5-18
Measurement:
1. Set the following condition:
Accelerator Pedal
Neutral
2. Release the parking brake and measure the pressure

at this time.
the mean values.
Evaluation:
Standard: 3.0 to 3.7 MPa (435 to 537 PSI)
Remedy:
T4-5-19
Brake Accumulator Pressure

B.)
Summary:
Measure the accumulated brake pressure at the test
port provided in the brake valve. The accumulated
brake pressure varies according to operation of the
brake. Record the maximum level.
To assure the accumulator performance, the following

two tests are recommended.
- Number of brake pedal applications
- Accumulator charge time T4GB-04-05-017
1
Preparation:

tires in order not to move the machine. Keep away A 4
from the front or back of the machine. 3
1. Stop the engine.
tank and bleed air.
3. Depress the brake pedal at least 50 strokes in order
to decrease the accumulated pressure left in the
brake circuit.
4. Install a pressure gauge to brake accumulator (4) 3
pressure measurement ports (G1/4) provided in
fittings (2) mounted to brake valve (3).
observed at the pressure gauge connection. 2 (PF)
6. Maintain the hydraulic oil temperature at 55±5 °C 2 (PR)

(131±9 °F).
Detail of A
95TNED-04-05-09
2- Fitting (at Pressure 3- Brake Valve

Measurement Port) 4- Brake Accumulators
T4-5-20
Accumulator pressure: Number of brake pedal applications:

1. Select the following conditions: 1. After running the engine at high idle for 1 minute,
stop the engine. (Turn the key switch "ON" with
Accelerator Power Mode Parking Forward/ engine off.)
Lever
Full stroke ON ON N 2. Count and verify the number of stepping on the
brake pedal is at least 3 times before the low
pressure alarm indicator turns ON.
2. Measure the pressure when fully depressing the
brake pedal at left side to the floor.
Accumulator charge time:

the mean values. 1. Run the engine at low idle.
2. Measure the time from the low pressure alarm

Evaluation: indicator turns OFF until when the unloader valve
set pressure reaches the cut-out pressure value
Standard: 11.8±0.5 MPa (1711±73 PSI)
(11.8±0.5 MPa (1711±73 PSI)).
Remedy: 3. Verify the time period is 15 seconds or less.

fNOTE: The maximum accumulated brake pressure
should equal to the unloader valve setting value (cut-
out). Refer to Primary Pilot Pressure (Unloader Valve
Setting Pressure) measurement procedure (p.T4-5-1).
T4-5-21
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:

tires in order not to move the machine. Keep away T4GB-04-05-017
1
1. Stop the engine.
2. Push air bleed valve (2) on top of the hydraulic oil
tank and bleed air. 3 4
3. Depress the brake pedal at least 50 strokes in
order to decrease the accumulated pressure left in
accumulator circuit. 2

combination valve (4).
Install a pressure gauge to the port.
(131±9 °F).
95Z7-04-05-01
2- Air Bleeder Valve 4- Combination Valve

3- Plug (Z1) (G1/4) (Manifold Block)
T4-5-22
Measurement:
Forward/Reverse Lever Parking Brake Switch

N ON
2. Stop the engine. Set the key switch to the ON

position.
3. Depress the brake pedal several times. Measure the
pressure when the buzzer sounds.
the mean values.
Evaluation:
Remedy:
T4-5-23
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:

tires in order not to move the machine. Keep away T4GB-04-05-017
1. Stop the engine. 1

tank and bleed air. 3 4
3. Depress the brake pedal at least 50 strokes in

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

combination valve.
Install the pressure gauge to the port.
(131±9 °F).
95Z7-04-05-01
2- Air Bleeder Valve 4- Combination Valve

3- Plug (Z1) (G1/4) (Manifold Block)
T4-5-24
Measurement:
Forward/Reverse Lever Parking Brake Switch

N ON
2. Stop the engine. Set the key switch to the ON

position.
3. Depress the brake pedal several times. Sound the
buzzer.
4. Start the engine. Measure the pressure when the
buzzer stops sounding. Notice that it is difficult to
read the gauge as the pressure increases rapidly.
the mean value.
Evaluation:
Remedy:
T4-5-25
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 : 6 mm (0.24 in)
m : 36 N·m (3.7 kgf/cm2) (26.6 lbf·ft)
fNOTE: Although the pressure can be measured by using

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

1. Set the following conditions: T4GB-04-05-017
1
Accelerator Brake Pedal Power Mode Clutch Cut Parking Brake
Pedal Switch Position Switch Switch
Full stroke Full stroke ON OFF OFF
2. Operate the forward/reverse lever and the shift

switch. Measure each clutch pressure. (As for the
combination of clutch pack, refer to the following
page.)
the mean values.
Evaluation:
1st, lock-up: 2.3~2.7 MPa (336~392 PSI)
R, 2nd, 3rd, H, L: 2.5~3.0 MPa (363~435 PSI)
T4-5-26
95T4GB-04-05-21
Transmission Clutch Pack Combination
Directional Control Clutch Pack Speed Control Clutch Pack

Selected Forward Low Forward Reverse (R) First Speed Second Third Speed Lock Up (LU)
Speed Shift (L) High (H) (1) Speed (2) (3)
F1  
F2  
F2L   
F3  
F3L   
F4  
F4L   
R1  
R2  
R3  
Neutral * * *
fNOTE:
In the neutral position, either clutch with an asterisk
(*) is engaged.
The operating pressure is applied to the clutch with
the mark  when setting the forward/reverse lever
and the shift switch to each selected speed shift.
T4-5-27
Torque Converter Pressure

Summary:
Measure the torque converter input/output pressure at
each sensor port. T4GB-04-05-017
1
Preparation:
1. Stop the engine.
2. Remove the plug (G1/4) from the input pressure test
port (2) and install a pressure gauge to the port.
Remove the plug from the output pressure test port
(3) and install a pressure gauge to the port.
l : 5 mm (0.2 in)
m : 6 N·m (0.6 kgf/cm2) (4.4 lbf·ft)

3
4. Maintain the torque converter oil temperature at 80
to 95 °C (176 to 203 °F). 2 95Z7-04-05-03
2- Torque Converter Input 3- Torque Converter Output

Pressure Test Port Pressure Test Port
Measurement:
Accelerator Brake Pedal Power Mode Clutch Cut Parking Brake

Pedal Switch Position Switch Switch
Full stroke Full stroke ON OFF OFF
2. Set the forward/reverse lever to F (Forward) and

the shift switch to 4 (Fourth Speed). Measure the
pressure.
the mean values.
Evaluation:
Input Pressure: 0.8±0.1 MPa (116±14.5 PSI)
Output Pressure: 0.6±0.1 MPa (87±14.5 PSI)
T4-5-28
Group 6 Adjustment
Rewrite of Exhaust Filter Serial No.

When the exhaust filter (DPF) has been replaced, rewrite 4. Input the following items of Oxidation Catalyst
the serial No. of DPF and upload the DPF replacement (DOC) and Filter.
results to e-Service.
 ASM
 SUB
1. Connect MPDr.
 Serial No.
2. Set the key switch to the ON position. 5. After inputting, select Setting.
IMPORTANT: After finishing DPF serial No. input,
3. Select Functions - Engine/MF (Muffler Filter) - MF upload the data to e-Service.
No.
fNOTE: When the input data is uploaded to e-Service,
the M-Find product specification and history will be
updated.
95Z7-04-06-01
T4-6-1
Group 6 Adjustment
Maintenance of Exhaust Filter

IMPORTANT: When the DPF has been replaced 5. Set or check the DPF serial No. (Refer to the previous
or cleaned, perform Reset all MF Status page.)
Sedimentation Signal Reset in order to reset
Muffler Filter maintenance history on the monitor.
6. Perform Reset all MF Status Sedimentation Signal
Reset (1). (Fig. B)
1. Connect MPDr.
IMPORTANT: After Setting DPF No. and Reset all MF

2. Set the key switch to the ON position. Status Sedimentation Signal Reset are performed,
upload the data to e-Service.
3. Select Functions - Engine/MF (Muffler Filter) - MF
Maintenance.
fNOTE: When the set data is uploaded to e-Service,
the M-Find product specification and history will be
updated.
4. Perform the followings.
Item Content
Change the Setting DPF No.
DOC
Change the Setting DPF No. and Reset all MF Status
Filter Sedimentation Signal Reset
Cleaning Setting DPF No. and Reset all MF Status
Sedimentation Signal Reset
Fig. A Fig. B
TNFA-04-06-05KC 1 TNFA-04-06-06KC
T4-6-2
Group 6 Adjustment
Measuring Method of No-Load-Max

Differential Pressure
Refer to Measurement of No-Load-Max Differential
When ECM fault code 10026, Muffler Filter PM Over- Pressure (Functions-Engine/Muffler Filter) on MPDr.
Restriction is displayed, measure No-Load-Max differential and measure No-Load-Max differential pressure while
pressure and check the exhaust filter condition. After monitoring the following items.
inspection, handle it according to the result.  Coolant Temperature (ECM)
 Actual Engine Speed (ECM)
 Muf/Fltr Inlet EGT (ECM)
 Muf/Fltr EGP DP (ECM)
Measuring Procedure
Step Content Condition Monitoring Item
1 Warm up the machine until coolant temperature reaches 70 °C - Coolant Temperature (ECM)
(158 °F) or more.
2 Return the accelerator pedal (not depressed) and set engine * Actual Engine Speed (ECM)
speed to the slow idle speed.
3 Lower CSF exhaust temperature to 200 °C (392 °F) under the * Muf/Fltr Inlet EGT (ECM)
state at step 2.
4 Depress the accelerator pedal (fully depressed) and set engine ** Actual Engine Speed (ECM)
speed to the fast idle speed.
5 Raise CSF exhaust temperature under the state at step 4. *, Coolant Muf/Fltr Inlet EGT (ECM),
Measure differential pressure (A) when CSF exhaust temperature: Muf/Fltr EGP DP (ECM)
temperature is 220 °C (428 °F). 70 °C (158 °F) or
more
*: Parking Brake: Applied, Front Attachment Control Lever: Not operated, Forward/Reverse Lever: N
**: Parking Brake: Applied, Front Attachment Control Lever: Not operated, Forward/Reverse Lever: F, Power Mode: ON
Timing Chart of No-Load-Max Differential Pressure
1 2 3 4 5
b
a
c
e
d
f
h
g
i
j k
l
n
m
A
t TDAA-04-06-001
A- Measuring Point
a- Coolant Temperature e- Operated j- CSF Exhaust Temperature n- No-Load-Max Differential

b- 70 °C (158 °F) or more f- Not Operated k- 220 °C (428 °F) Pressure
c- Ordinary Temperature g- Engine Speed l- 200 °C (392 °F) t- Time
d- Front Attachment Control h- Fast Idle m- Exhaust Filter Exhaust
Lever Operation i- Slow Idle Differential Pressure
1- Step 1 3- Step 3 5- Step 5

2- Step 2 4- Step 4
T4-6-3
Group 6 Adjustment
Evaluation (Specification of Differential Pressure)

Item Differential Pressure (kPa) Remarks
Condition for Differential Engine speed: 1950 min-1 - -
Pressure Check CSF temperature: 220 °C (428 °F) - -
Differential pressure Exhaust filter 0 5.6 Differential pressure whether
whether has been maintenance (h) 1000 5.6 has been cleaned up after
cleaned up 2000 5.6 completing regeneration.
3000 5.6
4000 5.6
4500 5.6
Regeneration starting Exhaust filter 0 6.5 Regeneration will be done
differential pressure maintenance (h) 1000 6.6 due to differential pressure.
(press3) 2000 6.8
3000 6.9
4000 7.0
4500 7.1
PM over-restriction Exhaust filter 0 8.0 The engine alarm is displayed
differential pressure maintenance (h) 1000 8.2 on the monitor.
(press5) 2000 8.3
3000 8.5
4000 8.7
4500 8.7
Filter replacement Exhaust filter 0 10.0 Allowable limit value.
differential pressure maintenance (h) 1000 10.2
2000 10.4
3000 10.6
4000 10.8
4500 10.9
Remedy
Step Content Evaluation Remedy
1 Measure No-Load-Max differential Less than filter Perform Manual Exhaust Filter Regeneration: Slow
pressure and check the filter replacement Regeneration of Engine Setting on the monitor. Then,
replacement differential pressure. differential pressure change the engine oil.
Filter replacement Replace the filter (CSF).
differential pressure
or more
fNOTE: Manual Exhaust Filter Regeneration: Slow

Regeneration is performed for about two hours.
T4-6-4
Group 6 Adjustment
Zero-Point Calibration (Correction)

< With the engine S/N 6WG1-620733 and thereafter >
Perform Zero-point calibration of the differential

pressure sensor after the following repairs and
inspections.
 When the differential pressure sensor is replaced

 When ECM is replaced
 When the ECM software is rewritten
fNOTE: On the machines with the engine S/N 620732

or before, this calibration is not required. Turn ON the
starter key SW to ON position, wait 30 seconds or more,
then turn the key SW to OFF position.
Zero-Point Calibration
1. Connect MPDr.
2. Set the key switch to the ON position.
3. Select Functions - Engine/MF (Muffler Filter) - MF

Differential Pressure Sensor Learning.
95Z7-04-06-01
T4-6-5
Group 6 Adjustment
4. After confirming that the 4 conditions (1-1 through

1-4) are satisfied, select Start Learning.
fNOTE: When the zero-point calibration is performed

normally, Differential Pressure Calibration Value is
displayed on MPDr.
5. Hold this state for 30 seconds. 95Z7-04-06-02
fNOTE: When operating the key switch during Zero-

point calibration, calibration is interrupted. (Calibration
Failure)
6. When Zero-point calibration is completed normally,

Calibration End is highlighted, and OK is displayed.
fNOTE: Verify that the value of MF Exhaust Differential

Pressure falls within the normal range: +/- 0.15 kPa.
95Z7-04-06-03
fNOTE: When Zero-point calibration is interrupted
(Calibration Failure), NG is displayed with MPDr. Repeat
the procedures from step 3.
T4-6-6
Group 6 Adjustment
7. Press End to complete the calibration program.
8. Set the key switch to the OFF position.
9. Hold this state for 60 seconds or more (until the

ECM main relay is turned OFF).
Calibration Conditions:
 CSF Exhaust Temperature: 100°C (212°F) or lower
 Coolant Temperature: 100°C (212°F) or lower
IMPORTANT: After Zero-point calibration is

completed normally, download the ECM data with
MPDr. In addition, upload the downloaded data to
e-Service.
T4-6-7
Group 6 Adjustment
(Blank)
T4-6-8
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure List of Operation Data ....................................................... T5-3-2

Introduction .......................................................................... T5-1-1 List of Daily Report Data ............................................. T5-3-2
Diagnosis Procedure .......................................................... T5-1-2 List of Frequency Distribution Data ........................ T5-3-4
Electric System Inspection............................................... T5-1-5 List of Total Operating Hours .................................... T5-3-5
Precautions for Inspection and Snapshot Data...................................................................... T5-3-6
Maintenance ................................................................... T5-1-6 Communication System ................................................... T5-3-7
Instructions for
Disconnecting Connectors ........................................ T5-1-8
Main Component (Overview) ......................................... T5-4-1
Fuse Inspection..................................................................T5-1-10
Electric Component Layout (Overview)...................... T5-4-4
Fusible Link Inspection ...................................................T5-1-12
Electrical System (Cab) ...................................................... T5-4-5
Battery Voltage Check .....................................................T5-1-13
Controller and Relays ................................................... T5-4-6
Alternator Check ...............................................................T5-1-14
Right Console.................................................................. T5-4-7
Continuity Check...............................................................T5-1-15
Monitor and Switches .................................................. T5-4-8
Voltage and Current Measurement ............................T5-1-16
Monitor Panel ................................................................. T5-4-9
24-Volt Circuit ...............................................................T5-1-16
Electrical System (Relays)..........................................T5-4-10
5-Volt Circuit ..................................................................T5-1-22
Electrical System (Around Hydraulic
Check by False Signal ......................................................T5-1-23
Oil Tank) .....................................................................T5-4-11
Test Harness ........................................................................T5-1-24
Electrical System (Around Fuel Tank) ...................T5-4-12
Group 2 Monitor Engine ...................................................................................T5-4-13
Outline .................................................................................... T5-2-1 Exhaust Filter .................................................................T5-4-14
Operating Procedures of Service Menu ...................... T5-2-2 Hydraulic Pump ................................................................T5-4-15
How to display service menu .................................... T5-2-3 Main Pump.....................................................................T5-4-15
Troubleshooting .................................................................. T5-2-4 Accessory Pump...........................................................T5-4-16
Monitoring ............................................................................ T5-2-6 Transmission and Torque Converter
List of Monitoring Item................................................ T5-2-8 Assembly ........................................................................T5-4-17
Controller Version .............................................................T5-2-16 Multiple Control Valve .....................................................T5-4-18
Issued Warning Record ...................................................T5-2-17 Unloader Valve (Brake Charge Valve) .........................T5-4-19
List of Alarm...................................................................T5-2-18 Steering Valve.....................................................................T5-4-19
Communication Terminal Status .................................T5-2-22 Combination Valve ...........................................................T5-4-19
List of Communication Terminal Flow Regulator Valve .......................................................T5-4-20
Status ..........................................................................T5-2-23 Secondary Steering Pump (Option) ...........................T5-4-20
Machine Setting ................................................................T5-2-24 Ride Control Valve (Option) ...........................................T5-4-20
List of Machine Setting Item ...................................T5-2-25
Transmission Learning ...............................................T5-2-26
Troubleshooting A (Base Machine Diagnosis
Lift Arm Angle Sensor Learning .............................T5-2-30
By Using Fault Codes) Procedure ............................. T5-5-1
Digging Position Adjustment .................................T5-2-32
MPDr. Fault Code List......................................................... T5-5-3
Muffler Filter No. ................................................................T5-2-34
MC Fault Code List .............................................................. T5-5-9
Engine Tachometer ..........................................................T5-2-35
SC Fault Code List .............................................................T5-5-23
Torque Converter Oil Temperature Gauge and Brake Oil
Monitor Controller (Monitor)
Pressure Gauge ............................................................T5-2-36
Fault Code List ..............................................................T5-5-34
Coolant Temperature Gauge ........................................T5-2-37
Monitor Controller (Information) Fault
Group 3 e-Service Code List .........................................................................T5-5-36
Outline .................................................................................... T5-3-1 Column Display Controller
Fault Code List ..............................................................T5-5-38
95Z7 Troubleshooting
Air Conditioner Controller MC Fault Codes 120001, 120005, 120008,
Fault Code List ..............................................................T5-5-40 120014, 120101 to 120104, 120106
Communication Terminal Fault ......................................................................................... T5-5-105
Code List .........................................................................T5-5-41 SC Fault Codes 120000, 120002 to 120004
ECM Fault Code List..........................................................T5-5-42 ......................................................................................... T5-5-106
MC Fault Codes 111000 to 111002 .............................T5-5-66 Column Display Controller Fault Code
SC Fault Codes 111000 to 111002 ..............................T5-5-66 115001 .......................................................................... T5-5-107
MC Fault Code 111003 ....................................................T5-5-66 Column Display Controller Fault Code
SC Fault Code 111003......................................................T5-5-66 115011 .......................................................................... T5-5-108
MC Fault Codes 111006, 111007, Monitor Controller (Monitor) Fault Codes
111009, 111012 ............................................................T5-5-69 120300, 120301 ......................................................... T5-5-110
SC Fault Codes 111015, 111017, Monitor Controller (Information) Fault Codes
111019, 111024 ............................................................T5-5-69 120400, 120401 ......................................................... T5-5-110
Monitor Controller (Monitor) Fault Codes Column Display Controller Fault Codes
113002, 113003, 113005, 113010 ..........................T5-5-70 120500 to 120507..................................................... T5-5-111
Monitor Controller (Information) Fault Codes 114010, Air Conditioner Controller Fault Codes
114011, 114013, 114018 ...........................................T5-5-70 11 to 22 ........................................................................ T5-5-112
CAN1 Harness Check .......................................................T5-5-71 Air Conditioner Controller Fault Codes
MC Fault Codes 111008, 111010, 43 to 92 ....................................................................... T5-5-113
111013, 111014, 111025 ...........................................T5-5-74
SC Fault Codes 111016, 111018, Group 6 Troubleshooting B
111020, 111021, 111026 ...........................................T5-5-74 Troubleshooting B (Machine Diagnosis by
Monitor Controller (Monitor) Fault Codes Using Troubleshooting Symptom)
113004, 113006, 113007, 113011 ..........................T5-5-75 Procedure ......................................................................... T5-6-1
Monitor Controller (Information) Fault Codes 114012, Contents of Diagnosis.................................................. T5-6-2
114014, 114015, 114019 ...........................................T5-5-75 Relationship between Machine Trouble Symptom and
CAN2 Harness Check ......................................................T5-5-76 Related Parts ................................................................... T5-6-3
MC Fault Codes 111103, 111105 .................................T5-5-79 Correlation between Trouble Symptom and
SC Fault Codes 111205, 111207 ...................................T5-5-80 Part Failures ...................................................................T5-6-27
SC Fault Codes 111200, 111202, 111203 Engine System Troubleshooting ............................T5-6-28
............................................................................................T5-5-81 All Actuator System Troubleshooting
MC Fault Codes 111204, 111312 .................................T5-5-82 ............................................................................................T5-6-30
SC Fault Codes 111206, 111217 ...................................T5-5-83 Front Attachment System
SC Fault Code 111208......................................................T5-5-84 Troubleshooting .....................................................T5-6-33
MC Fault Codes 111313, 111600 .................................T5-5-85 Steering System Troubleshooting .........................T5-6-37
MC Fault Codes 111210, 111211 .................................T5-5-86 Travel System Troubleshooting ..............................T5-6-39
MC Fault Codes 111214, 111215 .................................T5-5-87 Brake System Troubleshooting...............................T5-6-42
SC Fault Codes 111309, 111310 .................................. T5-5-88 Other System Troubleshooting ..............................T5-6-43
MC Fault Code 111406 ................................................... T5-5-89 Engine System Troubleshooting .................................T5-6-47
SC Fault Code 111407..................................................... T5-5-90 All Actuator System Troubleshooting........................T5-6-53
SC Fault Code 111410..................................................... T5-5-91 Front Attachment System
SC Fault Code 111411..................................................... T5-5-92 Troubleshooting ..........................................................T5-6-59
SC Fault Code 111412..................................................... T5-5-93 Steering System Troubleshooting ..............................T5-6-69
MC Fault Code 111413 ................................................... T5-5-94 Travel System Troubleshooting ...................................T5-6-73
MC Fault Codes 111414 to 111421 ............................ T5-5-95 Brake System Troubleshooting ....................................T5-6-83
MC Fault Code 111408 ....................................................T5-5-97 Other System Troubleshooting....................................T5-6-87
SC Fault Code 111422..................................................... T5-5-98 Exchange Inspection .................................................... T5-6-101
SC Fault Code 111423..................................................... T5-5-99 Air Bleeding Procedures
MC Fault Codes 111502, 111503, for Brake (Axle) .......................................................... T5-6-102
111506, 111507 ........................................................ T5-5-100 Group 7 Air Conditioner
SC Fault Code 111900.................................................. T5-5-101 Outline ................................................................................... T5-7-1
SC Fault Code 111901................................................... T5-5-102 Component Layout...................................................... T5-7-2
MC Fault Code 111903 ................................................. T5-5-103 Functions of Main Parts ................................................... T5-7-4
SC Fault Codes 111906, 111907 ................................ T5-5-104 Troubleshooting ................................................................. T5-7-9
Air Conditioner Controller
Fault Code List ............................................................. T5-7-10
Air Conditioner Controller Fault Codes
11 to 22 ...........................................................................T5-7-11
Air Conditioner Controller Fault Codes
43 to 92 .......................................................................... T5-7-12
Faulty cooling (1) ........................................................ T5-7-14
Faulty cooling (2) ........................................................ T5-7-16
Faulty cooling (3) ........................................................ T5-7-18
Faulty cooling (4) ........................................................ T5-7-20
Faulty cooling (5) ........................................................ T5-7-22
Faulty heating (1)........................................................ T5-7-24
Faulty heating (2)........................................................ T5-7-26
Others ............................................................................. T5-7-27
Blower motor does not operate. ........................... T5-7-30
Compressor clutch does not operate.
........................................................................................... T5-7-31
Cooling circuit check by using
manifold gauge...................................................... T5-7-32
Work after Replacing Components ........................... T5-7-34
Refill Compressor Oil ...................................................... T5-7-35
Charge Air Conditioner
with Refrigerant ...........................................................T5-7-36
Necessity of Purging.................................................. T5-7-36
Procedures for charging air
conditioner with refrigerant .............................. T5-7-37
Warm-up Operation .................................................. T5-7-42
Inspection ..................................................................... T5-7-42
Hose and Pipe Tightening Torque...............................T5-7-44
(Blank)
Introduction
Refer to the inspection and troubleshooting procedures
after any machine trouble has occurred. The inspection
and troubleshooting procedures are presented in an
orderly fashion in this section to quickly find the cause of
the machine trouble and solution.
The troubleshooting section in this manual consists of

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

This group explains procedures of troubleshooting Fault Codes)
and precautions and/or information for the electrical Refer to these procedures if any fault codes are
system inspection. displayed when each controller is diagnosed by
using MPDr. (or the the service menu of monitor).
Example: Fuse Inspection
IMPORTANT: The 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
 Component Layout electrical signal system malfunction in the form of
fault codes
Example: Fault Code 111000-2: Abnormal EEPROM
 Troubleshooting B (Machine Diagnosis by Using

Troubleshooting Symptom)
Refer to troubleshooting B for diagnosis by using
trouble symptom.
Refer to these procedures when no fault codes are
displayed after diagnosing the machine by using
MPDr. (or the service menu of monitor).
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
Color Red White Blue Green Yellow Black
Code O Lg Br P Gr V
Color Orange Light Brown Pink Gray Violet
green
fNOTE:
Code BW indicates a black base wire with white fine-
line marking.
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 T5-1-8.)
 The water-resistant connectors keep water out.
If water enters them, water will not easily drain TDAA-05-08-002
from them. When checking the water-resistant
connectors, take extra care not to allow water to
enter the connectors. In case water should enter the
connectors, reconnect only after the connectors are 1
thoroughly dried.
 Before connecting the terminal connectors, check 2
that no terminals are bent (3) or coming off. In
addition, as most connectors are made of brass, 3
check that no terminals are rusting (2).
 When connecting terminal connectors provided with
a lock, insert them together until the lock "clicks." 4
 Pull the harness near the connector in order to check TDAA-05-08-003
if it is correctly connected.
1- Correct 3- Incorrect (Deformation)
2- Rust 4- Incorrect (Deformation)
4. Precaution for using a circuit tester.

 Before using a circuit tester, refer to the instructions
in the circuit tester manual. Then, set the circuit TDAA-05-08-004
tester to meet the object to be measured, voltage
range and current polarity.
 Before starting the connector test, always check the
connector terminal numbers, referring to the circuit
diagram. When the connector size is very small, and
the standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or a pin
around the probe to make the test easier.
 When checking the connector by using a circuit
tester, insert a tester probe from the 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
T5-1-8
 Pull Lock and Switch the Lever Type
TDAA-05-08-005
 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
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.) e d e
2. Remove the fuse box cover. Set a circuit tester.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of circuit tester to
the body. Touch the terminals located (e) of fuse
box one-by-one with the positive probe of circuit
tester. When normal continuity of a fuse is intact,
the circuit tester will indicate 20 to 25 V (battery
voltage).
M178-07-034
d- Terminals connected to the e- Terminals connected to loads

power source (accessories)
a, b
11 1
12 2
b 13 3
a
14 4
15 5
16 6
17 7
18 8
19 9
Front 20 10
c
90MNEC-01-47
a- Fuse Box A c- Relay Box M178-07-034

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

1 5A Position 1 1 10 A MC (Main)
(Tail Lamp RH, Front Width Lamp LH) Load Dump Relay
2 5A Position 2 2 10 A MC (Sub)
(Tail Lamp LH, Front Width Lamp RH)
3 10 A Backup Lamp/Alarm 3 30 A ECM
4 10 A Starter Key Switch 4 5A Optional Control Unit
5 20 A Working Lamp (Front) 5 10 A Flasher Unit
Horn
6 5A Turn Signal 6 10 A Radio (US)
7 5A Head Lamp (Left) 7 5A Head Lamp (Right)
8 10 A Rear Wiper 8 15 A Front Wiper
9 10 A High Beam 9 20 A MC (Main/Sub)
10 5A Secondary Steering (Option) 10 10 A Neutral Relay
11 10 A Power ON 11 10 A Lighting Switch
12 10 A DC-DC Converter 12 20 A Room Lamp
13 5A Auto-Idling Stop 13 15 A OPT1 (Battery)
14 10 A Air Conditioner Unit 1 14 15 A OPT2 (ACC)
15 20 A Air Conditioner Unit 2 15 5A Parking Brake
16 - - 16 10 A Bucket Positioner
Loading Lever Safety Lock
Lift Arm (Boom) Kickout
Hydraulic Coupler SW (Option)
17 - - 17 20 A Working Lamp (Rear)
18 - - 18 15 A Seat Heater
19 - - 19 15 A 24 V Socket
20 - - 20 5A Radio (EU, JPN)
T5-1-11
Fusible Link Inspection

Inspection
1. Visually inspect fusible links (1, 2).
Replacement
1. Disconnect the negative cable from the battery.
2. To replace a fusible link, remove 2 bolts and pull it
up.
3. Connect the negative cable to the battery.
Battery box
95Z7-SlowBlow
90Z7-05-01-01
1- Fusible Link 2- Fusible Link (70 A)

(100 A x 2) 3- Cover
(S/N ~5058, ~0104) 4- Fuse Element
(140 A x 2)
(S/N 5059~, 0105~)
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. A
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.
TNED-05-01-002
A- Machine Front
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.
2. Measure voltage between terminals B and E of 1
alternator (2). If the measured voltage is around 24
V, the alternator circuit can be considered normal. MNEC-01-073
If the measured voltage is low, a shortage in battery
capacity or looseness of the wire connectors
of alternator circuit might be the cause of the
malfunction.
When voltage is 0 V, the wiring between fuse box
and alternator might be loose or disconnected.
Also, the alternator cannot generate electricity if the
ground line is disconnected.
3. Next, start the engine and measure voltage
generated while the alternator rotates.
As described above, measure voltage between
terminals B and E on the alternator side.
If voltage is around 28 V, the alternator is operating 2
normally.
If the rated voltage is not being generated (around
24 V), there is some trouble with the alternator or
the regulator.
Engine
95Z7-05-01-02
2
E
95Z7-05-01-01
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). T107-07-05-004
By conducting the multi-line continuity check twice, it is
possible to find out which line is discontinued.
With terminals (A) and (C) short-circuited, check
continuity between terminals (a) and (c).
 0 Ω = Line (B) - (b) has discontinuity.
A a
 ∞ Ω = Line (A) - (a) has discontinuity. 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 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: Glow Plug (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 (S/N ~5058: 100 A, S/N 26 to 30 V
5059~: 140 A)/Generating Voltage
Fast Speed ON Between (14) and Ground: Monitor Controller (A15) 13 to 30 V
Surge Voltage
Prevention Circuit
Idle Speed ON Between (9) and Ground: Alternator (B) 26 to 30 V
Idle Speed ON Between (13) and Ground: Key Switch ON Cut Relay (Option) 20 to 25 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 (12) and Ground: ACC Cut Relay (Option) 20 to 25 V
Stopped ON Between (15) and Ground: Monitor Controller, Switch Panel, Air 20 to 25 V
Conditioner Unit
Stopped ON Between (18) and Ground: Radio 20 to 25 V
Stopped ON Between (19) and Ground: Fusible Link (S/N ~5058: 100 A, S/N 20 to 25 V
5059~: 140 A)
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
95Z7-05-01-03
a- Battery f- Load Dump Relay k- Fuse Box A

b- Alternator g- Key Switch m- Fusible Link (100 A: S/N ~5058)
c- Fusible Link h- ACC Cut Relay (Option) (140 A: S/N 5059~)
d- Battery Relay i- Key Switch ON Cut Relay (Option)
e- Glow Plug j- 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 Relay 20 to 25 V
Started START Between (24) and Ground: Starter Relay 20 to 25 V
Started START Between (25) and Ground: Starter Cut Relay 0V
Started START Between (26) and Ground: Fuse Box B 20 to 25 V
Started START Between (27) and Ground: Key Switch 20 to 25 V
Started START Between (28) and Ground: Neutral Relay 20 to 25 V
Started START Between (29) and Ground: Monitor Controller (A17) (Key SW Start) 20 to 25 V
Started START Between (30) and Ground: Main Controller (MC) (E4) (Key ON) 20 to 25 V
Started START Between (31) and Ground: ECM (100) 20 to 25 V
Started START Between (32) and Ground: ECM Main Relay 20 to 25 V
Started START Between (33) and Ground: ECM Main Relay 20 to 25 V
T5-1-18
95Z7-05-01-04
a- Starter d- Starter Cut Relay g- Monitor Controller (DSZ) j Main Controller (MC)
b- Starter Relay e- Key Switch h- ECM Main Relay k- Neutral Relay
c- Battery Relay f- Fuse Box B i- ECM
T5-1-19

Neutral Engine Start
Circuit *
Stopped ON Between (36) and Ground: Key Switch 20 to 25 V
Stopped ON Between (37) and Ground: Key Switch ON Cut Relay (Option) 20 to 25 V
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
95Z7-05-01-05
a- Key Switch c- Neutral Relay

b- Key Switch ON Cut Relay (Option)
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
 Red (Positive) probe terminal of circuit tester: To
terminal #1

Evaluation: If the measuring voltage is within 5 ± 0.5 volts, T107-07-05-006
the circuit up to terminal #1 is normal.
Three Polarities
1 2 3
T107-07-05-007
 Voltage between terminal #1 and the ground terminal

Turn OFF the key switch, and disconnect the sensor Two Polarities
connector. Measure the voltage between terminal #1
(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)
 Red (Positive) probe terminal of circuit tester: To
T107-07-05-008
terminal #1

Evaluation: If the measuring voltage is within 5 ± 0.5
volts, the circuit up to terminal #1 or the ground terminal Three Polarities
(terminal #2 or #3) is normal.
1 2 3
T107-07-05-009
T5-1-22
Check by False Signal

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

to terminal #3 or to the body (ground) when
checking a three-polarity connector.
Three Polarities
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
Prepare appropriate tools as shown.
Install a test harness between connectors.

Check the circuit condition depending on whether the
test harness lamp lights or extinguishes during operation.
Check Lamp
Check Lamp
-
Use in order to check a single-line (discontinuity and/or +
voltage). -
During Operation: Light is ON.

+ GND
T107-07-05-012
 Solenoid Check Lamp Solenoid Check Lamp
Use in order to check the solenoid valve unit circuits.
When the corresponding control lever or switch is

operated: Light is ON.
To Solenoid 90T107-07-06-15
Connector
T5-1-24
 Pressure Sensor Test Harness
Connect a test harness to the harness end connector of

pressure sensor. Check the state of pressure sensor circuit.
Pressure Sensor Test Harness (Example)
2 1 3
TDAA-05-06-003
1- Test Harness (Ground, Output, 5 V Lines) 3- Harness Connector for Sensor Connection
2- Dummy Connector
1. Connect the male end connector of test harness (1)

to harness end connector (3).
2. Connect a dummy sensor (2) to the female end
connector of test harness (1).
3. Check the output voltage.
T5-1-25
(Blank)
T5-1-26
Group 2 Monitor
Outline
Basic Screen
23 1 2 3
4
19
18
17
20
6
16
115Z7-01-04
15 14 21 12 13 11 10 22 9 8 7
1- Engine Tachometer 8- Seat Belt Indicator 14- Dual Lift Arm Auto Leveler 20- Auto Brake Indicator
2- Economy (ECO) Indicator 9- Forward/Reverse Selector Indicator 21- Joystick Steering Indicator
3- Speedometer Switch Indicator 15- Clock, Hour Meter, Odometer (Option)
4- Torque Converter Oil 10- Declutch Indicator 16- Fan Reverse Rotation Indicator 22- Traction Control Indicator
Temperature Gauge 11- Exhaust Filter Indicator 17- Shift HOLD Display 23- Torque Converter Lock-Up
5- Brake Oil Pressure Gauge 12- Power Mode Indicator 18- Transmission Auto-shifting Indicator
6- Air Conditioner Display 13- Auto Idling-Stop Indicator Indicator
7- Ride Control Indicator (Option) 19- F-N-R/Shift Position Indicator
T5-2-1
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 Maintenance Pro Dr. (MPDr.)
 Troubleshooting:
Fault code is displayed.
 Monitoring:
A part of monitor items for MPDr. is displayed.
 Controller Version:
The controller version is displayed.
 Issued Warning Record:

Ten alarms which were issued recently are displayed.
 Machine Setting:
The learning and adjustment are performed.
 Exhaust Filter No.:

The manufacture number of exhaust filter is displayed.
T5-2-2
Group 2 Monitor
1 2
How to display service menu
1. Push rotating select / confirm knob (3) while pushing
return to previous screen switch (1) when the basic
screen is displayed with the key switch set in the ON
position or the engine running. 3
Then, Service Menu (4) is added to the Main Menu
screen.
2. Turn select / confirm knob (3) and select Service Menu
(4).
MNEC-01-006
3. Push select / confirm knob (3). The Service Menu screen 95TNED-05-02-14
appears.
4. When pushing return to previous screen switch (1), the 95TNED-05-02-10

previous screen appears.
5. When pushing return to basic screen switch (2), the
basic screen appears.
fNOTE: When the basic screen has appeared by using return

to previous screen switch (1) or return to basic screen switch
(2), Service Menu (4) on the Main Menu screen is deleted. In
order to display Service Menu (4), perform step 1 again.
T5-2-3
Group 2 Monitor
Troubleshooting 1 2
1. Turn select / confirm knob (3) and select
Troubleshooting (4) on Service Menu.
TNED-05-02-002
2. When pushing select / confirm knob (3), the 4

Troubleshooting screen appears.
95TNED-05-02-10
3. Turn select / set switch (3) and select the controller.
fNOTE: The number in parentheses to the right of menu

5
name indicates the number of listed fault codes for the menu.
4. When pushing select / confirm knob (3), the self-

diagnostic result of selected controller (fault code) is 95TNED-05-02-24
displayed.
The past fault codes as well as the current ones are
displayed at this time.
fNOTE: Main (Sub) (5) is shown as an example here.

6
5. Turn select / confirm knob (3), select CLEAR (6), and 95TNED-05-02-25
push select / confirm knob (3).
The past fault codes are deleted and only the current
fault codes can be displayed.
6. When pushing return to previous screen switch (1), the

95TNED-05-02-54
T5-2-4
Group 2 Monitor
(Blank)
T5-2-5
Group 2 Monitor
Monitoring 1 2
1. Turn select / confirm knob (3) and select Monitoring (4)

on Service Menu.
TNED-05-02-002
2. When pushing select / confirm knob (3), the Monitoring 95TNED-05-02-10

screen appears.
3. Turn select / confirm knob (3) and select the controller 5
for monitoring.
4. When pushing select / confirm knob (3), the monitoring
items for selected controller are displayed.
fNOTE: Main Controller (Sub) (5) is selected as an example

here.
95TNED-05-02-15
5. Turn select / confirm knob (3), select the item for

monitoring, and push select / confirm knob (3). (Up to 8
items can be selected.)
6. Push return to previous screen switch (1) and the

95TNED-05-02-16
Monitoring screen appears.
7. Turn select / confirm knob (3), select START (6), and
push select / confirm knob (3).
fNOTE: START (6) and CLEAR (7) are displayed only when one 6
or more monitoring items are selected. START (6) and CLEAR
(7) are not displayed when no monitoring item is selected. 7
95TNED-05-02-17
T5-2-6
Group 2 Monitor
8. The selected monitoring item is started monitoring.
fNOTE: Actual Engine Speed and Actual Vehicle Speed are

selected as an example here.
95TNED-05-02-19
1 2
9. When pushing select / confirm knob (3) while
monitoring, PAUSE (8) is displayed and the monitoring
value can pause (be held).
10. When pushing select / confirm knob (3) again, pausing 3
is stopped.
TNED-05-02-002
fNOTE: Even if the key switch is set to OFF position, the 8
selected monitoring item has been stored. In order to
release the selected monitoring item, select CLEAR (7) on the
Monitoring screen and push select / confirm knob (3) for a
while until START (6) and CLEAR (7) disappear.

95TNED-05-02-18
95TNED-05-02-17
T5-2-7
Group 2 Monitor
List of Monitoring Item

Engine Controller (ECM)
Item Unit Data
Fuel Filter Restriction Switch OFF/ON Clogged fuel filter status
Load Dump Relay Output OFF/ON Load dump relay ON/OFF status
Engine Torque % Input signal from ECM
Actual Engine Speed min-1 Input signal from crank speed sensor and cam angle sensor
Coolant Temperature °C Input signal from coolant temperature sensor
Fuel Temperature °C Input signal from fuel temperature sensor
Engine Oil Pressure kPa Input signal from engine oil pressure sensor
Atmospheric Pressure kPa Input signal from atmospheric pressure sensor
Intake Air Temperature °C Input signal from intake-air temperature sensor
Boost Pressure kPa Input signal from boost pressure sensor
Boost Temperature °C Input signal from boost temperature sensor
Fuel Consumption (Trip) L Input signal from ECM
Target Fuel Injection Quantity mm3/st Input signal from ECM
EGR Gas Temperature °C Input signal from ECM
EGR Opening Amount 1 % Input signal from ECM
EGR Opening Amount 2 % Input signal from ECM
ITH Opening Amount % Input signal from ECM
Common Rail Pressure MPa Input signal from common rail pressure sensor
Actual Turbo Opening Amount % Input signal from ECM
Muf/Fltr EGP Differential Pressure kPa Input signal from exhaust filter differential pressure sensor
Muf/Fltr Catalyst Inlet EGT °C Input signal from DOC exhaust temperature sensor
Muf/Fltr Inlet EGT °C Input signal from CSF exhaust temperature sensor
Intake Air Temperature in Manifold °C Input signal from intake manifold temperature sensor
Supply Pump Inlet Pressure kPa Input signal from suction control valve
Battery Voltage V Input signal from ECM
T5-2-8
Group 2 Monitor
Engine Controller (ECM)

Item Unit Data
Glow Signal OFF/ON Glow plug relay ON/OFF status
Starter Switch OFF/ON Key switch ON/OFF status
SCV Sweep Switch OFF/ON SCV sweep switch ON/OFF status
Load Signal Switch OFF/ON Load signal switch ON/OFF status
Regulation Select Switch OFF/ON Regulation select switch ON/OFF status
DIAG Select Switch OFF/ON DIAG select switch ON/OFF status
Muf/Fltr Switch OFF/ON Exhaust filter regeneration switch ON/OFF status
Memory Clear Switch OFF/ON Memory clear switch ON/OFF status
DIAG Switch OFF/ON DIAG switch ON/OFF status
Engine Stop Switch OFF/ON Engine stop switch ON/OFF status
Auxil Regeneration Signal 1 - -
Auxil Regeneration Signal 2 - -
Starter Cutoff Relay Signal OFF/ON Starter cutoff relay ON/OFF status
Muf/Fltr DP Learning Signal OFF/ON Input signal from ECM
Muf/Fltr Inlet EGT Level - Exhaust temperature level of exhaust filter inlet
Muf/Fltr PM Accumulation Status - -
Muf/Fltr Trip Status - -
Muf/Fltr Mode - -
Muf/Fltr Indicator Status - -
Muf/Fltr Regeneration Flag - -
Muf/Fltr Status - -
T5-2-9
Group 2 Monitor
Main Controller (T/M)

Item Unit Data
Demand Engine Speed min-1 Command value of engine speed from MC to ECM.
Actual Engine Speed min-1 Input signal from ECM
Accelerator Pedal V Input signal from accelerator pedal sensor
Transmission Oil Temperature °C Input signal from transmission oil temperature sensor
Pump Delivery Pressure MPa Input signal from pump delivery pressure sensor
Torque Converter Input Speed min-1 Input signal from torque converter input speed sensor
Transmission Output Speed min-1 Input signal from transmission output speed sensor
Actual Vehicle Speed km/h Converted signal from machine speed sensor into speed per
hour
Parking Brake Pressure MPa Input signal from pressure sensor (parking brake)
Service Brake Secondary Pressure (For MPa Input signal from pressure sensor (brake secondary pressure for
clutch Cut Off ) declutch)
Torque Converter Speed Ratio % Calculated signal from actual engine speed and torque
converter output speed by MC (T/M)
Vehicle Speed Pulse pulse Actual transmission output speed pulse
Warning Buzzer 0: OFF Auto idling-stop alarm ON/OFF status
1: ON
2: ON
3: ON
Forward Clutch Pressure MPa Input signal from pressure sensor (forward clutch solenoid)
Reverse Clutch Pressure MPa Input signal from pressure sensor (reverse clutch solenoid)
1st Clutch Pressure MPa Input signal from pressure sensor (1st speed clutch solenoid)
2nd Clutch Pressure MPa Input signal from pressure sensor (2nd speed clutch solenoid)
T/M Clutch Forward P/S Output mA Control signal to transmission forward clutch solenoid valve
T/M Clutch High P/S Output mA Control signal to transmission high clutch solenoid valve
T/M Clutch Reverse P/S Output mA Control signal to transmission reverse clutch solenoid valve
T/M Clutch 1st P/S Output mA Control signal to transmission 1st speed clutch solenoid valve
T/M Clutch 2nd P/S Output mA Control signal to transmission 2nd speed clutch solenoid valve
T/M Clutch 3rd P/S Output mA Control signal to transmission 3rd speed clutch solenoid valve
T/M Clutch Lock Up P/S Output mA Control signal to transmission lock up clutch solenoid valve
Pump Swash Angle P/S Output MPa Control signal to torque control solenoid valve
Auto Brake P/S Output mA Control signal to auto brake solenoid valve
Muf/Fltr Regeneration P/S Output MPa Control signal to exhaust filter (DPF) manual regeneration
control solenoid valve
T/M Clutch Forward P/S Output FB mA Feedback from transmission forward clutch solenoid valve
T/M Clutch High P/S Output FB mA Feedback from high clutch solenoid valve
T/M Clutch Reverse P/S Output FB mA Feedback from reverse clutch solenoid valve
T/M Clutch 1st P/S Output FB mA Feedback from 1st speed clutch solenoid valve
T/M Clutch 2nd P/S Output FB mA Feedback from 2nd speed clutch solenoid valve
T/M Clutch 3rd P/S Output FB mA Feedback from 3rd speed clutch solenoid valve
T/M Clutch Lock Up P/S Output FB mA Feedback from lock up clutch solenoid valve
Pump Swash Angle P/S Output FB mA Feedback from torque control solenoid valve output
Auto Brake P/S Output FB mA Feedback from auto brake solenoid valve output
Muf/Fltr Regeneration P/S Output FB mA Feedback from exhaust filter (DPF) manual regeneration control
solenoid valve
T5-2-10
Group 2 Monitor
Main Controller (T/M)

Item Unit Data
Quick Power Switch OFF/ON Quick power switch ON/OFF status
Power Mode Switch OFF/ON Power mode switch ON/OFF status
DSS Switch OFF/ON Downshift switch ON/OFF status
Hold Switch OFF/ON Shift hold switch ON/OFF status
Clutch Cut Off Position Switch 0: OFF Declutch mode status
1: N Mode
2: D Mode
Travel Mode Selector Switch 0: Manual Auto-shift mode status
Mode
1: AUTO_1
2: AUTO_2
Armrest Switch * OFF/ON Armrest switch ON/OFF status
Parking Brake Indicator OFF/ON Parking brake indicator ON/OFF status
Backup Light Relay OFF/ON Backup relay ON/OFF status
Neutral Relay OFF/ON Neutral relay ON/OFF status
Forward/Reverse Lever 0: N Forward/reverse lever selected position status
1: F
2: R
Forward/Reverse Switch 0: N Forward/reverse switch selected position status
1: F
2: R
Shift Switch 0: 1st speed Shift switch selected speed range status
1: 2nd speed
2: 3rd speed
3: 4th speed
T/M Rstr Switch ON/OFF Transmission oil filter restriction (clog monitoring) switch ON/
OFF status
Auto Shut-Down Relay OFF/ON Auto idling-stop relay ON/OFF status
T5-2-11
Group 2 Monitor
Main Controller (Sub)

Item Unit Data
Target Hydraulic Fan Speed min-1 Calculated signal from actual engine speed and control signal
to fan control valve
Actual Fan Speed min-1 Input signal from fan speed sensor
Hydraulic Oil Temperature °C Input signal from hydraulic oil temperature sensor
Torque Converter Oil Temperature °C Input signal from torque converter oil temperature sensor
Front Axle Oil Temperature °C Input signal from front axle oil temperature sensor
Rear Axle Oil Temperature °C Input signal from rear axle oil temperature sensor
Lift Arm Angle Sensor V Input signal from lift arm (boom) angle sensor
Service Brake Primary Pressure (Front) MPa Input signal from pressure sensor (front brake primary pressure)
Service Brake Primary Pressure (Rear) MPa Input signal from pressure sensor (rear brake primary pressure)
Hydraulic Fan Circuit Pressure MPa Input signal from hydraulic fan circuit pressure sensor
Emergency Steering Pump Delivery MPa Input signal from secondary steering pump delivery pressure
Pressure * sensor
Air Conditioner Refrigerant Pressure MPa Input signal from pressure sensor (refrigerant pressure)
Bucket Tilt Pilot Pressure MPa Input signal from pressure sensor (bucket roll back)
Bucket Dump Pilot Pressure MPa Input signal from pressure sensor (bucket dump)
Lift Arm Raise Pilot Pressure MPa Input signal from pressure sensor (lift arm raise)
Parallel/Tandem Control P/S Output MPa Control signal to parallel/tandem switching solenoid valve
Ride Control (Rod) P/S Output * mA Control signal to ride control proportional solenoid valve (boom
cylinder rod side)
Ride Control (Bottom) P/S Output * mA Control signal to ride control selector solenoid valve (boom
cylinder bottom side)
Hyd Fan Reverse Rotation P/S Output mA Control signal to fan reverse control solenoid valve
Hyd Fan Speed Control P/S Output mA Control signal to fan speed control solenoid valve
Lift Arm Speed Multiplication P/S mA Control signal to lift arm speed multiplication solenoid valve
Output
fNOTE: *:Optional
T5-2-12
Group 2 Monitor
Main Controller (Sub)

Item Unit Data
Parallel/Tandem Control P/S Output FB mA Feedback from parallel/tandem switching solenoid valve
Ride Control (Rod) P/S Output FB * mA Feedback from ride control proportional solenoid valve (boom
cylinder rod side)
Ride Control (Bottom) P/S Output FB * mA Feedback from ride control selector solenoid valve (boom
cylinder bottom side)
Hyd Fan Reverse Rotation P/S Output mA Feedback from fan reverse control solenoid valve
FB
Hyd Fan Speed Control P/S Output FB mA Feedback from fan speed control solenoid valve
Lift Arm Speed Multiplication P/S mA Feedback from lift arm speed multiplication solenoid valve
Output FB
Operation Lever Primary Pilot Pressure MPa Input signal from pressure sensor (pilot valve primary pressure)
Steering Pressure Switch * OFF/ON Steering pressure switch ON/OFF status
Emergency Steering Check Switch * OFF/ON Secondary steering operation check switch ON/OFF status
Fan Reversing Switch OFF/ON Fan reverse switch ON/OFF status
Fan Reversing Switch (Auto) * OFF/ON Fan reverse auto switch ON/OFF status
Ride Control Switch (Auto) * OFF/ON Ride control auto switch ON/OFF status
Ride Control Switch * OFF/ON Ride control switch ON/OFF status
Stick Steering Selector Switch * OFF/ON Stick Steering Selector Switch ON/OFF status
Emergency Steering Pump Relay * OFF/ON Secondary steering pump relay ON/OFF status
Low Steering Oil Pressure Indicator OFF/ON Steering pressure warning indicator ON/OFF status
Low Brake Oil Pressure Indicator OFF/ON Service brake warning indicator ON/OFF status
Lift Arm Auto Leveler Lower Kickout OFF/ON Lower kickout detent ON/OFF status
Lift Arm Auto Leveler Height Kickout OFF/ON Height kickout detent ON/OFF status
fNOTE: *:Optional
T5-2-13
Group 2 Monitor
Column Display Controller

Item Unit Data
Overheat Switch 1 OFF/ON Overheat switch ON/OFF status
Engine Oil Pressure Switch 1 OFF/ON Engine oil pressure switch ON/OFF status
Air Cleaner Restriction Switch OFF/ON Air cleaner restriction (clog monitoring) switch ON/OFF status
Hydraulic Oil Level Switch OFF/ON Hydraulic oil level switch ON/OFF status
Engine Trouble Switch OFF/ON Engine trouble switch ON/OFF status
Glow Switch OFF/ON Glow switch ON/OFF status
Model Selector Switch 1 OFF/ON Model selector switch 1 ON/OFF status
Model Selector Switch 2 OFF/ON Model selector switch 2 ON/OFF status
Front Washer Switch OFF/ON Front washer switch ON/OFF status
Front Wiper Switch OFF/INT/LO/HI Front wiper switch selection status
Light Switch OFF/ON Light switch ON/OFF status
Steering Pressure Switch OFF/ON Steering pressure switch ON/OFF status
Neutral Switch OFF/ON Main controller (T/M controller) neutral status
Digital Input 2 OFF/ON -
Digital Input 3 OFF/ON -
Front Wiper Relay 1 Output OFF/ON Front wiper relay 1 ON/OFF status
Front Wiper Relay 2 Output OFF/ON Front wiper relay 2 (fast speed) ON/OFF status
Buzzer Output OFF/ON Warning buzzer ON/OFF status
Transmission Trouble Switch OFF/ON Transmission trouble switch ON/OFF status
Service Brake Pressure Switch OFF/ON Service brake pressure switch ON/OFF status
T5-2-14
Group 2 Monitor
Air Conditioner Unit

Item Unit Data
Compressor Operation OFF/ON Compressor operating status
Outdoor Air Temperature °C Input signal from ambient temperature sensor
Indoor Air Temperature °C Input signal from air circulation sensor
Amount of Insolation W/m2 Input signal from solar radiation sensor
T5-2-15
Group 2 Monitor
Controller Version
1 2
1. Turn select / confirm knob (3) and select Controller
Version (4) on Service Menu.
TNED-05-02-002
95TNED-05-02-10
2. When pushing select / confirm knob (3), the version of
each controller appears.

95TNED-05-02-09
T5-2-16
Group 2 Monitor
Issued Warning Record

1 2
1. Turn select / confirm knob (3) and select Issued Warning
Record (4) on Service Menu.
TNED-05-02-002
2. When pushing select / confirm knob (3), the Issued

Warning Record screen appears. 95TNED-05-02-10
The symbol and trouble of maximum ten alarms which
occurred and reported recently are displayed. (Refer To
List of Alarm.)
3. Turn select / confirm knob (3) and select the displayed

95TNED-05-02-21
alarm. When pushing select / confirm knob (3), the
time (ON / OFF) when the selected alarm has occurred /
solved are displayed.
4. In case of currently occurring alarms, the resolving time

95TNED-05-02-22
(OFF) of the alarm is dashed (---).
fNOTE: The display of date and time depends on the setting.

(Refer to the operator’s manual.)
5. When pushing return to previous screen switch (1), the 95TNED-05-02-23

T5-2-17
Group 2 Monitor
List of Alarm
Symbol Alarm Monitor Message Remedy

Brake Oil Pressure Brake Oil Pressure Is Low. Refer to
Alarm Safely Park The Machine And Stop The Engine Immediately. Troubleshooting
Check Hydraulic Oil Level And Brake System For Damages A.
And Leaks
M4GB-01-013
Steering Oil Pressure Steering Oil Pressure Is Low. Refer to
Check Hydraulic Oil Level And Auto-Brake System For A.
M4GB-01-016
Damages And Leaks.
Secondary Steering Safely Park The Machine And Stop The Engine Immediately. Refer to
Alarm Check Hydraulic Oil Level And Secondary Steering System Troubleshooting
(Blinking) For Damages And Leaks. A.
M4GB-01-015
Hydraulic Oil Level Hydraulic Oil Level Is Low. Refer to
Check Hydraulic Oil Level And System For Damages And A.
Leaks.
M4GF-01-004
Exhaust Filter Alarm Exhaust Filter Is Abnormal. Follow Trouble
(Blinking) (Red) Safely Park The Machine And Stop The Engine Immediately. Screen on the
Contact Your Nearest Authorized Dealer. monitor.
MDAA-01-025
* Exhaust Filter Exhaust Filter Needs Immediate Regeneration To Prevent Follow Trouble
Regeneration Request Damage To The Filter. Screen on the
(Blinking) (Yellow) Safely Park The Machine With The Engine Running . monitor.
Turn The Exhaust Filter Switch To "Regeneration" Following
MDAA-01-026
The Instruction On Monitor.
* Exhaust Filter Exhaust Filter Needs Regeneration. Follow Trouble
Regeneration Request Safely Park The Machine With The Engine Running . Screen on the
(Lighting) (Yellow) Turn The Exhaust Filter Switch To "Regeneration" Following monitor.
MDAA-01-026 The Instruction On Monitor.
* Exhaust Filter Exhaust Filter Regeneration Operation Is Inhibited. Follow Trouble
Regeneration Inhibit Safely Park The Machine And Manually Perform Screen on the
Alarm Regeneration. monitor.
(Lighting) (Yellow)
MDAA-01-027
* Exhaust Filter Auto Auto Exhaust Filter Regeneration Is Deactivated. Follow Trouble
Regeneration Inhibit Safely Park The Machine And Manually Perform Screen on the
Alarm Regeneration. monitor.
(Lighting) (Yellow)
MDAA-01-027
fNOTE: *: These alarms are not displayed on the Issued

Warning Record screen.
T5-2-18
Group 2 Monitor

* Exhaust Filter Hydraulic Oil Temperature Is Too High For Manual Exhaust Follow Trouble
Regeneration Alarm Filter Regeneration. Screen on the
(Lighting) (Yellow) Safely Park The Machine With The Engine Running At Slow monitor.
Idle Speed.
MDAA-01-027 Regenerate After Hydraulic Oil Temperature Cools.
Overheat Alarm Coolant Temperature Is Abnormally High. Follow Trouble
Stop Operation. Screen on the
Run The Engine At Slow Idle To Cool Coolant Temperature. monitor.
MDAA-01-067
Hydraulic Oil Overheat Hydraulic Oil Temperature Is Abnormally High. Refer to
Alarm Stop Machine Operation. Troubleshooting
Run The Engine At Slow Idle Speed To Lower The Oil A.
Temperature.
MDAA-01-068
Axle Oil Temperature Axle Oil Temperature Is Abnormally High. Follow Trouble
Alarm Check If The Service Brake Is Daggled. Screen on the
If The Brake Pedal Is Continuously Stepped On, An Increase monitor.
Of The Axle Oil Temperature May Result.
M4GF-01-005
Transmission Oil Transmission Oil Temperature Is Abnormally High. Refer to
Overheat Alarm Stop Machine Operation. Troubleshooting
Run The Engine At Slow Idle Speed To Lower The Oil A.
Temperature.
M4GB-01-027
Engine Trouble Alarm Engine Or Accessory Are Abnormal. Refer to Engine
Safely Park The Machine And Stop The Engine Immediately. Troubleshooting
Contact Your Nearest Authorized Dealer. Manual.
MDAA-01-069
Transmission Warning Transmission Or accessory Is Abnormal. Refer to
Contact Your Nearest Authorized Dealer. A.
M4GB-01-024
Transmission Oil Transmission oil pressure is too low. Safely park the Refer to
Pressure Alarm machine. Check transmission oil level and check for leaks. Troubleshooting
A.
M183-01-073
Engine Oil Pressure Engine Oil Pressure Is Low. Refer to
Alarm Immediately Stop The Engine. Troubleshooting
Check The Engine Oil System And Oil Level. A.
M4GB-01-021
fNOTE: *: These alarms are not displayed on the Issued

Warning Record screen.
T5-2-19
Group 2 Monitor

Boost Temperature Rise Intake air temperature is abnormally high. Stop operation. Refer to
Alarm Check intercooler for clogging and intake air piping Troubleshooting
connections. A.
MDAA-01-029
Auto Brake Warning Auto brake system is abnormal.
Alarm Safely park the machine and stop the engine immediately.
Check hydraulic oil level and auto brake system for
95Z7-AutoBrakeAlarm
damages and leaks.
Transmission Filter Transmission Filter Clogging

Clogging
95Z7-TM-clog
Main Pump Oil Pressure Main Pump Oil Pressure Is Too Low. Refer to
Alarm Safely Park The Machine. Troubleshooting
Check For Leaks Especially At Front Attachment Piping. A.
MNEC-01-009
Exhaust Temperature Exhaust temperature is abnormally high.
Rise Alarm Stop machine operation, apply parking brake, and check
the exhaust lines.
M183-01-074
Intake Air Temperature Intake air temperature is abnormally high. Stop machine
Rise Alarm operation and apply parking brake. Check for any
abnormality such as disconnected intake air piping.
MDAA-01-031
Exhaust Filter Abnormal Exhaust Filter Is Abnormal. Contact Your Nearest Authorized Refer to
Dealer. Troubleshooting
A.
MDAA-01-071
Battery Charge Alarm Electrical System Is Abnormal. Refer to
Safely Park The Machine And Stop The Engine. Troubleshooting
Check Alternator And Battery Systems. A.
M183-01-071
Contact Your Nearest Authorized Dealer.
fNOTE: In case of Exhaust Filter Abnormal, the exhaust filter

is not abnormal, but the circuit corresponding to exhaust
filter regeneration is abnormal.
T5-2-20
Group 2 Monitor

Fuel Temperature Alarm Fuel temperature is abnormally high. Stop machine
operation and apply parking brake. Run the engine at slow
idle speed to lower the fuel temperature.
MDAA-01-032
Air Cleaner Clogging Air Cleaner Elements Are Clogged. Follow Trouble
Clean Or Replace Air Cleaner Element Following The Screen on the
Instruction In The Operator's Manual. monitor.
Serious Engine Damage Will Occur If Ignored.
M183-01-067
Fuel Filter Restriction Fuel filter is clogged.
Alarm Replace fuel filter element.
M1U1-01-116
EGR Gas Temperature EGR gas temperature is abnormally high. Stop operation,
Alarm apply parking brake, and check EGR cooler, EGR cooler
coolant circulation circuit, coolant level and intake air and
exhaust piping for any abnormality.
MDAA-01-035
Water Separator Alarm Water Separator Is Full. Follow Trouble
(Option) Drain Water. Screen on the
monitor.
MNEC-01-010
System Failure Alarm Machine Network System Is Abnormal. Refer to
Contact Your Nearest Authorized Dealer. Troubleshooting
A.
MDDA-01-034
T5-2-21
Group 2 Monitor
Communication Terminal Status

1 2
1. Turn select / set switch (3) and select
Communication Terminal Status (4) on Service
Menu.
TNED-05-02-002
2. When pushing select / set switch (3), the 4

Communication Terminal Status screen appears.
TNED-05-02-010EN
3. Each data of the communication terminals is
displayed. (Refer To List of Communication Terminal
Status.)
4. When pushing back switch (1), the previous screen

appears.
5. When pushing return to basic screen switch (2), the TNED-05-02-034EN
T5-2-22
Group 2 Monitor
List of Communication Terminal Status
Item Unit Data

Portable Terminal (Option) Satellite Terminal (Option)
GPS Status 0 to 2 0: Uncoupled Connection 0: Uncoupled Connection
1: Incomplete Positioning 1: Incomplete Positioning
2: Positioning State 2: Positioning State
Radio Wave Intensity 0 to 3, 250, 254 0: Reception Level: 0 0: Communication not
available
1: Reception Level: 1 1: Communication available
2: Reception Level: 2
3: Reception Level: 3
250: Out of range
254: Not detected
Talking Status 0, 1 0: Uncoupled Connection -
1: Connection
Comm Module Status 0, 1 0: Correct -
1: Incorrect
Portable Antenna Signal 0 to 31, 99 0 to 1: Out of range -
2 to 8: Reception Level: 0
99: Not detected
GPRS Ntwk Conn Status 0, 1 0: Failure -
1: Success
Frequency Band 0 to 3 0 to 3 -
fNOTE: The detail data of radio wave intensity are displayed for Antenna Signal.
T5-2-23
Group 2 Monitor
Machine Setting
1 2
 Learning/Adjustment
1. Turn select / confirm knob (3) and select Machine

Setting (4) on Service Menu. 3
TNED-05-02-002
95TNED-05-02-11
2. When pushing select / confirm knob (3), the Machine
Setting screen appears. (Refer to List of Machine Setting
Item.)
fNOTE: Items of learning/adjustment are as follows.
 Transmission Learning
 Lift Arm Angle Sensor Learning
 Digging Position Adjustment
95TNED-05-02-61
T5-2-24
Group 2 Monitor
List of Machine Setting Item
Item Unit Details

Transmission Learning - Performance of learning (calibration)
Lift Arm Angle Sensor Learning - Performance of learning
Digging Position Adjustment - Adjustment of position
T5-2-25
Group 2 Monitor
Transmission Learning
IMPORTANT: When transmission or transmission control
valve has been repaired/replaced, and Main Controller
(MC) has been replaced, perform transmission
learning.
Preparation:
1. Start the engine.
2. Select Service Menu screen on the monitor and
Machine Setting/Transmission Learning screen appears.
(Refer to Monitor Operation)
3. Stall the transmission with the following machine
conditions.
Stall Condition:
 Declutch Position Switch: OFF
 Travel Mode: Manual Mode
 Shift Switch: 4th
 Parking Brake Switch: OFF
 Brake Pedal: Fully Applied
 Accelerator Pedal: Fully Applied
 Forward/Reverse Lever: Forward Position
4. Raise transmission oil temperature (7) up to 60°C (140°F)

but not to exceed 115°C (239°F) by operating the
accelerator pedal moderately.
5. When transmission oil temperature (7) reaches 60°C
(140°F), stop transmission stalling, and set the machine
in the following conditions.
Learning Start Condition:

 Accelerator Pedal: Not Applied
 Forward/Reverse Lever: Neutral Position
 Parking Brake Switch: ON
 Brake Pedal: Not Applied
T5-2-26
Group 2 Monitor
Monitor Operation:
1 2
IMPORTANT: Do not operate control levers and other
switches when learning is performed.
1. Turn select / confirm knob (3) and select Machine 3

Setting (4) on Service Menu.
TNED-05-02-002
95TNED-05-02-11
2. When pushing select / confirm knob (3), the Machine 5

Setting screen appears.
3. Turn select / confirm knob (3) and select Transmission
Learning (5).
95TNED-05-02-61
T5-2-27
Group 2 Monitor
4. When pushing select / confirm knob (3), Transmission 6 7

Learning (5) screen appears.
5. When transmission oil temperature (7) is 50 to 60°C (122
to 140°F), "Start" (6) appears on the monitor display.
6. Push select / confirm knob (3) to start learning.
fNOTE: While transmission learning is in process, the

8
95TNED-05-02-71
learning progress (8) and the transmission oil temperature

are displayed.
F1~F3: Forward clutch
R1~R3: Reverse clutch
11~13: 1st speed clutch
21~23: 2nd speed clutch
fNOTE: While transmission learning is in process, input
signal to return to previous screen switch (1) and return to
basic screen switch (2) is invalid.
95Z7-05-02-01
7. When learning is completed, the Learning End screen

appears.
8. Set the key switch to the OFF position, and finish the
learning.
95TNED-05-02-83
T5-2-28
Group 2 Monitor
Transmission Learning Error:

9
 Learning failed to start
If the transmission learning failed to start, the error
number is indicated (9).
Solve the problem and restart transmission learning.
Error Description
Number
2 Forward/reverse lever and/or switch is not in
"Neutral" position.
3 Parking brake switch is not "ON". 95Z7-05-02-02
4 Machine is in running status.
5 Transmission Oil temperature is too low.
6 Transmission Oil temperature is too high.
7 Engine speed is too low.
8 Engine speed is too high.
 Learning cancelled
If the transmission learning is aborted, the error number
10
is indicated (10).
Solve the problem and restart transmission learning.
Error Description
Number
108 Starter key switch was turned "OFF".
208 Engine speed fell out of the specified range.
308 Parking brake switch was turned OFF.
408 Machine was made in running status.
508 Forward/reverse lever and/or switch was
operated. 95Z7-05-02-03
109
209 Calibration of 1st speed clutch failed.
309
110
210 Calibration of 2nd speed clutch failed.
310
111
211 Calibration of 3rd speed clutch failed.
311
112
212 Calibration of 4th speed clutch failed.
312
113
213 Calibration of forward clutch failed.
313
114 Calibration of reverse clutch failed.
214
314
fNOTE: When the machine is in deactivation condition while

learning, learning is stopped.
Turn the start key to OFF, wait for 10 seconds, and turn the
key ON. Perform the learning again.
T5-2-29
Group 2 Monitor
Lift Arm Angle Sensor Learning

IMPORTANT: When lift arm angle sensor has been 1
replaced, perform lift arm angle sensor learning.
Preparation:
2. Set front control lever lock switch (1) to UNLOCK

Position (3).
3. Raise lift arms to the highest level by lift arm raise

operation.
MNEC-01-041
4. Set front control lever lock switch (1) to LOCK Position

(2).
2 1
5. Set the key switch to the OFF position.
MNEC-01-015
2- LOCK 3- UNLOCK
T5-2-30
Group 2 Monitor
Monitor Operation:
1 2
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.
3
1. Set the key switch to the ON position.
Setting (4) on Service Menu. TNED-05-02-002
95TNED-05-02-11
3. When pushing select / confirm knob (3), the Machine
Setting screen appears.
4. Turn select / confirm knob (3) and select Lift Arm Angle 5
Sensor Learning (5).
95TNED-05-02-61
5. When pushing select / confirm knob (3), the Lift Arm

Angle Sensor Learning (5) screen appears.
6. When pushing select / confirm knob (3), the learning
starts.
95TNED-05-02-72
7. When learning is completed, the Learning End screen

appears.
8. Set the key switch to the OFF position, and finish the
learning.
fNOTE: When the learning is performed, input signal to

return to previous screen switch (1) and return to basic screen
switch (2) is invalid.
95TNED-05-02-84
T5-2-31
Group 2 Monitor
Digging Position Adjustment
1
IMPORTANT: When lift arm angle sensor has been
replaced, perform the digging position adjustment
after performing the lift arm angle sensor learning.
Preparation:

2. Set front control lever lock switch (1) to UNLOCK
Position (3).
3. Lower the lift arms and set the bucket on the ground
horizontally.
MNEC-01-041
2 1
MNEC-01-015
2- LOCK 3- UNLOCK
T5-2-32
Group 2 Monitor
Monitor Operation:
1 2
Setting (4) on Service Menu.
2. Push select / confirm knob (3) and turn it to select TNED-05-02-002

Machine Setting - Digging Position Adjustment (7)
menu.
3. When pushing select / confirm knob (3), the Digging

Position Adjustment screen appears.
4. Turn select / confirm knob (3) and select the check

mark.
When pushing select / confirm knob (3), the setting has
been completed.
5. When the digging position has been changed, the

digging position and lift arm angle position settings are
changed. 7

95TNED-05-02-61

95TNED-05-02-73
95TNED-05-02-85
T5-2-33
Group 2 Monitor
Muffler Filter No.

1 2
1. Turn select / confirm knob (3) and select Muffler Filter
No. (4) on Service Menu.
TNED-05-02-002
95TNED-05-02-11
2. When pushing select / confirm knob (3), the Muffler

Filter screen appears.
3. The manufacturing number (S/N) of exhaust filter (DPF)
is displayed.
95TNED-05-02-56

T5-2-34
Group 2 Monitor
Engine Tachometer
Engine Tachometer No. Engine Engine Speed

Tachometer (Unit: min-1)
Scale
- 0 Less than 600
A 1 More than 600, less than 830
(Low Idle: 800)
C B 2 More than 830, less than 1030
- 3 More than 1030, less than 1200
B - 5 More than 1400, less than 1600
A - 6 More than 1600, less than 1800
C 9 More than 2200, less than 2400
TNED-02-05-080
(High Idle: 2350)
fNOTE: Engine tachometer scales are 200 min-1 step.
T5-2-35
Group 2 Monitor
Torque Converter Oil Temperature Gauge and

Brake Oil Pressure Gauge
Torque Converter Oil Temperature Gauge No. Oil Torque Converter Oil Temperature (Unit:
Temperature °C (°F) )
Gauge Scale
- 0 Less than 40 (104)
E A 1 More than 40 (104), less than 45 (113)
D - 2 More than 45 (113), less than 50 (122)
C
B - 3 More than 50 (122), less than 55 (131)
- 4 More than 55 (131), less than 60 (140)
B 7 More than 100 (212), less than 115 (239)
C 8 More than 115 (239), less than 120 (248)
A D 9 More than 120 (248), less than 125 (257)
TNED-02-05-081
E 10 More than 125 (257)
fNOTE: When the oil temperature is more than scale "D", the
alarm mark and the service indicator appear on the basic
screen.
Brake Oil Pressure Gauge No. Brake Oil Brake Oil Pressure (Unit: MPa (psi))
Pressure
Gauge Scale
- 0 less than 3 (435)
E
A 1 More than 3 (435), less than 3.5 (508)
B 2 More than 3.5 (508), less than 4.4 (638)
C 3 More than 4.4 (638), less than 5 (725)
D
- 4 More than 5 (725), less than 5.5 (798)
- 5 More than 5.5 (798), less than 6 (870)
C
D 6 More than 6 (870), less than 7 (1015)
B - 7 More than 7 (1015), less than 8 (1160)
A
TNED-02-05-082
E 10 More than 10 (1450)
fNOTE: When the oil pressure is lower than scale "B", the
alarm mark and the service indicator appear on the basic
screen.
T5-2-36
Group 2 Monitor
Coolant Temperature Gauge
Coolant Temperature Gauge No. Coolant Temperature (ºC (ºF))

A 25 (77)
E
D B 40 (104)
C 95 (203)
D 105 (221)
E (120) (248)
C
A
TNED-05-02-003
1- Coolant Temperature Gauge

TNED-05-02-004
T5-2-37
Group 2 Monitor
(Blank)
T5-2-38
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 information controller.
The recorded data is able to be downloaded to the personal

computer and uploaded to the center server via LAN, so that
the data can be used as “e-Service” (option). The machine
equipped with the optional communication terminal 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 information 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
information controller.)
Machine Travel Distance Travel distance during a day.
Engine Power Mode OFF and Total hours of power mode (OFF) and TCS (OFF) with engine running during a
Operating TCS OFF Hours day. (Hours are recorded by the information from MC.)
Hours Power Mode ON and Total hours of power mode (ON) and TCS (OFF) with engine running during a
TCS OFF Hours day. (Hours are recorded by the information from MC.)
Power Mode OFF and Total hours of power mode (OFF) and TCS (ON) with engine running during a
TCS ON Hours day. (Hours are recorded by the information from MC.)
Power Mode ON and Total hours of power mode (ON) and TCS (ON) with engine running during a day.
TCS ON Hours (Hours are recorded by the information from MC.)
Idling Hours Total hours when setting forward/reverse lever and forward/reverse switch
(OPT) in (N) position and running engine at less than 950 min-1 during a day.
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
Radiator Coolant Temperature (79 °C or Total hours when coolant temperature is less than 80 °C (176 °F) during a
less) 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 (201.2 °F) during a day.
Radiator Coolant Temperature (94 to 104 Total hours when coolant temperature is 94 °C (201.2 °F) or more and less
°C) than 105 °C (221 °F) during a day.
Radiator Coolant Temperature (105 °C or Total hours when coolant temperature is 105 °C (221 °F) or more during a
more) 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.
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 and Total engine operating hours selecting power mode (OFF) and TCS (OFF)
Operating TCS OFF Hours
Hours Power Mode ON and Total engine operating hours selecting power mode (ON) and TCS (OFF)
TCS OFF Hours
Power Mode OFF and Total engine operating hours selecting power mode (OFF) and TCS (ON)
TCS ON Hours
Power Mode ON and Total engine operating hours selecting power mode (ON) and TCS (ON)
TCS ON Hours
Consumed Fuel Quantity Total amount of fuel usage amount
Idling Hours Total operating hours when setting forward/reverse lever and forward/reverse
switch (OPT) in (N) position and running engine at less than 950 min-1
T5-3-5
Group 3 e-Service
Snapshot Data
Item Details
Serial No. - Machine serial no.
Snapshot Model 1 Difference of large-sized crawler, middle-sized crawler, wheeled excavator, and
wheel loader
Model 2 Detail difference on model 1
DTC Code Fault code and frequency of occurrence
Priority -
Hour Meter Machine’s hour meter at a time when trouble occurred
Occurrence: Year Year at a time when trouble occurred
Occurrence: Date Date at a time when trouble occurred
Occurrence: Time Time at a time when trouble occurred
SA -
SPN Version 001: Version 1
010: Version 2
011: Version 3
100: Version 4
111: Missing version
fNOTE: The data on machine body system including MC are

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

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

terminal, GPS antenna and communication antenna.
The functions of each equipment are as follows.
 Communication Terminal:
Receives the data from information controller and GPS
antenna, and sends the data to the communication
antenna.
 GPS Antenna:
Receives positional information of the machine.
 Communication Antenna:
Communicates the data.
T5-3-7
Group 3 e-Service
(Blank)
T5-3-8
Main Component (Overview)
95TNED-01-02-1
95TNED-01-02-2
1- Bucket 4- Front Combination Light 7- Rear Combination Light (Turn 9- Lift Arm (Boom)
2- Bell Crank (Lever) (Headlight, Turn Signal Light, Signal Light, Hazard Light, 10- Bucket Link
3- Bucket Cylinder Clearance Light, Hazard Light) Tail Light, Brake Light, Backup
5- Front Work Light Light)
6- Rear Work Light 8- Lift Arm (Boom) Cylinder
T5-4-1
Main Component
95TNED-01-02-3
1- Fan Motor 11- Steering Pilot Valve (Orbitrol) 21- Fuel Filter 29- Ride Control Accumulator
2- Radiator 12- Pilot Valve 22- Torque Converter Cooler (Option)
3- Inter Charge Air Cooler 13- Steering Valve 23- Hydraulic Oil Cooler 30- Ride Control Valve (Option)
4- Coolant Level and Surge Tank 14- Loading Control Valve 24- Steering Accumulator 31- Parallel/Tandem Switching
5- Exhaust Filter/Muffler 15- Stop Valve 25- Reducing Valve Solenoid Valve
6- Air Cleaner 16- Flow Regulator Valve 26- Solenoid Valve (for DPF 32- Fuel Cooler
7- Service Brake Accumulator 17- Fuel Pre-Filter Regen.) 33- Reducing Valve (for Brake Oil
8- Brake Charge (Unloader) Valve 18- T/M Oil Filter 27- Fan Control Valve Pressure)
9- Manifold Valve 19- Hydraulic Tank 28- Priority Valve (for Fan Motor)
10- Brake Valve 20- Engine
T5-4-2
Main Component
95TNED-01-02-4
1- Front Axle 4- Hydraulic Pump 7- Propeller Shaft (Rear) 9- Fuel Tank

2- Propeller Shaft (Front) 5- Transmission 8- Pressure Sensor (Brake Primary 10- Engine Oil Filter
3- Steering Cylinder 6- Rear Axle Pressure)
T5-4-3
Electric Component Layout (Overview)
12, 13
95TNED-01-02-5
1- Bucket Proximity Switch 5- Components Related with 8- Battery 11- Secondary Steering Pump
2- Lift Arm Angle Sensor Hydraulic Tank (Refer to T5- 9- Components Related with Fuel (Option)
3- ECM (Engine Control Module) 4-11) Tank (Refer to T5-4-12) 12- Rear View Camera
4- Components Related with Cab 6- Components Related with 10- Components Related with 13- Outside Temperature Sensor
(Refer to T5-4-5) Engine (Refer to T5-4-13) Hydraulic Pump (Refer to
7- Backup Alarm T5-4-15)
T5-4-4
Electrical System (Cab)
1 2 3
10
7
5
8
6
95TNED-01-02-29
1- Radio 5- Components Related with 7- Solar Isolation Sensor 10- Components Related with
2- Upper Switch Panel (Option) Right Console (Refer to T5-4-7) 8- Brake Lamp Switch Monitor and Switches (Refer
3- Speaker 6- Components Related with 9- Front Wiper Motor to T5-4-8)
4- Rear Wiper Motor Controllers and Relays (Refer
to T5-4-6)
T5-4-5
Controller and Relays
95TNED-01-02-17
1- Monitor Controller 11- Back Lamp and Alarm Relay 21- Load Dump Relay 31- MC (Main Controller) (Sub)
2- Flasher Relay 12- Work Light Relay (Front) 22- Neutral Relay 32- Tech2 (Engine Diagnostic Tool)
3- Air Conditioner Controller 13- Work Light Relay (Rear) 23- Left Turn Signal Light Relay Connector
4- MC (Main Controller) (Main) 14- Right Turn Signal Light Relay 24- Front Washer Relay
5- Cigar Socket Relay 15- Horn Relay 25- Rear Wiper Relay
6- Radio Relay 16- Starter Cut Relay 26- Rear Washer Relay
7- Head Light Relay (Left) 17- Parking Brake Relay 1 27- Engine ECM Main Relay
8- Head Light Relay (Right) 18- Parking Brake Relay 2 28- Cab Working Light (Rear) Relay
9- High-Beam Relay 19- Pilot Shut-Off Relay 29- Fuse Box
10- Bucket Leveler Relay 20- Brake Light Relay 30- MPDr. Connector
T5-4-6
Right Console
20
Fingertip Control Type
4
5
6 7 8
3 9 10 21
11 12
2
1
22
19
18
13
14
15
16
17
MNEC-01-042
MNEC-01-041
Multi-Function Joystick Type

22 20 1
5
6 7 8
2310
11 12
25
24
26
27
19
13
14
15
16 MNEC-01-044
17
MNEC-01-043
1- Auxiliary Control Lever 9- Forward/Reverse Selector 15- Auxiliary 23- Forward/Reverse Selector
(Option) Switch 16- Auxiliary Switch
2- Bucket Control Lever 10- Fan Reverse Rotation Switch 17- Ride Control Switch (Option) 24- Forward/Reverse Switch
3- Lift Arm Control Lever 11- Hydraulic Coupler Switch 18- Hold Switch 25- Multi-Function Joystick Lever
4- Forward/Reverse Switch (Option) 19- Right Console Slide Lever 26- Hold Switch (Under the Lever)
5- Control Lever Lock Switch 12- Auxiliary 20- DSS (Down Shift Switch) 27- Horn Switch (Under the Lever)
6- Declutch Position Switch 13- Secondary Steering Operation 21- Horn Switch
7- Travel Mode Selector Switch Check Switch (Option) 22- Quick Power Switch
8- Power Mode Switch 14- Exhaust Filter Switch
T5-4-7
Monitor and Switches
90TNED-01-02-29a
2 3 4 5 6 7 8 9
MNEC-01-037 MNEC-01-038
1- Front/Rear Wiper Switch 4- Parking Brake Switch 6- Monitor Panel (Refer to T5-4-9) 8- Multi-Function Monitor/Air
2- Hazard Switch 5- Forward/Reverse Lever/Shift 7- Turn Signal Lever/Light Conditioner Switch Panel
3- Work Light Switch Switch Switch/High-Low Beam Switch 9- Key Switch
T5-4-8
Monitor Panel
21 22 1 2 3 4
20 5
6
19 7
8
9
18
10
17
11
16 15 12
14 13 MNEC-01-001
1- Left Turn Signal Indicator 7- Hydraulic Oil Level Indicator 12- Discharge Warning Indicator 18- Engine Warning Indicator
2- High Beam Indicator 8- Low Steering Oil Pressure 13- Fuel Gauge 19- Engine Oil Low Pressure
3- Work Light Indicator Indicator (Option) 14- Multi Function Monitor Indicator
4- Right Turn Signal Indicator 9- Transmission Warning 15- Communication System Error 20- Preheat Indicator
5- Parking Brake Indicator Indicator Indicator 21- Air Filter Restriction Indicator
6- Brake Oil Low Pressure 10- Control Lever Lock Indicator 16- Coolant Temperature Gauge 22- Clearance Light Indicator
Indicator 11- Low Fuel Level Indicator 17- Overheat Indicator
T5-4-9
Electrical System (Relays)
95TNED-01-02-6
1- Battery Relay 2- Fusible Link (100A: S/N ~5058, 3- Fusible Link (70A) x 2 5- Starter Relay
140A: S/N 5059~) x 2 4- Glow Relay
T5-4-10
Electrical System (Around Hydraulic Oil Tank)
95TNED-01-02-7
1- Hydraulic Oil Level Sensor 3- Hydraulic Oil Temperature

2- Hydraulic Tank Sensor
4- Window Washer Level Sensor
T5-4-11
Electrical System (Around Fuel Tank)
95TNED-01-02-8
1- Hydraulic Fan Circuit Pressure 2- Fan Motor Control Valve 4- Fuel Level Sensor
Sensor 3- Fuel Tank
T5-4-12
Engine
17
16 95TNED-01-02-18
95TNED-01-02-9
1- EGR Valves 6- Cam Angle Sensor 11- Common Rail Pressure Sensor 16- Fuel Priming Solenoid Pump
2- Injector Connector 7- Turbocharger 12- Fuel Temperature Sensor (Option)
3- Boost Temperature Sensor 8- Overheat Switch 13- Supply Pump 17- Fuel Pre-Filter
4- Boost Pressure Sensor 9- Coolant Temperature Sensor 14- Crank Revolution Sensor
5- Glow Plug 10- Intake Throttle 15- Engine Oil Pressure Sensor
T5-4-13
Exhaust Filter
Arrow View A
95TNED-01-02-10
1- Diesel Oxidation Catalyst 2- Diesel Particulate Filter (DPF) 3- Differential Pressure Sensor
(DOC) Exhaust Temperature Exhaust Temperature Sensor
Sensor
T5-4-14
Hydraulic Pump
Main Pump
95TNED-01-02-11
1- Steering and Loading Pump 3- Regulator 1

2- Proportional Reducing Valve 4- Regulator 2
T5-4-15
Accessory Pump
95TNED-01-02-12
5- Pilot, Fan and Brake Pump
T5-4-16
Transmission and Torque Converter Assembly
95TNED-01-02-13
1- Air Breather 5- Proportional Solenoid Valve 8- Proportional Solenoid Valve 11- Transmission Oil Temperature
2- Transmission Control Valve (For High Clutch) (For 2nd Speed Clutch) Sensor
3- Speed Sensor 6- Proportional Solenoid Valve 9- Proportional Solenoid Valve 12- Torque Converter Oil
4- Proportional Solenoid Valve (For Reverse Clutch) (For 3rd Speed Clutch) Temperature Sensor
(For Low Clutch 7- Proportional Solenoid Valve 10- Proportional Solenoid Valve
(For 1st Speed Clutch) (For Lock-Up Clutch)
T5-4-17
Multiple Control Valve
95TNED-01-02-14
1- Main Relief Valve 3- Overload Relief Valve (Bucket: 5- Solenoid Valve (for Ride 7- Load Sensing Control
2- Overload Relief Valve (Bucket: Bottom Side) Control) (Option) (Negative Control) Relief Valve
Rod Side) 4- Overload Relief Valve (Lift Arm: 6- Bleed-off Compensation Valve
Rod Side)
T5-4-18
Unloader Valve (Brake Charge Valve) Combination Valve
95TNED-01-02-15 95TNED-01-02-16
1- Pressure Sensor (Service 3- Reducing Valve (for Brake Oil 1- Safety Lock Solenoid Valve 4- Pressure Sensor (Parking
Brake Pressure Alarm) Pressure) 2- Parking Brake Solenoid Valve Brake Lamp)
2- Brake Accumulator 3- Pressure Sensor (Loading 5- Reducing Valve
Pilot Pressure) 6- Parallel/Tandem Switching
Solenoid Valve
Steering Valve
90T4GB-01-02-20
1- Main Relief Valve

2- Overload Relief Valve
T5-4-19
Flow Regulator Valve Ride Control Valve (Option)
90TNED-01-02-22 90Z7-01-02-RC
1- Pressure Sensor (Bucket Roll 3- Pressure Sensor (Lift Arm 1- Solenoid Valve
Back) (Boom) Raise)
2- Pressure Sensor (Bucket
Dump)
Secondary Steering Pump (Option)
90TNED-01-02-19
1- Electric Motor 2- Gear Pump 3- Relief Valve
T5-4-20
Troubleshooting A (Base Machine Diagnosis By

Using Fault Codes) Procedure
Refer to troubleshooting A procedure in case any fault codes fNOTE: The engine controller (ECM) judges the engine
are displayed after diagnosing by using MPDr. or the service malfunction. After the engine is repaired, select Fault
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.
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 List
Fault Code MPDr. Message Category Reference 1 Reference 2

111000-2 Abnormal EEPROM MC, SC T5-5-9, T5-5-22 T5-5-66
111001-2 Abnormal RAM MC, SC T5-5-9, T5-5-22 T5-5-66
111002-2 Abnormal A/D Converter MC, SC T5-5-9, T5-5-22 T5-5-66
111003-3 Abnormal Sensor Voltage MC, SC T5-5-9, T5-5-22 T5-5-66
111006-2 (MC) Engine Controller Communication Error MC T5-5-10 T5-5-69
111007-2 (MC) Information Controller Communication Error 1 MC T5-5-10 T5-5-69
111008-2 (MC) Information Controller Communication Error 2 MC T5-5-10 T5-5-74
111009-2 (MC) Monitor Controller Communication Error 1 MC T5-5-10 T5-5-69
111010-2 (MC) Monitor Controller Communication Error 2 MC T5-5-10 T5-5-74
111012-2 (MC) Sub-Controller Communication Error 1 MC T5-5-10 T5-5-69
111013-2 (MC) Sub-Controller Communication Error 2 MC T5-5-10 T5-5-74
111014-2 (MC) Air Conditioner Controller Communication Error MC T5-5-10 T5-5-74
111015-2 (SC) Information Controller Communication Error 1 SC T5-5-23 T5-5-69
111016-2 (SC) Information Controller Communication Error 2 SC T5-5-23 T5-5-74
111017-2 (SC) Monitor Controller Communication Error 1 SC T5-5-23 T5-5-69
111018-2 (SC) Monitor Controller Communication Error 2 SC T5-5-23 T5-5-74
111019-2 (SC) MC Controller Communication Error 1 SC T5-5-23 T5-5-69
111020-2 (SC) MC Controller Communication Error 2 SC T5-5-23 T5-5-74
111021-2 (SC) Air Conditioner Controller Communication Error SC T5-5-23 T5-5-74
111024-2 (SC) Engine Controller Communication Error SC T5-5-23 T5-5-69
111025-2 (MC) Column Monitor Controller Communication Error MC T5-5-10 T5-5-74
111026-2 (SC) Column Monitor Controller Communication Error SC T5-5-23 T5-5-74
111103-3 Accelerator Pedal Circuit High Input MC T5-5-11 T5-5-79
111103-4 Accelerator Pedal Circuit Low Input MC T5-5-11 T5-5-79
111105-3 Abnormal Engine Speed Sensor MC T5-5-11 T5-5-79
111200-3 Lift Arm Raise Pilot Pressure Sensor Circuit High Input SC T5-5-25 T5-5-81
111200-4 Lift Arm Raise Pilot Pressure Sensor Circuit Low Input SC T5-5-25 T5-5-81
111202-3 Bucket Tilt Pilot Pressure Sensor Circuit High Input SC T5-5-25 T5-5-81
111202-4 Bucket Tilt Pilot Pressure Sensor Circuit Low Input SC T5-5-25 T5-5-81
111203-3 Bucket Dump Pilot Pressure Sensor Circuit High Input SC T5-5-25 T5-5-81
111203-4 Bucket Dump Pilot Pressure Sensor Circuit Low Input SC T5-5-25 T5-5-81
111204-3 Pump Delivery Pressure Sensor Circuit High Input MC T5-5-12 T5-5-82
111204-4 Pump Delivery Pressure Sensor Circuit Low Input MC T5-5-12 T5-5-82
111205-3 Lift Arm Angle Sensor Circuit High Input SC T5-5-31 T5-5-80
111205-4 Lift Arm Angle Sensor Circuit Low Input SC T5-5-31 T5-5-80
111206-3 Hyd. Fan Circuit Pressure Sensor Circuit High Input SC T5-5-24 T5-5-83
111206-4 Hyd. Fan Circuit Pressure Sensor Circuit Low Input SC T5-5-24 T5-5-83
111207-3 Refrigerant Pressure Sensor Circuit High Input SC T5-5-31 T5-5-80
111207-4 Refrigerant Pressure Sensor Circuit Low Input SC T5-5-31 T5-5-80
111208-3 Emergency Steering Check Pressure Sensor Circuit High SC T5-5-24 T5-5-84
Input
111208-4 Emergency Steering Check Pressure Sensor Circuit High SC T5-5-24 T5-5-84
Input
T5-5-3
MPDr. Fault Code List (Continued)

111210-3 Clutch Pressure_1st Circuit High Input MC T5-5-13 T5-5-86
111210-4 Clutch Pressure_1st Circuit Low Input MC T5-5-13 T5-5-86
111211-3 Clutch Pressure_2nd Circuit High Input MC T5-5-13 T5-5-86
111211-4 Clutch Pressure_2nd Circuit Low Input MC T5-5-13 T5-5-86
111214-3 Clutch Pressure_F Circuit High Input MC T5-5-13 T5-5-87
111214-4 Clutch Pressure_F Circuit Low Input MC T5-5-13 T5-5-87
111215-3 Clutch Pressure_R Circuit High Input MC T5-5-13 T5-5-87
111215-4 Clutch Pressure_R Circuit Low Input MC T5-5-13 T5-5-87
111217-3 Pilot Pressure Sensor Circuit High Input SC T5-5-26 T5-5-83
111217-4 Pilot Pressure Sensor Circuit Low Input SC T5-5-26 T5-5-83
111309-3 Service Brake Pressure (Front) Sensor Circuit High Input SC T5-5-26 T5-5-88
111309-4 Service Brake Pressure (Front) Sensor Circuit Low Input SC T5-5-26 T5-5-88
111310-3 Service Brake Pressure (Rear) Sensor Circuit High Input SC T5-5-26 T5-5-88
111310-4 Service Brake Pressure (Rear) Sensor Circuit Low Input SC T5-5-26 T5-5-88
111312-3 Service Brake Secondary Pressure Sensor Circuit High MC T5-5-14 T5-5-82
Input
111312-4 Service Brake Secondary Pressure Sensor Circuit Low MC T5-5-14 T5-5-82
Input
111313-3 Parking Brake Pressure Sensor Circuit High Input MC T5-5-14 T5-5-85
111313-4 Parking Brake Pressure Sensor Circuit Low Input MC T5-5-14 T5-5-85
111406-2 Muffler Filter Regeneration Control P/S Valve Abnormal MC T5-5-15 T5-5-89
FB
111406-3 Muffler Filter Regeneration Control P/S Valve FB High MC T5-5-15 T5-5-89
Current
111406-4 Muffler Filter Regeneration Control P/S Valve FB Low MC T5-5-15 T5-5-89
Current
111407-2 Lift Speed Increase P/S Valve Abnormal FB SC T5-5-27 T5-5-90
111407-3 Lift Speed Increase P/S Valve FB High Current SC T5-5-27 T5-5-90
111407-4 Lift Speed Increase P/S Valve Low Current SC T5-5-27 T5-5-90
111408-2 Auto Brake P/S Valve Abnormal FB MC T5-5-18 T5-5-97
111408-3 Auto Brake P/S Valve FB High Current MC T5-5-18 T5-5-97
111408-4 Auto Brake P/S Valve FB Low Current MC T5-5-18 T5-5-97
111410-2 Parallel/Tandem Control P/S Valve Abnormal FB SC T5-5-28 T5-5-91
111410-3 Parallel/Tandem Control P/S Valve FB High Current SC T5-5-28 T5-5-91
111410-4 Parallel/Tandem Control P/S Valve FB Low Current SC T5-5-28 T5-5-91
111411-2 Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB SC T5-5-28 T5-5-92
111411-3 Hydraulic Fan Reverse Rotation P/S Valve FB High SC T5-5-28 T5-5-92
Current
111411-4 Hydraulic Fan Reverse Rotation P/S Valve FB Low Current SC T5-5-28 T5-5-92
T5-5-4

111412-2 Hyd. Fan P/S Valve Abnormal Feedback SC T5-5-28 T5-5-93
111412-3 Hyd. Fan P/S Valve Feedback High Current SC T5-5-28 T5-5-93
111412-4 Hyd. Fan P/S Valve Feedback Low Current SC T5-5-28 T5-5-93
111413-2 Pump Swash Angle P/S Valve Abnormal FB MC T5-5-15 T5-5-94
111413-3 Pump Swash Angle P/S Valve FB High Current MC T5-5-15 T5-5-94
111413-4 Pump Swash Angle P/S Valve FB Low Current MC T5-5-15 T5-5-94
111414-2 T/M Clutch 1st P/S Valve Abnormal FB MC T5-5-16 T5-5-95
111414-3 T/M Clutch 1st P/S Valve FB High Current MC T5-5-16 T5-5-95
111414-4 T/M Clutch 1st P/S Valve FB Low Current MC T5-5-16 T5-5-96
111415-2 T/M Clutch 2nd P/S Valve Abnormal FB MC T5-5-16 T5-5-95
111415-3 T/M Clutch 2nd P/S Valve FB High Current MC T5-5-16 T5-5-95
111415-4 T/M Clutch 2nd P/S Valve FB Low Current MC T5-5-16 T5-5-96
111416-2 T/M Clutch 3rd P/S Valve Abnormal FB MC T5-5-16 T5-5-95
111416-3 T/M Clutch 3rd P/S Valve FB High Current MC T5-5-16 T5-5-95
111416-4 T/M Clutch 3rd P/S Valve FB Low Current MC T5-5-16 T5-5-96
111418-2 T/M Clutch Forward P/S Valve Abnormal FB MC T5-5-17 T5-5-95
111418-3 T/M Clutch Forward P/S Valve FB High Current MC T5-5-17 T5-5-95
111418-4 T/M Clutch Forward P/S Valve FB Low Current MC T5-5-17 T5-5-96
111419-2 T/M Clutch Reverse P/S Valve Abnormal FB MC T5-5-17 T5-5-95
111419-3 T/M Clutch Reverse P/S Valve FB High Current MC T5-5-17 T5-5-95
111419-4 T/M Clutch Reverse P/S Valve FB Low Current MC T5-5-17 T5-5-96
111420-2 T/M Clutch Fast P/S Valve Abnormal FB MC T5-5-18 T5-5-95
111420-3 T/M Clutch Fast P/S Valve FB High Current MC T5-5-18 T5-5-95
111420-4 T/M Clutch Fast P/S Valve FB Low Current MC T5-5-18 T5-5-96
111421-2 Lockup P/S Valve Abnormal FB MC T5-5-18 T5-5-95
111421-3 Lockup P/S Valve FB High Current MC T5-5-18 T5-5-95
111421-4 Lockup P/S Valve FB Low Current MC T5-5-18 T5-5-96
111422-2 Ride Control (Bottom) P/S Valve Abnormal FB SC T5-5-29 T5-5-98
111422-3 Ride Control (Bottom) P/S Valve FB High Current SC T5-5-29 T5-5-98
111422-4 Ride Control (Bottom) P/S Valve FB Low Current SC T5-5-29 T5-5-98
111423-2 Ride Control (Rod) P/S Valve Abnormal FB SC T5-5-29 T5-5-99
111423-3 Ride Control (Rod) P/S Valve FB High Current SC T5-5-29 T5-5-99
111423-4 Ride Control (Rod) P/S Valve FB Low Current SC T5-5-29 T5-5-99
111502-2 T/M Clutch Pressure Decreased (1-speed) when MC T5-5-13 T5-5-100
Engaging the Clutch
111503-2 T/M Clutch Pressure Decreased (2-speed) when MC T5-5-13 T5-5-100
Engaging the Clutch
111506-2 T/M Clutch Pressure Decreased (F) when Engaging the MC T5-5-13 T5-5-100
Clutch
111507-2 T/M Clutch Pressure Decreased (R) when Engaging the MC T5-5-13 T5-5-100
Clutch
111600-4 T/M Out Speed Sensor Circuit Low Input MC T5-5-19 T5-5-85
111720-2 Lift arm angle sensor is uncalibrated. SC T5-5-31 -
T5-5-5

111900-3 Torque Converter Oil Temperature Sensor Circuit High SC T5-5-30 T5-5-101
Input
111900-4 Torque Converter Oil Temperature Sensor Circuit Low SC T5-5-30 T5-5-101
Input
111901-3 Hyd. Oil Temp Sensor Circuit High Input SC T5-5-30 T5-5-102
111901-4 Hyd. Oil Temp Sensor Circuit Low Input SC T5-5-30 T5-5-102
111903-3 T/M Oil Temp Sensor Circuit High Input MC T5-5-19 T5-5-103
111903-4 T/M Oil Temp Sensor Circuit Low Input MC T5-5-19 T5-5-103
111904-2 Column FNR SW Failure MC T5-5-19 -
111905-2 Implement FNR SW Failure MC T5-5-19 -
111906-3 F Axle Oil Temperature Sensor Circuit High Input SC T5-5-30 T5-5-104
111906-4 F Axle Oil Temperature Sensor Circuit Low Input SC T5-5-30 T5-5-104
111907-3 R Axle Oil Temperature Sensor Circuit High Input SC T5-5-30 T5-5-104
111907-4 R Axle Oil Temperature Sensor Circuit Low Input SC T5-5-30 T5-5-104
113002-2 (Monitor Controller) Engine Controller Monitor T5-5-33 T5-5-70
Communication Error
113003-2 (Monitor Controller) Main Controller Communication Monitor T5-5-33 T5-5-70
Error 1
113004-2 (Monitor Controller) Main Controller Communication Monitor T5-5-33 T5-5-75
Error 2
113005-2 (Monitor Controller) ICF Communication Error 1 Monitor T5-5-33 T5-5-70
113006-2 (Monitor Controller) ICF Communication Error 2 Monitor T5-5-33 T5-5-75
113007-2 (Monitor Controller) Column Controller Monitor T5-5-33 T5-5-75
Communication Error
113010-2 (Monitor Controller) Sub-Controller Communication Monitor T5-5-33 T5-5-70
Error 1
113011-2 (Monitor Controller) Sub-Controller Communication Monitor T5-5-33 T5-5-75
Error 2
113303-2 Abnormal thermistor temperature (monitor inside Monitor T5-5-34 -
temperature)
114001-2 Flash Memory Read/Write Error Information T5-5-35 -
114002-2 External RAM Read/Write Error Information T5-5-35 -
114003-2 Abnormal EEPROM Information T5-5-35 -
114008-2 Abnormal Internal RAM Information T5-5-35 -
114010-2 (Information Controller) Engine Controller Information T5-5-36 T5-5-70
Communication Error
114011-2 (Information Controller) Main Controller Information T5-5-36 T5-5-70
Communication Error 1
114012-2 (Information Controller) Main Controller Information T5-5-36 T5-5-75
114013-2 (Information Controller) Monitor Controller Information T5-5-36 T5-5-70
114014-2 (Information Controller) Monitor Controller Information T5-5-36 T5-5-75
T5-5-6

114015-2 (Information Controller) Column Controller Information T5-5-36 T5-5-75
Communication Error
114018-2 (Information Controller) Sub-Controller Information T5-5-36 T5-5-70
114019-2 (Information Controller) Sub-Controller Information T5-5-36 T5-5-75
114100-2 Communication Terminal: Abnormal EEPROM Communication T5-5-41 -
Terminal
114101-2 Communication Terminal: Abnormal IB/OB Queue Communication T5-5-41 -
Terminal
114102-2 Communication Terminal: Abnormal Local Loop Back Communication T5-5-41 -
Terminal
114103-2 Communication Terminal: No Satellite Found Communication T5-5-41 -
Terminal
114104-2 Communication Terminal: Remote Loop Back Error 1 Communication T5-5-41 -
Terminal
114105-2 Communication Terminal: Remote Loop Back Error 2 Communication T5-5-41 -
Terminal
114106-2 Communication Terminal: Transmission/Receiving Communication T5-5-41 -
Data Unmatched Terminal
115001-2 Abnormal REG input H level Column Display T5-5-38 T5-5-107
115002-2 CAN Communication Error 2 Column Display T5-5-38 -
115003-2 Abnormal EEPROM Column Display T5-5-38 -
115011-3 Fuel Level Sensor Circuit High Input Column Display T5-5-38 T5-5-108
115011-4 Fuel Level Sensor Circuit Low Input Column Display T5-5-38 T5-5-108
115018-2 Abnormal 24V Output Column Display T5-5-38 -
120000-2 Hydraulic Oil Overheat Alarm SC T5-5-32 T5-5-106
120001-2 Main Pump Pressure Alarm MC T5-5-20 T5-5-105
120002-2 Axle Oil Temperature Alarm SC T5-5-32 T5-5-106
120003-2 Emergency Steering Activated SC T5-5-32 T5-5-106
120004-2 Emergency Steering Activated Pressure Alarm SC T5-5-32 T5-5-106
120005-2 Transmission Oil Temperature Overheat Alarm MC T5-5-20 T5-5-105
120006-2 Transmission Oil Pressure Alarm MC T5-5-20 -
120007-2 Transmission Filter Restriction Alarm MC T5-5-20 -
120008-2 Muffler Filter Abnormal MC T5-5-21 T5-5-105
120013-2 Brake Oil Pressure Alarm MC T5-5-21 -
120014-2 Overrun Alarm MC T5-5-21 T5-5-105
120016-2 Auto Brake Alarm MC T5-5-20 -
120101-2 Exhaust Temperature Alarm MC T5-5-21 T5-5-105
120102-2 Intake Air Temperature Alarm MC T5-5-21 T5-5-105
120103-2 Boost Temperature Increase Alarm MC T5-5-21 T5-5-105
120104-2 Fuel Temperature Increase Alarm MC T5-5-21 T5-5-105
120106-2 EGR Gas Temperature Alarm MC T5-5-21 T5-5-105
T5-5-7

120300-2 System Failure Alarm Monitor T5-5-34 T5-5-110
120301-2 Muffler Filter Alarm Monitor T5-5-34 T5-5-110
120400-2 Fuel Filter Restriction Alarm Information T5-5-37 T5-5-110
120401-2 Water Separator Alarm (Option) Information T5-5-37 T5-5-110
120500-2 Overheat Alarm Column Display T5-5-39 T5-5-111
120501-2 Engine Error Column Display T5-5-39 T5-5-111
120502-2 Engine Oil Pressure Alarm Column Display T5-5-39 T5-5-111
120503-2 Air Cleaner Restriction Alarm Column Display T5-5-39 T5-5-111
120504-2 Hydraulic Oil Level Alarm Column Display T5-5-39 T5-5-111
120505-2 Brake Pressure Alarm Column Display T5-5-39 T5-5-112
120506-2 Steering Oil Pressure Alarm Column Display T5-5-39 T5-5-112
120507-2 T/M Malfunction Column Display T5-5-39 T5-5-112
fNOTE:
Refer to page T5-5-40 for the air conditioner controller
fault code list.
Refer to page T5-5-42 for the ECM fault code list.
T5-5-8
MC Fault Code List

Controller Hardware Failure
Fault Code Trouble or MP Dr. Cause Symptoms in Machine Remedy
Message Operation When Trouble
Occurs.
111000-2 Abnormal EEPROM Faulty MC - Replace MC.
111001-2 Abnormal RAM Faulty MC - Replace MC.
111002-2 Abnormal A/D Faulty MC - Replace MC.
Converter
111003-3 Abnormal Sensor Faulty MC Although the accelerator Check the sensor connected
Voltage Faulty sensor pedal is operated, the engine to MC.
Faulty harness speed does not change. Check the harness.
Replace MC.
fNOTE: MC here refers to the Main Controller (Main).

These error codes are observed on the Service Menu -
Troubleshooting - Main (T/M) screen.
T5-5-9
CAN Data Reception Failure

Fault Code Trouble or MP Dr. Cause Symptoms in Machine Operation Remedy
Message When Trouble Occurs.
111006-2 (MC) Engine Controller Faulty harness Even if accelerator pedal is operated, Check the harness.
Communication Error engine speed does not change.
The manual regeneration of exhaust
filter cannot be performed.
111007-2 (MC) Information Faulty monitor Nothing observed. Check the CAN1
Controller controller harness.
Communication Error Faulty CAN1 Replace monitor
1 harness controller.
111008-2 (MC) Information Faulty monitor Nothing observed. Check the CAN2
111009-2 (MC) Monitor Faulty monitor Nothing observed. Check the CAN1
111010-2 (MC) Monitor Faulty monitor Nothing observed. Check the CAN2
111012-2 (MC) Sub-Controller Faulty main Nothing observed. Check the CAN
Communication Error controller (sub) harness.
1 Faulty CAN1 or
CAN2 harness
111013-2 (MC) Sub-Controller Faulty main Nothing observed. Check the CAN
Communication Error controller (sub) harness.
2 Faulty CAN1 or
CAN2 harness
111014-2 (MC) Air Conditioner Faulty air The air conditioner does not work. Check the CAN2
Controller conditioner harness.
Communication Error controller Replace the
Faulty CAN2 air conditioner
harness controller.
111025-2 (MC) Column Faulty column The transmission warning indicator Check the CAN2
Monitor Controller display controller on column display controller do not harness.
Communication Error Faulty CAN2 light. Replace column
harness Overrun alarm control is disabled. display controller.

T5-5-10
Engine Failure
Occurs.
111103-3 Accelerator Pedal Voltage: more than The engine speed is fixed to Check the harness.
Circuit High Input 4.74 V 1000 min-1. Replace the accelerator
Although the accelerator pedal sensor.
pedal is operated, exhaust
filter manual/auto
regeneration control cannot
be deactivated.
111103-4 Accelerator Pedal Voltage: less than The engine speed is fixed to Check the harness.
Circuit Low Input 0.25 V 1000 min-1. Replace the accelerator
Although the accelerator pedal sensor.
pedal is operated, exhaust
filter manual regeneration
control cannot be
deactivated.
111105-3 Abnormal Engine Torque converter Although the accelerator Check the harness.
Speed Sensor input speed sensor pedal is operated, exhaust Check the engine speed
= 0 min-1 and filter manual regeneration sensor.
Engine speed sent control cannot be
from ECM (CAN) > deactivated.
500 min-1
fNOTE: These error codes are observed on the Service Menu -

T5-5-11
Pump Failure
111204-3 Pump Delivery Voltage: 4.75 V Engine speed regulator for Check the harness.
Pressure Sensor or more digging is deactivated. Replace the pump delivery
Circuit High Input pressure sensor.
111204-4 Pump Delivery Voltage: less Engine speed regulator for Check the harness.
Pressure Sensor than 0.25 V digging is deactivated. Replace the pump delivery
Circuit Low Input pressure sensor.

T5-5-12
Transmission Clutch Pressure Failure

111210-3 Clutch Pressure_1st Voltage: 4.75 V Transmission warning indicator on Check the harness.
Circuit High Input or more the monitor panel turns ON. Replace the 1st clutch
The shift change to the 1st range pressure sensor.
feels worse.
111210-4 Clutch Pressure_1st Voltage: less Transmission warning indicator on Check the harness.
Circuit Low Input than 0.25 V the monitor panel turns ON. Replace the 1st clutch
The shift change to the 1st range pressure sensor.
feels worse.
111211-3 Clutch Pressure_2nd Voltage: 4.75 V Transmission warning indicator on Check the harness.
Circuit High Input or more the monitor panel turns ON. Replace the 2nd clutch
The shift change to the 2nd range pressure sensor.
feels worse.
111211-4 Clutch Pressure_2nd Voltage: less Transmission warning indicator on Check the harness.
Circuit Low Input than 0.25 V the monitor panel turns ON. Replace the 2nd clutch
The shift change to the 2nd range pressure sensor.
feels worse.
111214-3 Clutch Pressure_F Voltage: 4.75 V Transmission warning indicator on Check the harness.
Circuit High Input or more the monitor panel turns ON. Replace the forward clutch
The machine direction change to pressure sensor.
forward feels worse.
111214-4 Clutch Pressure_F Voltage: less Transmission warning indicator on Check the harness.
Circuit Low Input than 0.25 V the monitor panel turns ON. Replace the forward clutch
forward feels worse.
111215-3 Clutch Pressure_R Voltage: 4.75 V Transmission warning indicator on Check the harness.
Circuit High Input or more the monitor panel turns ON. Replace the reverse clutch
reverse feels worse.
111215-4 Clutch Pressure_R Voltage: less Transmission warning indicator on Check the harness.
Circuit Low Input than 0.25 V the monitor panel turns ON. Replace the reverse clutch
reverse feels worse.
111502-2 T/M Clutch Pressure Pressure: less Transmission warning indicator on Check the harness.
Decreased (1-speed) than 2 MPa the monitor panel turns ON. Replace the 1st clutch
when Engaging the (290 PSI) Transmission oil pressure alarm pressure sensor.
Clutch appears on the monitor display.
Decreased (2-speed) than 2.2 MPa the monitor panel turns ON. Replace the 2nd clutch
when Engaging the (320 PSI) Transmission oil pressure alarm pressure sensor.
Clutch appears on the monitor display.
Decreased (F) when than 2.2 MPa the monitor panel turns ON. Replace the forward clutch
Engaging the Clutch (320 PSI) Transmission oil pressure alarm pressure sensor.
appears on the monitor display.
Decreased (R) when than 2.2 MPa the monitor panel turns ON. Replace the reverse clutch
Engaging the Clutch (320 PSI) Transmission oil pressure alarm pressure sensor.
appears on the monitor display.

T5-5-13
Pilot Failure
111312-3 Service Brake Voltage: 4.75 VThe declutch control becomes Check the harness.
Secondary Pressure or more ineffective. The declutch is Replace the pressure sensor
Sensor Circuit High impossible. (brake secondary pressure).
Input The speed shift does not
automatically downshift to first
speed with the travel mode set in
AUTO 1 mode.
111312-4 Service Brake Voltage: less The declutch control becomes Check the harness.
Secondary Pressure than 0.25 V ineffective. The declutch is Replace the pressure sensor
Sensor Circuit Low impossible. (brake secondary pressure).
Input The speed shift does not
automatically downshift to first
speed with the travel mode set in
AUTO 1 mode.
111313-3 Parking Brake Voltage: 4.75 V Although the parking brake Check the harness.
Pressure Sensor or more is applied, the parking brake Replace the pressure sensor
Circuit High Input indicator is not ON. (The parking (parking brake).
brake signal is forcibly fixed to the
Release side.)
111313-4 Parking Brake Voltage: less Although the parking brake Check the harness.
Pressure Sensor than 0.25 V is applied, the parking brake Replace the pressure sensor
Circuit Low Input indicator is not ON. (The parking (parking brake).
brake signal is forcibly fixed to the
Release side.)

T5-5-14
Proportional Solenoid Valve Failure

111406-2 Muffler Filter Solenoid valve Regeneration may not complete as Check the harness.
Regeneration Control output: 140 mA or the load cannot be applied during
P/S Valve Abnormal FB more, and manual or auto regeneration of the
Feedback current: exhaust filter.
more than 920 mA
or less than 70 mA
(both detected)
111406-3 Muffler Filter Current: more than Regeneration may not complete as Check the harness.
Regeneration Control 920 mA the load cannot be applied during
P/S Valve FB High manual or auto regeneration of the
Current exhaust filter.
111406-4 Muffler Filter Current: less than Regeneration may not complete as Check the harness.
Regeneration Control 70 mA the load cannot be applied during
P/S Valve FB Low manual or auto regeneration of the
Current exhaust filter.
111413-2 Pump Swash Angle P/S Solenoid valve Engine speed regulator for digging Check the harness.
Valve Abnormal FB output: 140 mA or is deactivated.
more, and
Feedback current:
more than 920 mA
or less than 70 mA
(both detected)
111413-3 Pump Swash Angle P/S Current: more than The engine stalls is remarkable Check the harness.
Valve FB High Current 920 mA at high loaded. In addition, the
engine lug-down is remarkable.
111413-4 Pump Swash Angle P/S Current: less than Engine speed regulator for digging Check the harness.
Valve FB Low Current 70 mA is deactivated.

T5-5-15

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

T5-5-16

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

T5-5-17

111420-2 T/M Clutch Fast P/S Solenoid valve High clutch gear engagement is Check the harness.
Valve Abnormal FB output: 140 mA or not possible.
more, and If forward is selected, T/M is in the
more than 920 mA
or less than 70 mA
(both detected)
111420-3 T/M Clutch Fast P/S Current: more than High clutch gear engagement is Check the harness.
Valve FB High Current 920 mA not possible.
If forward is selected, T/M is in the
neutral status.
111420-4 T/M Clutch Fast P/S Current: less than High clutch gear engagement is Check the harness.
Valve FB Low Current 70 mA not possible.
If forward is selected, T/M is in the
neutral status.
111421-2 Lockup P/S Valve Solenoid valve Lockup clutch gear engagement is Check the harness.
Abnormal FB output: 140 mA or not possible.
more, and Lockup shift range is not available.
Feedback current:
more than 920 mA
or less than 70 mA
(both detected)
111421-3 Lockup P/S Valve FB Current: more than Lockup clutch gear engagement is Check the harness.
High Current 920 mA not possible.
Lockup shift range is not available.
111421-4 Lockup P/S Valve FB Current: less than Lockup clutch gear engagement is Check the harness.
Low Current 70 mA not possible.
Lockup shift range is not available.
111408-2 Auto Brake P/S Valve Solenoid valve Auto brake does not work. Check the harness.
Abnormal FB output: 140 mA or Auto brake warning alarm appears
more, and on the monitor display.
Feedback current:
more than 920 mA
or less than 70 mA
(both detected)
111408-3 Auto Brake P/S Valve Current: more than Auto brake does not work. Check the harness.
FB High Current 920 mA Auto brake warning alarm appears
on the monitor display.
111408-4 Auto Brake P/S Valve Current: less than Auto brake does not work. Check the harness.
FB Low Current 70 mA Auto brake warning alarm appears
on the monitor display.

T5-5-18
Sensor Failure
111600-4 T/M Out Speed Sensor Harness Abnormal shift down feeling. Check the harness.
Circuit Low Input disconnection Selected speed range is not correctly Replace the T/M
detected at indicated at shift change. output revolution
starter key turns sensor (machine
ON and voltage is speed sensor).
1.1 V or less.
111903-3 T/M Oil Temp Sensor Voltage: 4.75 V or Abnormal shift change feeling. Check the harness.
Circuit High Input more
111903-4 T/M Oil Temp Sensor Voltage: less than Abnormal shift change feeling. Check the harness.
Circuit Low Input 0.25 V
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.

T5-5-19
Alarms on Monitor
Occurs.
120001-2 Main Pump Pressure Main pump oil The alarm is displayed on Check the harness.
Alarm pressure is high. the monitor. Replace the main pump oil
pressure sensor.
120005-2 Transmission Oil Transmission oil The alarm is displayed on Check the harness.
Temperature Overheat temperature is the monitor. Replace the torque converter
Alarm high. oil temperature sensor.
120006-2 Transmission Oil Transmission oil The alarm is displayed on Check the transmission clutch
Pressure Alarm pressure is low. the monitor. pressure sensors, and replace if
necessary.
Check the clutch solenoid
hydraulic circuit.
120007-2 Transmission Filter Transmission oil The alarm is displayed on Disconnect the transmission
Restriction Alarm filter is clogged. the monitor. filter clog detection switch
connector.
Check the harness between the
clog switch and MC.
120016-2 Auto Brake Alarm Faulty auto brake The alarm is displayed on Check the harness.
solenoid. the monitor. Replace the auto brake
solenoid valve.

T5-5-20
Alarms on Monitor
Occurs.
120008-2 Muffler Filter Abnormal Abnormal pump The alarm is displayed Check the harness.
delivery pressure on the monitor.
sensor. Regeneration may not
Abnormal current complete as the load
feedback of pump cannot be applied
torque control during manual or auto
solenoid valve. regeneration of the
Abnormal current exhaust filter.
feedback of
exhaust filter
regeneration
control solenoid
valve.
120013-2 Brake Oil Pressure Brake oil pressure The alarm is displayed Check the harness.
Alarm is low. on the monitor. Check/replace the brake oil
pressure sensor.
120014-2 Overrun Alarm The machine The buzzer sounds. Check the harness.
speed is beyond Replace the machine speed
the upper limit. sensor.
120101-2 Exhaust Temperature Exhaust - Check the harness.
Alarm temperature Check if any ECM fault code is
around the accompanied.
muffler is high. Replace the exhaust temperature
sensor.
120102-2 Intake Air Temperature Intake air - Check the harness.
increases. accompanied.
Replace the intake-air
temperature sensor.
120103-2 Boost Temperature Boost - Check the harness.
Increase Alarm temperature Check if any ECM fault code is
Replace the boost temperature
sensor.
120104-2 Fuel Temperature Fuel temperature - Check the harness.
Increase Alarm increases. Check if any ECM fault code is
accompanied.
Replace the fuel temperature
sensor.
120106-2 EGR Gas Temperature EGR gas - Check the harness.
Replace the intake manifold
temperature sensor.

T5-5-21
SC Fault Code List
Controller Hardware Failure

Occurs.
111000-2 Abnormal EEPROM Faulty SC - Replace SC.
111001-2 Abnormal RAM Faulty SC - Replace SC.
111002-2 Abnormal A/D Faulty SC - Replace SC.
Converter
111003-3 Abnormal Sensor Faulty SC Although the accelerator Check the sensor connected
Voltage Faulty sensor pedal is operated, the engine to SC.
Faulty harness speed does not change. Check the harness.
Replace SC.
fNOTE: SC (Sub-Controller) refers to the Main Controller

(Sub). These error codes are observed on the Service Menu -
Troubleshooting - Main (Sub) screen.
T5-5-22
CAN Data Reception Failure

111015-2 (SC) Information Faulty monitor Nothing observed. Check the CAN1
111016-2 (SC) Information Faulty monitor Nothing observed. Check the CAN2
111017-2 (SC) Monitor Controller Faulty monitor Nothing observed. Check the CAN1
Communication Error controller harness.
1 Faulty CAN1 Replace monitor
harness controller.
111018-2 (SC) Monitor Controller Faulty monitor Nothing observed. Check the CAN2
Communication Error controller harness.
2 Faulty CAN2 Replace monitor
harness controller.
111019-2 (SC) MC Controller Faulty main Nothing observed. Check the CAN
Communication Error controller (main) harness.
1 Faulty CAN1
harness
111020-2 (SC) MC Controller Faulty main The manual regeneration of exhaust Check the CAN
Communication Error controller (main) filter cannot be performed. harness.
2 Faulty CAN2
harness
111021-2 (SC) Air Conditioner Faulty air The air conditioner does not work. Check the CAN2
Controller conditioner harness.
Communication Error controller Replace the
Faulty CAN2 air conditioner
harness controller.
111024-2 (SC) Engine Controller Faulty harness Even if accelerator pedal is operated, Check the harness.
Communication Error engine speed does not change.
111026-2 (SC) Column Faulty column The control lever lock indicator on the Check the CAN2
Monitor Controller display controller column display controller does not harness.
Communication Error Faulty CAN2 light. Replace column
harness display controller.
fNOTE: MC refers to the Main Controller (Main) and SC (Sub-

Controller) refers to the Main Controller (Sub). These error
codes are observed on the Service Menu - Troubleshooting -
Main (Sub) screen.
T5-5-23
Pump Failure
111206-3 Hyd. Fan Circuit Voltage: 4.75 V Fan rotation direction (in normal / Check the harness.
Pressure Sensor or more reverse) cannot change manually Replace the fan pump
Circuit High Input or automatically. delivery pressure sensor.
111206-4 Hyd. Fan Circuit Voltage: less Fan rotation direction (in normal / Check the harness.
Pressure Sensor than 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 The initial automatic check for Check the harness.
Check Pressure or more secondary steering operation Replace the secondary
Sensor Circuit High cannot be performed. (When the steering pump delivery
Input engine starts) pressure sensor.
Secondary steering indicator on
monitor blinks.
111208-4 Emergency Steering Voltage: less The initial automatic check for Check the harness.
Check Pressure than 0.25 V secondary steering operation Replace the secondary
Sensor Circuit Low cannot be performed. (When the steering pump delivery
Input engine starts) pressure sensor.
Secondary steering indicator on
monitor blinks.

T5-5-24
Pilot Failure
111200-3 Lift Arm Raise Pilot Voltage: 4.75 V Bucket speed is slow during Check the harness.
Pressure Sensor or more combined operation of lift arm Replace the pressure sensor
Circuit High Input and bucket. (lift arm raise).
Ride control is not activated.
Speed shift delay control is always
delayed at AUTO 2 mode.
111200-4 Lift Arm Raise Pilot Voltage: less Bucket speed is slow during Check the harness.
Pressure Sensor than 0.25 V combined operation of lift arm Replace the pressure sensor
Circuit Low Input and bucket. (lift arm raise).
Ride control is not activated.
111202-3 Bucket Tilt Pilot Voltage: 4.75 V Bucket speed is slow during Check the harness.
Circuit High Input and bucket. (bucket tilt (roll back)).
111202-4 Bucket Tilt Pilot Voltage: less Bucket speed is slow during Check the harness.
Circuit Low Input and bucket. (bucket tilt (roll back)).
111203-3 Bucket Dump Pilot Voltage: 4.75 V Bucket speed is slow during Check the harness.
Circuit High Input and bucket. (bucket dump).
111203-4 Bucket Dump Pilot Voltage: less Bucket speed is slow during Check the harness.
Circuit Low Input and bucket. (bucket dump).

T5-5-25
Pilot Failure
111217-3 Pilot Pressure Voltage: 4.75 V Front control lever lock indicator Check the harness.
Sensor Circuit High or more on monitor is always OFF. Replace the pressure sensor
Input Exhaust filter manual regeneration (loading pilot pressure).
control is not deactivated
although front control lever lock is
released.
111217-4 Pilot Pressure Voltage: less Front control lever lock indicator Check the harness.
Sensor Circuit Low than 0.25 V on monitor is always OFF. Replace the pressure sensor
Input Exhaust filter manual regeneration (loading pilot pressure).
control is not deactivated
although front control lever lock is
released.
111309-3 Service Brake Voltage: 4.75 V The low brake oil pressure Check the harness.
Pressure (Front) or more indicator is always ON. Replace the pressure sensor
Sensor Circuit High Although the service brake is (brake primary pressure)
Input applied, the brake oil pressure in the front service brake
gauge points at the minimum circuit.
value, zero.
111309-4 Service Brake Voltage: less The low brake oil pressure Check the harness.
Pressure (Front) than 0.25 V indicator is always ON. Replace the pressure sensor
Sensor Circuit Low Although the service brake is (brake primary pressure)
Input applied, the brake oil pressure in the front service brake
gauge points at the minimum circuit.
value, zero.
111310-3 Service Brake Voltage: 4.75 V The low brake oil pressure Check the harness.
Pressure (Rear) or more indicator is always ON. Replace the pressure sensor
Sensor Circuit High Although the service brake is (brake primary pressure) in
Input applied, the brake oil pressure the rear service brake circuit.
gauge points at the minimum
value, zero.
111310-4 Service Brake Voltage: less The low brake oil pressure Check the harness.
Pressure (Rear) than 0.25 V indicator is always ON. Replace the pressure sensor
Sensor Circuit Low Although the service brake is (brake primary pressure) in
Input applied, the brake oil pressure the rear service brake circuit.
gauge points at the minimum
value, zero.

T5-5-26

111407-2 Lift Speed Increase P/S Solenoid valve Lift arm speed multiplication control Check the harness.
Valve Abnormal FB output: 140 mA or is disabled.
more, and
Feedback current:
more than 920
mA or less than
70 mA
(both detected)
111407-3 Lift Speed Increase P/S Current: more Lift arm speed multiplication control Check the harness.
Valve FB High Current than 920 mA is always activated.
111407-4 Lift Speed Increase P/S Current: less than Lift arm speed multiplication control Check the harness.
Valve Low Current 70 mA is always deactivated.
111410-2 Parallel/Tandem Solenoid valve Bucket speed is slow during Check the parallel/
Control P/S Valve output: 140 mA or combined operation of lift arm and tandem switching
Abnormal FB more, and bucket. solenoid valve
Feedback current: Check the harness.
more than 920
mA or less than
70 mA
(both detected)
111410-3 Parallel/Tandem Current: more Lift arm raise speed becomes slow Check the parallel/
Control P/S Valve FB than 920 mA during combined operation of lift arm tandem switching
High Current and bucket. solenoid valve
Check the harness.
111410-4 Parallel/Tandem Current: less than Bucket speed is slow during Check the parallel/
Control P/S Valve FB 70 mA combined operation of lift arm and tandem switching
Low Current bucket. solenoid valve
Check the harness.

T5-5-27

111411-2 Hydraulic Fan Reverse Solenoid valve The fan reverse rotation control Check the harness.
Rotation P/S Valve output: 140 mA or becomes ineffective.
Abnormal FB more, and Fan rotation direction (in normal /
Feedback current: reverse) cannot change manually nor
more than 920 automatically.
mA or less than
70 mA
(both detected)
111411-3 Hydraulic Fan Reverse Current: more Fan rotation direction is fixed in Check the harness.
Rotation P/S Valve FB than 920 mA reverse.
High Current
111411-4 Hydraulic Fan Reverse Current: less than Fan rotation direction (in normal / Check the harness.
Rotation P/S Valve FB 70 mA reverse) cannot change manually and
Low Current automatically.
111412-2 Hyd. Fan P/S Valve Solenoid valve The fan speed is fixed to the Check the harness.
Abnormal Feedback output: 140 mA or maximum.
more, and
Feedback current:
more than 920
mA or less than
70 mA
(both detected)
111412-3 Hyd. Fan P/S Valve Current: more The fan speed is fixed to the Check the harness.
Feedback High Current than 920 mA minimum.
111412-4 Hyd. Fan P/S Valve Current: less than The fan speed is fixed to the Check the harness.
Feedback Low Current 70 mA maximum.

T5-5-28

111422-2 Ride Control (Bottom) Solenoid valve Ride control selector solenoid valve Check the harness.
P/S Valve Abnormal FB output: 140 mA or (boom cylinder bottom side) control
more, and is disabled.
Feedback current:
more than 920
mA or less than
70 mA
(both detected)
111422-3 Ride Control (Bottom) Current: more Ride control selector solenoid valve Check the harness.
P/S Valve FB High than 920 mA (boom cylinder bottom side) control
Current is always activated.
111422-4 Ride Control (Bottom) Current: less than Ride control selector solenoid valve Check the harness.
P/S Valve FB Low 70 mA (boom cylinder bottom side) control
Current is always deactivated.
111423-2 Ride Control (Rod) P/S Solenoid valve Ride control proportional solenoid Check the harness.
Valve Abnormal FB output: 140 mA or valve (boom cylinder rod side) control
more, and is disabled.
Feedback current:
more than 920
mA or less than
70 mA
(both detected)
111423-3 Ride Control (Rod) P/S Current: more Ride control proportional solenoid Check the harness.
Valve FB High Current than 920 mA valve (boom cylinder rod side) control
is always activated.
111423-4 Ride Control (Rod) P/S Current: less than Ride control proportional solenoid Check the harness.
Valve FB Low Current 70 mA valve (boom cylinder rod side) control
is always deactivated.

T5-5-29
Temperature Sensor Failures

111900-3 Torque Converter Oil Voltage: more The fan speed is always fixed to the Check the harness.
Temperature Sensor than 4.75 V maximum.
Circuit High Input Fan reverse rotation control is
disabled.
Lift arm speed multiplication control
is disabled.
Auto idling stop 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.
Auto idling stop is disabled.
111901-3 Hyd. Oil Temp Sensor Voltage: more When hydraulic oil temperature is less Check the harness.
Circuit High Input than 4.35 V than 0 °C, the auto-warm up control is
not effective.
Regeneration may not complete as
the load cannot be applied during
manual or auto regeneration of the
exhaust filter.
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, the auto-warm up control is
not effective.
Regeneration may not complete as
the load cannot be applied during
manual or auto regeneration of the
exhaust filter.
The fan speed is always fixed to the
maximum. The fan reverse rotation
control is not activated.
111906-3 F Axle Oil Temperature Voltage: more Nothing observed. Check the harness.
Sensor Circuit High Input than 4.75 V
111906-4 F Axle Oil Temperature Voltage: less than Nothing observed. Check the harness.
Sensor Circuit Low Input 0.1 V
111907-3 R Axle Oil Temperature Voltage: more Nothing observed. Check the harness.
Sensor Circuit High Input than 4.75 V
111907-4 R Axle Oil Temperature Voltage: less than Nothing observed. Check the harness.
Sensor Circuit Low Input 0.1 V

T5-5-30
Learning Failure
111720-2 Lift arm angle sensor is The lift arm angle Dual lift arm auto leveler cannot be Perform lift arm
uncalibrated. sensor calibration set. angle sensor
is not performed. calibration.
Or, it fails.
Other Sensor Failures

111205-3 Lift Arm Angle Sensor Voltage: 4.75 V or Dual lift arm auto leveler operation is Check the harness.
Circuit High Input more not effective. Replace the lift arm
Speed shift delay control is always angle sensor.
delayed at 2nd speed.
111205-4 Lift Arm Angle Sensor Voltage: less than Dual lift arm auto leveler operation is Check the harness.
Circuit Low Input 0.25 V not effective. Replace the lift arm
Speed shift delay control is always angle sensor.
delayed at 2nd speed.
111207-3 Refrigerant Pressure Voltage: more The fan speed is always fixed to the Check the harness.
Sensor Circuit High than 4.74 V maximum. Replace the
Input 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.

T5-5-31
Alarms on Monitor
120000-2 Hydraulic Oil Overheat Hydraulic oil The alarm is displayed on the monitor. Check the harness.
Alarm temperature is Replace the
high. hydraulic oil
temperature
sensor.
120002-2 Axle Oil Temperature Axle oil The alarm is displayed on the monitor. Check the harness.
Alarm temperature is Replace the axle
high. oil temperature
sensor.
120003-2 Emergency Steering Steering oil The alarm is displayed on the monitor. Check the harness.
Activated pressure is low. Check/replace the
steering pressure
switch.
120004-2 Emergency Steering Secondary The alarm is displayed on the monitor. Check the harness.
Activated Pressure steering pump Replace the
Alarm delivery pressure pressure sensor.
does not increase
up to the
specified value.
(When the engine
starts)

T5-5-32
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.
1
113004-2 (Monitor Controller) Main Faulty monitor controller Check the CAN2 harness.
2
113005-2 (Monitor Controller) ICF Faulty monitor controller Check the CAN1 harness.
Communication Error 1 Faulty CAN1 harness Replace the monitor controller.
113006-2 (Monitor Controller) ICF Faulty monitor controller Check the CAN2 harness.
Communication Error 2 Faulty CAN2 harness Replace the monitor controller.
113007-2 (Monitor Controller) Column Faulty monitor controller Check the CAN2 harness.
113010-2 (Monitor Controller) Sub- Faulty monitor controller Check the CAN1 harness.
1
113011-2 (Monitor Controller) Sub- Faulty monitor controller Check the CAN2 harness.
2
T5-5-33

Message Operation When
Trouble Occurs
113303-2 Abnormal thermistor Thermistor The screen of the Cool the monitor
temperature (monitor temperature: 85°C monitor becomes and so on until the
inside temperature) (185°F) or more dark. temperature inside the
monitor is less than
85°C (185°F).
Replace the monitor.
120300-2 System Failure Alarm Faulty CAN System failure alarm Check the CAN
communication bus appears on the harness.
line. monitor display.
120301-2 Muffler Filter Alarm Faulty pump swash Exhaust filter alarm Check the CAN
angle proportional appears on the harness.
solenoid valve monitor display. Check the solenoid
valve.
T5-5-34
Monitor Controller (Information) Fault Code List
Fault Code Trouble or MP Dr. Cause Remedy

Message
114001-2 Flash Memory Read/ The internal After initializing the monitor controller (information) by
Write Error memory of monitor using MPDr., retry the troubleshooting. If the fault code is
controller is displayed after retry, the monitor controller may be broken.
abnormal. Replace the monitor controller.
When initializing the monitor controller (information), all
stored data is deleted.
114002-2 External RAM Read/ The internal After initializing the monitor controller (information) by
Write Error memory of monitor using MPDr., retry the troubleshooting. If the fault code is
controller is displayed after retry, the monitor controller may be broken.
abnormal. Replace the monitor controller.
When initializing the monitor controller (information), all
stored data is deleted.
114003-2 Abnormal EEPROM The internal Retry the troubleshooting by using MPDr. If the fault code is
memory of monitor displayed after retry, the monitor controller may be broken.
controller is Replace the monitor controller.
abnormal.
114008-2 Abnormal Internal The internal Retry the troubleshooting by using MPDr. If the fault code is
RAM memory of monitor displayed after retry, the monitor controller may be broken.
controller is Replace the monitor controller.
abnormal.
T5-5-35

Message
114010-2 (Information Controller) Faulty monitor controller Check the CAN1 harness.
Engine Controller Faulty CAN1 harness Replace the monitor controller.
Communication Error
Main Controller Faulty CAN1 harness Replace the monitor controller.
Main Controller Faulty CAN2 harness Replace the monitor controller.
114013-2 (Information Controller) Faulty monitor controller Replace the monitor controller.
Monitor Controller
114014-2 (Information Controller) Faulty monitor controller Replace the monitor controller.
Monitor Controller
Column Controller Faulty CAN2 harness Check/replace the monitor controller.
Communication Error
Sub-Controller Faulty CAN1 harness Replace the monitor controller.
Sub-Controller Faulty CAN2 harness Replace the monitor controller.
T5-5-36

Message
120400-2 Fuel Filter Restriction Fuel filter is clogged. Check the harness.
Alarm Replace the fuel filter element.
120401-2 Water Separator Alarm The water separator is full. Check the harness.
(Option) Open circuit in harness. Drain off water.
T5-5-37
Column Display Controller Fault Code List

Message Operation When
Trouble Occurs.
115001-2 Abnormal REG input Alternator generating The alternator Check the harness.
H level voltage: 33.5 V or more indicator is ON. Check the battery.
Check the alternator.
115002-2 CAN Communication Faulty column display Alarm lamps and Check the harness.
Error 2 controller indicators do not light Replace the column
Faulty CAN2 harness correctly. 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 Check the harness.
Circuit High Input continues for 5 (pointer) points to E. Replace the fuel level
seconds. sensor.
115011-4 Fuel Level Sensor 4±2 Ω or less The fuel gauge Check the harness.
Circuit Low Input continues for 5 (pointer) points to E. Replace the fuel level
seconds. sensor.
115018-2 Abnormal 24V Output Faulty column display - Check the harness.
controller. Replace the column
display controller.
T5-5-38

Message
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 Engine oil pressure is reduced. Check the harness.
Alarm Replace the engine oil pressure switch.
120503-2 Air Cleaner Clogged air cleaner. Check the harness.
Restriction Alarm Replace the air cleaner restriction switch.
120504-2 Hydraulic Oil Level Hydraulic oil level is lowered. Check the harness.
Alarm Replace the hydraulic oil level switch.
120505-2 Brake Pressure Brake oil pressure decreases. Check the harness.
Alarm Replace the pressure sensor (brake primary
pressure).
120506-2 Steering Oil Faulty steering pressure switch Check the harness.
Pressure Alarm (Optional) Replace the steering pressure switch.
120507-2 T/M Malfunction Faulty transmission system Refer to the accompanied T/M related fault
code.
T5-5-39
Air Conditioner Controller Fault Code List

Occurs.
11 Open circuit in air Voltage: more than 4.95 V Operation is controlled under Check the harness.
circulation sensor such circumstance as no air Replace the air
circulation sensor is provided. circulation 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 sensor is provided. circulation sensor.
13 Open circuit in fresh Voltage: more than 4.88 V Operation is controlled under Check the harness.
air sensor such circumstance as no fresh Replace the fresh air
air sensor is provided. sensor.
14 Shorted circuit in Voltage: less than 0.096 V Operation is controlled under Check the harness.
fresh air sensor such circumstance as no fresh Replace the fresh air
air sensor is provided. sensor.
17 Open circuit in solar - Operation is controlled under Check the harness.
radiation sensor such circumstance as no solar Replace the solar
radiation sensor is provided. radiation sensor.
18 Shorted circuit in solar Voltage: more than 5.04 V Operation is controlled under Check the harness.
radiation sensor such circumstance as no solar Replace the solar
21 Open circuit in Voltage: more than 4.79 V The compressor clutch is Check the harness.
evaporator sensor disengaged. (The compressor Replace the
stops.) evaporator sensor.
22 Shorted circuit in Voltage: less than 0.096 V The compressor clutch is Check the harness.
evaporator sensor disengaged. (The compressor Replace the
stops.) evaporator sensor.
43 Abnormal air vent Shorted circuit: Voltage: 0 V Air vent damper servo motor Check the harness.
damper Open circuit: Voltage: more becomes inoperable. Replace the air vent
than 5 V damper servo motor.
44 Abnormal air mix Shorted circuit: Voltage: Air mix damper servo motor Check the harness.
damper less than 0.2 V becomes inoperable. Replace the air vent
Open circuit: Voltage: more damper servo motor.
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/
stops.) low pressure switch.
91 CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1
error between monitor harness.
controller and air Replace air
conditioner controller conditioner
controller.
92 CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1
controller harness.
Faulty CAN1 harness Replace air
conditioner
controller.
T5-5-40
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
T5-5-41
ECM Fault Code List
Fault Code Trouble Cause

ISUZU MPDr.
P2453 81-0 High Muffler Filter Differential Pressure Exhaust filter pressure difference is more than
60 kPa.
P2452 81-1 Low Muffler Filter Differential Pressure Exhaust filter pressure difference is less than 0.5
kPa. (1800 min-1 or more)
P2456 81-2 Zero-point calibration of Exhaust Filter differential Learning value is 4.5 kPa or more.
pressure sensor is abnormal.
P2455 81-3 Muffler Filter Differential Pressure Sensor Circuit Voltage at the exhaust filter pressure difference
High Input sensor is more than 4.89 V.
P2454 81-4 Muffler Filter Differential Pressure Sensor Circuit Voltage at the exhaust filter pressure difference
Low Input sensor is less than 0.18 V.
P2138 91-2 Accelerator Pedal Position Sensor 1-2 Correlation Opening amount difference between
accelerator sensors 1 and 2 is 45 % or more.
P2123 91-3 Accelerator Pedal Position Sensor 1 High Input Voltage at accelerator sensor 1 is more than 4.9
V.
P2128 91-3 Accelerator Pedal Position Sensor 2 High Input Voltage at accelerator sensor 2 is more than 4.9
V.
P2122 91-4 Accelerator Pedal Position Sensor 1 Low Input Voltage at accelerator sensor 1 is less than 0.2 V.
P2127 91-4 Accelerator Pedal Position Sensor 2 Low Input Voltage at accelerator sensor 2 is less than 0.2 V.
P0523 100-3 Engine Oil Pressure Sensor Circuit High Input Voltage at the engine oil pressure sensor is more
than 4.85 V.
P0522 100-4 Engine Oil Pressure Sensor Circuit Low Input Voltage at the engine oil pressure sensor is less
than 0.1 V.
P0234 102-0 Over Boost-Pressure Boost pressure is more than 300 kPa.
P0238 102-3 Boost Pressure Sensor Circuit High Input Voltage at the boost pressure sensor is more
than 4.9 V.
P0237 102-4 Boost Pressure Sensor Circuit Low Input Voltage at the boost pressure sensor is less than
0.1 V.
P1113 105-3 Boost Temperature Sensor Circuit High Input Voltage at the boost temperature sensor is more
than 4.94 V.
P1112 105-4 Boost Temperature Sensor Circuit Low Input Voltage at the boost temperature sensor is less
than 0.1 V.
P2229 108-3 Atmospheric Pressure Sensor Circuit High Input Voltage at the atmospheric pressure sensor is
more than 4 V.
P2228 108-4 Atmospheric Pressure Sensor Circuit Low Input Voltage at the atmospheric pressure sensor is
less than 0.5 V.
P0217 110-0 Overheat Coolant temperature is more than 110 °C.
T5-5-42
Symptoms in Machine Operation When Trouble Occurs. Assumptive Conditions at Backup
The output power decreases. Regenerative control is impossible.
The output power decreases. Exhaust filter pressure difference is 0 kPa.
Abnormal system 1: No backup The accelerator opening amount signal cannot be used.
Abnormal system 2: Accelerator opening amount is limited (The limited value is changed according to the quantity of
to 0 %. faulty systems.)
Nothing special. Engine oil pressure is 120 kPa.
Nothing special. Engine oil pressure is 120 kPa.
The output power decreases. Malfunction of VGS turbo

The output power decreases. Boost pressure is 100 kPa.
The output power decreases. Boost pressure is 100 kPa.
Nothing special. Boost temperature is 50 °C.
Nothing special. Boost temperature is 50 °C.
The output power decreases. Atmospheric pressure is 95 kPa.
The output power decreases. Atmospheric pressure is 95 kPa.
There is no influence when operating the machine. Injection amount is regulated by overheat protection.
T5-5-43
Fault Code Trouble Influence to Engine Performance (Presumption)

ISUZU MPDr.
P2453 81-0 High Muffler Filter Differential Pressure The output power decreases.
P2452 81-1 Low Muffler Filter Differential Pressure The output power decreases.
P2456 81-2 Zero-point calibration of Muffler Filter The output power decreases.
differential pressure sensor is abnormal.
P2455 81-3 Muffler Filter Differential Pressure Sensor The output power decreases.
Circuit High Input
P2454 81-4 Muffler Filter Differential Pressure Sensor The output power decreases.
Circuit Low Input
P2138 91-2 Accelerator Pedal Position Sensor 1-2 Abnormal system 1: No output power change
Correlation Abnormal system 2: Idle speed operation
No influence while operating CAN Communication
P2123 91-3 Accelerator Pedal Position Sensor 1 High Abnormal system 1: No output power change
Input Abnormal system 2: Idle speed operation
P2128 91-3 Accelerator Pedal Position Sensor 2 High Abnormal system 1: No output power change
P2122 91-4 Accelerator Pedal Position Sensor 1 Low Abnormal system 1: No output power change
P2127 91-4 Accelerator Pedal Position Sensor 2 Low Abnormal system 1: No output power change
P0523 100-3 Engine Oil Pressure Sensor Circuit High No output power decrease.
Input
P0522 100-4 Engine Oil Pressure Sensor Circuit Low No output power decrease.
Input
P0234 102-0 Over Boost-Pressure Rotation speed is limited, the output power decreases.
P0238 102-3 Boost Pressure Sensor Circuit High Input The output power decreases.
P0237 102-4 Boost Pressure Sensor Circuit Low Input The output power decreases.
P1113 105-3 Boost Temperature Sensor Circuit High No output power decrease.
Input
P1112 105-4 Boost Temperature Sensor Circuit Low No output power decrease.
Input
P2229 108-3 Atmospheric Pressure Sensor Circuit High The output power decreases.
Input
P2228 108-4 Atmospheric Pressure Sensor Circuit Low The output power decreases.
Input
P0217 110-0 Overheat Rotation speed is limited, the output power decreases.
T5-5-44
Operating Rank (Current) Remark

A B C D
 Limit Q is performed as regeneration stops.
 In case accelerator sensor system 2 is connected

 The boost pressure is reduced due to turbo control and the
output power decreases.
 Boost temperature alarm stops.
 Boost temperature alarm stops.
 The indicator does not light due to overheat switch alarm

in the same way as Tier 3. Send the CAN fault code.
Operating Rank
A: Digging / travel is operable.
B: Machine can travel on a level ground and a downhill.
C: The engine only runs. (Travel and operation are impossible even in light load.)
D: The engine cannot stop / start.
T5-5-45

ISUZU MPDr.
P0118 110-3 Engine Coolant Temperature Circuit High Input Voltage at the coolant temperature sensor is
more than 4.85 V.
P0117 110-4 Engine Coolant Temperature Circuit Low Input Voltage at the coolant temperature sensor is less
than 0.1 V.
P0103 132-3 Air Flow Sensor Circuit High Input Voltage at the air flow sensor is more than 4.9 V.
P0102 132-4 Air Flow Sensor Circuit Low Input Voltage at the air flow sensor is less than 0.1 V.
P0088 157-0 Pressure Increase in Common Rail (Secondary) The first stage "Abnormal common rail pressure"
is approved and common rail pressure is 190
MPa or more.
P0193 157-3 Common Rail Pressure Sensor Circuit High InputVoltage at the common rail pressure sensor is
more than 4.8 V.
P0192 157-4 Common Rail Pressure Sensor Circuit Low Input Voltage at the common rail pressure sensor is
less than 0.7 V.
P0089 157-15 Abnormal Common Rail Pressure (Over Pumping) Actual rail pressure is more than 40 MPa higher
than the target rail pressure.
P0088 157-16 Pressure Increase in Common Rail Rail pressure is 185 MPa or more.
P0563 158-3 Abnormally High Battery System Voltage IG-KEY voltage is more than 32 V.
P0113 172-3 Intake Air Temperature Sensor Circuit High Input Voltage at the intake-air temperature sensor is
more than 4.85 V.
P0112 172-4 Intake Air Temperature Sensor Circuit Low Input Voltage at the intake-air temperature sensor is
less than 0.1 V.
T5-5-46
The output power decreases. When starting: Coolant temperature is -20 °C.
When operating: Coolant temperature is 90 °C.
The output power decreases. When starting: Coolant temperature is -20 °C.
The output power decreases. The MAF sensor value is 250 g/sec.
The output power decreases. The MAF sensor value is 250 g/sec.
Vibration of the engine may be large, rough idle, output Prevent fuel leaks.
power decrease may occur, faulty increasing of rotation
speed, dark smoke may occur, output power may be too
large.
The engine may be stalled. The output power decreases. Rail pressure is 80 MPa.
The output power decreases. Rail pressure is 80 MPa.
large.
large.
The battery may be faulty. -
The output power decreases. Intake-air temperature is -10 °C.
The output power decreases. Intake-air temperature is -10 °C.
T5-5-47

ISUZU MPDr.
P0118 110-3 Engine Coolant Temperature Circuit High Input The output power decreases.
P0117 110-4 Engine Coolant Temperature Circuit Low Input The output power decreases.
P0103 132-3 Air Flow Sensor Circuit High Input The output power decreases.
P0102 132-4 Air Flow Sensor Circuit Low Input The output power decreases.
P0088 157-0 Pressure Increase in Common Rail (Secondary) The output power decreases.
P0193 157-3 Common Rail Pressure Sensor Circuit High Input The output power decreases.
P0192 157-4 Common Rail Pressure Sensor Circuit Low Input The output power decreases.
P0089 157-15 Abnormal Common Rail Pressure (Over Pumping) The output power decreases.
P0088 157-16 Pressure Increase in Common Rail (Primary) The output power decreases.
P0563 158-3 Abnormally High Battery System Voltage No output power change
P0113 172-3 Intake Air Temperature Sensor Circuit High Input The output power decreases.
P0112 172-4 Intake Air Temperature Sensor Circuit Low Input The output power decreases.
T5-5-48

A B C D
The boost pressure is reduced due to turbo control and the
The boost pressure is reduced due to turbo control and the
 Limit Q is performed just in case as regeneration evaluation
stops.
 Limit Q is performed just in case as regeneration evaluation
stops.
 Limit Q is performed as rail pressure cannot be controlled
and regeneration stops.
 Limit Q is performed as rail pressure cannot be controlled
and regeneration stops.

Operating Rank
T5-5-49

ISUZU MPDr.
P0426 173-0 Abnormally High Intake Air Temperature Sensor 1 Temperature of exhaust temperature sensor 1 is
(CSF Inlet) 880 °C or more.
P0428 173-3 Exhaust Temperature Sensor 1 Circuit High Input Voltage at exhaust temperature sensor 1 is more
(CSF Inlet) than 4.85 V.
P0427 173-4 Exhaust Temperature Sensor 1 Circuit Low Input Voltage at exhaust temperature sensor 1 is less
(CSF Inlet) than 0.2 V. (Exhaust temperature is equivalent to
1000 °C.)
P0183 174-3 Combustion Temperature Sensor Circuit High Voltage at the fuel temperature sensor is more
Input than 4.85 V.
P0182 174-4 Combustion Temperature Sensor Circuit Low Voltage at the fuel temperature sensor is less
Input than 0.1 V.
P0219 190-0 Engine Overrun Engine speed is more than specification (2800
min-1).
P0601 628-2 Abnormal ROM Check sum is NG.
P0087 633-7 Common Rail Pressure Limiter Open It is judged by rail pressure change pattern.
P0340 636-2 Abnormal Cam Angle Sensor (No Signal) Engine speed: 90 min-1 or more, the signal from
cam sensor is not present.
P0016 636-7 Phase Difference between Cam and Sensor The correct cam pulse is not present at the gap
in the crank.
U0101 639-2 Abnormal CAN Time-out TSC1 message from SA=228 is not received.
U0073 639-19 Abnormal CAN Bus The bus line OFF is detected.
T5-5-50
The output power decreases. Exhaust temperature sensor 2 is substituted for muffler
filter regeneration evaluation temperature. Exhaust
temperature 1 is 0 °C.
The output power decreases. Exhaust temperature sensor 2 is substituted for muffler
filter regeneration evaluation temperature. Exhaust
temperature 1 is 0 °C.
Nothing special. When starting: Coolant temperature is -20 °C.
Nothing special. When starting: Coolant temperature is -20 °C.
Engine speed may not increase 2800 min-1 or more. Protect the engine.
The engine cannot start. Malfunction of ROM

The output power decreases. Limitter open status
While the engine runs, there is nothing abnormal with While the engine runs, operate according to standard of
machine operation. the crank sensor.
After the engine is stalled, the re-start is impossible. When the engine stops, the start is impossible.
While the engine runs, there is nothing abnormal with While the engine runs, operate according to standard of
machine operation. the crank sensor.
After the engine is stalled, the re-start is impossible. When the engine stops, the start is impossible.
The engine speed is fixed to 1000 min-1. CAN communication is impossible.
The engine runs at idle speed. CAN communication is impossible.
T5-5-51

ISUZU MPDr.
P0426 173-0 Abnormally High Intake Air Temperature Sensor 1 The output power decreases.
(CSF Inlet)
P0428 173-3 Exhaust Temperature Sensor 1 Circuit High Input The output power decreases.
(CSF Inlet)
P0427 173-4 Exhaust Temperature Sensor 1 Circuit Low Input The output power decreases.
(CSF Inlet)
P0183 174-3 Combustion Temperature Sensor Circuit High No output power decrease.
Input
P0182 174-4 Combustion Temperature Sensor Circuit Low No output power decrease.
Input
P0219 190-0 Engine Overrun No output power change
P0601 628-2 Abnormal ROM The engine cannot start.

P0087 633-7 Common Rail Pressure Limiter Open The output power decreases.
P0340 636-2 Abnormal Cam Angle Sensor (No Signal) No influence during operation.
After stopping, the re-start is impossible.
P0016 636-7 Phase Difference between Cam and Sensor No influence during operation.
After stopping, the re-start is impossible.
U0101 639-2 Abnormal CAN Time-out Engine speed is fixed.
U0073 639-19 Abnormal CAN Bus Idle speed
T5-5-52

A B C D
 The diagnosis stops.
 The indicator does not light as the repair is not required in

particular. The past fault codes are kept just in case.

 
 


Operating Rank
T5-5-53

ISUZU MPDr.
P0201 651-5 Cylinder 1 Injector Circuit Open No input signal of injector 1 monitor.
P0335 723-2 Crank Position Sensor Failure (No Signal) Engine speed: 90 min-1 or more, even if the cam
signal is present, the crank signal is not present.
P0336 723-2 Crank Position Sensor Failure (Abnormal Signal) Engine speed: 750 min-1 or more, the pulse of
crank signal is not matched.
P0606 1077-2 Abnormal CPU Failure of main CPU is detected by sub CPU.
(Sub CPU resets CPU.)
P0641 1079-2 Abnormal 5V-Electric Power Circuit #1 Voltage of 5 V1 or 5 V5 power source is 5.5 V or
more or 4.5 V or less.
P041C 1131-3 Manifold Temperature Sensor Circuit High Input Voltage at the manifold temperature sensor is
more than 4.94 V.
P041D 1131-4 Manifold Temperature Sensor Circuit Low Input Voltage at the manifold temperature sensor is
less than 0.1 V.
P0093 1239-1 Pressure Decline in Common Rail (No Pumping Engine speed: 900 min -1 or more, rail pressure:
Pressure) 15 MPa or less
P1093 1239-17 Pressure Decline in Common Rail (Lack of Actual rail pressure is 50 MPa or more lower
Pumping Pressure) than the target rail pressure.
T5-5-54
Vibration of the engine is large, rough idle, output power The injector cannot be controlled.
decrease, faulty increasing of rotation speed, exhaust gas
becomes bad.
becomes bad.
becomes bad.
becomes bad.
becomes bad.
becomes bad.
The output power may decrease, white smoke may occur The engine is operated according to the cam sensor
and vibration may occur, the engine may be stalled. (If the standard.
cam senor is normal, the engine can re-start.)
The output power may decrease, white smoke may occur The engine is operated according to the cam sensor
and vibration may occur, the engine may be stalled. (If the standard.
cam senor is normal, the engine can re-start.)
The output power decreases. Malfunction of CPU
The output power decreases. -
Nothing special. Manifold temperature is 60 °C.
Nothing special. Manifold temperature is 60 °C.
Vibration of the engine may be large, rough idle, output Fuel leakage is too much.
large.
Vibration of the engine may be large, rough idle, output Fuel leakage is too much.
large.
T5-5-55

ISUZU MPDr.
P0201 651-5 Cylinder 1 Injector Circuit Open The output power decreases.
Five cylinders in operation
P0335 723-2 Crank Position Sensor Failure (No Signal) The output power decreases.
P0336 723-2 Crank Position Sensor Failure (Abnormal Signal) The output power decreases.
P0606 1077-2 Abnormal CPU Rotation speed limit control, the output power
decreases.
P0641 1079-2 Abnormal 5V-Electric Power Circuit #1 The output power decreases.
P041C 1131-3 Manifold Temperature Sensor Circuit High Input No output power decrease.
P041D 1131-4 Manifold Temperature Sensor Circuit Low Input No output power decrease.
P0093 1239-1 Pressure Decline in Common Rail (No Pumping The output power decreases.
Pressure)
P1093 1239-17 Pressure Decline in Common Rail (Lack of The output power decreases.
Pumping Pressure)
T5-5-56

A B C D




Operating Rank
T5-5-57

ISUZU MPDr.
P0092 1347-3 SCV Drive Circuit + Short Circuit B SCV current is 2400 mA or more or difference
between SCV current and target current is 1000
mA or more.
P0091 1347-4 SCV Drive Circuit Open or Short Circuited to GND SCV current is 50 mA or less or difference
between SCV current and target current is 1000
mA or more.
P1294 1381-3 Fuel Filter Restriction Sensor Circuit High Input Voltage at the restriction sensor is more than 4.9
V.
P1293 1381-4 Fuel Filter Restriction Sensor Circuit Low Input Voltage at the restriction sensor is less than 0.1
V.
P0685 1485-5 Abnormal Main Relay Circuit (Inactivation) Voltage in the main relay system is 1 V or less
with the main relay coil output ON.
P0687 1485-6 Abnormal Main Relay Circuit (Kept closed) Even if the main relay coil output is turned OFF,
the main relay is kept ON.
P0409 10001-2 EGR Position Error The condition which the output signal of EGR
position sensor cannot be present in.
P1404 10001-13 Abnormal EGR Zero-point calibration Zero-point calibration value is beyond the
specification.
P0404 10002-2 Abnormal EGR Valve Control Circuit Difference between the target valve lift and
actual position is more than 20 %.
P2146 10003-2 Abnormal Injector Common 1 Circuit No monitor input signal of injectors 1, 2, and 3.
P2149 10004-2 Abnormal Injector Common 2 Circuit No monitor input signal of injectors 4, 5, and 6.
P1261 10005-2 Abnormal Charge Circuit (Bank 1) Voltage at bank 1 of charge circuit in ECM is low.
P1262 10006-2 Abnormal Charge Circuit (Bank 2) Voltage at bank 2 of charge circuit in ECM is low.
P0606 10007-2 Abnormal CPU Monitor IC No change of RUN-SUB pulse in 20 msec.

P060B 10008-2 Abnormal A/D Converter A/D conversion cannot be done.
P0560 10012-2 Abnormal 12V Circuit Voltage of 12 V power source is 19 V or more or
7 V or less.
P1621 10013-2 Abnormal EEPROM Abnormal EEPROM is detected.
T5-5-58
The output power decreases, there is influence to exhaust The supply pump can not be controlled.
gas.
The output power decreases, there is influence to exhaust The supply pump can not be controlled.
gas, the supply pump can not be controlled, the engine  Prevent the engine from increasing the rotation speed
may increase the rotation speed automatically and automatically and abnormally. (The engine is protected
abnormally. from damage.)
Nothing special. Fuel pressure is 0 kPa.
Nothing special. Fuel pressure is 0 kPa.
The engine cannot start. -
Electrical power is kept supplying to the machine. -
The output power decreases. EGR opening amount is not certain.
The output power decreases. EGR cannot be controlled.
The output power decreases. EGR cannot be controlled.
Vibration of the engine may be large, rough idle, output The injector cannot be controlled.
speed may occur, the engine may be stalled.
The output power decreases. Malfunction of sub CPU
The output power decreases, dark smoke occurs. All analogue sensor cannot be used.
Nothing special. Learning value and correction value cannot be used.
T5-5-59

ISUZU MPDr.
P0092 1347-3 SCV Drive Circuit + Short Circuit B The output power decreases.
P0091 1347-4 SCV Drive Circuit Open or Short Circuited to GND The output power decreases.
P1294 1381-3 Fuel Filter Restriction Sensor Circuit High Input No output power decrease.
P1293 1381-4 Fuel Filter Restriction Sensor Circuit Low Input No output power decrease.
P0685 1485-5 Abnormal Main Relay Circuit (Inactivation) The engine stops.
P0687 1485-6 Abnormal Main Relay Circuit (Kept closed) No output power change
P0409 10001-2 EGR Position Error The output power decreases.
P1404 10001-13 Abnormal EGR Zero-point calibration The output power decreases.
P0404 10002-2 Abnormal EGR Valve Control Circuit The output power decreases.
P2146 10003-2 Abnormal Injector Common 1 Circuit Three cylinders in operation
P2149 10004-2 Abnormal Injector Common 2 Circuit Three cylinders in operation
P1261 10005-2 Abnormal Charge Circuit (Bank 1) Three cylinders in operation
P1262 10006-2 Abnormal Charge Circuit (Bank 2) Three cylinders in operation
P0606 10007-2 Abnormal CPU Monitor IC The output power decreases.

P060B 10008-2 Abnormal A/D Converter The output power decreases.
P0560 10012-2 Abnormal 12V Circuit The output power decreases.
P1621 10013-2 Abnormal EEPROM No output power change
T5-5-60

A B C D



 The battery may run out.
 Although regeneration stops, limit Q is not performed as
the output power decreases too much.



Operating Rank
T5-5-61

ISUZU MPDr.
P0638 10022-2 Abnormal Intake Throttle Control Circuit Difference between the target valve lift and
actual position is more than 40 %.
P0123 10022-3 Intake Throttle Position Sensor Circuit High Voltage at the intake throttle position sensor is
Input more than 4.9 V.
P0122 10022-4 Intake Throttle Position Sensor Circuit Low Voltage at the intake throttle position sensor is
Input less than 0.3 V.
U0110 10023-2 Abnormal CAN VNT Time-out/ISO-CAN VNT The message from turbo controller is not
Communication Error received.
P0045 10023-12 Abnormal VNT Turbo The abnormal message from turbo controller
has been received.
U0411 10023-19 VNT Communication Error Rotation speed limit control, the output power
decreases.
P042D 10024-3 Exhaust Temperature Sensor 2 Circuit High Input Voltage at exhaust temperature sensor 2 is more
(DOC Inlet) than 4.85 V.
P042C 10024-4 Exhaust Temperature Sensor 2 Circuit Low Input Voltage at exhaust temperature sensor 2 is less
(DOC Inlet) than 0.2 V.
(Exhaust temperature is equivalent to 800 °C.)
P1669 10025-5 Muffler Filter Light Failure No muffler filter lamp monitor signal.
P1455 10026-0 Muffler Filter PM Over-Restriction 2 In case it is evaluated that PM trapping amount
is out of muffler filter regeneration level
(evaluated by the operating period)
P242F 10026-15 Muffler Filter PM Over-Restriction In case it is evaluated that PM trapping amount
is out of muffler filter regeneration level
(evaluated by a pressure difference)
P1471 10027-0 Muffler Filter Cleaning Decision Error In case cleaning evaluation after regeneration is
NG continuously twice
P042B 10028-0 Abnormally High Exhaust Temperature Sensor 2 Temperature of exhaust temperature sensor 2 is
(DOC Outlet) 870 °C or more.
P2458 10029-0 Over Frequent Muffler Filter Regeneration Time- In case regeneration time out is continuously
Out * three times
P0602 10032-2 QR Code Error QR code and Q adjust have not been written.
P0604 10033-2 Abnormal RAM Abnormal RAM is detected.
U0001 10040-19 Abnormal ISO-CAN Bus The bus line OFF is detected.
U2106 10034-2 Abnormal Wheel Loader CAN Time -out The TS1 message from SA=3 is not received.
T5-5-62
The output power decreases. ITH cannot be controlled.
The output power decreases. The intake throttle opening amount is not certain.
The output power decreases. The intake throttle opening amount is not certain.
The output power decreases. The information from turbo controller cannot be received.
The output power decreases. Turbo controller performs fail- safe control and the boost
pressure decreases.
pressure decreases.
The output power decreases. Exhaust temperature 2 is 0 °C.
The output power decreases. Exhaust temperature 2 is 0 °C.
There is no influence when operating the machine. -

Combustion sound may change. The injector cannot be corrected.

The engine cannot start. Malfunction of RAM
pressure decreases.
There is no influence when operating the machine. CAN communication is impossible.
T5-5-63
Fault Code Trouble Influence to Engine Performance

ISUZU MPDr. (Presumption)
P0638 10022-2 Abnormal Intake Throttle Control Circuit The output power decreases.
P0123 10022-3 Intake Throttle Position Sensor Circuit High The output power decreases.
Input
P0122 10022-4 Intake Throttle Position Sensor Circuit Low The output power decreases.
Input
U0110 10023-2 Abnormal CAN VNT Time-out/ISO-CAN VNT Rotation speed limit control, the output power
Communication Error decreases.
P0045 10023-12 Abnormal VNT Turbo Rotation speed limit control, the output power
decreases.
U0411 10023-19 VNT Communication Error Rotation speed limit control, the output power
decreases.
P042D 10024-3 Exhaust Temperature Sensor 2 Circuit High Input The output power decreases.
(DOC Inlet)
P042C 10024-4 Exhaust Temperature Sensor 2 Circuit Low Input The output power decreases.
(DOC Inlet)
P1669 10025-5 Muffler Filter Light Failure No output power change
P1455 10026-0 Muffler Filter PM Over-Restriction 2 The output power decreases.
P242F 10026-15 Muffler Filter PM Over-Restriction The output power decreases.
P1471 10027-0 Muffler Filter Cleaning Decision Error The output power decreases.
P042B 10028-0 Abnormally High Exhaust Temperature Sensor 2 The output power decreases.
(DOC Outlet)
P2458 10029-0 Over Frequent Muffler Filter Regeneration Time- The output power decreases.
Out *
P0602 10032-2 QR Code Error No output power change
P0604 10033-2 Abnormal RAM The engine cannot start.
U0001 10040-19 Abnormal ISO-CAN Bus Rotation speed control, the output power
decreases.
U2106 10034-2 Abnormal Wheel Loader CAN Time -out Engine speed is fixed.
IMPORTANT: In case fault code 10029-0 is displayed, Normal value of exhaust temperature (reference)
delete it once. Measure exhaust temperature of diesel Temperature (°C) 420 (788 °F)
oxidation catalyst (DOC) and filter (CSF) under the
following conditions. Then, when difference between
two exhaust temperature is beyond 35 °C (95 °F), the
temperature sensor at lower-temperature side may
be faulty.
Condition:
 Condition after warming-up
 Power mode: ON
 Parking brake: ON
 Forward/reverse lever: F
 Bucket relief operation
 Engine runs at fast idle speed without load for six minutes.
T5-5-64

A B C D

Code clear operation is required twice.
 The diagnosis stops.




Operating Rank
T5-5-65
MC Fault Codes 111000 to 111002

SC Fault Codes 111000 to 111002
Fault Code Trouble or MP Dr. Message Cause

111000-2 Abnormal EEPROM Faulty Main Controller (Main or Sub)
111001-2 Abnormal RAM Faulty Main Controller (Main or Sub)
111002-2 Abnormal A/D Converter Faulty Main Controller (Main or Sub)
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.
MC Fault Code 111003

SC 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 Main
Controller (Main or
Sub)
T5-5-66
95TNED-05-05-01
1- Main Controller (Main )
2- Main Controller (Sub )
T5-5-67
Connector (Harness end of connector viewed from the

open end side)
 Pressure Sensor (Lift Arm Raise)  Lift Arm Angle Sensor

 Pressure Sensor (Bucket Dump)
 Pressure Sensor (Bucket Roll Back)
 Pressure Sensor (Brake Secondary Pressure)
 Pressure Sensor (Primary Pilot Pressure)
 Pressure Sensor (Parking Brake)
90Z7-05-CN04
 Pressure Sensor (Refrigerant Pressure)
90Z7-05-CN01
 Steering Pressure Switch
90Z7-05-CN05
 Accelerator Pedal Sensor
90Z7-05-CN02
 Pump Delivery Pressure Sensor

 Hydraulic Fan Circuit Pressure Sensor
 Secondary Steering Pump Delivery Pressure Sensor
(Option)
90Z7-05-CN06
 Pressure Sensor (Brake Primary Pressure)
fNOTE: P: 5 V or 24 V power supply

S: Signal
G: Ground (chassis)
90Z7-05-CN03
T5-5-68
MC Fault Codes 111006, 111007, 111009,

111012
SC Fault Codes 111015, 111017, 111019,
111024
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 T5-5-71 to 73.)
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.
111009-2 (MC) Monitor Controller Continuity check (open circuit) Open circuit in harness.
111012-2 (MC) Sub-Controller Continuity check (open circuit) Open circuit in harness.
111015-2 (SC) Information Controller Continuity check (open circuit) Open circuit in harness.
111017-2 (SC) Monitor Controller Continuity check (open circuit) Open circuit in harness.
111019-2 (SC) MC Controller Continuity check (open circuit) Open circuit in harness.
111024-2 (SC) Engine Controller Continuity check (open circuit) Open circuit in harness.
Communication Error
T5-5-69
Monitor Controller (Monitor) Fault Codes

113002, 113003, 113005, 113010
Monitor Controller (Information) Fault Codes
114010, 114011, 114013, 114018
Preparation
113002-2 (Monitor Controller) Engine Continuity check (open circuit) Open circuit in harness.
Controller Communication
Error Discontinuity check (shorted circuit) Shorted 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.
113010-2 (Monitor Controller) Sub- 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.
114013-2 (Information Controller) --- Defective monitor controller

Monitor Controller
114018-2 (Information Controller) Sub- Continuity check (open circuit) Open circuit in harness.
T5-5-70
CAN1 Harness Check

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

Controller
Continuity check High side #D2 #154 #A24 -
between Main Low side #D3 #132 #A23 -
Controller (MC) and
each controller
Discontinuity check High side #D2-#E1 #154-#61 #A24-#B36 -
between CAN circuit #D2-#E2 #154-#62 - -
and ground circuit in #D2-#F4 #154-#63 - -
each controller
#D2-#F5 #154-#64 - -
#D2-#F6 #154-#65 - -
- #154-#66 - -
- #154-#97 - -
- #154-#119 - -
- #154-#137 - -
Low side #D3-#E1 #132-#61 #A23-#B36
#D3-#E2 #132-#62 - -
#D3-#F4 #132-#63 - -
#D3-#F5 #132-#64 - -
#D3-#F6 #132-#65 - -
- #132-#66 - -
- #132-#97 - -
- #132-#119 - -
- #132-#137 - -
T5-5-71
CAN1 Harness Check
Inspection CAN Harness MC ECM Monitor Controller Column Display

Controller
between CAN circuit #D2-#E6 #154-#89 - -
and power circuit in #D2-#F1 #154-#111 - -
each controller
#D2-#F2 #154-#133 - -
#D2-#F3 - - -
Low side #D3-#E5 #132-#67 #A23-#B18 -
#D3-#E6 #132-#89 - -
#D3-#F1 #132-#111 - -
#D3-#F2 #132-#133 - -
#D3-#F3 - - -
between CAN circuit
and key signal circuit
Low side #D3-#E4 #132-#134 #A23-#B17 -
in each controller
Discontinuity check - #D2-#D3 #154-#132 #A24-#A23 -

between CAN (High
side) circuit and CAN
(Low side) circuit in
each controller
T5-5-72
Connector (Harness end)
 MC-D Connector  Monitor Controller-A Connector
TNED-05-05-005 TNED-05-05-011
 MC-E Connector  Monitor Controller-B Connector
TNED-05-05-006 TNED-05-05-012
 MC-F Connector  Column Display Controller 1 Connector
TNED-05-05-007
TNED-05-05-004
 Column Display Controller 2 Connector
 Central Connector (ECM) 1 TNED-05-05-013
115Z7-05-CN07
 Central Connector (ECM) 2
115Z7-05-CN08
T5-5-73
MC Fault Codes 111008, 111010, 111013,

111014, 111025
SC Fault Codes 111016, 111018, 111020,
111021, 111026
Preparation
111008-2 (MC) Information Controller Continuity check (open circuit) Open circuit in harness.
111010-2 (MC) Monitor Controller Continuity check (open circuit) Open circuit in harness.
111013-2 (MC) Sub-Controller Continuity check (open circuit) Open circuit in harness.
111014-2 (MC) Air Conditioner Controller Continuity check (open circuit) Open circuit in harness.
Communication Error
111016-2 (SC) Information Controller Continuity check (open circuit) Open circuit in harness.
111018-2 (SC) Monitor Controller Continuity check (open circuit) Open circuit in harness.
111020-2 (SC) MC Controller Continuity check (open circuit) Open circuit in harness.
111021-2 (SC) Air Conditioner Controller Continuity check (open circuit) Open circuit in harness.
Communication Error
111025-2 (MC) Column Monitor Continuity check (open circuit) Open circuit in harness.
Communication Error
111026-2 (SC) Column Monitor Continuity check (open circuit) Open circuit in harness.
T5-5-74
Monitor Controller (Monitor) Fault Codes

113004, 113006, 113007, 113011
114012, 114014, 114015, 114019
Preparation
113004-2 (Monitor Controller) Main Continuity check (open circuit) Open circuit in harness.
113006-2 (Monitor Controller) ICF Continuity check (open circuit) Open circuit in harness.
113007-2 (Monitor Controller) Column Continuity check (open circuit) Open circuit in harness.
113011-2 (Monitor Controller) Sub- Continuity check (open circuit) Open circuit in harness.
114012-2 (Information Controller) Main Continuity check (open circuit) Open circuit in harness.
114014-2 (Information Controller) --- Defective monitor

Monitor Controller controller
114015-2 (Information Controller) Continuity check (open circuit) Open circuit in harness.
Column Controller
Communication Error Discontinuity check (shorted circuit) Shorted circuit in harness.
114019-2 (Information Controller) Sub- Continuity check (open circuit) Open circuit in harness.
T5-5-75
CAN2 Harness Check

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

Controller Controller
Continuity check High side #D4 #A26 #1-8 #A10(A/C2)
between MC and each Low side #D5 #A25 #1-9 #A11(A/C2)
controller
Discontinuity check High side #D4-#E1 - #1-8-#1-19 #A10(A/C2)-#A05(A/C1)
between CAN circuit #D4-#E2 #A26-#B36 - -
and ground circuit in #D4-#F4 - - -
each controller
#D4-#F5 - - -
#D4-#F6 - - -
Low side #D5-#E1 - #1-9-#1-19 #A11(A/C2)-#A05(A/C1)
#D5-#E2 #A25-#B36 - -
#D5-#F4 - - -
#D5-#F5 - - -
#D5-#F6 - - -
T5-5-76
Inspection CAN Harness MC Monitor Column Display A/C

Controller Controller
Discontinuity check High side #D4-#E5 - #1-8-#2-1 #A10(A/C2)-#A01(A/C1)
between CAN circuit #D4-#E6 #A26-#B18 - #A10(A/C2)-#A41(A/C1)
and power circuit in #D4-#F1 - - -
each controller
#D4-#F2 - - -
#D4-#F3 - - -
Low side #D5-#E5 - #1-9-#2-1 #A11(A/C2)-#A01(A/C1)
#D5-#E6 #A25-#B18 - #A11(A/C2)-#A41(A/C1)
#D5-#F1 - - -
#D5-#F2 - - -
#D5-#F3 - - -
Discontinuity check High side #D4-#E4 #A26-#B17 #1-8-#2-2 #A10(A/C2)-#A17(A/C1)
between CAN circuit
and key signal circuit Low side #D5-#E4 #A25-#B17 #1-9-#2-2 #A11(A/C2)-#A17(A/C1)
in each controller
Discontinuity check - #D4-#D5 #A26-#A25 #1-8-#1-9 #A10(A/C2)-#A11(A/C2)

between CAN (High
side) circuit and CAN
(Low side) circuit in
each controller
T5-5-77
 MC-D Connector  Column Display Controller 1 Connector
TNED-05-05-005
TNED-05-05-004
 MC-E Connector  Column Display Controller 2 Connector
TNED-05-05-006
TNED-05-05-013
 MC-F Connector  A/C1 Connector
TNED-05-05-007
TNED-05-05-018
 Monitor Controller-A Connector  A/C2 Connector
TNED-05-05-011
TNED-05-05-019
 Monitor Controller-B Connector
TNED-05-05-012
T5-5-78
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 Open circuit accelerator
check. pedal sensor.
111103-4 Accelerator Pedal Circuit Measure voltage between Voltage: less than Open circuit in harness #1.
Low Input accelerator pedal sensor 0.25 V
harness end #1 and chassis.
Measure voltage between Voltage: less than Open circuit in harness #6.
accelerator pedal sensor 0.25 V
harness end #1 and #6.
--- 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
90Z7-05-CN06

S: Signal
G: Ground (chassis)
T5-5-79
SC Fault Codes 111205, 111207

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.
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
lift arm angle sensor 0.25 V
- 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
refrigerant pressure sensor 0.25 V
- Normal in above Faulty refrigerant pressure
check. sensor.

 Lift Arm Angle Sensor  Refrigerant Pressure Sensor
90Z7-05-CN04 90Z7-05-CN05

S: Signal
G: Ground (chassis)
T5-5-80
SC Fault Codes 111200, 111202, 111203

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

Message
111200-3 Lift Arm Raise Pilot Retry by using MPDr. Un-displayed fault code Faulty sensor.
Pressure Sensor Circuit Measure voltage between B Voltage: 4.75 V or more Shorted circuit in harness
High Input and chassis. #1 and #2.
111200-4 Lift Arm Raise Pilot 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 harness #1.
Low Input and chassis.
Measure voltage between A Voltage: less than 0.25 V Open circuit in harness #3.
and C (GND).
- Normal in above check. Open circuit in harness #2.
111202-3 Bucket Tilt Pilot Retry by using MPDr. Un-displayed fault code Faulty sensor.
111202-4 Bucket Tilt Pilot Retry by using MPDr. Un-displayed fault code Faulty sensor.
and C (GND).
111203-3 Bucket Dump Pilot Retry by using MPDr. Un-displayed fault code Faulty sensor.
111203-4 Bucket Dump Pilot Retry by using MPDr. Un-displayed fault code Faulty sensor.
and C (GND).
C B A
TDAA-05-06-003
T5-5-81

Preparation
 Connect the test harness and dummy sensor.
 Before inspection, set the key switch to the ON
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
and chassis. more #1 and #2.
111204-4 Pump Delivery Pressure Retry by using MPDr. Un-displayed fault Faulty sensor.
Sensor Circuit Low Input code
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.
111312-3 Service Brake Secondary Retry by using MPDr. Un-displayed fault Faulty sensor.
Pressure Sensor Circuit code
High Input Measure voltage between B Voltage: 4.75 V or Shorted circuit in harness
111312-4 Service Brake Secondary Retry by using MPDr. Un-displayed fault Faulty sensor.
Pressure Sensor Circuit code
Low Input 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
check.
C B A
TDAA-05-06-003
T5-5-82

Preparation
position.

Message
111206-3 Hyd. Fan Circuit 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
111206-4 Hyd. Fan Circuit 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.
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
check.
C B A
TDAA-05-06-003
T5-5-83

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
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.
and chassis. 0.25 V
and C (GND). 0.25 V
check.
C B A
TDAA-05-06-003
T5-5-84

Preparation
position.

Message
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
111600-4 T/M Out Speed Sensor Check harness Abnormal in harness Abnormal harness.
Circuit Low Input check
Normal in harness check Faulty sensor.
C B A
TDAA-05-06-003
T5-5-85

Preparation
position.

Message
111210-3 Clutch Pressure_1st Retry by using MPDr. Un-displayed fault code Faulty sensor.
Circuit High Input
111210-4 Clutch Pressure_1st Retry by using MPDr. Un-displayed fault code Faulty sensor.
Circuit Low Input Measure voltage between A Voltage: less than 0.25 V Open circuit in
harness #2
111211-3 Clutch Pressure_2nd Retry by using MPDr. Un-displayed fault code Faulty sensor.
Circuit High Input Measure voltage between B Voltage: 4.75 V or more Shorted circuit in
111211-4 Clutch Pressure_2nd Retry by using MPDr. Un-displayed fault code Faulty sensor.
Circuit Low Input Measure voltage between A Voltage: less than 0.25 V Open circuit in
harness #2.
C B A
TDAA-05-06-003
T5-5-86

Preparation
position.

Message
111214-3 Clutch Pressure_F Circuit Retry by using MPDr. Un-displayed fault code Faulty sensor.
High Input
111214-4 Clutch Pressure_F Circuit Retry by using MPDr. Un-displayed fault code Faulty sensor.
Low Input Measure voltage between A Voltage: less than 0.25 V Open circuit in
harness #2
111215-3 Clutch Pressure_R Circuit Retry by using MPDr. Un-displayed fault code Faulty sensor.
High Input Measure voltage between B Voltage: 4.75 V or more Shorted circuit in
111215-4 Clutch Pressure_R Circuit Retry by using MPDr. Un-displayed fault code Faulty sensor.
Low Input Measure voltage between A Voltage: less than 0.25 V Open circuit in
harness #2.
C B A
TDAA-05-06-003
T5-5-87

Preparation
position.

Message
111309-3 Service Brake Pressure Retry by using MPDr. Un-displayed fault code Faulty sensor.
(Front) Sensor Circuit
High Input Measure voltage between B Voltage: 4.75 V or more Shorted circuit in
(Front) Sensor Circuit Measure voltage between A Voltage: less than 0.25 V Open circuit in
Low Input and chassis. harness #1.
harness #2
(Rear) Sensor Circuit Measure voltage between B Voltage: 4.75 V or more Shorted circuit in
High Input and chassis. harness #1 and #2.
(Rear) Sensor Circuit Low Measure voltage between A Voltage: less than 0.25 V Open circuit in
Input and chassis. harness #1.
harness #2
C B A
TDAA-05-06-003
T5-5-88

Preparation

Message
111406-2 Muffler Filter Measure resistance 0/∞Ω Faulty solenoid valve.
Regeneration Control between solenoid valve #1 (Normal value:
P/S Valve Abnormal FB and #2. 22±0.4 Ω)
Measure voltage between 0V Open circuit in harness #1.
solenoid valve harness end
#1 and chassis.
Muf/Fltr Regeneration Load 0 mA Open circuit in harness #2.
P/S FB
- Normal in above Shorted circuit in harness
check. #1 and #2.
111406-3 Muffler Filter Measure resistance 0Ω Faulty solenoid valve.
P/S Valve FB High and #2. 22±0.4 Ω)
Current - Normal in above Shorted circuit in harness
check. #1 and #2.
111406-4 Muffler Filter Measure resistance ∞Ω Faulty solenoid valve.
P/S Valve FB Low Current and #2. 22±0.4 Ω)
#1 and chassis.
P/S FB

 Solenoid Valve Connector
90Z7-05-CN10
T5-5-89

Preparation

Message
111407-2 Lift Speed Increase 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.
P/S FB
check. #1 and #2.
Valve FB High Current between solenoid valve #1 (Normal value:
and #2. 10.3±0.515 Ω)
check. #1 and #2.
Valve Low Current between solenoid valve #1 (Normal value:
and #2. 10.3±0.515 Ω)
#1 and chassis.
P/S FB

90Z7-05-CN11
T5-5-90

Preparation

Message
111410-2 Parallel/Tandem Control Measure resistance 0/∞Ω Faulty solenoid valve.
P/S Valve Abnormal FB between solenoid valve #1 (Normal value:
and #2. 22±0.4 Ω)
#1 and chassis.
Parallel/Tandem Switch P/S 0 mA Open circuit in harness #2.
FB
check. #1 and #2.
111410-3 Parallel/Tandem Control Measure resistance 0Ω Faulty solenoid valve.
P/S Valve FB High between solenoid valve #1 (Normal value:
Current and #2. 22±0.4 Ω)
check. #1 and #2.
111410-4 Parallel/Tandem Control Measure resistance ∞Ω Faulty solenoid valve.
P/S Valve FB Low Current between solenoid valve #1 (Normal value:
and #2. 22±0.4 Ω)
#1 and chassis.
Parallel/Tandem Switch P/S 0 mA Open circuit in harness #2.
FB

TNED-05-05-020
T5-5-91

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 and #2. 22±0.4 Ω)
#1 and chassis.
Oil Pressure Driving Fan 0 mA Open circuit in harness #2.
Reverse P/S FB
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 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 and #2. 22±0.4 Ω)
#1 and chassis.
Reverse P/S FB

TNED-05-05-020
T5-5-92

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

TNED-05-05-020
T5-5-93

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.

90Z7-05-CN11
T5-5-94
MC Fault Codes 111414 to 111421

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.
111418-2 T/M Clutch Forward P/S Monitor each clutch P/S FB 0 mA Open circuit in harness #2.
Valve Abnormal FB
111419-2 T/M Clutch Reverse P/S
Valve Abnormal FB
check. #1 and #2.
111420-2 T/M Clutch Fast P/S Valve
Abnormal FB
111421-2 Lockup 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
111418-3 T/M Clutch Forward P/S
Valve FB High Current
check. #1 and #2.
Valve FB High Current
FB High Current
111421-3 Lockup P/S Valve FB High
Current

TNED-05-05-020
T5-5-95

Message
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
111418-4 T/M Clutch Forward P/S #1 and chassis.
Valve FB Low Current
Valve FB Low Current Monitor each clutch P/S FB 0 mA Open circuit in harness #2.
FB Low Current
111421-4 Lockup P/S Valve FB Low
Current

TNED-05-05-020
T5-5-96

Preparation

Message
111408-2 Auto Brake P/S Valve Measure resistance 0/∞Ω Faulty solenoid valve.
Abnormal FB between solenoid valve #1 (Normal value:
and #2. 22±0.4 Ω)
#1 and chassis.
Monitor auto brake P/S FB 0 mA Open circuit in harness #2.
check. #1 and #2.
111408-3 Auto Brake P/S Valve FB Measure resistance 0Ω Faulty solenoid valve.
High Current between solenoid valve #1 (Normal value:
and #2. 22±0.4 Ω)
check. #1 and #2.
111408-4 Auto Brake P/S Valve FB Measure resistance ∞Ω Faulty solenoid valve.
Low Current between solenoid valve #1 (Normal value:
and #2. 22±0.4 Ω)
#1 and chassis.
Monitor auto brake P/S FB 0 mA Open circuit in harness #2.

TNED-05-05-020
T5-5-97

Preparation

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

90Z7-05-CN10
T5-5-98

Preparation

Message
111423-2 Ride Control (Rod) P/S Measure resistance 0/∞Ω Faulty solenoid valve.
Valve Abnormal FB between solenoid valve #1 (Normal voltage:
and #2. 22±0.4 Ω)
#1 and chassis.
check. #1 and #2.
111423-3 Ride Control (Rod) P/S Measure resistance 0Ω Faulty solenoid valve.
Valve FB High Current between solenoid valve #1 (Normal voltage:
and #2. 22±0.4 Ω)
check. #1 and #2.
111423-4 Ride Control (Rod) P/S Measure resistance ∞Ω Faulty solenoid valve.
Valve FB Low Current between solenoid valve #1 (Normal voltage:
and #2. 22±0.4 Ω)
#1 and chassis.

90Z7-05-CN10
T5-5-99
MC Fault Codes 111502, 111503, 111506,

111507
Preparation
 Check the pressure sensor connections first.
Fault Code Trouble or MP Dr. Message Inspection Method Evaluation Cause

111502-2 T/M Clutch Pressure Measure pressure at the Pressure: less than 2 Faulty 1st clutch
Decreased (1-speed) when 1st clutch MPa (290 PSI) pressure sensor.
Engaging the Clutch
111503-2 T/M Clutch Pressure Measure pressure at the Pressure: less than 2.2 Faulty 2nd clutch
Decreased (2-speed) when 2nd clutch MPa (320 PSI) pressure sensor.
Engaging the Clutch
111506-2 T/M Clutch Pressure Measure pressure at the Pressure: less than 2.2 Faulty low clutch
Decreased (F) when low clutch MPa (320 PSI) pressure sensor.
Engaging the Clutch
111507-2 T/M Clutch Pressure Measure pressure at the Pressure: less than 2.2 Faulty reverse clutch
Decreased (R) when reverse clutch MPa (320 PSI) pressure sensor.
Engaging the Clutch
fNOTE: Refer to page T4-5-26 for the transmission clutch

pressure measurement.
T5-5-100

Preparation

Message
111900-4 Torque Converter Oil Measure resistance Refer to the table. Faulty sensor.
Temperature Sensor between sensor #1 and #2.
Circuit Low Input - Normal in above Shorted circuit in harness
check. #1.
111900-3 Torque Converter Oil Measure resistance Refer to the table. Faulty sensor.
Temperature Sensor between sensor #1 and #2.
Circuit High Input Measure voltage between 0V Open circuit in harness #1.
sensor harness end #1 and
chassis.
check.
Specification of Transmission Oil Temperature Sensor Connector (Harness end)

Transmission Oil Resistance (kΩ)  T/M Oil Temperature Sensor
Temperature (°C (°F))
-30 (-22) -
-20 (-4) 77.0
-10 (14) 47.4
90Z7-05-CN11
0 (32) 30.0
10 (50) 19.5
20 (68) 13.0
30 (86) 8.9
40 (104) 6.2
50 (122) 4.0
60 (140) 3.1
70 (158) 2.3
80 (176) 1.8
90 (194) 1.3
100 (212) 1
110 (230) 0.8
120 (248) 0.6
T5-5-101

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.
Specification of Hydraulic Oil Temperature Sensor

Hydraulic Oil Resistance (kΩ)
1
-30 (-22) 25.4
-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
2
60 (140) 0.584
3
70 (158) 0.428
80 (176) 0.318
90 (194) 0.24
95Z7-05-05-02
100 (212) 0.1836
110 (230) 0.1417
1- Hydraulic Oil Tank 3- Hydraulic Oil Level Switch
120 (248) 0.1108 2- Hydraulic Oil Temperature
Sensor

 Hydraulic Oil Temperature Sensor
90Z7-05-CN11 35829-60160
T5-5-102

Preparation

Message
111903-3 T/M Oil Temp Sensor Measure resistance Refer to the table. Faulty sensor.
Circuit High Input between sensor #1 and #2.
chassis.
check.
111903-4 T/M Oil Temp Sensor Measure resistance Refer to the table. Faulty sensor.
Circuit Low Input between sensor #1 and #2.
check. #1.
Specification of Transmission Oil Temperature Sensor Connector (Harness end)

Transmission Oil Resistance (kΩ)  Transmission Oil Temperature Sensor
-30 (-22) -
-20 (-4) 77.0
-10 (14) 47.4
0 (32) 30.0 90Z7-05-CN11
10 (50) 19.5
20 (68) 13.0
30 (86) 8.9
40 (104) 6.2
50 (122) 4.0
60 (140) 3.1
70 (158) 2.3
80 (176) 1.8
90 (194) 1.3
100 (212) 1
110 (230) 0.8
120 (248) 0.6
T5-5-103

Preparation

Message
111906-3 F Axle Oil Temperature Measure resistance Refer to the table. Faulty sensor.
Sensor Circuit High between sensor #1 and #2.
Input Measure voltage between 0V Open circuit in harness #1.
chassis.
111906-4 F Axle Oil Temperature Measure resistance Refer to the table. Faulty sensor.
Sensor Circuit Low between sensor #1 and #2.
Input - Normal in above check. Shorted circuit in harness
#1.
111907-3 R Axle Oil Temperature Measure resistance Refer to the table. Faulty sensor.
Sensor Circuit High between sensor #1 and #2.
Input Measure voltage between 0V Open circuit in harness #1.
chassis.
111907-4 R Axle Oil Temperature Measure resistance Refer to the table. Faulty sensor.
Sensor Circuit Low between sensor #1 and #2.
Input - Normal in above check. Shorted circuit in harness
#1.
Specification of Axle Oil Temperature Sensor

Axle Oil Temperature (°C (°F)) Resistance (kΩ) Axle Oil Temperature (°C (°F)) Resistance (kΩ)
-30 (-22) 112.5 110 (230) 0.78
-20 (-4) 67.9 120 (248) 0.62
-10 (14) 42.4 130 (266) 0.49
0 (32) 27.2 140 (284) 0.39
10 (50) 17.9 150 (302) 0.32
20 (68) 12.1 160 (320) 0.27
25 (77) 10 170 (338) 0.22
30 (86) 8.3 180 (356) 0.18
40 (104) 5.8
50 (122) 4.2 Connector (Harness end)
60 (140) 3.1  Axle Oil Temperature Sensor
70 (158) 2.3
80 (176) 1.7
90 (194) 1.3
100 (212) 1.0
90Z7-05-CN12
T5-5-104
MC Fault Codes 120001, 120005, 120008,

120014, 120101 to 120104, 120106

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. Un-displayed fault Faulty main pump oil
Retry by using MPDr. code pressure sensor.
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. Un-displayed fault Faulty transmission oil
Retry by using MPDr. code temperature sensor.
120008-2 Muffler Filter Abnormal Diagnose on fault codes of - -
others.
120014-2 Overrun Alarm Disconnect the connector - -
from the machine speed
sensor.
Retry by using MPDr.
120101-2 Exhaust Temperature Diagnose on fault codes of - -
Alarm ECM.
120102-2 Intake Air Temperature Diagnose on fault codes of - -
Alarm ECM.
120103-2 Boost Temperature Diagnose on fault codes of - -
Increase Alarm ECM.
120104-2 Fuel Temperature Increase Diagnose on fault codes of - -
Alarm ECM.
120106-2 EGR Gas Temperature Diagnose on fault codes of - -
Alarm ECM.
T5-5-105
SC Fault Codes 120000, 120002 to 120004

120000-2 Hydraulic Oil Overheat Disconnect the connector Displayed fault code Faulty SC or shorted
Alarm from the hydraulic oil circuit in harness.
temperature sensor. Un-displayed fault Faulty hydraulic oil
120002-2 Axle Oil Temperature Disconnect the connector Displayed fault code Faulty SC or shorted
Alarm from the axle oil circuit in harness.
temperature sensor. Un-displayed fault Faulty axle oil
120003-2 Emergency Steering Disconnect the connector Correct Faulty harness.
Activated from the steering oil Incorrect Faulty secondary
pressure switch. steering check switch.
Retry by using MPDr.
120004-2 Emergency Steering Disconnect the connector Displayed fault code Faulty SC or shorted
Activated Pressure Alarm from the steering oil circuit in harness.
pressure switch. Un-displayed fault Faulty transmission oil
fNOTE: SC (Sub-Controller) refers to the Main Controller

(Sub).
T5-5-106
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
#A15 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-A Connector
TNED-05-05-011
T5-5-107

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) 100-4
A B 50 34±5
C 0 (EMPTY) 90+100
C
TNED-05-05-008

 Fuel Sensor
90Z7-05-CN11
T5-5-108
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.
T5-5-109
Monitor Controller (Monitor) Fault Codes 120300,

120301

120300-2 System Failure Alarm Check CAN harness. - Faulty CAN harness
120301-2 Muffler Filter Alarm Check pump swash angle - Faulty pump swash
proportional solenoid angle proportional
valve. solenoid valve
Fault code 111413 should
be accompanied.

120400, 120401

120400-2 Fuel Filter Restriction Diagnose on fault codes of - -
Alarm ECM.
120401-2 Water Separator Alarm Disconnect a connector Displayed fault code Faulty monitor
from the water level controller or shorted
warning switch. Retry by circuit in harness.
using MPDr. Un-displayed fault Faulty water level
code warning switch.

 Monitor Controller-A Connector
TNED-05-05-011
Water Separator
95Z7-7-64-1 95Z7-05-05-01
T5-5-110
Column Display Controller Fault Codes 120500 to 120507

120500-2 Overheat Alarm Disconnect a connector Displayed fault code Faulty column display
from the overheat switch. controller or shorted
Retry by using MPDr. circuit in harness.
Un-displayed fault Faulty overheat
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.
120504-2 Hydraulic Oil Level Alarm Disconnect a connector Displayed fault code Faulty column display
from the hydraulic oil level controller or shorted
switch. Retry by using circuit in harness.
MPDr. Un-displayed fault Faulty hydraulic oil
code level switch.
120505-2 Brake Pressure Alarm Disconnect a connector Displayed fault code Faulty column display
from the brake oil pressure controller or shorted
sensor. Retry by using circuit in harness.
MPDr. Un-displayed fault Faulty brake oil
code pressure sensor.
120506-2 Steering Oil Pressure Alarm Disconnect a connector Displayed fault code Faulty column display
from the steering oil controller or shorted
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.

 Column Display Controller 1 Connector
TNED-05-05-004
T5-5-111
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.
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.
check. #1 and #2.
T5-5-112

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.
T5-5-113
(Blank)
T5-5-114
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
 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 (Main) Accelerator Pedal (Accelerator Travel Mode Selector Switch
SC: Main Controller (Sub) 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 during exhaust filter always Manual mode.
operation As pump displacement is held at manual regeneration, hydraulic Shorted circuit: Travel mode is
when trouble minimum, all actuator speeds are load is not released. always AUTO 1/ AUTO 2 mode.
occurs slow.
Evaluation by 111000, 111001, 111002, 111003 111103 -
Fault Code
Evaluation by - MC: Demand Engine Speed MC: Travel Mode Selector Switch
Monitoring ECM: Actual Engine Speed
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
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
(Operational
Principle
Section in
S/M)
T5-6-4
Parts Fan Reverse Rotation Switch Forward/Reverse Lever
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
(Operational
Principle
Section in
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
(Operational
Principle
Section in
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
(Operational
Principle
Section in
S/M)
T5-6-7
Parts Exhaust Filter Switch Ride Control Switch, Ride Control

Switch (AUTO) (Optional)
Item
Function Shifts exhaust filter regeneration Shifts ride control solenoid valves
control solenoid valve and (rod side and bottom side) and
performs manual regeneration of activates or deactivates the ride
the exhaust filter. control.
Symptoms Same as shown below. Same as shown below.
in control
system when
trouble occurs
Symptoms Although exhaust filter manual Open circuit: Ride control switch
in machine regeneration switch is turned ON, is always OFF. Although ride
operation regeneration of the exhaust filter control switch is turned ON, the
when trouble is not performed. ride control is not activated.
occurs The exhaust filter indication mark Shorted circuit: Ride control
of exhaust filter indicator on switch is always ON.
monitor is not ON.
Evaluation by - -
Fault Code
Evaluation by ECM: Muf/Fltr Switch SC: Ride Control Switch, Ride
Monitoring Control Switch (AUTO)
Evaluation - -
by using Test
Harness
Note When exhaust filter manual -
regeneration is required
Descriptions T2-2 T2-2, T2-4
of Control
(Operational
Principle
Section in
S/M)
T5-6-8
Parts Parking Brake Switch Front Control Lever Lock Switch Pilot Shut-Off Solenoid Valve
Item
Function Shifts parking brake solenoid Shifts pilot shut-off solenoid Opens and closes the front pilot
valve. valve. circuit.
Symptoms Same as shown below. Same as shown below. Same as shown below.
in control
system when
trouble occurs
Symptoms Although the parking brake Open circuit: Front control lever When closed: The lift arm and
in machine switch is turned ON/OFF, the lock switch is always OFF. Pilot bucket are not operated. (Pilot
operation parking brake is not released/ shut-off solenoid valve is not pressure oil is not supplied to
when trouble applied with the engine running. shifted. The lift arm and bucket pilot valve.)
occurs are not operated although the When open: Pilot pressure oil is
control lever is operated with the always supplied to pilot valve.
front control lever lock switch set
in UNLOCK position.
Shorted circuit: Front control
lever lock switch is always ON.
Evaluation by - - -
Fault Code
Evaluation by Column Display Controller: SC: Pilot Primary Pressure -
Monitoring Parking Brake Signal Output
Evaluation - - -
by using Test
Harness
Note Although the parking brake is - The pilot shut-off solenoid valve
turned OFF, the parking brake is can be manually turned ON/OFF.
applied with the engine stopped.
Descriptions T2-2, T2-5 T2-4 T2-5
of Control
(Operational
Principle
Section in
S/M)
T5-6-9
Parts Hydraulic Oil Temperature Sensor Torque Converter Oil T/M Oil Temperature Sensor
Temperature Sensor
Item
Function Monitors hydraulic oil Monitors torque converter oil Monitors transmission oil
temperature. temperature. temperature.
Symptoms SC (Main Controller (Sub)) SC recognizes that torque MC recognizes that transmission
in control recognizes that hydraulic oil converter oil temperature is oil temperature is 120°C (248°F)
system when temperature is 120°C (248°F) 120°C (248°F) when open circuit when open circuit occurs.
trouble occurs when open circuit occurs. occurs.
(Hydraulic oil temperature:
120°C (248°F) is not displayed on
monitoring.)
Symptoms When hydraulic oil temperature The color of transmission oil Shift change becomes unsmooth.
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 Fan speed control becomes
abnormal.
Evaluation by 111901 111900, 120005 111903
Fault Code
Evaluation by SC: Hydraulic Oil Temperature SC: Torque Converter Oil MC: Transmission Oil Temperature
Monitoring Temperature
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
S/M)
fNOTE: The T/M oil temperature sensor value is used only in the Service Menu-Monitoring, and Transmission Learning
programs. The others are value from the torque converter oil temperature sensor.
T5-6-10
Parts Exhaust Filter Differential Muf/Fltr Inlet Exhaust Gas Muf/Fltr Outlet Exhaust Gas
Pressure Sensor Temperature Sensor Temperature Sensor
Item
Function Measures differential pressure Detects exhaust temperature Detects exhaust temperature
before and after the filter and before diesel oxidation catalyst. before the filter.
detects PM trapping amount.
Symptoms ECM judges that differential ECM judges that exhaust DOC exhaust temperature
in control pressure is 0 kPa (psi). temperature is 0 °C (32 °F). sensor is used as muffler
system when filter regeneration judging
trouble occurs temperature.
ECM judges that exhaust
temperature is 0 °C (32 °F).
Symptoms Engine output power decreases. Engine output power decreases. Engine output power decreases.
in machine Regeneration of the exhaust filter Regeneration of the exhaust filter Regeneration of the exhaust filter
operation is not performed. is not performed. is not performed.
when trouble
occurs
Evaluation by ECM: 81 ECM: 10024 ECM: 173
Fault Code
Evaluation by ECM: Muf/Fltr EGP Differential ECM: Muf/Fltr Catalyst Inlet EGT ECM: Muf/Fltr Inlet EGT
Monitoring Pressure
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
S/M)
T5-6-11
Parts Pump Delivery Pressure Sensor Hyd. Fan Circuit Pressure Sensor Secondary Steering Pump
Delivery Pressure Sensor
Item (Optional)
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 SC: Hydraulic Fan Circuit Pressure SC: Secondary Steering Pump
Monitoring Delivery Pressure
Evaluation - - -
by using Test
Harness
Note 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
(Operational
Principle
Section in
S/M)
T5-6-12
Parts Steering Pressure Switch Pressure Sensor (Parking Brake Pressure Sensor (Brake Primary
(Optional) 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 111309, 111310
Fault Code
Evaluation by MC: Steering Pressure Switch MC: Parking Brake Pressure MC: Service Brake Primary
Monitoring Pressure
Evaluation - - -
by using Test
Harness
Note Possible to judge if pressure Possible to judge if pressure 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 switch with by switching pressure sensor with by switching pressure sensor with
pump delivery pressure switch. other pressure sensor. other pressure sensor.
Descriptions T2-2 T2-2, T2-4 T2-2, T2-4
of Control
(Operational
Principle
Section in
S/M)
T5-6-13
Parts Pressure Sensor (Brake Secondary Lift Arm Angle Sensor Pressure Sensor (Lift Arm Raise)
Pressure)
Item
Function Detects front brake pressure. Detects operating angle of the Detects lift arm raise pilot
lift arm. pressure.
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 SC: Lift Arm Angle Sensor SC: Lift Arm Raise Pilot Pressure
Monitoring Pressure (For Declutch)
Evaluation - - -
by using Test
Harness
Note - - Possible to judge if pressure
sensor is faulty or port is clogged
by switching pressure sensor with
other pressure sensor.
Descriptions T2-2 T2-2 T2-2, T2-4
of Control
(Operational
Principle
Section in
S/M)
T5-6-14
Parts Pressure Sensor (Bucket Dump) Pressure Sensor (Bucket Roll Pressure Sensor (Primary Pilot
Back) Pressure)
Item
Function Detects bucket dump pilot Detects bucket roll back (tilt) pilot Detects primary pilot pressure.
pressure. pressure.
system when
trouble occurs
Symptoms Front attachment operation Front attachment operation Although front control lever lock
in machine circuit selection control is not circuit selection control is not solenoid valve is operated with
operation activated during combined activated during combined front control lever lock switch set
when trouble operation of lift arm and bucket. operation of lift arm and bucket. in the OFF (Lock) position, front
occurs control lever lock indicator is not
ON.
Evaluation by 111203 111202 111217
Fault Code
Evaluation by SC: Bucket Dump Pilot Pressure SC: Bucket Tilt Pilot Pressure SC: Pilot Pressure Sensor
Monitoring
Evaluation - - -
by using Test
Harness
Note 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 sensor with
other pressure sensor. other pressure sensor. other pressure sensor.
Descriptions T2-2, T2-4 T2-2, T2-4 T2-2, T2-4
of Control
(Operational
Principle
Section in
S/M)
T5-6-15
Parts Torque Converter Input Speed Forward/Reverse/1st/2nd Clutch

Sensor Pressure Sensors
Item
Function Detects torque converter input Detects clutch solenoid pressure
shaft speed.
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 change feeling Transmission Oil Pressure Alarm is
in machine becomes bad extremely during reported.
operation automatic speed shift. The gear shift to the selected
when trouble Possible to judge if sensor is range may feel worse.
occurs faulty by switching sensor with
other sensor.
Evaluation by 111105-3 MC: 111210, 111211, 111214,
Fault Code 111215
Evaluation by Torque Converter Actual Input MC: Transmission Clutch Oil
Monitoring Speed Pressure Sensor
Evaluation - -
by using Test
Harness
Note Possible to judge if speed sensor Possible to judge if pressure
is faulty by switching a sensor sensor is faulty by switching
with other speed sensor. a sensor with other pressure
sensor.
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
S/M)
T5-6-16
Parts Vehicle 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.
Evaluation by 111600 111207
Fault Code
Evaluation by MC: Machine Speed Pulse SC: Air Conditioner Refrigerant
Monitoring Pressure
Evaluation - -
by using Test
Harness
Note Possible to judge if speed sensor -
is faulty by switching pressure
sensor with other speed sensor.
of Control
(Operational
Principle
Section in
S/M)
T5-6-17
Parts Ride Control Solenoid Valves (Rod Parallel/Tandem Switching Exhaust Filter Regeneration
Side and Bottom Side) Solenoid Valve Control Solenoid Valve
Item
Function Shifts ride control main spool in Shifts selector valve in lift arm Shifts bleed-off compensation
control valve. flow rate control valve. Limits spool in control valve.
Connects the rod side circuit to flow rate to lift arm during
the tank. combined operation of lift arm
raise and bucket.
in control
system when
trouble occurs
Symptoms High current: The ride control is High current: Lift arm speed Regeneration may not be
in machine always activated. becomes slow as the lift arm flow performed during manual or auto
operation Low current: The ride control is rate control valve (selector valve) regeneration of the exhaust filter.
when trouble not effective. is always restricted.
occurs Low current: The operation
combined with the lift arm is not
smooth as the lift arm flow rate
control valve (selector valve) is
always opened.
Evaluation by 111422, 111423 111410 111406
Fault Code
Evaluation by SC: Ride Control (Rod) P/S SC: Parallel/Tandem Control P/S SC: Muf/Fltr Regeneration P/S
Monitoring Output, Ride Control (Rod) P/S Output, Parallel/Tandem Switch Output, Muf/Fltr Regeneration
Output FB, Ride Control (Bottom) P/S Output FB Load P/S Output FB
P/S Output, Ride Control
(Bottom) P/S Output FB
Evaluation Install light harness tool. Install light harness tool. Install light harness tool.
by using Test Check output signals from SC Check output signals from SC Check output signals from SC
Harness (Main Controller (Sub)) and (Main Controller (Sub)) and (Main Controller (Sub)) and
harness condition. harness condition. harness condition.
Note - - Exhaust filter alarm turns ON.
Descriptions T2-2, 2-4 T2-2, 2-4 T2-2, 2-4
of Control
(Operational
Principle
Section in
S/M)
T5-6-18
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 The exhaust filter alarm is
in machine is not released. (Pilot pressure oil displayed on the monitor.
operation is not supplied to parking brake.) High current: Pump torque of
when trouble When open: The parking brake main pump is kept minimum.
occurs is applied. (Pilot pressure oil is The loading movement becomes
supplied to parking brake.) slow.
Low current: Engine speed
regulation for digging is
deactivated.
Evaluation by - 111413
Fault Code
Evaluation by - SC: 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 -
manually turned ON/OFF.
Descriptions T2-2, 2-4 T2-2
of Control
(Operational
Principle
Section in
S/M)
T5-6-19
Parts Hyd. Fan Speed Control Solenoid Hyd. Fan Reverse Rotation
Valve Control Solenoid Valve
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
Evaluation by 111412 111411
Fault Code
Evaluation by SC: Hyd Fan Speed Control P/S SC: Hyd Fan Reverses Rotation
Monitoring Output, Hyd Fan Speed Control P/S Output, Hyd Fan Reverses
P/S Output FB Rotation P/S Output FB
Evaluation - -
by using Test
Harness
Note - -
Descriptions T2-2, 2-4 T2-2, 2-4
of Control
(Operational
Principle
Section in
S/M)
T5-6-20
Parts Forward/Reverse/High/Lockup Speed Shift Solenoid Valves (1, 2,

Clutch Solenoid 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, 111420 MC: 111414, 111415, 111416,
Fault Code 111421
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 Lockup P/S Valve
T/M Clutch Fast P/S Valve Output Output
T/M Clutch Fast P/S Valve FB T/M Clutch Lockup P/S Valve FB
Evaluation - -
by using Test
Harness
Note -
of Control
(Operational
Principle
Section in
S/M)
T5-6-21
Parts Lift Speed Increase Solenoid Auto Brake Solenoid Valve

Valve
Item
Function Shifts spools in lift arm speed Shifts spools in auto brake
multiplication solenoid valve of solenoid valve.
priority hammer valve.
in control
system when
trouble occurs
Symptoms Oil flow to increase lift arm Auto brake does not work.
in machine raising speed cannot be directed Auto brake warning alarm
operation as expected. appears on the monitor display.
when trouble
occurs
Evaluation by MC: 111407 MC: 111408
Fault Code
Evaluation by Lift Speed Increase P/S Valve Auto Brake P/S Valve Output
Monitoring Output Auto Brake P/S Valve FB
Lift Speed Increase P/S Valve FB
Evaluation - -
by using Test
Harness
Note - -
of Control
(Operational
Principle
Section in
S/M)
T5-6-22
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
(Operational
Principle
Section in
S/M)
T5-6-23
Parts Lift Arm Flow Rate Control Valve Pump Control Valve
Item
Function Is shifted by pilot pressure from Supplies pressure oil from the
lift arm flow rate control solenoid main pump to the regulator of
valve. Restricts lift arm circuit pump device and increases/
and keeps bucket speed during decreases the pump delivery flow
combined operation of lift arm rate.
and bucket.
in control
system when
trouble occurs
Symptoms If poppet valve or selector valve Load is applied to the pump
in machine is stuck in fully closed position, as the pump delivery flow rate
operation boom operation is not smooth. does not decrease with the front
when trouble If poppet valve or selector attachment control lever set in
occurs valve is stuck in fully open neutral.
position, bucket tilt operation As pump torque increases,
is not smooth during combined acceleration is not smooth when
operation of lift arm lower and staring the engine.
bucket roll back. Machine speed does not increase.
Evaluation by - -
Fault Code
Evaluation by - -
Monitoring
Evaluation - -
by using Test
Harness
Note - -
of Control
(Operational
Principle
Section in
S/M)
T5-6-24
Parts Ride Control Valve Main Spool Bleed-Off Compensation Spool Fan Reversing Spool (Fan Valve)
(Optional Ride Control Valve) (Control Valve)
Item
Function Is shifted by pilot pressure from Is shifted by main pump pressure Is shifted by pilot pressure
ride control solenoid valve. sent by activated exhaust filter from fan reverse rotation
Connects the accumulator to regeneration solenoid valve. control solenoid valve in fan
lift arm cylinder circuit and Sends more pressurized oil to the valve. Changes the fan rotation
increases/decreases the lift arm steering circuit or forcibly relieves direction (in normal / reverse).
cylinder bottom pressure. the main circuit pressure to
increase hydraulic load in order
to raise exhaust temperature.
in control
system when
trouble occurs
Symptoms If stuck in neutral position, the If stuck in neutral position, If stuck in normal direction
in machine ride control is not activated. steering is not smooth. position, the fan always rotates in
operation If stuck in ride control operating If stuck in steering position, front normal direction.
when trouble position, digging operation is not attachment operating power is If stuck in reverse direction
occurs smooth. lack and moves slower. position, the fan always rotates
If stuck in exhaust filter in reverse direction. Overheating
regeneration position, loading occurs easily.
operation becomes impossible.
Overheating occurs easily.
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
S/M)
T5-6-25
(Blank)
T5-6-26
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.
T5-6-27
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
Engine Control Module (ECM)  
Monitor Controller
Monitor
MPDr.
Key Switch   
Accelerator Pedal Sensor
Forward/Reverse Lever  (Neutral)  (Neutral)
Forward/Reverse Selector  
Switch
Forward/Reverse Switch  (Neutral)  (Neutral)
Battery 
Battery Relay 
Fuse Box A  (#4, #11)
Fuse Box B  (#3)  (#3)  (#10)
Neutral Relay  
Starter Cut Relay 
Starter Relay 
ECM Main Relay  
Starter 
Engine Unit 
Coolant Temperature Sensor
Glow Plug (Heater) Relay
Glow Plug
Pump Delivery Pressure Sensor
: Check required : Related
T5-6-28
Trouble Symptom E-4 E-5 E-6

Power mode is not shifted Even if key switch is turned Auto idling-stop is not
down when pushing power OFF, engine does not stop. activated.
Parts mode switch.
Main Controller (Main)   
Engine Control Module (ECM)  
Monitor Controller  
Monitor  
MPDr.   (Setup)
Key Switch  
Accelerator Pedal Sensor 
Power Mode Switch 
Parking Brake Switch 
Forward/Reverse Lever  (Neutral)
Forward/Reverse Selector 
Switch
Forward/Reverse Switch  (Neutral)
Exhaust Filter Switch 
Battery 
Battery Relay  
Fuse Box A  (#11, #13)
Fuse Box B
Key Switch ON Cut Relay 
ACC Cut Relay 
Auto Shut-Down Relay 
Starter Relay
ECM Main Relay  
Starter
Engine Unit 
Coolant Temperature Sensor 
Pump Delivery Pressure Sensor 
Hydraulic Oil Temperature 
Sensor
Torque Converter Oil 
Temperature Sensor
Pressure Sensor (Parking Brake) 
T5-6-29
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 (Sub) 
Battery
Fuse Box B  (#16)
Pilot Shut-Off Relay 
Front Control Lever Lock Switch 
Power Mode Switch 
Accessory pump 
Unloader (Brake Charge) Valve
Brake Priority Valve 
Reducing Valve (Combination 
Valve)
Manifold Valve (Combination  
Valve)
Torque Control Solenoid Valve 
(Main Pump)
Pilot Shut-Off Solenoid Valve  
Pilot Valve  
Pressure Sensor (Primary Pilot  
Pressure)
Flow Regulator Valve
Pressure Sensor (Lift Arm Raise) 
Pressure Sensor (Bucket Dump) 
Pressure Sensor (Bucket Roll 
Back)
Spool (Multiple Control Valve)  
Spool (Steering Valve) 
Main Relief Valve (Multiple 
Control Valve)
Pump Control Valve 
Cylinder
Main Pump 
Bleed-Off Compensation Spool  
(Multiple Control Valve)
Pump Regulator 
Pilot Filter 
T5-6-30

Actuator of front attachment Auto or manual regeneration
does not stop even if a of exhaust filter cannot be
Parts control lever is set to neutral. performed. (It fails.)
Main Controller (Main) 
Engine Control Module (ECM) 
Monitor Controller 
Monitor 
Key Switch
Accelerator Pedal Sensor 
Forward/Reverse Lever  (Neutral)
Forward/Reverse Selector
Switch
Forward/Reverse Switch  (Neutral)
Pilot Shut-Off Relay
Front Control Lever Lock Switch 
Exhaust Filter Switch 
Battery
Exhaust Filter Differential 
Pressure Sensor
Engine Unit
Engine Speed Sensor (Main)
Engine Speed Sensor (Sub)
Exhaust Temperature Sensor
Main Pump 
Accessory Pump
Pump Regulator 
Manifold Valve
Torque Control Solenoid Valve 
Pilot Shut-Off Solenoid Valve
Pressure Sensor (Primary Pilot 
Pressure)
Pilot Valve 
Control Valve  
Bleed-Off Compensation Spool 
Exhaust Filter Regeneration 
Control Solenoid Valve
Pilot Filter
Hydraulic Oil Temperature
Sensor
Torque Converter Oil
Temperature Sensor
T5-6-31

Fan speed does not change. Fan does not rotate in
reverse when pushing fan
Parts reverse rotation switch.
Main Controller (Sub)  
Engine Control Module (ECM) 
Monitor Controller
Monitor
MPDr. 
Key Switch
Power Mode Switch
Fan Reverse Rotation Switch 
Battery
Fuse Box A
Fuse Box B
Fan Valve  
Fan Speed Control Solenoid 
Valve
Fan Reverse Rotation Control 
Solenoid Valve
Fan Control Valve  
Fan Motor  
Accessory Pump (Fan Pump)  
Engine Unit
Engine Speed Sensor (Main)
Engine Speed Sensor (Sub)
Boost Temperature Sensor 
Hydraulic Fan Circuit Pressure  
Sensor
Hydraulic Oil Temperature 
Sensor
Torque Converter Oil 
Temperature Sensor
Pressure Sensor (Refrigerant 
Pressure)
T5-6-32
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 (Sub) 
Battery
Fuse Box B
Pilot Shut-Off Relay
Front Control Lever Lock Switch
Power Mode Switch
Accessory Pump  
Priority Valve (Unloader Valve) 
Valve)
Torque Control Solenoid Valve 
(Main Pump)
Front Control Lever Lock
Solenoid Valve (Combination
Valve)
Pilot Valve 
Pressure Sensor (Primary Pilot 
Pressure)
Shockless Valve (Flow Regulator
Valve)
Parallel/Tandem Switching
Solenoid Valve
Lift Arm Flow Rate Control Valve
Pressure Sensor (Bucket Roll
Back)
Spool (Multiple Control Valve)  
Main Relief Valve (Multiple   (Overload)
Control Valve)
Pump Control Valve (Multiple 
Control Valve)
Cylinder 
Main Pump 
Pump Delivery Pressure Sensor
Bleed-Off Compensation Spool 
Pump Regulator
Pilot Filter 
T5-6-33

Front attachment drifts Shock during bucket
remarkably (when the engine dumping is large when
is stopped). stopping lift arm raise /
Parts lower operation.
Main Controller
Monitor Controller
Monitor
Lift Arm Angle Sensor
Accessory pump
Combination Valve
Pilot Valve  
Shockless Valve (Flow Regulator  (Lift Arm Raise)
Valve)
Shockless Valve (Flow Regulator  (Lift Arm Lower)
Valve)
Restriction Valve (Flow  (Bucket Dump)
Regulator Valve)
Back)
Spool (Multiple Control Valve)  
Load Check Valve (Multiple 
Control Valve)
Cylinder 
Main Pump
T5-6-34

Bucket auto leveler control is Lift arm float control is not
not activated. (Detent is not activated. (Detent is not
Parts held.) held.)
Monitor
Battery
Battery Relay
Fuse Box B  (#16)  (#16)
Lift Arm Angle Sensor 
Bucket Proximity Switch 
Accessory pump
Combination Valve
Pilot Valve  (Bucket)  (Lift Arm)
Spool (Multiple Control Valve)  (Bucket)  (Lift Arm)
Cylinder
Main Pump
T5-6-35
Trouble Symptom F-7 F-8 F-9

Lift arm auto leveler height Lift arm auto leveler lower Ride control is not activated.
kickout control is not kickout control is not
Parts activated. activated.
Main Controller (Sub)   
Monitor Controller
Monitor  (Setting: ON)  (Setting: ON)  (Setting: ON)
MPDr. 
Fuse Box B  (#16)  (#16)
Lift Arm Angle Sensor   
Machine Speed Sensor 
Ride Control Switch 
Accessory pump
Pilot Shut-Off Solenoid Valve
(Combination Valve)
Pilot Valve  (Lift Arm)  (Lift Arm)
Lift Arm Raise Side Coil (Pilot 
Valve)
Lift Arm Lower Side Coil (Pilot 
Valve)
Pressure Sensor (Primary Pilot
Pressure)
Pressure Sensor (Bucket Dump)
Back)
Ride Control Solenoid Valve 
(Option)
Ride Control Selector Solenoid 
Valve (Multiple Control Valve)
Spool (Ride Control Valve)  (Lift Arm)  (Lift Arm) 
Cylinder  (Lift Arm)
Accumulator (Ride Control) 
Main Pump
T5-6-36
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 (Sub) 
Accessory pump  
Reducing Valve (for Orbitrol) 
Shuttle Valve 
Torque Control Solenoid Valve  
(Main Pump)
Orbitrol (Steering Wheel)  
Stop Valve (Left, Right)  
Steering Valve (Spool)    (Orifice)
Overload Relief Valve (Steering
Valve)
Steering Pressure Switch 
Steering Cylinder (Left, Right)  
Main Pump  
Steering Relief Valve (Steering  
Valve)
Bleed-Off Compensation Spool  
Pilot Filter (Bleed-Off  (Orifice)
Compensation Valve)
Pump Regulator  
Pilot Filter 
T5-6-37
Trouble Symptom S-4

Secondary steering
(optional) does not operate.
(Automatic operation check
Parts when the engine starts)
Monitor Controller
Monitor  (Setup)
MPDr. 
Battery
Fuse Box A  (#10)
Secondary Steering Relay 
Machine Speed Sensor 
Accessory pump
Combination Valve
Orbitrol (Steering Wheel)
Stop Valve (Left, Right)
Spool (Steering Valve)
Steering Pressure Switch 
Secondary Steering Pump 
Delivery Pressure Sensor
Steering Cylinder (Left, Right)
Main Pump
Secondary Steering Motor 
Secondary Steering Pump 
T5-6-38
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)
Monitor Controller
Monitor 
Battery
Fuse Box B  (#1, #9)  (#1, #9)  (#1, #9)
Brake Pedal (Right) Switch
Brake Valve 
Forward/Reverse Lever  (Forward / Reverse)  (Neutral)  (Forward)
Forward/Reverse Switch  
Forward/Reverse Selector  
Switch
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) 
T5-6-39

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)
Monitor Controller
Monitor
Battery
Fuse Box B  (#1, #9)
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)
T5-6-40

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 (Main)   
Monitor
Key Switch  (ON)
Battery 
Fuse Box A
Fuse Box B  (#1, #9)  (#1, #9)
Travel Mode Selector Switch 
Forward/Reverse Lever 
Forward/Reverse Switch 
Forward/Reverse Selector 
Switch
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   
Transmission Oil Filter 
Transmission Oil Filter
Restriction Switch
Pressure Sensor (Parking Brake)
Lift Arm Angle Sensor
T5-6-41
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. )
Main Controller (Main)  
Monitor Controller
Column Display Controller 
Key Switch  (ON)
Battery
Fuse Box A  (#11)  (#11)
Fuse Box B  (#15)  (#15)
Parking Brake Switch  (Released)  (Operated)
Parking Brake Relay 1  (OFF)  (ON)
Parking Brake Relay 2  (ON) 
Parking Brake Solenoid Valve  
Parking Brake  
Parking Brake Accumulator
Brake Charge Valve  
Pressure Sensor (Parking Brake)  
Valve)
Pressure Sensor (Brake Primary 
Pressure)
Service Brake Accumulator 
Brake Valve 
Axle (Service Brake) 
Pressure Sensor (Brake 
Secondary Pressure)
Accessory 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.
T5-6-42
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.
Main Controller (Main)
Monitor Controller
Column Display Controller  (Indicator)  (Indicator)  (Indicator)
Key Switch  (ON)  (ON)
Battery 
Fuse Box A  (#1, #2)  (#7)  (#9)
Fuse Box B  (#11)  (#7, #11)  (#11)
Light Switch   
Dimmer Switch  
Head Light Relay (Left) 
Head Light Relay (Right) 
High Beam Relay 
Head Light   (High Beam)
Clearance Light 
Tail Light 
License Plate Light (Optional) 
T5-6-43

Hazard light is not operated. Turn signal light is not Horn does not sound.
operated.
Parts
Monitor Controller
Column Display Controller  (Indicator)  (Indicator)
Key Switch  (ON)
Battery  
Fuse Box A  (#6)
Fuse Box B  (#5)  (#5)  (#5)
Hazard Light Switch 
Turn Signal Lever 
Horn Switch 
Flasher Relay  
Turn Signal Light Relay (Left)  
Turn Signal Light Relay (Right)  
Horn Relay 
Turn Signal Light (Hazard Light)  
Horn 
T5-6-44

Reverse light is not ON. Brake light is not ON. Work light does not light.
Reverse buzzer does not
Parts sound.
Monitor Controller
Column Display Controller  (Indicator)
Key Switch  (ON)  (ON)  (ON)
Battery
Fuse Box A  (#3, #11)  (#3)  (#5)
Fuse Box B  (#11, #17)
Forward/Reverse Lever  (R)
Forward/Reverse Selector
Switch
Forward/Reverse Switch  (R)
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 
T5-6-45

Wiper is not operated. Washer is not operated. Cab light is not ON.
Parts
Monitor Controller
Column Display Controller 
Key Switch  (ON)  (ON)
Battery 
Fuse Box A  (#8)  (#8)
Fuse Box B  (#8)  (#8)  (#12)
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 
T5-6-46

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 and - The measured values Faulty battery
electrolyte density are out of normal
range
(Normal range:
Voltage: 24 V or more,
Electrolyte density:
1.26 or more)
2 Replace the neutral relay with Set the key switch Starter: Rotating Faulty neutral relay
other general relay to START after
replacing relays
3 Measure voltage between Key switch: START 0V Open circuit in harness between
neutral relay harness end #3 key switch and neutral relay
and chassis
4 Measure voltage at starter Key switch: START 0V Open circuit in harness between
relay harness end terminal S neutral relay and starter relay
5 Replace the starter cut relay Set the key switch Starter: Rotating Faulty starter cut relay
with other general relay to START after
replacing relays
starter cut relay harness end starter relay and starter cut relay
#3 and chassis
7 Check continuity between Key switch: ON 0Ω Shortcircuit in harness between
starter cut relay harness end starter cut relay and ECM
#2 and chassis
8 Measure voltage at battery Key switch: ON 0V Faulty battery relay
relay terminal A
9 Measure voltage at starter Key switch: START 0V Faulty starter relay
terminal S
10 Check continuity between Key switch: START ∞Ω Faulty key switch
key switch #1 and #6
11 Monitor Forward/Reverse Forward/reverse OFF is displayed Faulty forward/reverse lever
Lever (N) lever: N
12 - - The above checks Faulty starter
resulted all normal.
T5-6-47
E-2 Even if starter rotates, engine does not start.
Preparation
 Check the wiring connections first.  Check that the fuel filter is not clogged.
 Check that #3 fuse in fuse box B is not abnormal.

1 Measure voltage between Key switch: ON 0V Open circuit in harness between
ECM main relay harness end ECM main relay and #3 fuse in
#13 and rear chassis fuse box B
ECM main relay harness end ECM main relay and ECM #114
#712 and rear chassis terminal
3 Replace ECM main relay with Key switch: ON 0V Faulty ECM main relay
other general relay
4 - - The check (1) above Faulty ECM or engine unit
resulted normal.
T5-6-48
E-3 Engine starts with forward/reverse lever set in

the positions except N.
Preparation
 Even if the key switch is set to the START position
with the forward/reverse lever set in the positions
except N (neutral), the starter does not rotate.
 Check #10 fuse in fuse box B.
 Refer to SYSTEM / Electrical System / Neutral Engine

Start Circuit.
 Refer to SYSTEM / Hydraulic System.

neutral relay harness end #3 key switch and neutral relay
and rear chassis
2 Replace the neutral relay with Set the key switch Starter: Rotating Faulty neutral relay
other general relay to START after
replacing relays
3 - - The above checks Find out cause of trouble by
resulted all normal. tracing other trouble symptoms
T5-6-49
E-4 Power mode is not activated when pushing

power mode switch.
Preparation

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

not stop.
1
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.

Battery Box
95MNEC-01-82
T5-6-51
E-6 Auto idling-stop is not activated.
Preparation
 Check the auto idling-stop setting with the monitor
or MPDr. first.
 Refer to SYSTEM / Control System and SYSTEM /

Electrical System / Auto Idling-Stop Control.

1 Replace auto idling-stop relay - The symptom Faulty auto idling-stop relay
with other general relay disappears
2 Replace key switch ON cut - The symptom Faulty key switch ON cut relay
relay with other general relay disappears
3 Replace ACC cut relay with - The symptom Faulty ACC cut relay
other general relay disappears
4 Monitor Forward/Reverse Forward/reverse F or R is displayed Faulty forward/reverse lever
Lever (N) lever: N
5 Monitor Parking Brake Parking brake The measured values Stuck spool in parking brake
Pressure switch: ON are out of normal solenoid valve
Engine: Running range
(Normal range:
3.0 ~ 3.7 MPa)(435 ~
537 psi)
6 Monitor Pilot Primary Front control Pressure is not Faulty pilot shut-off circuit (A-1)
Pressure lever lock switch: detected
UNLOCK position
7 Monitor Exhaust Filter Switch Exhaust ON is displayed Faulty exhaust filter manual
filter manual regeneration switch
regeneration
switch: OFF
8 - - The above checks Faulty Main Controller (MC)
resulted all normal
T5-6-52

A-1 Actuator of only front attachment do not
work.
Preparation
 If other function (steering) is operated normally, the  Pilot valve and multiple control valve spools are
main pump is considered to be normal. unlikely to be faulty at the same time.
Check that the main circuit pressure increases in
the neutral status. If the pressure increases to the  Refer to SYSTEM / Electrical System.
specified level, the cause of trouble may exist in
the bleed-off compensation spool or exhaust filter  Check the wiring connections first.
regeneration control solenoid valve.
 Check that #16 fuse in fuse box B is not abnormal.

1 Monitor Pump Delivery No steering or Pressure increases up Stuck spool in bleed-off
Pressure loading operation to the main relief set compensator.
pressure. Faulty or malfunction of exhaust
filter regen. control solenoid
valve.
2 Replace pilot shut-off relay Pilot shut-off lever: The symptom Faulty pilot shut-off relay
with other general relay UNLOCK position disappears
3 Monitor Pilot Primary Front control Pressure is not Faulty front control lever lock
Pressure lever lock switch: detected switch
UNLOCK position
4 Measure resistance between - 0/∞ Ω Faulty pilot shut-off solenoid
pilot shut-off solenoid valves valve
#1 and #2
5 Check voltage between Key switch: ON 0V Open circuit in harness between
pilot shut-off solenoid valve pilot shut-off solenoid valve and
harness end #1 and chassis pilot shut-off relay
6 - - The above checks Faulty pilot valve
T5-6-53
A-2 Actuator speed of front attachment and

steering are slow.
Preparation
 The pump flow rate is minimized due to some  If actuator speed of only steering is slow, the circuit
reasons. after the steering pilot valve may be faulty (S-3).
 Even if speed is satisfactory, in case power is weak,  Refer to SYSTEM / Hydraulic System.
refer to the troubleshooting for faulty main relief
valve (F-1/S-1).
 If actuator speed of only front attachment is slow, the

pilot system may be faulty (A-1) or the circuit after
the pilot valve may be faulty (F-2).

1 Monitor Main Pump Delivery No steering or The measured value Faulty bleed-off compensation
Pressure loading operation exceeds 3.5 ~ 5.0 MPa spool (stuck)
Engine: High idling (508 ~ 725 psi)
2 Measure steering time (full Disconnect the Both of the measured Faulty torque control solenoid
turn) and lift arm raising time connector of times are out of valve
(fully up) torque control normal range Faulty main pump
solenoid valve (Full turn: 3.0±0.4 sec Faulty main pump regulator
Lift arm fully up:
6.8±0.3 sec)
Only the steering Faulty steering valve
time is out of normal Problem in the circuit after the
range: 3.0 ± 0.4 sec Orbitrol (steering pilot valve)
(full turn)
Only the lift arm Faulty multiple control valve
raising time is out of Problem in the pilot circuit after
normal range: 6.8 ± the pilot valve
0.3 sec (fully up)
Both of the measured Faulty torque control solenoid
times are within the valve
normal range. Faulty Main Controller (SC)
fNOTE: The normal range differs depending on the

machine condition. Refer to Section 4 for details.
90TNED-05-01-03
a- Torque Control Solenoid

Valve Connector
T5-6-54
A-3 Actuator of front attachment does not stop

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

1 Set the front control lever - Actuator stops Faulty pilot valve (stuck spool)
lock switch to LOCK position
2 - - The check (1) above Faulty multiple control valve
resulted normal. (stuck spool)
T5-6-55
A-4 Auto or manual regeneration of exhaust filter

cannot be performed or failed.
Preparation
 Refer to SYSTEM / Control System / Exhaust Filter
Manual/Auto Regeneration Control.

1 Monitor Forward/Reverse Forward/reverse F or R is displayed Faulty forward/reverse lever
Lever (N) lever: N
Pressure switch: OFF are out of normal solenoid valve
Engine: Running range (Normal range:
3.0 ~ 3.7 MPa) (435 ~
537 psi)
3 Monitor Pilot Primary Front control Pressure is not Faulty pilot shut-off circuit (A-1)
Pressure lever lock switch: detected
UNLOCK position
4 Monitor Exhaust Filter Switch Exhaust filter ON is displayed Faulty exhaust filter switch
switch: OFF
5 Measure pressure at port Exhaust The measured values Faulty exhaust filter manual
PLS of exhaust filter manual filter manual are out of normal regeneration control solenoid
regeneration control solenoid regeneration: ON range (Normal range: valve
valve 30.9 ~ 31.9 MPa (4482
~ 4627 psi))
6 Monitor Pump Delivery Control lever in The measured values Bleed-off compensation spool
Pressure neutral are out of normal is stuck.
Accelerator pedal: range (Normal range:
Fully depressed 4.5 MPa (653 psi))
7 - - The above checks Faulty Main Controller (MC)
T5-6-56
A-5 Fan speed does not change.
Preparation
 The sensors detect the conditions necessary to  Refer to SYSTEM / Control System / Fan Reverse
operate fan speed control. Therefore, if these sensors Rotation Control.
fail, 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 involved in the fan speed control.
If these sensors fail, other operating functions will be
also affected.

1 Monitor Target Hydraulic Fan Engine: Running Fan speed does not Faulty engine control module
Speed change according (ECM) or main controller (MC)
to accelerator pedal
depressing amount
2 Disassemble and inspect the - There is abnormality Faulty fan speed control
fan speed control solenoid solenoid valve
valve
3 Disassemble and inspect the - There is abnormality Faulty fan control valve
fan control valve
4 Monitor Hydraulic Fan Circuit Engine: Running Fan pump delivery Faulty fan pump
Pressure pressure does not
change according
to accelerator pedal
depressing amount
5 - - The above checks Faulty fan motor
T5-6-57
A-6 Fan does not rotate in reverse when pushing

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

1 Monitor Fan Reversing Switch Parking brake is OFF is displayed Faulty fan reverse rotation
applied switch
Fan reverse
rotation switch:
ON
2 Measure resistance between - 0/∞ Ω (Normal value: Faulty fan reverse rotation
fan reverse rotation control 26.2 Ω) control solenoid valve
solenoid valves #1 and #2
fan reverse rotation control fan reverse rotation control
solenoid valve harness end #1 solenoid valve and Main
and chassis Controller (Sub)
4 - - The above checks Faulty Main Controller (Sub)
T5-6-58

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

Set Pressure
Lift arm and 31.4 ± 0.5 MPa
bucket relief (4554 ± 73 psi)
operation
Preparation
 If operating speeds are extremely slow, pump control
may be faulty.
Faulty pilot system may also cause this trouble.

1 Monitor Pump Delivery Lift arm relief The measured Faulty main relief valve
Pressure operation values are out of the (readjust)
specified range.
2 - - The check (1) above Find out cause of trouble by
resulted normal. tracing other trouble symptoms
T5-6-59
F-2 Some cylinders are not operated or speeds

are slow.
Overload Relief Specification Remark

Valve Set Pressure
Lift Arm Lower 37.3 ± 0.5 MPa
(5410 ± 73 psi)
Bucket 37.3 ± 0.5 MPa
(5410 ± 73 psi)
Preparation
 When parking brake is released normally, the
primary pilot pressure is considered to be normal.

1 Monitor Bucket Roll Back Pilot Full operation of The measured Faulty pilot valve
Pressure, Bucket Dump Pilot bucket roll back/ values are out of the
Pressure, Lift Arm Raise Pilot dump and lift arm specified range.
Pressure raise (Normal range: 3.0 ~
3.7 MPa (435 ~ 537
psi))
2 Replace overload relief valves, - Symptom is observed Faulty overload relief valve
of which the set pressure are with the replaced
the same relief valve.
3 - - The above checks Faulty control valve spool (stuck)
resulted all normal. Faulty cylinder (faulty seal kit)
T5-6-60
F-3 Front attachment drifts remarkably.
Leakage Check Within the Lift Arm Cylinder

1. Lower the bucket edge onto the ground with the
bucket cylinder rod slightly extended from the fully
retracted position.
2. Remove the hose from the lift arm cylinder rod side,
and drain the oil from the cylinder and the hose.
(Cover the removed hose ends to prevent dust or
dirt.)
3. Extend the bucket cylinder rod, and lift the bucket.
If any oil comes out from the hose connection port
and the lift arm cylinder rod retracts, oil leakage
occurs within the cylinder.
If no oil comes out from the hose connection port
but the lift arm cylinder rod retracts, oil leakage
occurs in the multiple control valve.

1 Set the front control lever - The symptom Faulty pilot valve
lock switch to LOCK position disappears
2 Replace the overload relief - The symptom Faulty overload relief valve
valve disappears
3 Disassemble and inspect the - Abnormality found Faulty cylinder (seal kit)
cylinder
4 - - The above checks Damaged control valve spool
resulted all normal. Broken spring
Loosened spool end
T5-6-61
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.
 The flow regulator valve may be faulty. Refer to

COMPONENT OPERATION / Others / Flow Regulator
Valve.

1 Disassemble and inspect the - Abnormality found Faulty shockless valve in flow
shockless valve regulator valve
2 Disassemble and inspect the - Abnormality found Faulty restriction valve in flow
restriction valve regulator valve
3 - - The above checks Bound control valve spool, or
resulted all normal. faulty cylinder (faulty seal kit)
T5-6-62
F-5 Bucket auto leveler control is not activated.

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

pilot valve bucket roll back #16 fuse in fuse box B and pilot
side coil harness end #1 and valve bucket roll back side coil
chassis
2 Replace the bucket auto- Bucket roll back The symptom Faulty bucket auto-leveler
leveler relay with other detent control disappears
general relay lever operation
3 Measure resistance between - 0/∞ Ω Faulty pilot valve bucket roll
pilot valve bucket roll back back side coil
side coil harness ends #1 and
#2
4 Measure voltage between Bucket roll back 0V Open circuit in harness between
bucket leveler relay harness detent control bucket proximity switch and
end #1 and chassis lever operation bucket leveler relay
5 - - The above checks Faulty bucket proximity switch
T5-6-63
F-6 Lift arm float control is not activated. (Detent

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

pilot valve lift arm lower #16 fuse in fuse box B and pilot
side coil harness end #1 and valve lift arm lower side coil
chassis
2 Check resistance between - 0/∞Ω Faulty pilot valve lift arm lower
pilot valve lift arm lower side side coil
coil harness ends #1 and #2
3 Check continuity between Lift arm lower ∞Ω Open circuit in harness between
pilot valve lift arm lower control lever pilot valve lift arm lower side coil
side coil harness end #2 and operation and Main Controller (Sub)
chassis
T5-6-64
F-7 Lift arm auto leveler height kickout control is

not activated.
Preparation
 Check the lift arm auto leveler height kickout setting  Check #16 fuse in fuse box B.
with the monitor first. The activating conditions
for lift arm auto leveler height kickout control are  Check the wiring connections first.
different according to the settings.
 Refer to SYSTEM / Control System / Lift Arm Auto

Leveler Height Kickout Control.

pilot valve lift arm raise side #16 fuse in fuse box B and pilot
coil harness end #1 and valve lift arm raise side coil
chassis
2 Check resistance between - 0/∞Ω Faulty pilot valve lift arm raise
pilot valve lift arm raise side side coil
3 Check continuity between Lift arm raise, ∞Ω Open circuit in harness between
pilot valve lift arm raise side detent control pilot valve lift arm lower side coil
coil harness end #2 and lever operation and Main Controller (Sub)
chassis
T5-6-65
F-8 Lift arm auto leveler lower kickout control is

not activated.
Preparation
 Check the lift arm auto leveler lower kickout setting  Check the wiring connections first.
with the monitor first. The activating conditions  Check #16 fuse in fuse box B.
for lift arm auto leveler lower kickout control are
different according to the settings.
 Refer to SYSTEM / Control System / Lift Arm Auto
Leveler Lower Kickout Control.

pilot valve lift arm lower #16 fuse in fuse box B and pilot
side coil harness end #1 and valve lift arm lower side coil
chassis
2 Check resistance between - 0/∞Ω Faulty pilot valve lift arm lower
pilot valve lift arm lower side side coil
3 Check continuity between Lift arm lower, ∞Ω Open circuit in harness between
pilot valve lift arm lower detent control pilot valve lift arm lower side coil
side coil harness end #2 and lever operation and Main Controller (Sub)
chassis
T5-6-66
F-9 Ride control is not activated.
Preparation
 Check the ride control setting with the monitor or  When the parking brake is released normally, the
MPDr. first. The activating conditions for ride control primary pilot pressure is considered to be normal.
are different according to the settings.
 Refer to SYSTEM / Control System / Ride Control.

1 Monitor Ride Control Switch Ride control OFF is displayed Faulty ride control switch or
switch: ON open circuit in harness between
ride control switch and Main
Controller (Sub)
2 Measure resistance at ride - 0/∞ Ω (Normal value: Faulty ride control solenoid
control solenoid valves rod Rod side: 26.2 Ω valve (rod side or bottom side)
side (multiple control valve) Bottom side: 17.5 Ω)
and bottom side (ride control
valve)
3 - - The above checks Stuck control valve spool or
resulted all normal. faulty accumulator
T5-6-67
(Blank)
T5-6-68

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

Set Pressure
Steering relief 27.4 ± 0.5 MPa
operation (3974 ± 73 psi)
Preparation
 If operating speeds are extremely slow, pump control
may be faulty. Faulty pilot system may also cause this
trouble.

1 Measure Steering Cylinder Steering relief The measured Faulty steering relief valve
Pressure operation values are out of the (readjust)
specified range.
2 - - The check (1) above Find out cause of trouble by

resulted normal. tracing other trouble symptoms
T5-6-69
S-2 Steering operation is slow.
Specification Remark
Steering cylinder 3.0 ± 0.4 Accelerator pedal:
operation time Fully depressed
(sec) Power mode
switch: ON
Bucket: Empty
Preparation
 If speed of front attachment is also slow, the pilot  Check that the steering wheel is not abnormal first.
system or main system may be faulty (A-2).  Refer to SYSTEM / Hydraulic System.
 If the pilot system is faulty, the circuit after the
steering pilot valve may be faulty.

1 Measure Main Pump Pressure Engine: Running The measured values Stuck or clogged bleed-off
Steering relief are out of normal compensator (in multiple
operation range (Normal range: control valve)
28.0 MPa (4061 psi)
or more
2 Measure pressure at port B in Engine: Running The measured values Faulty reducing valve or shuttle
reducing valve (for Orbitrol) Accelerator pedal: are out of normal valve
Fully depressed range (Normal range: Clogged filter
3.5 ± 0.5 MPa (508 ±
73 psi)
3 Measure pressure at port A in Engine: Running The measured values Faulty Orbitrol (steering pilot
stop valve (left/right) Steering (left or are out of normal valve)
right) operation range (Normal range:
3.5 ± 0.5 MPa (508 ±
73 psi)
4 Measure pressure at port B in Engine: Running The measured values Faulty stop valve
stop valve (left/right) Steering (left or are out of normal
right) operation range (Normal range:
3.5 ± 0.5 MPa (508 ±
73 psi)
5 - - The above checks Stuck steering valve spool or
resulted all normal. faulty steering cylinder (faulty
seal kit)
1
1- Reducing Valve Port B
3 2- Stop Valve Port A
3- Stop Valve Port B
95Z7-05-06-01
T5-6-70
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 Disassemble and inspect the - There is abnormality Faulty stop valve
stop valve
2 Disassemble and inspect the - There is abnormality Faulty steering valve (stuck
steering valve spool, clogged orifice)
3 - - The above checks Faulty steering cylinder (faulty
resulted all normal. seal kit)
T5-6-71
S-4 Secondary steering (optional) is not operated.

(Automatic operation check when the engine starts)
Preparation
 Check the secondary steering control setting with  Check the wiring connections first.
the monitor first.
 The secondary steering check switch may be faulty
 Refer to SYSTEM / Control System / Emergency when secondary steering operation cannot be
Steering Control (Optional). checked manually.
 Check that #10 fuse in fuse box A is not abnormal.

1 Monitor Secondary Steering Engine starts The measured values Faulty secondary steering pump
Pump Delivery Pressure are not at the normal unit
level (4.8 MPa) (696
psi)
2 Measure resistance between - 0/∞ Ω Faulty secondary steering relay
secondary steering relays #1
and #2
T5-6-72

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 (Optional).

1 Monitor Forward/Reverse Forward/reverse OFF is displayed Faulty forward/reverse lever, or
Lever (F) lever: F, R open circuit in harness between
forward/reverse lever and Main
Controller (Main)
2 Measure transmission clutch - The measured values Faulty transmission control valve
pressure are out of normal
range (Normal range:
2.5 ~ 3.0 MPa (363 ~
435 psi))
3 Measure torque converter - The measured values Faulty transmission control valve
pressure (at inlet port) are out of normal
0.7 ~ 0.9 MPa (102 ~
131 psi))
4 - - The above checks Faulty Main Controller (Main)
T5-6-73
T-2 Although forward/reverse lever is set to

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

1 Monitor Forward/Reverse Forward/reverse OFF is displayed Faulty forward/reverse lever
Lever (N) lever: N
2 - - The above check (1) Faulty Main Controller (Main)
resulted normal.
T5-6-74
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 (87 psi) or more 1.5 MPa (218 psi) or more
Preparation
 Refer to SYSTEM / Control System / Declutch Control.
 When other actuator (steering) is operated normally,

the pilot pump (primary pilot pressure) is considered
to be normal.

1 Monitor Declutch Position Declutch position OFF is displayed Faulty declutch position switch
Switch switch: N, D (0 is displayed on the Open circuit in harness between
monitor) declutch position switch and
2 Monitor Service Brake Brake pedal (right) The measured Faulty brake system (brake
Secondary Pressure (For operation values are out of the valve)
Declutch) specified range
3 Measure transmission clutch - The measured values Faulty transmission control
pressure are out of normal valve
1st, LU: 2.3 ~ 2.7 MPa
(334 ~ 392 psi),
R, L, 2, 3, H: 2.5 ~ 3.0
MPa (363 ~ 435 psi))
T5-6-75
T-4 Travel mode can not be changed.
Preparation

1 Monitor Travel Mode Selector Driving mode Manual mode is Faulty driving mode switch
Switch switch: AUTO 1/ always displayed (0 Open circuit in harness between
AUTO 2 mode is displayed on the driving mode switch and Main
monitor) Controller (Main)
2 - - The check (1) above Faulty Main Controller (Main)
resulted normal.
T5-6-76
T-5 Although shift switch is operated, speed shift

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

Shift Control.

1 Monitor Shift Switch Shift switch: The position of shift Faulty shift switch
1/2/3/4 position switch is not identical Open circuit in harness between
to the displayed shift switch and Main Controller
range on monitor (Main)
2 Measure transmission clutch - The measured values Faulty transmission control
pressure are out of normal valve
1st, LU: 2.3 ~ 2.7 MPa
(334 ~ 392 psi),
R, L, 2, 3, H: 2.5 ~ 3.0
MPa (363 ~ 435 psi))
T5-6-77
T-6 Although vehicle speed changes, speed shift

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

Shift Control.

1 Monitor Travel Mode Selector Driving mode Manual mode is Faulty driving mode switch
Switch switch: AUTO 1/ always displayed (0 Open circuit in harness between
AUTO 2 mode is displayed on the driving mode switch and Main
monitor). Controller (Main)
2 Monitor Power Mode Switch Power mode OFF is displayed. Faulty power mode switch
switch: ON Open circuit in harness between
power mode switch and Main
Controller (Main)
resulted normal.
T5-6-78
T-7 Speed shift is not shifted down when pushing

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

Control.

1 Monitor DSS Switch Downshift switch OFF is displayed Faulty downshift switch (DSS)
(DSS): ON Open circuit in harness between
While machine is downshift switch (DSS) and
travelling Main Controller (Main)
resulted normal.
T5-6-79
T-8 Speed shift is not held when pushing hold

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

Control.

1 Monitor Shift Hold Switch Hold switch: ON OFF is displayed Faulty shift hold switch
Open circuit in harness between
shift hold switch and Main
Controller (Main)
resulted normal.
T5-6-80
T-9 Speed shift retard control is not activated.
Preparation
 Check the speed shift delay control setting with the
monitor first.
 Check the parking brake is OFF (not applied).
 Refer to SYSTEM / Control System / Speed Shift Delay

Control.

1 Monitor Forward/Reverse Forward/reverse N is displayed Faulty forward/reverse lever
Lever (F), (R) lever: F and R Open circuit in harness between
forward/reverse lever and Main
Controller (Main)
2 Monitor Travel Mode Selector Travel mode: Manual mode is Faulty driving mode switch
Switch AUTO 1/AUTO 2 displayed (0 is Open circuit in harness between
mode displayed on the driving mode switch and Main
monitor) Controller (Main)
3 Monitor Machine Speed (For Travel operation Speedometer: 0 km/h Faulty machine speed sensor
Speedometer) (mph) Open circuit in harness between
machine speed sensor and
monitor controller
4 Monitor Shift Switch Shift switch: 2nd Other than 2nd is Faulty shift switch
displayed Open circuit in harness between
shift switch and Main Controller
(Main)
5 - - The above checks Find out cause of trouble by
resulted all normal. tracing other trouble symptoms
T5-6-81
(Blank)
T5-6-82
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 Signal Parking brake OFF is displayed Faulty parking brake switch
switch: ON
(applied)
Engine: Running
Pressure switch: OFF are out of normal solenoid valve
(released) range (Normal range:
Engine: Running 3.0 ~ 3.7 MPa (435 ~
537 psi))
3 Monitor Primary Pilot Front control The measured values Faulty reducing valve
Pressure (Loading) lever lock switch: are out of normal
UNLOCK position range (Normal range:
Engine: Running 3.5 ± 0.5 MPa (508 ±
73 psi))
4 Monitor Service Brake Parking brake The measured values Faulty unloader valve (brake
Primary Pressure switch: OFF are out of normal charge valve)
Engine: Running range (Normal range:
6.9 ~ 11.8 MPa (1000
~ 1711 psi))
5 Replace parking brake relay 1 Parking brake The symptom Faulty parking brake relay 1
with other general relay switch: OFF disappears
Engine: Running
6 Replace parking brake relay 2 Parking brake The symptom Faulty parking brake relay 2
with other general relay switch: OFF disappears
Engine: Running
T5-6-83
B-2 Parking brake is not applied.
Wear amount of Specification Allowable Limit

parking brake mm (in) mm (in)
Brake Disc 7.4 (0.291) 7.2 (0.283)
Brake Plate 5.0 (0.197) 4.8 (0.189)
Preparation

1 Monitor Parking Brake Switch Parking brake OFF is displayed Faulty parking brake switch
switch: ON
Key switch: ON
2 Monitor Parking Brake Key switch: ON Pressure is detected Stuck spool in parking brake
Pressure solenoid valve
3 Check the wear amount of - Allowable limit or less Faulty brake disc and faulty
parking brake brake friction pad
4 - - The above checks Faulty main controller (MC)
T5-6-84
B-3 Service brake function lowers.
Wear amount of Specification mm Allowable Limit

service brake (in) mm (in)
Brake Disc 7.2 (0.28) 6.1 (0.24)
Brake Ring 7.0 (0.27) 6.4 (0.25)
Preparation

1 Monitor Service Brake - The measured values Faulty unloader valve (brake
Primary Pressure are out of normal charge valve)
6.9 ~ 11.8 MPa (1000
~ 1711 psi))
2 Monitor Service Brake Brake pedal: Fully The measured Faulty brake valve
Secondary Pressure depressed values are not within
the normal values
(Normal value:
3.7 ~ 4.3 MPa (537 ~
624 psi))
3 Measure Service Brake Refer to page T4- The measured Faulty brake accumulator
Accumulator Pressure 5-20. values are not within
the normal values
(Normal value: 11.8
± 0.5 MPa (1711 ± 73
psi))
4 Check the wear amount of Refer to page T4- - The wear amount of brake disc is
service brake 4-6. beyond the allowable limit
T5-6-85
(Blank)
T5-6-86

O-1 Clearance light, tail light, and license plate
light are not ON.
Preparation
 Check that the clearance light, tail light, and license  Failure of the clearance light indicator lighting will be
plate light are not broken first. also affected.
 Check #11 fuse in fuse box B when the clearance  Refer to SYSTEM / Electrical System.
lights, tail light, and license plate light on both sides
are not ON at the same time.  Check the wiring connections first.
 Check #1 or #2 fuse in fuse box A when only the

lights on left or right side is ON.

1 Monitor Lighting Switch Light switch: OFF is displayed. Faulty lighting switch
Clearance light Open circuit in harness between
position (or Head light switch and fuses #1 or #2 in
light position) fuse box A
2 - - The check (1) above Faulty fuse #1, #2 in fuse box A
resulted normal. Faulty fuse #11 in fuse box B
T5-6-87
O-2 Head light is not ON.
Preparation
 Check that the head lights are not broken first.  Check that the light switch is the head light position.
 The light switch may be faulty (O-1) or the dimmer  Refer to SYSTEM / Electrical System.
switch may be faulty when the head lights on both
sides are not ON at the same time.  Check the wiring connections first.
 Check #7 fuse in fuse box A and #7 fuse in fuse box B

when only the light on right or left side is ON.

1 Set the dimmer switch to the Key switch: ON The head lights (left/ Faulty dimmer switch
low beam position Light switch: Head right) are not ON Open circuit in harness between
light position dimmer switch and light switch
2 Replace head light relay (left/ Key switch: ON The head lights (left/ Faulty head light relay (left/
right) with other general relay Dimmer switch: right) are ON right)
Low beam position
head light relay (left/right) Dimmer switch: head light relay (left/right) and
harness end #1 and chassis Low beam position light switch
Faulty dimmer switch
head light relay (left) harness Dimmer switch: head light relay (left) and #7 fuse
end #3 and chassis Low beam position in fuse box A
Faulty #7 fuse in fuse box A
head light (left) harness end Dimmer switch: head light (left) and head light
#512 and chassis Low beam position relay (left)
head light relay (right) Dimmer switch: head light relay (left) and #7 fuse
harness end #3 and chassis Low beam position in fuse box B
Faulty #7 fuse in fuse box B
head light (right) harness end Dimmer switch: head light (right) and head light
#513 and chassis Low beam position relay (right)

 Head Light Relay  Head Light (Left/Right)
(Left/Right)
#512
#513
T183-05-04-003 90Z7-05-06CN-01
T5-6-88
O-3 Head light is not shifted to high beam.
Preparation
 Check #9 fuse in fuse box A when the high beams at  Failure of the high beam indicator lighting will be
both sides are not ON. also affected.
 Check that the light switch is the head light position.  Refer to SYSTEM / Electrical System.

1 Set the dimmer switch to the Key switch: ON High beam is not ON Faulty dimmer switch
high beam position Light switch: Head Open circuit in harness between
light position dimmer switch and light switch
2 Replace high beam relay with Key switch: ON High beam is ON Faulty high beam relay
other general relay Dimmer switch:
High beam
position
high beam relay harness end Dimmer switch: high beam relay and dimmer
#1 and chassis High beam switch
position
high beam relay harness end Dimmer switch: high beam relay and #9 fuse in
#3 and chassis High beam fuse box A
position Faulty #9 fuse in fuse box A
head light (left) harness end Dimmer switch: head light (left) and high beam
#514 and chassis High beam relay
position
6 Measure voltage between Key switch: ON 0V Faulty head light (right)
head light (right) harness end Dimmer switch: Open circuit in harness between
#514 and chassis High beam head light (right) and high beam
position relay
7 - - The above checks Faulty head light (right/left)
resulted all normal. Faulty grounding

 High Beam Relay  Head Light (Left/Right)
#514
T183-05-04-003 90Z7-05-06CN01
T5-6-89
O-4 Hazard light is not operated.
Preparation
 Check that the turn signal lights (hazard lights) are  Failure of blinking of the turn signal light indicators
not broken first. at both sides will be also affected.
 Check #5 fuse in fuse box B when all turn signal lights  Refer to SYSTEM / Electrical System.
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 switch Key switch: OFF Hazard light is not Faulty hazard light switch
ON operated. Open circuit in harness between
hazard light switch and #5 fuse
in fuse box B
2 Measure voltage at terminal L Hazard light 0V Faulty flasher relay
in flasher relay switch: ON Faulty grounding
3 Replace turn signal light relay Hazard light Symptom is observed Faulty turn signal light relays
(left) with turn signal light switch: ON on the opposite side. (left/right)
relay (right)
4 Measure voltage between Hazard light 0V Open circuit in harness between
turn signal light relay (left/ switch: ON turn signal light relay (left/right)
right) harness end #1 and and hazard light switch
chassis Faulty diode P(k)
turn signal light relay (left/ switch: ON turn signal light relay (left/right)
right) harness end #3 and and flasher relay
chassis
hazard lights (right front/ switch: ON hazard lights (right front/ right
right rear) harness end #530 rear) and turn signal light relay
and chassis (right)
hazard lights (left front/ left switch: ON hazard lights (left front/ left rear)
rear) harness end #531 and and turn signal light relay (left)
chassis
8 - - The above checks Faulty #5 fuse in fuse box B
 Turn Signal Light Relay  Hazard Light (Front)  Hazard Light (Rear)  Flasher Relay
(Left/Right)
#530
#531
L
T183-05-04-003 90Z7-05-06CN02 90Z7-05-06CN03 TNED-05-06-001
T5-6-90
O-5 Turn signal light is not operated.
Preparation
 Check #6 fuse in fuse box A when all turn signal
lights do not blink.

1 Operate the turn signal lever Key switch: ON All turn signal lights Faulty turn signal lever
to the right and left do not blink. Open circuit in harness between
turn signal lever and #6 fuse in
fuse box A
turn signal light relay (left) Turn signal lever: turn signal light relay (left) and
harness end #1 and chassis Left position turn signal lever
Faulty diode P
turn signal light relay (right) Turn signal lever: turn signal light relay (right) and
harness end #1 and chassis Right position turn signal lever
Faulty diode k
4 - - The above checks Faulty #6 fuse in fuse box A

 Turn Signal Light Relay
(Left/Right)
T183-05-04-003
T5-6-91
O-6 Horn does not sound.
Preparation
 Check that the horn is not broken first.
 Check #5 fuse in fuse box B when the horn does not

sound by pushing two horn switches.

1 Switch horn relay with other Horn switch: ON Horn sounds Faulty horn relay
general relay
2 Measure voltage between Horn switch: ON 0V Open circuit in harness between
horn relay harness end #1 horn relay and #5 fuse in fuse
and body box B
3 - - The above checks Faulty horn switch
resulted all normal. Open circuit in harness between
horn switch and horn relay
 Turn Signal Light Relay
(Left/Right)
T183-05-04-003
T5-6-92
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 #3 fuse in fuse box A when the reverse lights  Refer to SYSTEM / Electrical System.
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 Switch reverse buzzer relay Key switch: ON Reverse light is ON Faulty reverse buzzer relay
with other general relay and reverse buzzer
sounds.
reverse lights (left/right) reverse lights (left/right) and
harness end #537 and chassis reverse buzzer relay
reverse buzzer harness end reverse buzzer and reverse
#2 and chassis buzzer relay
reverse buzzer relay harness reverse buzzer relay and #11
end #1 and chassis fuse in fuse box A, or faulty #11
fuse
reverse buzzer relay harness reverse buzzer relay and #3 fuse
end #3 and chassis in fuse box A
6 - - The above checks Faulty reverse lights (left/right)
resulted all normal. Faulty grounding

 Reverse Buzzer Relay  Reverse Buzzer  Reverse Light
(Left/Right)
#537
T183-05-04-003 90Z7-05-CN10 90Z7-05-06CN03
T5-6-93
O-8 Brake light is not ON.
Preparation
 Check that the brake lights are not broken first.
 Check #3 fuse in fuse box A when the brake lights at

both sides are not ON.

1 Replace brake light relay with Brake light switch: The symptom Faulty brake light relay
other general relay ON (Brake pedal is disappears
applied)
2 Measure voltage between Brake light switch: 0 V Open circuit in harness between
brake light relay harness end ON (Brake pedal is brake light relay and #3 fuse in
#1 and body applied) 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

 Reverse Buzzer Relay
T183-05-04-003
T5-6-94
O-9 Work light does not light.
Preparation
 Check that the work lights are not broken first.  Failure of blinking of the work light indicator will be
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.
same time.
 Check #5 fuse in fuse box A and #17 fuse in fuse box
B when only the light at one side is ON.

1 Set work light switch to ON 1/ Key switch: ON Work light is not ON. Faulty work light switch
ON 2 Light switch: Open circuit in harness between
Clearance light/ work light switch and light
Head light position switch
2 Replace work light relays Key switch: ON Work light on the Faulty work light relay (front/
(front/rear) each other Work light switch: opposite side is ON. rear)
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) Work light switch: work light relay (front) and #5
harness end #3 and chassis ON 2 position fuse in fuse box A
work light relay (front) Work light switch: work light (front) and work light
harness end #515 and chassis ON 2 position relay (front)
work light relay (rear) harness Work light switch: work light relay (right) and #17
end #3 and chassis ON 2 position fuse in fuse box B
work light (rear) harness end Work light switch: work light (rear) and work light
#517 and chassis ON 2 position relay (rear)
8 - - The above checks Faulty work light relay (front/
resulted all normal. rear)
Faulty grounding

 Work Light Relay  Work Light (Front)  Work Light (Rear)
#515 #517
T183-05-04-003 90Z7-05-06CN02 90Z7-05-06CN04
T5-6-95
O-10 Wiper is not operated.
Preparation
 The wiper is driven by electric power routed via  In case the front washer is also not operated, check
the relay circuit. The relay circuit of front wiper is #8 fuse in fuse box B. In case the rear washer is also
controlled by the column display controller. not operated, check #8 fuse in fuse box A.
 In case the wiper is not operated, first check if the  Refer to SYSTEM / Electrical System.
wiper relay is activated. Next, check if electric power
is routed to the wiper motor.  Check the wiring connections first.
 Front Wiper
1 Monitor Front Wiper Relay 1 Key switch: ON OFF is displayed. Open circuit in harness between
Output Front wiper/ front wiper relay 1 and column
washer switch: display controller
LOW
2 Monitor Front Wiper Relay 2 Key switch: ON OFF is displayed. Open circuit in harness between
Output Front wiper/ front wiper relay 2 and column
washer switch: HI display controller
3 Monitor Front Wiper Switch Key switch: ON The position of front Faulty front wiper/ washer
Front wiper/ wiper/ washer switch switch
washer switch: is not identical to the Open circuit in harness between
LOW/HI display on monitor. front wiper/ washer switch and
column display controller
Open circuit in harness between
front wiper relay 1, 2 and
4 Replace front wiper relay 1, 2 Key switch: ON The opposite wiper is Faulty front wiper relay 1, 2
with each other Front wiper/ operated.
washer switch:
LOW
5 - - The above checks Faulty column display controller
T5-6-96
 Rear Wiper
Preparation
 The rear wiper/ washer switch may be faulty when
the rear wiper is not operated.

1 Set rear wiper/ washer switch Key switch: ON Rear wiper is not Faulty rear wiper/ washer switch
to LOW operated. Open circuit in harness between
rear wiper/ washer switch and
rear wiper relay
2 Replace rear wiper relay with Key switch: ON Rear wiper is Faulty rear wiper relay
other general relay Rear wiper/ operated.
washer switch:
LOW
rear wiper relay harness end Rear wiper/ rear wiper relay and rear wiper/
#2 and chassis washer switch: washer switch
LOW
rear wiper relay harness end Rear wiper/ rear wiper relay and #8 fuse in
#1 and chassis washer switch: fuse box A
LOW Faulty #8 fuse in fuse box A
5 - - The above checks Faulty rear wiper motor

 Rear Wiper Relay
T183-05-04-003
T5-6-97
O-11 Washer is not operated.
Preparation
 Front Washer
1 Replace the front washer Key switch: ON Front washer is Faulty front washer relay
relay with other general relay operated.
2 Measure voltage between Front wiper/ 24 V Open circuit in harness between
front washer relay harness washer switch: ON front washer relay and front
end #2 and chassis position wiper/ washer switch
3 Measure voltage between Front wiper/ 0V Open circuit in harness between
front washer relay harness washer switch: ON front washer relay and #8 fuse in
end #1 and chassis position fuse box B
4 Measure voltage between Front wiper/ 24 V Open circuit in harness between
front washer motor harness washer switch: ON front washer relay and front
end #5 and chassis position washer motor
5 Monitor Front Washer Switch Front wiper/ Front washer is not Faulty front wiper/ washer
washer switch: operated. switch
Washer ON Open circuit in harness between
front wiper/ washer switch and
6 - - The above checks Faulty front washer motor

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

1 Replace the rear washer relay Key switch: ON Rear washer is Faulty rear washer relay
with other general relay Rear wiper/ operated
washer switch:
Washer ON
2 Measure voltage between Key switch: ON 24 V Open circuit in harness between
rear washer relay harness end Rear wiper/ rear washer relay and rear wiper/
#2 and chassis washer switch: washer switch
Washer ON
rear washer relay harness end Rear wiper/ rear washer relay and #8 fuse in
#1 and chassis washer switch: fuse box A
Washer ON
4 Measure voltage between Key switch: ON 24 V Open circuit in harness between
rear washer motor harness Rear wiper/ rear washer relay and rear wiper
end #5 and chassis washer switch: motor
Washer ON
5 - - The above checks Faulty rear wiper motor or faulty
resulted all normal. #8 fuse in fuse box A

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

1 Set cab dome light switch to Door open/close Cab dome light is not Faulty door open/close switch
Door Interlocking Position switch: ON ON.
2 Set cab dome light switch to - Cab dome light is not Faulty cab dome light
ON position ON. Open circuit in harness between
cab light and #12 fuse in fuse
box B
3 Set cab rear dome light - Cab rear dome light Faulty cab dome light
switch to ON position is not ON. Open circuit in harness between
cab rear dome light and #12 fuse
in fuse box B
4 - - The above checks Faulty #12 fuse in fuse box B
T5-6-100
Exchange Inspection
3 2 4
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.
1
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: Lift Arm Raise Pilot Pressure Sensor High Input

(MC Fault Code 111200-3)
Check Method:
1. Switch connectors of pressure sensor (lift arm raise)
and pressure sensor (bucket dump).
2. Retry troubleshooting. 90TNED-01-02-22a
Result: 1- Flow Regulator Valve 3- Pressure Sensor (Lift Arm

2- Pressure Sensor (Bucket Tilt Raise)
In case Bucket Dump Pilot Pressure Sensor High Input
(Roll Back)) 4- Pressure Sensor (Bucket
(MC fault code 111203-3) is displayed, the pressure sensor Dump)
(lift arm raise) is considered to be faulty.
In case Lift Arm Raise Pilot Pressure Sensor High Input

(MC fault code 111200-3) is displayed, the pressure sensor
(lift arm raise) harness is considered to be faulty.
fNOTE: To find the identical part to try exchange

inspection, refer to the index pages in the parts catalog.
Using the search program incorporated in the electrical
parts catalog system, when available, is more effective.
T5-6-101
Air Bleeding Procedures for Brake (Axle)

1
IMPORTANT: If air is mixed in the brake system, the
brake function is reduced and serious hazard
replacing hydraulic oil.
In addition, bleed air from the brake system until
hydraulic oil (about 0.5 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 plugs (1) are located on both
front and rear axles.
1. Set the parking brake switch of front console to the

1
ON position, start the engine, and increases service
brake oil pressure.
95TNED-04-05-10
2. Connect clear vinyl tube (2) to either one of two air

bleed plugs (1).
Insert the other end of clear vinyl tube (2) into clear 2
container (3) filled with hydraulic oil.
1
T4GB-05-04-005
T5-6-102
3. Depress brake pedal (4) several times.

Then, depress and hold brake pedal (4) to the stroke
end.
4. Loosen air bleed plug (1) under condition in step 3
and drain hydraulic oil and air for several seconds.
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. 4
T4GB-05-04-006
7. Bleed air at other 3 places in the same way as step 3

to step 5.
IMPORTANT: After air bleeding is completed at 4

places, bleed air at 4 places again.
Bleed air in the same way as step 3 to step 5 twice
and check that no air remains inside.
T5-6-103
(Blank)
T5-6-104
Outline
Operation layout of the air conditioning system is The vents (operator’s front/rear vent, foot vent, and the
illustrated below. front window) can be simultaneously or independently
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 front widow and operator’s front vents are manually
selectable. The air conditioning controller controls the air
The induced air flows out of the vents through evaporator conditioning system.
(5) or heater (15) by blower motor (11).
Evaporator (5) is a device used to cool the air. The air conditioning controller controls the damper
Heater (15) is a device used to warm the air. operation by corresponding to the job site conditions
In the air conditioning system, after the refrigerant is such as atmospheric and cab inside air temperatures,
compressed by the compressor, it is sent to evaporator (5) coolant temperature, operator’s set-temperature, and
in which the refrigerant expands to cool the air. the selected ventilation mode. In addition, the air
Heater (15) warms air by first absorbing heat from conditioning controller displays the air conditioning
warmed engine coolant. Evaporator (5) and heater (15) system operation status on the monitor.
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
1 2
6
4
3
7
8
A
10
TNED-05-07-001
11
95TNED-05-07-02
15
14 27
12
13
View A
90Z7-05-07-01
95TNED-05-07-03
1- Solar Radiation Sensor 4- AUTO/OFF Switch / Blower 8- Air Conditioner Unit 12- High/Low Pressure Switch
2- Column Display Controller Switch 9- Fresh Air Filter 13- Refrigerant Pressure Sensor
3- Temperature Control Switch/ 5- Accelerator Pedal 10- Air Conditioner Controller 14- Air Conditioner Condenser
Mode Switch 6- Key Switch 11- Outdoor Ambient 15- Receiver Tank
7- Monitor Controller Temperature Sensor 27- Compressor
T5-7-2
19
18
17
16
15
20
21
22
23
24
25
TDAA-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
TDAA-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 pressure switch consists of a pressure
gauge and a switch. The pressure gauge detects the TDAA-05-07-007
lower pressure range (0.196 ~ 0.225 MPa) (28.4 ~ 32.6
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. 90TDAA-05-07-14
Therefore, damage to the compressor due to a lack of
refrigerant is prevented. In case the pressure increases
to the surge range, damage to the air conditioner circuit
parts due to excessively high circuit pressure is prevented.
 Re-circulated Air Sensor (CN11)

Monitors the temperature 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 temperature 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 (CN15)
Monitors the temperature around the front 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
T5-7-6
 Air Mix Damper Servo Motor (CN9)

Controls opening/closing of the air mixing door in
response to the set temperature.
The damper consists of a motor, link mechanism, and
potentiometer.
The motor opens or closes the air mix door via the link
mechanism.
The potentiometer converts the link movements (the TDAA-05-07-012
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).
T5-7-7
 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
T5-7-8
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.
T5-7-9
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 Check the harness.
circulated air sensor 4.95 V such circumstance as no re- Replace the re-
circulated air sensor is provided. circulated air
sensor.
12 Shorted circuit in re- Voltage: less than 0.3 V Operation is controlled under Check the harness.
circulated air sensor such circumstance as no re- Replace the re-
circulated air sensor is provided. circulated air
sensor.
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
temperature sensor ambient temperature sensor is outdoor ambient
provided. temperature
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
temperature sensor ambient temperature sensor is outdoor ambient
provided. temperature
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
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 frost Voltage: less than The compressor clutch is Check the harness.
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
Open circuit: Voltage: vent damper servo
more than 5 V motor.
44 Abnormal air mix Shorted circuit: Air mix damper servo motor Check the harness.
damper servo motor Voltage: less than 0.2 V servo motor becomes inoperable. Replace the air
Open circuit: Voltage: vent damper servo
more than 4.8 V motor.
51 Abnormal high/low Voltage: 0 V The compressor clutch is Check the harness.
refrigerant pressure disengaged. (The compressor Replace the high/
stops.) low pressure
switch.
91 CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1
error between monitor harness.
controller and air Replace air
conditioner controller conditioner
controller.
92 CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1
controller harness.
Faulty CAN1 harness Replace air
conditioner
controller.
T5-7-10

22
Preparation
position.
Fault Code Trouble Inspection Method Evaluation Cause

11 Open circuit in re- Measurement of resistance ∞ Ω (Normal value: Faulty sensor.
Measurement of voltage 0V Open circuit in harness #1.
between sensor harness
end #1 and chassis.
check.
12 Shorted circuit in re- Measurement of resistance 0 Ω (Normal value: Faulty sensor.
check. #1 and #2.
13 Open circuit in outdoor Measurement of resistance ∞ Ω (Normal value: Faulty sensor.
ambient temperature between sensor #1 and #2. 100 to 210 kΩ)
sensor Measurement of voltage 0V Open circuit in harness #1.
end #1 and chassis.
check.
14 Shorted circuit in Measurement of resistance 0 Ω (Normal value: Faulty sensor.
outdoor ambient between sensor #1 and #2. 100 to 210 kΩ)
temperature sensor - Normal in above Shorted circuit in harness
check. #1 and #2.
18 Shorted circuit in solar Continuity check between 0Ω Shorted circuit in harness
radiation sensor sensor harness end #1 and #1 and #2.
#2.
- Normal in above Faulty sensor.
check.
21 Open circuit in frost Measurement of resistance ∞ Ω (Normal value: Faulty sensor.
Measurement of voltage 0V Open circuit in harness #1.
end #1 and chassis.
check.
22 Shorted circuit in frost Measurement of resistance 0 Ω (Normal value: Faulty sensor.
check. #1 and #2.
T5-7-11

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 between air vent damper servo in harness between controller
motor motor harness end 7C and and air vent damper servo
chassis. (AUTO/OFF switch / motor.
blower switch: ON)
Measurement of voltage 0V Faulty controller or open circuit
between air vent damper servo in harness between controller
motor harness end 7C and 25D. and air vent damper servo
(AUTO/OFF switch / blower motor.
switch: ON)
- Normal in Faulty air vent damper servo
above check. motor.
44 Abnormal air mix Measurement of voltage 0V Faulty controller or open circuit
damper servo between air mix damper servo in harness between controller
motor motor harness end 7D and and air mix damper servo motor.
chassis. (AUTO/OFF switch /
blower switch: ON)
Measurement of voltage 0V Faulty controller or open circuit
between air mix damper servo in harness between controller
motor harness end 7D and 25E. and air mix damper servo motor.
(AUTO/OFF switch / blower
switch: ON)
- Normal in Faulty air mix damper servo
above check. motor.
51 Abnormal high/ Measurement of voltage 0V Faulty controller or open circuit
low refrigerant between high/low pressure in harness between controller
pressure switch harness end A21 and and high/low pressure switch.
A05. (AUTO/OFF switch / blower
switch: ON)
- Normal in Faulty high/low pressure switch.
above check.
91 CAN Continuity check in CAN1 Normal Faulty controller.
communication harness. Abnormal Faulty CAN1 harness.
error
92 CAN bus off error Continuity check in CAN1 Normal Faulty controller.
harness. Abnormal Faulty CAN1 harness.
T5-7-12
(Blank)
T5-7-13
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 chassis Make sure to ground
Faulty wiring, disconnection of connector Wirings inspection
Blowout of power transistor thermal fuse due to locked motor Replace motor
Blowout of fuse Replace with the Blower motor is locked Replace blower motor
same capacity fuse Faulty wiring Refer to wiring diagram and
check
Shorted circuit Wirings inspection
T5-7-14
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 evaporator
characteristics sensor.
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
T5-7-15
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
T5-7-16
(Blank)
T5-7-17
Faulty cooling (3)
Condition:
 Compressor: Compressor rotates normally
 Compressor pressure: Abnormal
Pressure on low- Overcharge air conditioner Remove refrigerant thoroughly and recharge refrigerant to proper
pressure side is too with refrigerant level after purging
high (approx. 0.29 Faulty compressor Breakage of head gasket Replace compressor
MPa or more) Breakage of inlet valve Replace compressor
Clogged foreign matter into inlet Replace compressor
valve
Excessive open of Faulty valve Replace valve
expansion valve
Pressure on high- Abnormally low ambient temperature
pressure side is too Low refrigerant To B
low (pressure is not Faulty compressor Swash plate shoe is locked Replace compressor
approx. 0.98 MPa or Piston is locked Replace compressor
more) Faulty suction discharge valve Replace compressor
Faulty expansion valve Clogged valve (foreign matter) Replace valve
Temporary clogged due to freezing Thoroughly perform purging
valve (water intrusion) after replacing valve and
receiver
Pressure on low- Abnormally low ambient temperature
pressure side is too Low refrigerant To B
low (pressure is Clogged during refrigeration cycle To C
approx. 0.05 MPa or Faulty expansion valve To D
less) Frosted evaporator To A
Pressure is high on Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing)
both sides of high- Overcharge air conditioner Remove refrigerant thoroughly and recharge refrigerant to proper
pressure and low- with refrigerant level after purging
pressure
Cooling in the Faulty hydraulic fan control Check hydraulic fan control
condenser is function
insufficient
Pressure is low on Lack of refrigerant
both sides of high-
pressure and low-
pressure
T5-7-18
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
T5-7-19
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
Cooling in the condenser is Faulty hydraulic fan control Check hydraulic fan
insufficient control function
T5-7-20
sensor
Faulty frost sensor Characteristic check Replace evaporator
characteristics sensor
B: Low refrigerant
Low refrigerant Low refrigerant quantity Charge refrigerant to proper level
Gas leak Check leak and charge with refrigerant
after repairing faulty
C: Clogged during refrigeration cycle

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

Temporary clogged due to freezing valve Thoroughly perform purging after
(water intrusion) replacing valve and receiver
T5-7-21
Faulty cooling (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
Cooling in the condenser Faulty hydraulic fan control Check hydraulic fan control
is insufficient function
T5-7-22
(Blank)
T5-7-23
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 chassis Make sure to ground
Faulty wiring, disconnection of connector Wirings inspection
Blowout of power transistor thermal fuse due to locked Replace motor
motor
Air flow volume Coolant temperature is low
is normal Coolant Disconnection of air mix damper link Setting link again
temperature is Air incorporation in hot-water circuit Air Bleeding Circuit
normal Clogging, breakage and bending of piping Repair or replace.
Extremely low ambient temperature
Low engine coolant level Charge engine coolant
to proper level
Broken heater core Replace heater core
T5-7-24
Faulty wiring of Shorted circuit check Repair
evaporator sensor
Faulty the evaporator Characteristic check Replace frost sensor
sensor characteristics
Evaporator sensor is Reinsert (floating distance from evaporator is 3
out of evaporator range mm or less)
T5-7-25
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
T5-7-26
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
T5-7-27
 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.
T5-7-28
(Blank)
T5-7-29
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.
chassis.
between terminal #43B of blower Blower Switch: ON between blower motor
motor harness end and chassis. 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 and power transistor.
chassis.
6 Measurement of voltage Key Switch: ON 0V Faulty air conditioner
between terminal #9B of power Blower Switch: ON controller.
transistor harness end and
chassis.
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
T5-7-30
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 chassis.
between terminal #42A of Blower Switch: ON between compressor relay
compressor clutch relay harness and compressor clutch.
end and chassis.
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
T5-7-31
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
T5-7-32
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
T5-7-33
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
T5-7-34
Refill Compressor Oil

When replacing the cooling circuit parts, refill compressor
oil to the specified level.
Replacement Compressor Condenser Evaporator

parts
Oil- Refer to the 40 cm3 40 cm3
replenishing following. (2.4 in3) (2.4 in3)
quantity
 In case of replacing compressor

New compressor (1) is charged with oil required for
cooling circuit. When replacing new compressor (1), drain
excess oil from new compressor (1). Adjust oil level so
that it is the same level as oil (B) in compressor (2) to be
replaced.
fNOTE: Compressor oil quantity: 160 cm3 (9.8 in3)
1 2
TDAA-05-07-015
1- New Compressor 2- Replacing Compressor
T5-7-35
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
T5-7-36
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

(7) on manifold gauge (1). 1
Perform purging for 10 minutes or more by 7
operating vacuum pump (4).
W115-02-10-005
T5-7-37
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 2

-0.1 MPa (-750 mmHg) (-14.5 PSI), close high
pressure valve (2) and low pressure valve (7) and
stop vacuum pump (4).
Wait for approximately five minutes and confirm
that the pointer does not return to 0.
W115-02-10-005
7 1
4. With high pressure valve (2) and low pressure valve
(7) on manifold gauge (1) closed, connect charge
hose (5) to refrigerant container (8).
W115-02-10-007
10 1
5. Open valve (9) of refrigerant container (8).
Push air bleed valve (10) on manifold gauge (1) to
purge air in charge hose (5) with the refrigerant
pressure.
When draining refrigerant, immediately release air
bleed valve (10).
5
9
W115-02-10-007
T5-7-38
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).
W115-02-10-008
Charge with refrigerant (R134a).
Close high pressure valve (2) and valve (9) of
refrigerant container (8) when high pressure gauge
1
(11) reading reaches 98 kPa (1 kgf/cm2) (14.2 PSI).
fNOTE: Use warm water of 40˚C (104˚F) or less to warm

11
refrigerant container (8) to aid in charging operation.
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
T5-7-39
8. Confirm that high pressure valve (2) and low 1

pressure valve (7) on gauge manifold (1) and valve
7
(9) of refrigerant container (8) are closed. Start the
engine and operate the air conditioner.
Operating Conditions of the Air Conditioner 2
 Engine Speed: Slow Idle
9
W115-02-10-007
IMPORTANT: Do not open high pressure valve (2) on
manifold gauge (1).
9. Open low pressure valve (7) on manifold gauge (1)
1
and valve (9) of refrigerant container (8) to charge
with refrigerant. 7
fNOTE: Required refrigerant quantity: 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:
 Close high pressure valve (2) and low pressure valve 9
(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.
T5-7-40
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.
T5-7-41
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 (1832°F) 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
T5-7-42
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
T5-7-43
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 11.8 to 14.7
TDAA-05-07-016
(Fig. A) (1.2 to 1.5)
(8.7 to 10.8)
B
Pipe with D1/2 19.6 to 24.5
(2.0 to 2.5)
(14.5 to 18.1)
Pipe with D5/8 29.4 to 34.3
(3.0 to 3.5)
(21.7 to 25.3)
Block joint Receiver M6 Bolt 4.0 to 6.8
(Fig. B) (4T) (0.4 to 0.7)
(3.0 to 5.0)
M6 Bolt (6T) 7.9 to 11.8
for other than (0.8 to 1.2)
Receiver (5.8 to 8.7)
TDAA-05-07-017
T5-7-44
INDEX
111000 to 111002...................................................................T5-5-66 114012........................................................................................T5-5-75
111003........................................................................................T5-5-66 114013........................................................................................T5-5-70
111006, 111007 .......................................................................T5-5-69 114014, 114015 .......................................................................T5-5-75
111008........................................................................................T5-5-74 114018........................................................................................T5-5-70
111009........................................................................................T5-5-69 114019........................................................................................T5-5-75
111010........................................................................................T5-5-74 115001..................................................................................... T5-5-107
111012........................................................................................T5-5-69 115011..................................................................................... T5-5-108
111013, 111014 .......................................................................T5-5-74 120000..................................................................................... T5-5-106
111015........................................................................................T5-5-69 120001..................................................................................... T5-5-105
111016........................................................................................T5-5-74 120002 to 120004................................................................ T5-5-106
111017........................................................................................T5-5-69 120005..................................................................................... T5-5-105
111018........................................................................................T5-5-74 120008..................................................................................... T5-5-105
111019........................................................................................T5-5-69 120014..................................................................................... T5-5-105
111020, 111021 .......................................................................T5-5-74 120101 to 120104................................................................ T5-5-105
111024........................................................................................T5-5-69 120106..................................................................................... T5-5-105
111025........................................................................................T5-5-74 120300, 120301 .................................................................... T5-5-110
111026........................................................................................T5-5-74 120400, 120401 .................................................................... T5-5-110
111103........................................................................................T5-5-79 120500 to 120507................................................................ T5-5-111
111105........................................................................................T5-5-79 24-Volt Circuit ..........................................................................T5-1-16
111200........................................................................................T5-5-81 5-Volt Circuit.............................................................................T5-1-22
111202, 111203 .......................................................................T5-5-81
A
111204........................................................................................T5-5-82
111205........................................................................................T5-5-80 Accessory Pump......................................................................T5-4-16
111206........................................................................................T5-5-83 Accumulator Charge Time ..................................................T4-5-21
111207........................................................................................T5-5-80 Air Bleeding Procedures for Brake (Axle) .................... T5-6-102
111208........................................................................................T5-5-84 Air Conditioner, Component Layout ................................. T5-7-2
111210, 111211 .......................................................................T5-5-86 Air Conditioner, Functions of Main Parts ......................... T5-7-4
111214, 111215 .......................................................................T5-5-87 Air Conditioner, Outline ......................................................... T5-7-1
111217........................................................................................T5-5-83 Air Conditioner, Troubleshooting ....................................... T5-7-9
111309, 111310 .......................................................................T5-5-88 Air Conditioner Controller Fault Code List ...T5-5-40, T5-7-10
111312........................................................................................T5-5-82 Air Conditioner Controller Fault Codes
111313........................................................................................T5-5-85 11 to 22 ............................................................. T5-5-112, T5-7-11
111406........................................................................................T5-5-89 43 to 92 ............................................................. T5-5-113, T5-7-12
111407........................................................................................T5-5-90 Alarm, List..................................................................................T5-2-18
111408........................................................................................T5-5-97 All Actuator System Troubleshooting ............T5-6-30, T5-6-53
111410........................................................................................T5-5-91 Alternator Check .....................................................................T5-1-14
111411........................................................................................T5-5-92 B
111412........................................................................................T5-5-93 Battery Voltage Check ..........................................................T5-1-13
111413........................................................................................T5-5-94 Bell Crank Stopper Clearance............................................... T4-4-8
111414 to 111421...................................................................T5-5-95 Blower motor does not operate. .......................................T5-7-30
111422........................................................................................T5-5-98 Brake (Axle) Air Bleeding Procedure ............................. T5-6-102
111423........................................................................................T5-5-99 Brake Accumulator Pressure...............................................T4-5-20
111502, 111503 .................................................................... T5-5-100 Brake Accumulator Pressure Test ......................................T4-5-21
111506, 111507 .................................................................... T5-5-100 Brake Charge Valve ................................................................T5-4-19
111600........................................................................................T5-5-85 Brake Oil Pressure Gauge.....................................................T5-2-36
111900..................................................................................... T5-5-101 Brake System Troubleshooting.........................T5-6-42, T5-6-83
111901..................................................................................... T5-5-102 Brake Warning Pressure (Pressure-Decreasing) ...........T4-5-22
111903..................................................................................... T5-5-103 Brake Warning Pressure (Pressure-Increasing).............T4-5-24
111906, 111907 .................................................................... T5-5-104 Bucket Levelness ....................................................................T4-4-13
113002, 113003 .......................................................................T5-5-70 Bucket Stopper Clearance ..................................................... T4-4-8
113004........................................................................................T5-5-75
113005........................................................................................T5-5-70 C
113006, 113007 .......................................................................T5-5-75 CAN1 Harness Check .............................................................T5-5-71
113010........................................................................................T5-5-70 CAN2 Harness Check ............................................................T5-5-76
113011........................................................................................T5-5-75 Charge Air Conditioner with Refrigerant .......................T5-7-36
114010, 114011 .......................................................................T5-5-70 Check by False Signal ............................................................T5-1-23
95Z7
INDEX
115001 ............................................................................... T5-5-107 Faulty heating (2)....................................................................T5-7-26
115011 ............................................................................... T5-5-108 Flow Regulator Valve .............................................................T5-4-20
120500 to 120507 .......................................................... T5-5-111 Frequency Distribution Data, List ....................................... T5-3-4
Column Display Controller Fault Code List ...................T5-5-38 Front Attachment System
Combination Valve.................................................................T5-4-19 Troubleshooting ...............................................T5-6-33, T5-6-59
Communication System......................................................... T5-3-7 Fuse Inspection .......................................................................T5-1-10
Communication Terminal Fault Code List .....................T5-5-41 Fusible Link Inspection.........................................................T5-1-12
Communication Terminal Status ......................................T5-2-22
H
Communication Terminal Status, List .............................T5-2-23
Component Layout.................................................................. T5-4-1 Hose and Pipe Tightening Torque ....................................T5-7-44
Compressor clutch does not operate..............................T5-7-31 Hydraulic Cylinder Cycle Time ...........................................T4-4-10
Connectors ................................................................................. T5-1-8 Hydraulic Pump .....................................................................T5-4-15
Contents of Diagnosis............................................................. T5-6-2 I
Continuity Check ....................................................................T5-1-15 Inspection .................................................................................T5-7-42
Control Lever Operating Force ..........................................T4-4-14 Instructions for Disconnecting Connectors .................... T5-1-8
Control Lever Stroke ..............................................................T4-4-16 Issued Warning Record .........................................................T5-2-17
Control Valve ............................................................................T5-4-18
Controller .................................................................................... T5-4-6 L
Controller Version...................................................................T5-2-16 Lever Stopper Clearance........................................................ T4-4-8
Coolant Temperature Gauge ..............................................T5-2-37 Lift Arm Angle Sensor Learning ........................................T5-2-30
Cooling circuit check by using manifold gauge ..........T5-7-32 Loading Circuit Main Relief Set Pressure ......................... T4-5-8
Correlation between Trouble Symptom and M
Part Failures .........................................................................T5-6-27 Machine Setting......................................................................T5-2-24
Current Measurement ..........................................................T5-1-16 Machine Setting Item, List ..................................................T5-2-25
Cylinder Drift Check ..............................................................T4-4-12 Main Component (Overview) .............................................. T5-4-1
D Main Pump................................................................................T5-4-15
Daily Report Data, List ............................................................ T5-3-2 Main Pump Delivery Pressure .............................................. T4-5-6
Diagnosing Procedure, Introduction................................. T5-1-1 Main Relief Valve Pressure Adjustment Procedure....... T4-5-9
Diagnosis Procedure ............................................................... T5-1-2 Maintenance of Exhaust Filter ............................................. T4-6-2
Digging Position Adjustment ............................................T5-2-32 MC Fault Code
111000 to 111002 .............................................................T5-5-66
E 111003 ..................................................................................T5-5-66
e-Service, Outline ..................................................................... T5-3-1 111406 ..................................................................................T5-5-89
ECM Fault Code List ...............................................................T5-5-42 111408 ..................................................................................T5-5-97
Electric Component Layout (Overview) ........................... T5-4-4 111413 ..................................................................................T5-5-94
Electric System Inspection .................................................... T5-1-5 111903 ............................................................................... T5-5-103
Electrical System (Around Fuel Tank) ..............................T5-4-12 111006, 111007, 111009, 111012................................T5-5-69
Electrical System (Around Hydraulic Oil Tank) .............T5-4-11 111008, 111010, 111013, 111014, 111025...............T5-5-74
Electrical System (Cab) ........................................................... T5-4-5 111103, 111105 .................................................................T5-5-79
Electrical System (Relays) ....................................................T5-4-10 111204, 111312 .................................................................T5-5-82
Engine.........................................................................................T5-4-13 111210, 111211 .................................................................T5-5-86
Engine Speed ............................................................................. T4-3-1 111214, 111215 .................................................................T5-5-87
Engine System Troubleshooting ......................T5-6-28, T5-6-47 111313, 111600 .................................................................T5-5-85
Engine Tachometer ................................................................T5-2-35 111414 to 111421 .............................................................T5-5-95
Engine Test .................................................................................. T4-3-1 111502, 111503, 111506, 111507............................. T5-5-100
Exchange Inspection .......................................................... T5-6-101 120001, 120005, 120008, 120014............................. T5-5-105
Exhaust Filter............................................................................T5-4-14 120101 to 120104, 120106 ......................................... T5-5-105
Exhaust Filter, Maintenance.................................................. T4-6-2 MC Fault Code List ................................................................... T5-5-9
Exhaust Filter Serial No., Rewrite......................................... T4-6-1 Monitor ........................................................................................ T5-4-8
F Monitor, Outline........................................................................ T5-2-1
Faulty cooling (1) ....................................................................T5-7-14 Monitor Controller (Information) Fault Code
Faulty cooling (2) ....................................................................T5-7-16 120400, 120401 .............................................................. T5-5-110
Faulty cooling (3) ....................................................................T5-7-18 114010, 114011, 114013, 114018................................T5-5-70
Faulty cooling (4) ....................................................................T5-7-20 114012, 114014, 114015, 114019................................T5-5-75
Faulty cooling (5) ....................................................................T5-7-22 Monitor Controller (Information) Fault Code List .......T5-5-36
Faulty heating (1)....................................................................T5-7-24
95Z7
INDEX
Monitor Controller (Monitor) Fault Code SC Fault Codes
120300, 120301 .............................................................. T5-5-110 111000 to 111002 .............................................................T5-5-66
113002, 113003, 113005, 113010................................T5-5-70 111015, 111017, 111019, 111024................................T5-5-69
113004, 113006, 113007, 113011................................T5-5-75 111016, 111018, 111020, 111021, 111026...............T5-5-74
Monitor Controller (Monitor) Fault Code List ...............T5-5-34 111200, 111202, 111203 ................................................T5-5-81
Monitor Panel ............................................................................ T5-4-9 111205, 111207 .................................................................T5-5-80
Monitoring .................................................................................. T5-2-6 111206, 111217 .................................................................T5-5-83
Monitoring Item, List............................................................... T5-2-8 111309, 111310 .................................................................T5-5-88
MPDr. Fault Code List .............................................................. T5-5-3 111906, 111907 .............................................................. T5-5-104
Muffler Filter No. .....................................................................T5-2-34 120000, 120002 to 120004 ......................................... T5-5-106
Multiple Control Valve ..........................................................T5-4-18 Secondary Pilot Pressure ....................................................... T4-5-3
Secondary Steering Pump (Option) ................................T5-4-20
N
Sensor Activating Range .....................................................T4-2-10
Necessity of Purging..............................................................T5-7-36 Service Brake Function Check.............................................. T4-4-4
Number of Brake Pedal Applications ..............................T4-5-21 Service Brake Pressure (Front and Rear) .........................T4-5-16
O Service Brake Wear Amount ................................................. T4-4-6
Operation Data, List ................................................................. T5-3-2 Service Menu, Operating Procedures ............................... T5-2-2
Operational Performance Standard Table ....................... T4-2-1 Service menu, How to display ............................................. T5-2-3
Operational Performance Tests ........................................... T4-1-1 Snapshot Data ........................................................................... T5-3-6
Other System Troubleshooting ........................T5-6-43, T5-6-87 Standard ...................................................................................... T4-2-1
Overload Relief Valve Set Pressure ...................................T4-5-14 Steering Circuit Main Relief Set Pressure .......................T4-5-12
Steering Circuit Pilot Pressure............................................T4-5-10
P Steering Relief Valve Pressure
Parallel/Tandem Switching Solenoid Valve Adjustment Procedure ....................................................T4-5-13
Adjustment Procedure ...................................................... T4-5-5 Steering System Troubleshooting ...................T5-6-37, T5-6-69
Set Pressure ........................................................................... T4-5-4 Steering Valve ..........................................................................T5-4-19
Parking Brake Function Check ............................................. T4-4-3 Switches ....................................................................................... T5-4-8
Parking Brake Pressure .........................................................T4-5-18
Precautions for Inspection and Maintenance ................ T5-1-6 T
Preparation for Performance Tests ..................................... T4-1-2 Test Harness..............................................................................T5-1-24
Primary Pilot Pressure ............................................................. T4-5-1 Torque Converter Assembly ...............................................T5-4-17
Procedures for charging air conditioner Torque Converter Oil Temperature Gauge ....................T5-2-36
with refrigerant ..................................................................T5-7-37 Torque Converter Pressure..................................................T4-5-28
Total Operating Hours, List ................................................... T5-3-5
R Transmission Assembly ........................................................T5-4-17
Reducing Valve Setting Pressure ........................................ T4-5-3 Transmission Clutch Pack Combination .........................T4-5-27
Refill Compressor Oil .............................................................T5-7-35 Transmission Clutch Pressure ............................................T4-5-26
Relationship between Machine Trouble Symptom Transmission Learning..........................................................T5-2-26
and Related Parts ................................................................ T5-6-3 Travel Speed ............................................................................... T4-4-1
Relays ............................................................................................ T5-4-6 Travel System Troubleshooting ........................T5-6-39, T5-6-73
Rewrite of Exhaust Filter Serial No. .................................... T4-6-1 Troubleshooting ....................................................................... T5-2-4
Ride Control Valve (Option) ................................................T5-4-20 Troubleshooting A (by Using Fault Codes)...................... T5-5-1
Right Console............................................................................. T5-4-7 Troubleshooting B (by Symptom) ...................................... T5-6-1
S U
SC Fault Code Unloader Valve ........................................................................T5-4-19
111003 ..................................................................................T5-5-66 Unloader Valve Setting Pressure ......................................... T4-5-1
111208 ..................................................................................T5-5-84
111407 ..................................................................................T5-5-90 V
111410 ..................................................................................T5-5-91 Voltage Measurement ..........................................................T5-1-16
111411 ..................................................................................T5-5-92 W
111412 ..................................................................................T5-5-93 Warm-up Operation ..............................................................T5-7-42
111422 ..................................................................................T5-5-98 Work after Replacing Components..................................T5-7-34
111423 ..................................................................................T5-5-99
111900 ............................................................................... T5-5-101
111901 ............................................................................... T5-5-102
SC Fault Code List ...................................................................T5-5-23
95Z7
INDEX
(Blank)
95Z7

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93215-00602

Operational Performance Test

Powered by ISUZU 6WG1 ENGINE

Serial No. 97J1-0101 and up

All information, illustrations and

This manual is written for trained and skilled technicians

 Be sure to thoroughly read this manual for correct

In this manual, the following safety alert symbol and

Quantity To Convert From Into Multiply By

fNOTE: The numerical value in this manual might be

OPERATIONAL PERFORMANCE TEST

Group 1 Introduction Group 5 Component Test

95Z7 Performance Test

95Z7 Performance Test

Operational Performance Tests

Precautions for Evaluation of Test Data

Preparation for Performance Tests

TEST AREA and TOOL

MAKE PRECISE MEASUREMENT

Performance Test Designation Unit Performance Remarks Reference

Performance Test Designation Unit Performance Remarks Reference

Performance Test Designation Unit Performance Remarks Reference

Performance Test Designation Unit Performance Remarks Reference

Performance Test Designation Unit Performance Remarks Reference

fNOTE: MF: Multi-Function

Performance Test Designation Unit Performance 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

Sensor Activating Range

Engine Speed Power Mode

• Monitor each sensor by using MPDr.

2. Sensor Activating Range

Item Operation Specification

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 Control Lever

 Radial Tire (29.5R25):

 Bias Tire (29.5-25-28PR):

2. Provide a flat, solid test track 50 m (164 ft) in length,

dCAUTION: Do not perform measurement in

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

Shift Switch Parking Brake Accelerator Pedal Power Mode

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

1- Machine Speed Sensor

Service Brake Function Check

 Radial Tire (29.5R25):

 Bias Tire (29.5-25-28PR):

2. On a paved dry road, prepare a 150 m (492

dCAUTION: Do not perform measurement in

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

Service Brake Wear Amount

1- Plug (of Inspection Hole) 5- Piston

Parking Brake Function Check

Bucket Stopper Clearance, Lever (Bell Crank)

4. At the same time, measure the contact condition of

c- Bucket Roll Back Stopper

Clearance between Stopper and Lever G (mm (in))

Hydraulic Cylinder Cycle Time Lift Arm Cylinder:

dCAUTION: Select ground filled with sand or

A- 550 mm (1.8 ft)

Accelerator Pedal Parking Brake Forward/ Power Mode